ABS SSANGYONG MUSSO 2003 Repair Manual

5D2-12 TRANSFER CASE (TOD)Pin1 2345 6 78
Function
Motor HI-LO Motor LO-HI EMC
Battery (+)
Ignition
Position Return
Diagnosis Display - Pin
9
10 11
1213 14 1516 Function
HI / LO Switch Position 2
Front Speed
TPS Supply (Diesel) Speed/TPS Return
Motor HI-LOMotor LO-HI
Speed Reference Pin
1718192021 22 2324 Function
GroundGround
Battery (+) K-LINE
4L Illumination
CAN-HCAN-L
Auto T/M, Neutral Pin
2526272829 30 - - Function ABS Input
Brake Switch
Position 1 Position 3
Rear Speed
Position 4 --
TOD CONTROL UNIT
Shape and function of TOD Control Unit

5D2-50 TRANSFER CASE (TOD)
19. Install wave spring, insulator washer and armature. (Threeoffset slots must align with housing to be installed) NoticeThree slots on the thrust washer must be aligned with the three tabs on the clutch pack housing.
20. Install apply cam onto the rear output shaft, install three balls into the apply cam, install cam and coil housing assembly onto rear output shaft. Install thrust bearing assembly onto output shaft.
21. If removed, drive the front output shaft ball bearing into
the rear cover bore with Front Shaft Needle Bearing Replacer and Driver Handle.
22. If removed, install the rear output bearing in the rear case bore. Drive the bearing into the rear case bore with OutputShaft Bearing Replacer and Driver Handle. Make sure thatthe bearing is not cocked in the bore. Install the internalsnap ring that retains the bearing to the rear case.
23. Install the clutch coil from inside the rear case until the wire and studs extend through the cover. Install the washersand nuts and tighten. CAUTIONDo not kink or trap the wire while seating the clutch coil to the case.
24. Slide the spring spacer on the camshaft and position it beneath the drive tang. Place the torsion spring on thecamshaft. Position the first spring tang to the left of thecamshaft drive tang(View A). Wind the second spring tang clockwise past the drive tang(View B). Push the torsion spring and sleeve in as far as it will go (View C). This willseat the second spring tang on the right side of the drivetang. Install the helical cam and slide the drive tang betweenthe torsion spring tangs as far as it will go.

9A-6 BODY WIRING SYSTEM Engine Room Fuse (EF) and Relay Box1 Fuse (15A) : ABS, ABD
2 Fuse (20A) : Sun Roof
3 Fuse (10A) : Air Bag
4 Fuse (15A) : Audio, Clock, Out Side Mirror
5 Fuse (30A) : Cigarette lighter, Power Socket
6 Fuse (30A) : Heater
7 Fuse (15A) : Door Lock
8 Fuse (30A) : Rear Heated
9 Fuse (10A) : Audio, Buzzer, Chime, Clock
10 Fuse (30A) : Power Window
11 Fuse (10A) : Immobilizer
12 Fuse (20A) : T/C
13 Fuse (15A) : Interior Lamp
14 Fuse (15A) : Hazard Lamp
15 Fuse (15A) : Stop Lamp
16 Fuse (15A) : Turn signal Lamp, Head Lamp
17 Fuse (10A) : Back up Lamp
18 Fuse (15A) : Cluster, STICS
19 Fuse (15A) : A/T, Diagnosis
20 Fuse (15A) : Over Voltage Protection Relay (Gasolin Only)
21 Fuse (15A) : Seat Heater
22 Fuse (15A) : ECS
23 Fuse (15A) : Front Wiper & Washer
24 Fuse (10A) : Rear Wiper & Washer, A/C
25 Relay : Front Wiper 26 Relay : ABS Warning Lamp
27 Relay : Flasher Unit
28 Relay : Fuel Pump (Gasoline Only)
29 Relay : Shift Lock (A/T)
30 Relay : Clutch Interlock & Neutral
31 Relay : Sun Roof
32 Relay : A/T ‘B’ Interlock (MB A/T)
33 Relay : Power Window
34 Relay : Rear Fog Lamp
35 Relay : ECS
36 Relay : Compressor (Diesel E/G)
Condenser Fan (Gasoline E/G)
37 Relay : Condenser Fan
38 Relay : Air Conditioner
39 Fuse (10A) : Tail Lamp
40 Fuse (15A) : Head Lamp(LH)
41 Fuse (15A) : Head Lamp(RH)
42 Fuse (15A) : Front Fog Lamp
43 Fuse (10A) : Horn
44 Fuse (10A) : Compressor
45 Relay : Resistor with Diode (Gasoline E/G)
46 Relay : Front fog Lamp
47 Relay : Condenser Fan
48 Relay : Tail Lamp
49 Relay : Horn

