Fuel pump SSANGYONG MUSSO 2003 Repair 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.

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

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

3) PEDAL MODULE, THROTTLE MOTOR & SENSOR, CTS, SENSOR(KNOCK, INTAKE AIR TEMP',HEATED O 2) CIRCUIT ...................................................................................................................... ......................5-28
(1) W/O EURO III ............................................................................................................... ..................................................................... 5-28
(2) W/ EURO III ................................................................................................................ ....................................................................... 5-30
4) VSS, CLUTCH SWITCH, IMMOBILIZER CIRCUIT ...................................................................................... .........5-32
(1) W/O EURO III ............................................................................................................... ..................................................................... 5-32
(2) W/ EURO III ................................................................................................................ ....................................................................... 5-34
5. ECM (E32, MSE) ............................................................................................................... .......... 5-36
1) OVPR, FUEL PUMP, CCP SOLENOID CIRCUIT ........................................................................................ ....... 5-36
(1) W/O EURO III ............................................................................................................... ..................................................................... 5-36
(2) W/ EURO III ................................................................................................................ ....................................................................... 5-38
2) IGNITION COIL, SENSOR (CAM SHAFT POSITION, HFM, CKP), CAM SHAFT ACTUATOR, RESONANCE FLAP CIRCUIT ............................................................................................................................... . 5-40
3) PEDAL MODULE, THROTTLE MOTOR & SENSOR, SENSOR(KNOCK, ECT, HEATED O 2) CIRCUIT ....... 5-42
(1) W/O EURO III ............................................................................................................... ..................................................................... 5-42
(2) W/ EURO III ................................................................................................................ ....................................................................... 5-44
4) VSS, CLUTCH SWITCH, IMMOBILIZER CIRCUIT ...................................................................................... ....... 5-46
5) HEATED O 2 SENSOR(1,2,3,4) ............................................................................................................... ............... 5-48
6. ECM (E20, HFM).............................................................................................................. ........... 5-50
1) INJECTOR, OVPR, IGNITION COIL, FUEL PUMP CIRCUIT ............................................................................ 5-50
2) CCP SOLENOID, SENSOR (MAF, CKP) CIRCUIT ...................................................................................... ...... 5-52
3) THROTTLE MOTOR & SENSOR, ECT SENSOR, VSS, HEATED O 2 SENSOR CIRCUIT ............................ 5-54
7. ECM(E23, HFM) ............................................................................................................... ........... 5-56
1) INJECTOR, OVPR, IGNITION COIL, FUEL PUMP CIRCUIT(W/ IMMOBILIZER) ........................................... 5-56
2) INJECTOR, OVPR, IGNITION COIL, FUEL PUMP CIRCUIT(W/O IMMOBILIZER) ........................................ 5-58
3) SENSOR (CKP, CMP, KNOCK, MAF), CAM SHAFT ACTUATOR CIRCUIT ...................................................... 5-60
4) THROTTLE MOTOR & SENSOR, ECT SENSOR, VSS, HEATED O 2, SENSOR CIRCUIT ............................. 5-62

8. ECM(E32, HFM) .......................................................................................................................... 5-64
1) INJECTOR, OVPR, IGNITION COIL, FUEL PUMP CIRCUIT(W/ IMMOBILIZER) ........................................... 5-64
2) INJECTOR, OVPR, IGNITION COIL, FUEL PUMP CIRCUIT(W/O IMMOBILIZER) ........................................ 5-66
3) SENSOR (CKP, CMP, KNOCK, MAF), CCP SOLENOID, CAM SHAFT ACTUATOR CIRCUIT ....................... 5-68
4) THROTTLE MOTOR & SENSOR, SENSOR (IAT, ECT, HEATED O 2), VSS, CIRCUIT (UNLEAD) ................. 5-70
5) THROTTLE MOTOR & SENSOR, SENSOR (IAT, ECT), CO POTENTIO METER, VSS CIRCUIT(LEAD) ..... 5-72
9. DLC CIRCUIT ................................................................................................................. ............. 5-74
10. TCM(GSL, BTRE) .............................................................................................................. ......... 5-76
1) POWER SUPPLY, GROUND, INDICATION LAMP CIRCUIT ............................................................................. 5- 76
2) KICK DOWN SWITCH, SELECT LEVER POSITION SENSOR, TRANSMISSION CIRCUIT ........................ 5-78
11. TCM(DSL, BTRE) .............................................................................................................. ......... 5-80
1) POWER SUPPLY, GROUND, INDICATION LAMP, SENSOR (TR, ENGINE SPEED) CIRCUIT .................... 5-80
2) KICK DOWN SWITCH, SELECT LEVER POSITION SENSOR, TRANSMISSION CIRCUIT ........................ 5-82
12. KICK DOWN RELAY, 'B' SWITCH CIRCUIT (MB A/T) ........................................................... 5-84
13. TCCU-PART TIME .............................................................................................................. ........ 5-86
1) POWER SUPPLY, GROUND, INDICATION LAMP, PNP RELAY, CLUTCH SWITCH CIRCUIT ..................... 5-86
2) 4WD SWITCH, T/C SPEED SENSOR, T/C MOTOR CIRCUIT ........................................................................ 5-88
14. TCCU-FULL TIME .............................................................................................................. ........ 5-90
1) POWER SUPPLY, GROUND, INDICATION LAMP, NEUTRAL RELAY, CLUTCH CIRCUIT ............................ 5-90
2) 4WD SWITCH, T/C SPEED SENSOR, T/C MOTOR CIRCUIT ........................................................................ 5-92
15. TOD(TORQUE ON DEMAND)-E32,MSE .................................................................................. 5-94 1) POWER SUPPLY, GROUND, WARNING LAMP, 4WD SWITCH, T/C MOTOR CIRCUIT .............................. 5-94
2) T/C SPEED SENSOR, PNP RELAY, CLUTCH SWITCH, CAN CIRCUIT .......................................................... 5-96
16. ECS ......................................................................................................................... ..................... 5-98
1) POWER SUPPLY, GROUND, SENSOR(WHEEL'G, VERTICAL, LATERAL) CIRCUIT ................................... 5-98
2) ECS SWITCH, DAMPER CIRCUIT ...................................................................................................................... 5-100

