service SSANGYONG MUSSO 2003 Service Manual

TRANSFER CASE (TOD) 5D2-33
9 - 16 Vdc 6 - 16 Vdc2 mA1 A 7 A
20 A
Removal & Installation Procedure
1. Turn the ignition switch to "OFF" position.
2. Remove 30 pin connector from TOD control unit.
3. Unscrew 2 bolts (1). Installation Notice
1 Bolt (M6 x 16, 2pieces)................ 9-11 Nm
2 TOD control unit
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
TOD CONTROL UNIT TOD Electric CharacteristicsVoltage Parasitic Current
(Under max. operation Voltage)Max. Operation Current
(Under max. operation Voltage) Normal Operation Range
CAN communication Operation Range Ignition “OFF ”
Ignition “ON ”
Motor “OFF ”
Motor “ON ”
4. Installation should follow the removal procedure in the
reverse order. Notice When replace TOD control unit, it is required to make a coding correspondent with vehicle specification.
Tightening Torque 9 - 11 Nm

5D2-40 TRANSFER CASE (TOD)
REPLACEMENT OF OIL Oil Specification Specified Oil Level
SpecificationStandard
Capacity Service A.T.F S-3, S-4 or Dexron II, III
1.4 Litre
Inspection every 15,000km, Replacement every 50,000km =
Oil Replacement
1. Lift on vehicle then make sure on safety.
2. Prepare a vessel to drain transfer case oil.
3. Release filler plug.
4. Drain oil completely.
5. Wash drain plug and than tighten. Installation Notice
Tightening Torque 19 - 30 Nm
6. Replenish standardized oil by specified level through filler plug hole.
7. Tighten filler plug after washing.
Installation Notice
8. Check oil leakage.
Tightening Torque 19 - 30 Nm
. .

5D2-48 TRANSFER CASE (TOD)
6. Install the front planet to the sun gear and input shaft.Install the internal snap ring to the planetary carrier.
7. Place the tanged snap ring in the case. Expand snap ring with snap ring pliers and install planetary carrier assembly. Check installation by holding the case and carefully tappingthe face of the input shaft against a wooden block to makesure the snap ring is installed.
8. Remove all traces of gasket sealant from the front case and mounting adapter mating surfaces. Install a bead ofgasket sealant on the surface of the front case.
9. Install the high-low shift fork and high-low collar as an assembly into the front planet. Notice Make sure that the nylon wear pads are installed on the shift fork and snapped securely into place.
12 Rear Output Shaft
13 Oil Strainer
14 Coupling Hose
15 Hose Clamp
16 Pump Body
10. If new pump is used, align the flat of the output shaft and
the flat of the pump. Slide the pump onto the output shaft.
Do not disassemble oil pump. It is serviced only as an
assembly. Check the pump to make sure the pump
rotates freely.
Do not remove the plastic insert from the bore of the
new pump. Discard it after it slides out during pumpinstallation to the rear output shaft.
While turning the output shaft, prime the pump through
the oil filter pickup tube or housing inlet hole with clean
Automatic Transmission Fluid or equivalent.
11. Inspect the outside surfaces and bore of the oil pump. If there is no discoloration in the pump housing, gear or cover,and the pump bore and the lube holes of the output shaft show evidence of oil, the pump is working.

Application
Steering Wheel Steering Gear Box Oil Pump Steering Column
Minmum Turning Radius Oil SECTION 6A
POWER STEERING SYSTEM
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 6A-1
General Specifications . . . . . . . . . . . . . . . . . . 6A-1
Fastener Tightening Specifications . . . . . . . . . 6A-1
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2
Hard Steering . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2
Steering Pulls to One Side . . . . . . . . . . . . . . . 6A-2
Excessive Wheel Play . . . . . . . . . . . . . . . . . . . 6A-2
Poor Return of Steering Wheel . . . . . . . . . . . . 6A-2
Steering Wheel Shimmy . . . . . . . . . . . . . . . . . 6A-3
SPECIFICATIONS
GENERAL SPECIFICATIONS Abnormal Noise From Steering System . . . . . 6A-3
Component Locator . . . . . . . . . . . . . . . . . . . 6A-4
Steering System . . . . . . . . . . . . . . . . . . . . . . . 6A-4
Maintenance and Repair . . . . . . . . . . . . . . . 6A-5
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 6A-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-5
Oil Pump Pressure Check . . . . . . . . . . . . . . . . 6A-6
Bleeding of Power Steering System . . . . . . . . 6A-6
Steering Gear Box . . . . . . . . . . . . . . . . . . . . . 6A-7
Number of Spoke Outer Diameter
Type Gear Ratio Inner Steering AngleOuter Steering Angle
TypeMaximum Pressure
Upper Tilting Angle
Lower Tilting Angle
Type Capacity Change Interval
Description
4
396 mm
Rack and Pinion

33°37'
31°50' Vane
75-82 kg/cm 2
4.646° 6.969°
5.25m
ATF DEXRON II
1 L
Every 24,000 km
FASTENER TIGHTENING SPECIFICATIONS
Application
Steering Shaft Bolt Pressure Hose BoltReturn Pipe Nut Slotted Nut Steering Gearbox Bolt
N m
30 - 40 12 - 1812 - 1835 - 45 35 - 45