9A-8 BODY WIRING SYSTEM1 Fuse Box
2 Door Lock Relay
3 Relay Box
3.1 Front Wiper Relay
3.2 ABS Warning Lamp Relay ....................................ABD 5.0
3.3 Flasher Unit
3.4 Fuel Pump Relay ................................................. Gasoline E/G
3.5 Shift Lock Relay ................................................... Automatic Transmission
3.6 Clutch Interlock & Neutral Relay ...........................Manual Transmission or Automatic Transmission
3.7 Sun Roof Relay
3.8 Automatic T ransmission ‘B’ Switch Interlock ....... Automatic Transmission
3.9 Power Window Relay
3.10 Rear Fog Lamp Relay .......................................... Rear Fog Lamp
3.11 ECS Relay 4 Defogger Relay
5 Ground 1
6 Roof Wiring Connector
7 Diode 1
8 Front Door Wiring Connector
9 Front Door Wiring Connector
10 Front Door Wiring Connector 11 Front Door Wiring Connector
12 Kick Down Relay .................................................. Automatic Transmission
13 Floor Wiring Connector
14 Floor Wiring Connector
15 Floor Wiring Connector
16 ABD Floor Wiring Connector ................................ABD 5.0
17 ECS Floor Wiring Connector
18 Rear Iper & Washer Switch
19 Clutch Switch ........................................................ Manual Transmission
19-1 Clutch Switch ........................................................ E32 Gasoline E/G with Manual Transmission
20 Stop Lamp Switch
21 Outside Mirror Switch
22 Ignition Switch
23 Multi Function Switch
24 Multi Function Switch
25 Black Out Switch .................................................. Black Out Lamp
26 Black out switch ................................................... Black Out Lamp
27 Joint Connector (Tail)
28 Joint Connector (Ignition)
29 Cluster
30 Cluster ................................................................. Automatic Transmission
31 Cluster
32 Cluster
33 4WD Switch .......................................................... Except TOD
33-1 4WD Switch .......................................................... TOD
3 4 Hazard Switch
35 Ground 2
36 Pedal Module ....................................................... Gasoline E/G with MSE ECU
37 Audio Switch
3 8 Immobilizer ........................................................... Crypto Type, Gasoline E/G with MSE ECU or Diesel E/G
39 Ignition Switch
40 Multi Function Switch
4 1 STICS
4 2 STICS
4 3 REKES ................................................................. Remote Keyless

