161 SSANGYONG MUSSO 2003 Service Manual

5D2-6 TRANSFER CASE (TOD) Input/Output diagram TOD control unit and main wiring harness is linked by 30 pin
connector. Each pin joins with switche and actuator whosedetails refer to the below diagram.
Battery Power
Ignition ON/OFF
Position Encoder 1
Position Encoder 2
Position Encoder 3
Position Encoder 4
4H / 4L Switch Signal
A/T “N” Position Signal
Speed / TPS Supply
Front Speed Sensor Input
Rear Speed Sensor Input
ABS Operation Signal
Brake Switch Signal
4 5271028309241611292526
19 CAN H
CAN L
Shift Motor output port (LO-HI)
Shift Motor output port (HI-LO)
EMC
'4L' Indicator
Position Return
'4WD CHECK' IND
TPS/speed Sensor Ground (Speed / TPS Return)
2 13216713
1514
K-Line
20
22
23
17 18

TRANSFER CASE (TOD) 5D2-17
ClassificationTCCU
EMC
Speed Sensor
Shift Motor
Position Encoder
DIAGNOSTIC TROUBLE CODES (DTC
’s)
1. Diagnostic Trouble Code Retention The first time a fault is detected a DTC is stored in the TCCU ’s
Non-Volatile memory. This DTC will remain in memory until the TCCU is instructed to erase DTC ’s by SCAN-100. DTC ’s
will not be erased by disconnecting power to the TCCU.
2. Diagnostic Trouble Code AssignmentsCode 1714 171517161721 1722 1731173217331734 1735 173617411742 1743 1750175117521753 1754 Description
EEPROM Checksum Fault TPS Loss of Signal
TPS Out of Range
EMC Open / Short to Battery
EMC Short to ground
Front Speed Sensor Voltage Low
Front Speed Sensor Voltage High
Rear Speed Sensor Voltage Low
Rear Speed Sensor Voltage High
Speed Sensor Reference Voltage Low
Speed Sensor Reference Voltage High Motor Open / Shorted to Battery
Motor Output Shorted to Ground
Shift System Timeout
General Position Encoder Fault (Invalid Code) Position 1 Shorted to Ground Position 2 Shorted to GroundPosition 3 Shorted to Ground Position 4 Shorted to Ground

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

5-86 ELECTRICAL WIRING DIAGRAMS
13. TCCU-PART TIME
1) POWER SUPPLY, GROUND, INDICATION LAMP, PNP RELAY, CLUTCH SWITCH CIRCUIT
TCM
B1
A1 B6
B7B14
A15 A30
A14
Main - Engine Main - Engine Main - Engine DLC Connector - Main MainMain
C101 (21Pin, Colorless)C102 (2Pin, Colorless)
C103 (2Pin, White) C211 (14Pin, Black) G201 G205
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
a. CONNECTOR INFORMATION
CONNECTOR(NUMBER)
CONNECTING. WIRING HARNESSCONNECTOR POSITION
Inside The Engine Room Fuse Block Inside The Engine Room Fuse Block Inside The Engine Room Fuse Block Beside The Steering ColumnRight The I/P Fuse Block Beside The TCCU
12
11 2
29 38
28
13 2021
39 434842
CLUSTER
C101
W/H MAIN
12345 678910
11 12 13 14 15 16 17 18 19 20 21
C103
W/H MAIN
141516 13 12 11 10 9
87654321
DLCCLUTCH SWITCH C102
W/H MAIN
C211
W/H DLC
87654321
23222120191817161514131211109
TCCU
30 15 BAT+IGN 1
31 GND
E
f2
E
f9
C103 RB LB BrW
BrW Cluster
Clustor(4WD)
RB YW
TCCU YW
G201 G201
B
2
1
G205
18
4H 4L
34
80A
60A F22
10A
LB
B
BB
F20
10A
"A1"TCM
F10
10 8
9
20A
B+ SIG
5V
B+
IGN 1
GND
2
C211
4
C208
5
C208B LgW
LgW
35
"A15"TCM
L
LB
32
31
GrR
"13" DLC
Cluster
(N)
TCM"A9" (E23
MB
A/T) "N"
Start Lock Switch (E32
MB
A/T) "N"
Clutch switch (M/T) 87 85
30 86
B
Y
LLLL
LL
PNP
Relay (A/T)
(M/T) 15 19
11
22
14 GND
3
: M/T
9
910 1213
12
11
34
56
71 4
81
2

5-88 ELECTRICAL WIRING DIAGRAMS
2) 4WD SWITCH , T/C SPEED SENSOR, T/C MOTOR CIRCUIT
Engine - Main Main - T/M Main Engine Main
C104 (15Pin, Black)C205 (3Pin, Black)
S203 (Gray) G101 G203
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
a. CONNECTOR INFORMATION
HUB LOCKSOLENOID
CONNECTOR(NUMBER) CONNECTING. WIRING HARNESSCONNECTOR POSITION
Under The Engine Room Fuse Block Upper The T/C Motor Under Right The Audio Behind The Left LampUpper The ECM
12123
C101
W/H MAIN
12345 678910
11 12 13 14 15 16 17 18 19 20 21
4WD SWITCH
1 5678910 23
4
45
12
67
3
T/C MOTOR
C205
W/H MAIN
C104
W/H ENG. MAIN
1452
8
14
79
3
15131011
6
12
87654321
23222120191817161514131211109
TCCU
M
Ef10
C101
GW 10A
4
31
58
13 7 412V
12V 6
C205
WL
YYW
WL Y
YW
2
Magnetic
Coil
TCCU
T/C SpeedSensor
1
18
5YW
F
3
21
W
C
GND
G203 G101
ILL
4WD
Switch 76
4H
2H 4L
9
GW
B5
Br L
10 1 7
S203
3
B
21
SIG
5V
1
12
LgW
D SIG
5V
2 5
RY
E SIG
5V
4
20
Br
A
2
R
7
T/C Motor
1
R
G
6
17
RW
G
B
G B
Hub
Lock Sol
Value 1 2 16
23
RW SIG
5V
SIG
5V SIG
SIG
5V
C104
15 ILL

