EGR SSANGYONG MUSSO 2003 Owner's Manual

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.

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-34 MUSSO-SPORTS
SUPPLEMENT
15 IGN1
31
* ( ) : A/T
* A/T TPS, RPM Signal : TCU A5
30
GND
F24
LW A/T
TCU A5 Clutch SW
"1" TPSM/T
41 2
2 RPM Sensor
S201
1 3
LW GrW HUBER EGR ECU (K2004) BG
C R G BrB BrWLRG
10A
BAT+
F17
RY RY 3 9 28 62 61 81 10 29
1
4 6 0798 05 675 4 324 3 332 3 736
WR W WB BrW GR
WR W WB BrW GR BG BrG GL LG YL LB
WR Lift Sensor
EGR Valve Water Sensor
Temp EGR Modulator Exhanst Gas
RecirculationModulator Sol Valve
W WB BrW GR BG BrG GL LG YL LB
S201
8
12 10A
213 7 8
B
13(11) 14(12) 11(9) 12(10) 9(7) (10)8
C901 (C902)
C901
C108
C105
C104
G204
Ef 2 Ef 8
80A60A
C103
2
56 7 2 1
16 15 1411 10
4. HUBER EGR CIRCUIT(MUSSO SPORT)

MUSSO-SPORTS 1A-35
SUPPLEMENT
Main - Engine Engine - Engine Genertor - EngineMain - T/M Main - T/M MainMain
C103 (2Pin, White) C105 (8Pin, Black) C108 (16Pin, Black)C901 (16Pin, Black) C902 (12Pin, Black) S201 (Black)G204
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
a. CONNECTOR INFORMATION
C902
W/H T/M
C101
W/H MAIN C102
W/H MAIN C108
W/H ENGINE
CONNECTOR(NUMBER) CONNECTING. WIRING HARNESSCONNECTOR POSITION
Inside The Engine Room Fuse Block
Beside Pre-Heating Unit (DSL):MUSSO SPORT
Under The Air Cleaner Housing (DSL, N/Turbo) Upper The T/C(M/T)Upper The T/C(A/T) Behind The Cluster Upper The Huber EGR
1
2
1234
5678
1234 5678
9 101112
13 14 15 16
1234 5678
9 101112
13 14 15 16
C901
W/H T/M
1234
5678
9101112
HUBER EGR
CONTROL UNIT
24
43
23
42
22
41
21
40
20
39
19
38
18
37
17
36
16
35
15
34
14
33
13
32
12
31
11
30
10
29
9
28
8
27
7
26
6
25
62
81
61
80
60
79
59
78
58
77
57
76
56
75
55
74
54
73
53
72
52
71
51
70
50
69
49
68
48
67
47
66
46
65
45
64
12 45 3
44
63

POSITION OF CONNECTORS AND GROUNDS 2-9
S204 (DSL/GSL)
S101 (DSL/GSL)
11) SPLICE PACK S202 (DSL/GSL)
S201 (DSL/GSL)
S205 (DSL/GSL)
3 2 1Ef2
80A Ef6
40A
Ef14
15A
WFusible Link Box
Head Lamp Relay (Low) '30' Fog Lamp Relay '30'
Tail Lamp Relay '30'GL
GL
GL GL
GL
1 2 3 4
5 6 7 8
5C204
LW
LW
DLC '2' Stics '29'
EGR Control unit '3' (DLC) Clock '3'VSS '3' F24 (10A)
Seat Warmer Control unit '9'
Stop Lamp Switch '3' (GSL)
LW LW LW LW LW
1 2 3 4
5 6 7 8RY RY RY RY
RYRY RY RYStics '1'
F17 (10A)
Seat belt Switch '3'
Chime Bell '2', Buzzer '3' DLC '14'
Key Reminder Switch '3' Clock '1'
C212 '10' Audio '5'
S203 (DSL/GSL)
1 2 3 4
5 6 7 8
16
Thermo AMP '3'(DSL)
Thermo AMP '4'(GSL)
Rear Wiper/WasherSwitch '8'LW
LW LW
C212
LWF19 (10A)
Blower Relay 'S1'A/C Switch '3'
S401 (DSL/GSL)
1 2 3 4
5 6 7 84
7
Ef10
10A
C212 C101ECS Switch '4'
Rear Wiper/Washer Switch '6'
A/C Control Panel '11' Tail Lamp Relay '87'
Door unlock Switch '4' Defroster Switch '4'
Audio '3', 4WD Switch '7'
Front Cigar Lighter '2'
Seat Warmer Switch '6' Fog Lamp Switch '4'
Hazard Switch '2'Clock '4'GW GW
GW
GW GW
GW
GW GW
1 2 3 4
5 6 7 8BrW BrW BrB YW
BrBBrB BrW LYECM '38'
'37' ECM
TCM 'A23' 'A24' TCM
TOD 'A10' 'A11' TOD
RESISTOR (M/T)
1 2 3 4
8 9
10 11B B
BRear RH Combi Lamp '4' Rear LH Combi Lamp '4'
5 6 7
12 13 14
2
Door lock Actuator '2'
G302B
B B
C402 BRear Wiper Motor '3' High Maunted Stop Lamp '2'
BLicense Lamp '2'
License Lamp '2'