BODY WIRING SYSTEM 9A-9
44 Joint Connector.................................................... Ground
45 Door Unlock Switch
46 Front Fog Lamp Switch
47 Rear Defogger Switch
4 8 ECS Switch
49 Rear Fog Lamp Switch ........................................Rear Fog Lamp
50 Digital Clock
51 Thermo Amplifier
52 Glove Box Lamp Switch
53 Air Conditioner Wiring Connetor
54 Glove Box Lamp
55 Ground 6
56 Ground 6 ............................................................. Gasoline E/G
57 Ground 7 ............................................................. Gasoline E/G
58 Wheel Speed Sensor (FR) ..................................ABS 5.0 or ABD 5.0
59 O 2 Sensor
............................................................ E32 Gasoline E/G
60 Engine Main Wiring Connector ............................Gasoline E/G with MSE ECU
61 HFM ..................................................................... Gasoline E/G with HFM ECU
61-1 MSE ..................................................................... Gasoline E/G with MSE ECU
62 Front Door Wiring Connector (Passenger Side)
63 Front door Wiring Connector (Passenger Side)
64 Joint Connector (B+)
65 Audio
66 Audio
67 Air Bag Wiring Connector
68 Chime Bell
6 9 Buzzer
70 Kick Down Switch ................................................. Automatic Transmission
71 Diode 2 ................................................................ Manual Transmission
72 Ground 3
73 Ground 4
74 Front Cigarette Lighter
75 Diode 3 ................................................................ Automatic Transmission, MB
76 S/E Mode Selector Switch ....................................Automatic Transmission
76-1 Mode Switch ........................................................ Automatic Transmission
77 “B” Position Switch .............................................. Automatic Transmission
78 “P” Position Switch .............................................. Automatic Transmission
79 Shift Lock Solenoid Valve .....................................Automatic Transmission
8 0 TCCU
81 Ground 5 ............................................................. Gasoline E/G
81-1 Ground 7 ............................................................. Diesel E/G
82 Seat Extension Wiring Connector
83 Transmission Extension Wiring Connector ...........E23 & E32 Gasoline E/G with Manual Transmission
83-1 T ransmission Extension Wiring Connector ...........Diesel E/G with MB A/T
84 Transmission Extension Wiring Connector ...........Gasoline E/G with Manual Transmission
84-1 T ransmission Extension Wiring Connector ...........Diesel E/G with Manual Transmission or BTRE A/T
85 Transmission Extension Wiring Connector ...........E23 & E32 Gasoline E/G with A/T
85-1 T ransmission Extension Wiring Connector ...........Diesel E/G with BTRE A/T
86 Transfer Case Motor
87 Transfer Case Motor
88 Vehicle Speed Sensor
89 Fuel Gauge
90 Acceleration Sensor ............................................. ABS 5.0
91 Seat Belt Switch (Passenger)
92 Seat Heater Switch
93 Head Lamp Leveling Device Switch .....................Leveling Device

9A-10 BODY WIRING SYSTEM94 Seat Belt Switch (Driver)
95 Seat Belt Switch (Dirver)
96 Parking Brake Switch
97 Rear Cigarette Lighter
9 8 OVPR ................................................................. Gasoline E/G
99 LH Side Repeater ............................................... Rear Fog Lamp
100 Engine Wiring Connector
101 Engine Joint Connector
102 Engine Joint Connector ......................................Gasoline E/G
103 ECS Engine Wiring Connector ...........................Diesel E/G & Gasoline E/G with HFM ECU
104 ABD Engine Wiring Connector ...........................ABD 5.0
105 ABD Engine Wiring Connector ...........................ABD 5.0
105-1 ABS Engine Wiring Connector ............................ABS 5.0
106 Canister Purge Solenoid Valve ...........................Gasoline E/G with MSE ECU
106-1 Canister Purge Solenoid Valve ...........................E20 & E23 Gasoline E/G with FHM ECU
107 Econo/Standard Solenoid Valve .........................Gasoline E/G with Automatic Transmission
108 CO Potentio Meter .............................................. Gasoline E/G with HFM ECU & CO Potentio Meter
109 Front Wiper Motor 11 0 O 2 Sensor
........................................................... E20 or E23 Gasoline E/G
111 RH Side Repeater
112 Engine Wiring Connector
113 Vertical Sensor
114 Lateral Sensor
115 Diagnosis
11 6 Joint Box ............................................................. Gasoline E/G (E32)
117 Canister Purge Solenoid Valve ...........................E32 Gasoline E/G with HFM ECU
118 Led Antenna ...................................................... Rolling code type Immobilizer
119 E-key Connector ................................................ Gasoline E/G with Rolling Code Type Immobilizer
120 Receiver Unit ...................................................... Gasoline E/G with Rolling Code Type Immobilizer
121 Receiver Unit ...................................................... Gasoline E/G with Rolling Code Type Immobilizer
122 Receiver Antenna .............................................. Gasoline E/G with Rolling Code Type Immobilizer
123 Receiver Connector ........................................... Gasoline E/G with Rolling Code Type Immobilizer
124 ICU Connector .................................................... Gasoline E/G with Rolling Code Type Immobilizer
125 ICU ..................................................................... Gasoline E/G with TOD (MSE ECU 3.2 Engine Only)
126 CAN Line ............................................................ Gasoline E/G with TOD (MSE ECU 3.2 Engine Only)
127 TOD ................................................................... Gasoline E/G with TOD (MSE ECU 3.2 Engine Only)
128 TOD ................................................................... Gasoline E/G with TOD (MSE ECU 3.2 Engine Only)
129 Transfer Case Speed Sensor .............................Gasoline E/G with TOD (MSE ECU 3.2 Engine Only)
130 Engine Main Wiring Connector ...........................Gasoline E/G with MSE ECU
131 Remote Engine Start .......................................... Diesel E/G with A/T & Black Out Lamp
132 Remote Engine Start .......................................... Diesel E/G with A/T & Black Out Lamp
133 TCU .................................................................... Diesel E/G with BTRE A/T
134 TCU .................................................................... Diesel E/G with BTRE A/T
135 Ground 5 ............................................................ Diesel E/G
136 Start Protection Relay .........................................Diesel E/G with Rolling Code Type Immobilizer
137 EGR control unit ................................................. Diesel E/G
1 3 8 ICU 1 .................................................................. Diesel E/G with Rolling Code Type Immobilizer
1 3 9 ICU 2 .................................................................. Diesel E/G with Rolling Code Type Immobilizer
140 Injection Pump Valve Extension ..........................Diesel E/G with Rolling Code Type Immobilizer
141 Injection Pump Valve Extension ..........................Diesel E/G with Rolling Code Type Immobilizer
142 EGR Solenoid .................................................... Diesel E/G
143 ICU led ................................................................ Diesel E/G with Rolling Code Type Immobilizer
144 Immobilizer Solenoid Valve ..................................Diesel E/G with Crypto Type Immobilizer
147 Immobilizer Unit ................................................... Diesel E/G with Crypto Type Immobilizer

