power steering SSANGYONG MUSSO 2003 Owner's Guide

6A-6 POWER STEERING SYSTEM
OIL PUMP PRESSURE CHECK Oil Pump Pressure Check
1. Disconnect the pressure hose from the oil pump connect apressure gauge between the oil pump and pressure hose
2. Bleed the system . Start the engine and turn the steering wheel form lock several times until oil temperature is up to
50°C
3. Run the engine at 1,000 rpm.
4. Close the pressure gauge valve and check oil pressure.
NoticeDo not keep the valve closed for more than 10 seconds.
5. Remove the pressure gauge and connect the pressure hose.
6. Do bleeding procedure. BLEEDING OF POWER STEERING SYSTEM Bleeding of Power Steering System
1. Disconnect the fuel line. Using a starter motor, crank the engine and turn the steering wheel from lock to lock 5 or 6 times. Notice Do bleeding with engine cranking. If bleed with idling, there can be a air contact with oil.
2. Connect the fuel feed line and start the engine at idle speed.
3. Turn the steering wheel from lock to lock until there is no more air in oil reservoir.
4. Connect the oil level is within specification.
5. By turning the steering wheel left to right, check the oil level change. Notice
If oil is not changes more than 5mm, do bleeding again.
If oil level rises suddenly when stopped engine, again.
Relief Pressure
75 - 82 kg/cm2

POWER STEERING SYSTEM 6A-7
STEERING GEAR BOX1 Bolt ....................................................... 30-40Nm
2 Spring Washer
3 Lower Shaft
4 Pressure Hose ...................................... 12-18Nm
5 Return Pipe .......................................... 12-18Nm
6 Cotter Pin
7 Slotted Nut ............................................ 35-45Nm
8 Nut
9 Spring Washer
10 Bolt ....................................................... 35-45Nm
11 Washer
12 Steering Gearbox Assembly

6A-8 POWER STEERING SYSTEM
Tightening Torque 35 - 45 Nm
Removal & Installation Procedure
1. Remove the cotter pin and nut and separate the steering
gear box tie rod from the steering knuckle arm using the
puller. Installation Notice
2. Remove the bolt and separate the lower sha from the steering gear box. Installation Notice
Tightening Torque 30 - 40 Nm
3. Remove the oil pipe from the steering gear box and drain the oil. Installation Notice
4. Remove the clamp bolts and remove the steering gear box assembly. Installation Notice
Tightening Torque 12 - 18 Nm
Notice
Be careful not to damage the rubber(1).
When installing tighten the bolt (3) with the rubber
(2)being inserted to the hole of clamp.
5. Bleed the air from system.
6. Check the toe-in.
Tightening Torque 70 - 90 Nm
Tighten the bolt toward threadless side of lower shaft coupling.

POWER STEERING SYSTEM 6A-9
Inspection Procedure
1. Check the distance of tie rod and toe-in data and, ifnecessary, adjust as below.
2. Adjustment Unscrew the adjuster nut (1) and adjust the distance by
turning the rod (2) counterclockwise.
Distance of Tie Rod 152mm
Toe-in 0 - 4 mm
Tightening Torque 65 - 80Nm

Check the toe-in date (A~B)
If the ton-in is normal, tighten the adjuster nut (1) to the
specified toque with tie rod (2) being fixed. Tightening

SUPPLEMENTAL RESTRAINT SYSTEM(SRS) 8B-3
CAUTIONS
Failure to follow the correct service procedure can cause air bag damage or personal injury due to unexpected air
bag deployment. Before service (removal and installation of part, check for replacement), please be weal noticed offollowing items for your correct service.
1. For service, turn the ignition switch to ‘LOCK’ position and wait for 30 seconds after disconnecting the negative battery cable.
2. If the vehicle collapsed, remove the air bag ECU first to reserve the crash records.
3, Never use other vehicles’ air bag components and replace with specified new part.
4. Never disassemble or repair the air bag module, air bag unit and wiring harness to re-use.
5. Replace the air bag module and air bag unit with new if it dropped, cracked or damaged.
6. Only qualified technicians in service shop should check or repair the air bag,
7. Before service, should be well noticed of warning labels on the vehicle.
A. Sun Visor Side
[Warning] Pull down the sun visor and see SRS air bag warning lamp on the head lining. B. Head Lining
[Warning]
1 . This vehicle is equipped with air bag. Air bag is supplemental device for the seatbelt. Fasten your seatbelt.
2. This air bag should be replaced by authorized supplier within replacement intervals.
3. When the ignition key is turned to ON position, SRS warning lamp will turn on for 6 sec. and go off. In this case, the system is normal. For the following cases, see service manual. - SRS warning lamp does not turn on. - SRS warning lamp does not go off.- SRS warning lamp continues to blink.
C. Steering Wheel Body Inner
[Warning] Before removing the steering wheel, read service manual first. Set the front wheels straight forward
and align the center position marks of SRS clock spring. Improper removal or installation of the steering wheel can damage the SRS components. D. Engine Compartment
[Warning] This vehicle is equipped with air bag. Before checking the engine compartment, read servicemanual first. Faultuy check and service can cause SRS air bag deployment and system defects that can be led to severe damage. E. Battery Cable
[Warning]
Before disconnecting the battery power, read service manual first.