5-20 ELECTRICAL WIRING DIAGRAMS
4. ECM (E23, MSE)
1) OVPR, FUEL PUMP, CCP SOLENOID CIRCUIT(1) W/O EURO III Main - Engine Engine Main - ECM Main Engine Main - ECM Main Main - Fuel TankMain - ECM Main Main Main Main
C103 (2Pin, White) C111 (40Pin, Black) C112 (6Pin, Gray) C206B (4Pin, Black) C213 (6Pin, Colorless) G203G205 G207
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
a. CONNECTOR INFORMATION
C213
W/H ECM MAIN
C111
W/H ECM MAIN C112
W/H ENG. MAIN C206B
W/H MAIN
C103
W/H MAIN
OVPR
CONNECTOR(NUMBER) CONNECTING. WIRING HARNESSCONNECTOR POSITION
Inside The Engine Room Fuse Block Center The Engine Room Dash Panel Center The Engine Room Dash PanelUpper The T/C (GSL) Beside The ECM (MSE) Upper The ECM Beside The TCCU Beside THe ECM
2167
5348
FUEL PUMP
12 34
INJECTOR
21
CCP
SOLENOID
12
ECM(MSE)
10 1
20 11
30 21
40 31
1
2321
65412 34321
654
1
13
37
36
60
23456789101112
61
73
97
96
120
62 63 64 65 66 67 68 69 70 71 72

5-22 ELECTRICAL WIRING DIAGRAMS(2) W/ EURO III
Main - Engine Engine Main - ECM Main Engine Main - ECM Main Main - Fuel TankMain - ECM Main Main Main Main
C103 (2Pin, White) C111 (40Pin, Black) C112 (6Pin, Gray) C206B (6Pin, Black) C213 (6Pin, Colorless) G203G205 G207
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
a. CONNECTOR INFORMATION
C213
W/H ECM MAIN
C111
W/H ECM MAIN C112
W/H ENG. MAIN C206B
W/H MAIN
C103
W/H MAIN
OVPR
CONNECTOR(NUMBER) CONNECTING. WIRING HARNESSCONNECTOR POSITION
Inside The Engine Room Fuse Block Center The Engine Room Dash Panel Center The Engine Room Dash PanelUpper The T/C (GSL) Beside The ECM (MSE) Upper The ECM Beside The TCCU Beside THe ECM
321
654321
654321
654
10 1
20 11
30 21
40 31
2167
5348
FUEL PUMP
321
654
INJECTOR
21
CCP
SOLENOID
12
1
13
37
36
60
23456789101112
61
73
97
96
120
62 63 64 65 66 67 68 69 70 71 72
ECM(MSE)
30 15 BAT+IGN 1
31 GND
E
f2
E f9
C103
R RW
RG
OVPR
CCP Solenoid
IGN 1 B+
ECM
G205 G207 G205
B
G203
80A
60A
F11 1
58 6 2
7
BW RL
PR YG BW
11
BW BW
BW LgW
BR
BR
PR
RL
RG
RL
2
63 1
YG 34
20A
15A
K3
K2 K1
2
GND GND GND
Ignition
Coil Immobilizer
"1"
HFM Sensor "2"
Cam Shaft ControlActator
"1" CMP
Sensor "3"
F23 10A
F1020A F9
20A
C213
3
1
C112
4
6
CYL12
641
CYL2
2
651
CYL3
2
66 69 5 10
GrB GrG GrY
GrV
GrB GrG GrY
GrV
GrB GrG GrY
GrV Br
B Fuel Pump
Fuel
Pump Relay
BB
B
BR
BR
GR YR
LR
1
CYL4 5
3
86 30
85 87
C111 8
547
C213
2
C112 2 1
34 12 33
5 C213
Injec-Tor
5
C206B
2 C206B
3
M
1
2