BODY WIRING SYSTEM 9A-11
ENGINE ROOM1 Engine Room Relay Box
1.1 Main Wiring Connector
1.2 Main Wiring Connector
1.3 Main Wiring Connector ........................................Gasoline E/G
1.4 Joint
1.5 Compressor, Condenser Fan Relay .....................Diesel E/G
1.6 Condenser Fan Relay 2
1.7 Air Conditioner Relay
1.8 Resistor with Diode .............................................. Gasoline E/G
1.9 Front Fog Lamp Relay
1.10 Condenser Fan Relay 1
1.11 Tail Lamp Relay
1.12 Horn Relay
2 Octane Selector ................................................... Gasoline E/G with HFM
3 Preheating Unit .................................................... Diesel E/G
4 Preheating Timer Unit .......................................... Diesel E/G
5 ECS Main Wiring Connector ................................ ECS
6 Brake Leveling Fluid Sensor
7 ABD Main Wiring Connector ................................ABD 5.0
7 - 1 ABS Main Wiring Connector ................................ABD 5.0
8 ABD main Wiring Connector ................................ABD 5.0
9 Engine Temperature Sensor ................................Diesel E/G
10 ABS 5.0 ECU ....................................................... ABS 5.0
10-1 ABD 5.0 Modulator ............................................... ABD 5.0
11 Front Washer Motor ............................................. Diesel E/G
12 Head Lamp Relay
13 Compressor ......................................................... Air Conditioner
14 Wheel Speed Sensor ........................................... ABS 5.0 or ABD 5.0