5-76 ELECTRICAL WIRING DIAGRAMS
10. TCM (GSL, BTRE)
1) POWER SUPPLY, GROUND, INDICATION LAMP CIRCUIT
TCM
B1
A1 B6
B7B14
A15 A30
A14
DLC Connector - Main Main MainMain
C211 (14Pin, Black)
S205 (Colorless) G201 G208
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
a. CONNECTOR INFORMATION
MODE SWITCH
CONNECTOR(NUMBER) CONNECTING. WIRING HARNESSCONNECTOR POSITION
Beside The Steering Column Upper Left The AudioRight The I/P Fuse Block Under THe CO-Driver Seat
123
141516 13 12 11 10 9
87654321
DLC
C211
W/H DLC
11 2
29 38
28
13 2021
39 434842
CLUSTER
910 1213
12
11
34
56
71 4
8
31
15
GND
G208
G208 G20112V
PW
3
4H 4L
1
2
A2
A30
A23
B 6
7 2
3
S205
1
5 A24 A22 A14 A5
SIG
12V A1
SIG
12V A15 A6 A12
SIG
12V
C211
5
"38" "A3"
TOD
"37"
ECM
(MSE)
"A10" TOD "A11"
TOD "14"
DLC
"8"
TCCU
F20
LW34
18
35 23 24
LW
BrW
BrW BrW
BrB BrB BrB
LG LGBBY
HL
CAN GB
BrW
"15"
TCCU TOD
"A9" Y GBr
TCM
BrW
LB
ClusterPOWER WIN- TER27
LgW
LgW
LgW
Mode
Switch
10A
F22
10A IGN 1

5-80 ELECTRICAL WIRING DIAGRAMS
11. TCM (DSL, BTRE)
1) POWER SUPPLY, GROUND, INDICATION LAMP, SENSOR (TR, ENGINE SPEED) CIRCUIT
TCM
B1
A1 B6
B7B14
A15 A30
A14
Main - Engine Main - T/M DLC Connector - Main Main Main
C101 (21Pin, Colorless)C208 (12Pin, Black)C211 (14Pin, Black) G201 G208
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
a. CONNECTOR INFORMATION
MODE SWITCH
CONNECTOR(NUMBER)CONNECTING. WIRING HARNESSCONNECTOR POSITION
Inside The Engine Room Fuse Block Upper The T/C (DSL) Beside The Steering Column Right The I/P Fuse BlockUnder THe CO-Driver Seat
12312Ð
4
TP SENSOR
C211
W/H DLC
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
C208
W/H MAIN
141516 13 12 11 10 9
87654321
DLC
ENGINE SPEED
SENSOR
31
15
GND
G208
G208 G201
12V
PW
3
4H 4L
1
2
A2
A30
A17 A16 A18 A21 A7 A19 A22 A4 A14
BLRG LRG
BrW BrB
BrW BrBY
Y Y
Y LG LG
SIG
SIG SIG
SIG
5V
5V SIG A1
SIG
12V A15 A6 A12
SIG
12V
5V
C211
5
C101
14
C208
43 7 6 5
42 1 1 2 "14"
DLC
"35"
Stics
(Vehicle Speed)
"87"A/C
Compresser Relay
"4"
EGR
Control Unit
Throttle Position
(TP) Sensor Engine Speed
Sensor "17"
Cluster
(Vehicle Speed)
"8"
TCCU
F20
LW
34
18
35 23 24
LW G B BrW
"15"
TCCU Y GBr
B
B
B
TCM
BrW
LB
ClusterPOWER WIN- TER27
LgW LgW
Mode
Switch
10A
F22
10A IGN 1910 1213
12
11
34
56
71 4
8
1234 5678
9 101112
13 14 15 16
12

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

5-90 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

5-98 ELECTRICAL WIRING DIAGRAMS
16. ECS
1) POWER SUPPLY, GROUND, SENSOR (WHEEL'G, VERTICAL, LATERAL) CIRCUIT Main - Engine Engine - Main DLC Connector - Main Main - Floor MainMain
C103 (21Pin, White)
C109 (16Pin, Black)
C211 (14Pin, Black)
C303 (14Pin, White) G201 G302
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
a. CONNECTOR INFORMATION
CONNECTOR(NUMBER)
CONNECTING. WIRING HARNESSCONNECTOR POSITION
Inside The Engine Room Fuse Block Under The Coolant Reservoir Tank Beside The Steering Column Beside The I/P Relay BlockRight The I/P Fuse Block Beside The Left Rear Speaker
C103
W/H MAIN
ECS CLUSTER
1
14 13 2611
2
29 38
28
13 2021
39 434842
C303
W/H MAIN
12 45
78 3
9 101112 13 6
14
C109
W/H ENGINEC211
W/H DLC
LATERAL SENSOR
VERTICAL SENSOR
231
WHEEL 'G'
SENSOR
231
G201 G302
LW
LB
YR
30
18
YR
R R GW GB GB
B+
5V
LAMP
16
13
SIG
Ef8
60A
F16 15A
Ef2 80A
ECS
Relay
30
86
87
85
1
C103
1 C303
F24
10A
F22 10A
B
12 14
B
GND
YW
11
5V
GND
9 C303 Cluster
(ECS WarningLamp)4
C303
Y Y
Cluster
(Speed Meter)
"17"
23 ECS Control Unit
7C211
13
C303
G G G
DLC
"1"
+
3
BY
7
SIG
1BL
YW BY
YW BY
BL
8
_
2
85 6
C303
15 13 14C109
Wheel 'G' Sensor
+
3
20
SIG
1
YW GBr GBr
BG
GY
_
2
Lateral Sensor
+
3
10
SIG
1
YW BG GY_
2
Vertical Sensor
7 C303
12 C303
30 BAT+
15 IGN 1
31 GND
1
2910 1213
12
11
34
56
71 4
8