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

5-18 ELECTRICAL WIRING DIAGRAMS
3. EGR CONTROL UNITMain - Engine Main - T/M Main - T/M MainEngine Main Main
C109 (16Pin, Black)C208 (12Pin, Black) C209 (8Pin, Black) S201 (Black) G103 G203G205
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
a. CONNECTOR INFORMATION
ENGINE RPMSENSOR
C208
W/H MAIN C209
W/H MAIN EGR CONTROL
UNIT
C109
W/H ENGINE
MICRO SWITCH
CONNECTOR(NUMBER) CONNECTING. WIRING HARNESSCONNECTOR POSITION
Inside The Engine Room Fuse Block Upper The T/C (DSL) Upper The T/C (DSL)Behind The Cluster Behind The Right Head Lamp Upper The ECM Beside The TCCU
1234
567812 3
4567812
1234 5678
9 101112
13 14 15 16
1234 5678
9 101112
13 5
24 6
EGR SOLENOID
12
31
15
GND
G103
G203 G205 G205
F24
LWS201
1 8 3
45 7 6 8
LW
EGR Control Unit
R>R5IN
A>15
10A IGN 1
C109
11
C208
1
2 BrW
BrW BrW
6
TCM "A7" TCM
"A21"
R>R4 IN
R>R3
IN
A>10
C209
Engine RPM
Sensor
8
C208
C209 BrB
BrB (M/T)
B (A/T)
RY RY
4 2 31RL RL B
B
B B
B MS1 MS2
BrB EGR Sol.V/V
MicroSwitch 1 2
C209
3
C208
2
75 C208
8 C209
1 LY LYC208
1 C209
2
: M/T

ELECTRICAL WIRING DIAGRAMS 5-19
 W/H T/M
c. POSITION OF CONNECTORS AND GROUNDS
 W/H MAIN (I/P)
S201C201C351
C301~C303
G201
S202
C212
G204
C203
C110C361C213
S204
S203
S205G202
C204
G205TCCU
C305
EBCM
G209
C206B, C206,
C207, C208,
C208B, C209,C210G207
C304G203
TCM
G208
d. SPLICE PACK S201 (BLACK)
1 2 3 4
5 6 7 8
5C204
LW
LW
DLC '2' Stics '29'
EGR Control unit '3' (DLC) Clock '3'VSS '3' F24 (10A)
Seat Warmer Control unit '9'
Stop Lamp Switch '3' (GSL)
LW LW LW LW LW

ELECTRICAL WIRING DIAGRAMS 5-33
 W/H MAIN (I/P)
c. POSITION OF CONNECTORS AND GROUNDS
d.SPLICE PACK
S201 (BLACK)
1 2 3 4
5 6 7 8
5C204
LW
LW
DLC '2' Stics '29'
EGR Control unit '3' (DLC) Clock '3'VSS '3' F24 (10A)
Seat Warmer Control unit '9'
Stop Lamp Switch '3' (GSL)
LW LW LW LW LW
S205 (COLORLESS)
1 2 3 4
5 6 7 8BrW BrW BrB YW
BrBBrB BrW LYECM '38'
'37' ECM
TCM 'A23' 'A24' TCM
TOD 'A10' 'A11' TOD
RESISTOR (M/T)