POWER STEERING SYSTEM 6A-5
MAINTENANCE AND REPAIR ON-VEHICLE SERVICE INSPECTION Steering Wheel Freeplay Inspection Procedure
1. Start the engine and set the wheels in straight ahead position.
2. Slightly move the steering wheel to the left and right andmeasure steering wheel free play when the front wheel is
start to move. Notice
If exceeds specification, the steering column shaft
connections and steering linkage .clearance. Replace orrepair if necessary.
Steering Angle Inspection Procedure
1. Place the front wheel on a measuring tool.
2. Rotate steering wheel all the way right and left and measure steering angle Notice If out of standard, check or adjust toe-in.
Standard 33°37'
31°50'Inner
Outer
Steering Effort Inspection Procedure
1 Place a vehicle on the paved flat ground with front wheels in a straight ahead position.
2 Start the engine and run it at 1,000rpm.
3 Using a scale, measure the steering effort in both directions.
NoticeThe difference in steering effort of left and right should be within 0.6 kg.
Standard Max. 3.0kg
StandardMax. 30mm

SECTION 6E
STEERING WHEEL AND COLUMN
TABLE OF CONTENTS
Specification . . . . . . . . . . . . . . . . . . . . . . . . 6E-1
Fastener Tightening Specifications . . . . . . . . . 6E-1
Maintenance and Repair . . . . . . . . . . . . . . . 6E-2
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application
Steering Wheel Mounting Nut Steering Lower Shaft BoltSteering Column Shaft Bolt Steering Column Mounting Bolt
N m
50 - 80 30 - 40
9 - 14
15 - 20
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . 6E-2
Steering Column . . . . . . . . . . . . . . . . . . . . . . . 6E-2

6E-2 STEERING WHEEL AND COLUMNMAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
STEERING COLUMN
1 Horn Pad
2 Nut ....................................................... 50-80 Nm
3 Washer
4 Steering Wheel
5 Combination Switch Assembly
6 Combination Switch Lower Cover
7 Combination Switch Upper Cover
8 Bolt
9 Bolt
10 Bolt
11 Crash Pad Panel
12 Bolt ...................................................... 30-40 Nm
13 Spring Washer
14 Steering Column Shaft
15 Bolt ........................................................ 9-14 Nm
16 Bolt ...................................................... 13-40 Nm
17 Column & Shaft Assembly

SECTION 7D
FULL AUTOMATIC TEMPERATURECONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 7D-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 7D-1
Service Specifications . . . . . . . . . . . . . . . . . . . 7D-3
Schematic and Routing Diagrams . . . . . . . . 7D-4
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . 7D-4
FATC Block Diagram . . . . . . . . . . . . . . . . . . . . 7D-5
Component Locator . . . . . . . . . . . . . . . . . . . 7D-6 TABLE OF CONTENTS
Ventilation System . . . . . . . . . . . . . . . . . . . . . . 7D-6
Function Description . . . . . . . . . . . . . . . . . . . . 7D-7
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 7D-8
Diagnosis Test . . . . . . . . . . . . . . . . . . . . . . . . 7D-8
Maintenance and Repair . . . . . . . . . . . . . . 7D-11 FATC Control Panel . . . . . . . . . . . . . . . . . . . 7D-11
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 7D-15
FATC (Full Automatic Temperature Control) is full automatic heater and airconditioning system that detects incar temperature, ambient temperature, sun load and coolant temperature and controls airconditioner system
blowing capacity, outlet temperature and intaking/outlet mode to maintain interior comfort.
SPECIFICATIONSSPECIFICATIONS
Application
Core Size (LxWxT)
Core Type
Expansion Valve Type Thermostat
Resister TypeCooling Capacity Description
237.0x232.0x92.0 Aluminum plate
Angle
ON:4.5±0.6 °C, OFF:1.5±0.6 °C
Aluminum plate
4,500 Kcal/h(AT 420 CMH)
Evaporator Unit
Application
Capacity
Type Description
650-750 g R134a
Refrigerant

FATC-HAVC 7D-3
SERVICE SPECIFICATIONSResistance (25 °C)
Voltage Rating Current RatingResistance (25 °C)
Voltage Rating Current Rating Resistance (25 °C)
Voltage RatingCurrent Rating
Application
Incar Sensor Ambient Sensor
Coolant Temperature Sensor
Description
Input Section
2.186k
±0.07k
5V
3mA
1.0k ±0.03k
5V
3mA
0.55k ±0.02k
5V
3mA
Current Rating (at 12V) LOCK CurrentCurrent Rating (at 12V)LOCK CurrentCurrent Rating (at 12V) LOCK Current IcPc
Application
Intake Actuator Mode Actuator Mix Actuator Power TRBlower Motor Power Consumption
Description
Output Section
70±30mA
Less than 500mA 100±40mA
Less than 500mA 100±40mA
Less than 500mA 30A
200W 220W

FATC-HAVC 7D-15
TROUBLESHOOTING Check and Service Incar sensor is a sensor that detects interior air temperature and a thermistor that decreases its resistance when temperature up and increases when temperature down.
1. Check that there are incar sensor fault code (11,12) by using self-diagnosis function.
2. Disconnect incar sensor 2-pin connector that installed on
inner lower instrument panel cover of driver ’s side and
remove the sensor.
3. Check that measured resistance value among incar sensor terminals is as shown in the right side graph. Notice Measure resistance value by soaking the sensor in the ice water and check changes in resistance values after soaking
it in the very hot water.
4. If resistance value is out of specification, replace the incar sensor.
5. Install the sensor and turn the ignition switch to ON position and check that voltage between No. 12A terminal of incar
sensor and body (-) is 5V.
6. Check current between the No. 12B and 12A connector terminals of the incar sensor and the No. 1 and 5 connector terminals of the airconditioner control unit and repair the wire if defective.