9A-12 BODY WIRING SYSTEM
15 LH Damper........................................................... ECS
16 Ground 1
17 Ground 2
18 Locking Hub Solenoid
19 Condenser Fan Relay .........................................Gasoline E/G
20 LH Position Lamp
21 LH Head Lamp
22 LH Head Lamp Leveling Device ...........................Leveling Device
23 Thermo Switch 2 .................................................. Gasoline E/G with HFM
24 Thermo Switch 3 .................................................. Gasoline E/G with HFM & Air Conditioner
25 LH Front Fog Lamp
26 LH Horn ............................................................... Black Out Driving Lamp (Domestic)
27 Condenser Fan Motor .........................................Diesel E/G
28 Black Out Driving Lamp .......................................Black Out Driving Lamp (Domestic)
29 LH Horn ............................................................... Leveling Device
30 LH Condenser Fan Motor ....................................Gasoline E/G with Air Conditioner
31 Thermo Switch 1 .................................................. Diesel E/G or Gasoline E/G with HFM
32 Resistor ............................................................... Gasoline E/G with Air Conditioner
33 Thermo Switch 4 .................................................. Gasoline E/G with HFM & Air Conditioner
34 Ambient Censor ................................................... Air Conditioner
35 RH Condenser Fan Motor ....................................Gasoline E/G
36 RH Horn
37 RH Front Fog Lamp
38 RH Position Lamp
39 RH Head Lamlp
40 RH Head Lamp Leveling Device ..........................Leveling Device
41 Wheeling Sensor ................................................. ECS
42 Wheel Speed Sensor (FR) ..................................ABS 5.0, 5.3 or ABD 5.0, 5.3
43 RH Damper .......................................................... ECS
44 Alternator Extension Connector ...........................Gasoline E/G
45 Alternator ............................................................. Gasoline E/G
46 Alternator Extension Joint box ..............................Diesel E/G
47 Alternator Extension Connector ...........................Diesel E/G
48 Ground 3
49 Fusible Link Box ................................................... Gasoline E/G
49-1 Fusible Link Box ................................................... Diesel E/G
50 Receiver Dryer ..................................................... Gasoline E/G with Air Conditioner
50-1 Receiver Dryer ..................................................... Diesel E/G with Air Conditioner
51 Hood Switch ......................................................... Diesel E/G with Black Out Driving Lamp
52 Front Washer Motor ............................................. Gasoline E/G
53 Main Wiring Connector

BODY WIRING SYSTEM 9A-13
FLOOR1 ECS Main Wiring Connector ........................ ECS
2 Main Wiring Connector
3 Main Wiring Connector
4 Main Wiring Connector
5 ABD Main Wiring Connector ........................ ABD
6 LH Front Door Switch
7 LH Tension Reducer
8 Ground 1
9 LH Rear Door Wiring Connector
10 Wheel Speed Sensor (RL) ..................ABD, ABS
11 Damper (RL) ................................................ ECS
12 LH Rear Door Switch
13 LH Rear Speaker
14 Ground 2
15 Power Socket
16 Power Antenna
17 Diode
18 LH Rear Combination Lamp
19 Tail Gate Wiring Connector
20 Tail Gate Wiring Connector 21 Tail Gate Wiring Connector
22 Rear Heated
23 Luggage Lamp
2 4 ABD ECU
..................................................... ABD
25 Ground 4 ..................................................... ABD
26 ECS ............................................................. ECS
27 Wheel Speed Sensor (RR) .................ABD, ABS
28 Damper (RR) ............................................... ECS
29 RH Rear Door Switch
30 RH Rear Speaker
31 Ground 3
32 RH Rear Combination Lamp
33 Trailer Connector
34 Rear Washer Motor
35 RH Tension Reducer
36 RH Front Door Switch
37 RH Rear Door Wiring Connector
38 RH Front Door Wiring Connector
39 Wheel Speed Sensor (RR) .................ABD, ABS
40 Acceleration Sensor ..................................... ABD

INSTRUMENTATION/DRIVER INFORMATION 9E-3
COMBINATION METER
COMPONENT LOCATOR
1. Speedometer
2. Odometer
3. Trip odometer
4. Tachometer
5. Coolant temperature gauge
6. Fuel gauge
7. Low fuel level warning light
8. Turn signal indicator (left)
9. Turn signal indicator (right)
10. Outside rearview mirror & tailgate heating switch
11. Reset button
12. Auto shift indicator*
13. Door open warning light
14. TCS indicator (equipped with ABD)*
21. ABS warning light* 22. EBD warning light*
23. ECS / SPORT warning light*
24. 4 - wheel warning light*
25. 4 - wheel high indicator
26. 4 - wheel low indicator
27. WINTER indicator
28. POWER indicator
29. High beam indicator
15. Alternator warning light
16. Engine oil pressure warning light
17. Brake system warning light
18. Glow indicator light (For Diesel engine)
19. Airbag warning light*
20. Seat belt reminder