5-90 ELECTRICAL WIRING DIAGRAMS
14. TCCU-FULL TIME
1) POWER SUPPLY, GROUND, INDICATION LAMP, PNP RELAY, CLUTCH SWITCH CIRCUIT Main - Engine Main - Engine Main - Engine DLC Connector - Main MainMain
C101 (21Pin, Colorless)C102 (2Pin, Colorless)C103 (2Pin, White) C211 (14Pin, Black) G201 G207
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
a. CONNECTOR INFORMATION
CONNECTOR(NUMBER)
CONNECTING. WIRING HARNESSCONNECTOR POSITION
Inside The Engine Room Fuse Block Inside The Engine Room Fuse Block Inside The Engine Room Fuse Block Beside The Steering ColumnRight The I/P Fuse Block Beside THe ECM
12
11 2
29 38
28
13 2021
39 434842
CLUSTER
C101
W/H MAIN
12345 678910
11 12 13 14 15 16 17 18 19 20 21
C103
W/H MAIN
141516 13 12 11 10 9
87654321
DLC
CLUTCH SWITCH
C102
W/H MAIN
C211
W/H DLC
87654321
23222120191817161514131211109
TCCU
5
C208B
"40"
Cluster (N) TCM
"A9" (E23
MB
A/T) "N"
Start Lock Switch (E32
MB
A/T) "N"
LL L L
LL
9C208B
30 15
BAT+IGN 1
31 GND
E
f2
C103 RB
LB
Cluster
YW
Full Time TCCU
YW
G201 G201
B
2
1
G207
18
4WD
Low 4WD
Check
35
80A
F22
10A
LW
B
BB
F20
10A
F10 10 15
9
20A
B+ SIG
5V
B+
IGN 1
GND
2
C211
3
GrR
LgW 31
L
W
"12" DLC
Clutch switch(M/T) 87 86
30 85
B
Y Y
PNP
Relay (A/T) (A/T)
(M/T) 22 19
11
4
C211
4
L
BrW
"13" DLC 8
14 GND
3
: M/T
910 1213
12
11
34
56
71 4
81
2

5-92 ELECTRICAL WIRING DIAGRAMS
2) 4WD SWITCH , T/C SPEED SENSOR, T/C MOTOR CIRCUIT
Main - T/M Main Main
C205 (3Pin, Black)S203 (Gray)G203
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
a. CONNECTOR INFORMATION
CONNECTOR(NUMBER)
CONNECTING. WIRING HARNESSCONNECTOR POSITION
Upper The T/C Motor Under Right The Audio Upper The ECM
123
4WD SWITCH
1
5678910 23
445
12
67
3
T/C MOTOR
C205
W/H MAIN
87654321
23222120191817161514131211109
TCCU
M
31
58
13 7 412V6 C205
WL
YYW
WL Y
YW
2
Magnetic
Coil
TCCU
T/C SpeedSensor
1
18
5YW
F
3
21
W
C
GND
G203
ILL
4WD
Switch 76
4H 4L
9
GW
B5
Br L
10 1 7
S203
3
B
21
SIG
5V
1
12
LgW
D SIG
5V
2 5
RY
E SIG
5V
4
20
Br
A
2
R
7
T/C Motor
1
R
G
6
17
RW
B
B
16
23
RW SIG
5V
SIG
51 SIG
SIG
5V ILL
Ef10
C101
GW 10A
4

5-126 ELECTRICAL WIRING DIAGRAMS
23. ILLUMINATION CIRCUIT
C101
W/H MAIN
12345 678910
11 12 13 14 15 16 17 18 19 20 21
Main - Engine Main - Air Con Main MainMain Main Main Main Main
C101 (21Pin, Colorless)C212 (17Pin, White) S101 (Black)
S203 (Gray) G201 G203G204 G205 G208
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
a. CONNECTOR INFORMATION
CONNECTOR(NUMBER)
CONNECTING. WIRING HARNESSCONNECTOR POSITION
Inside The Engine Room Fuse Block Behind The Glove Box Inside The Engine Room Fuse BlockUnder Right The Audio Right The I/P Fuse Block Upper The ECM Behind The Ashtray Beside The TCCUUnder THe CO-Driver Seat
C212
W/H MAINFRONT
FOG
SWITCH DOOR
UNLOCK
SWITCH
HAZARD SWITCH 4WD
SWITCH AUDIO
CIGAR
LIGHTER A/C
SWITCH
MULTI-FUNCTION SWITCH
POSITION
SWITCH
12
5678910 34
12345 678910
11 12 13 14 15 16 1712
34561
345 2
12
5678910 341231234 5678
9 101112131415161718
1
231234
C1 C2
C3 C4
B1 B2 B3 B4
B5 B6 B7 B8 B9B10
A1 A2 A3 A4 A5 A6
A7 A8 A9A10 A11 A12 A13 A14