5-32 ELECTRICAL WIRING DIAGRAMS
4) VSS, CLUTCH SWITCH, IMMOBILIZER CIRCUIT(1) W/O EURO III
1
13
37
36
60
23456789101112
61
73
97
96
120
62 63 64 65 66 67 68 69 70 71 72
ECM(MSE)
DLC Connector - Main Main Main MainMain Main
C211 (14Pin, Black) S201 (Black)
S205 (Colorless) G201 G202 G205
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
a. CONNECTOR INFORMATION
VSSIMMOBILIZER
UNIT DLC
C211
W/H DLC
STOP LAMP SWITCH
CONNECTOR(NUMBER) CONNECTING. WIRING HARNESSCONNECTOR POSITION
Beside The Steering Column Behind The Cluster Upper Left The AudioRight The I/P Fuse Block Beside The STICS Beside The TCCU
1234
141516 13 12 11 10 9
8765432112
3
CLUTCH
SWITCH 1
2112
34
CRUISE
CONTROL SWITCH
12
3456
910 1213
12
11
34
56
71 4
8
15 IGN 1
31 GND
G205
BrB
BRG202
LR
G201
S201
Cruise Control Switch
1
7
BrW Y
VSS
(M/T)
59 55YB
Y 5
F24
2
1 LW
BrWBrB BrW
S205BrB
3
3 2
57
Gr
4
52
13
43 12 2 1
14 43 49 21 29 58 60
ECM
GY
WB
W
Y
RGBr
YW BrBGY
YR
5
54
YGr
6
7
2
53 38 37
BR
BrB
"L"CAN "H"CAN BrW
1
3 6
15
10A
TOD
"A11"
"7"
DLC
Stop Lamp
Switch"4"
Clutch Switch(M/T) Stop Lamp
Switch
"2"
"7"
OVPR
"86"
Fuel Pump Relay "33"
Cluster (MIL) "29"
Cluster (RPM)
TCM
"A24" TCM
"A23"
TOD
"A11"
"16"
Cluster
Immobilizer C211
14
SIG
SIG SIG
5V
Read

5-34 ELECTRICAL WIRING DIAGRAMS(2) W/ EURO III
1
13
37
36
60
23456789101112
61
73
97
96
120
62 63 64 65 66 67 68 69 70 71 72
ECM(MSE)
DLC Connector - Main Main - Fuell Tank Main MainMain Main Main
C211 (14Pin, Black)C206B (6Pin, Black) S201 (Black) S205 (Colorless) G201 G202G205
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
a. CONNECTOR INFORMATION
VSSIMMOBILIZER
UNIT DLC
C211
W/H DLC
STOP LAMP SWITCH
CONNECTOR(NUMBER) CONNECTING. WIRING HARNESSCONNECTOR POSITION
Beside The Steering Column Upper The T/C (GSL) Behind The ClusterUpper Left The Audio Right The I/P Fuse Block Beside The STICS Beside The TCCU
1234
141516 13 12 11 10 9
8765432112
3
CLUTCH
SWITCH 1
2112
34
CRUISE
CONTROL SWITCH
12
3456
5
40 56 1
YG Y
Fuel Gauge
GC206B
6
1
15 IGN 1
31 GND
G205
BrB
BRG202
LR
G201
S201
Cruise Control Switch
1
7
BrW Y
VSS
(M/T)
59 55YB
Y 5
F24
2
1 LW
BrWBrB BrW
S205BrB
3
3 2
57
Gr
4
52
13
43 12 2 1
14 43 49 21 29 58 60
ECM
GY
WB
W
Y
RGBr
YW BrBGY
YR
5
54
YGr
6
7
2
53 38 37
BR
BrB
"L"CAN "H"CAN BrW
1
3 6
15
10A
TOD
"A11"
"7"
DLC
8
RY
Cluster "15" Stop Lamp
Switch"4"
Clutch Switch(M/T) Stop Lamp
Switch
"2"
"7"
OV PR
"86"
Fuel Pump Relay "33"
Cluster
(MIL) "29"
Cluster
(RPM)
TCM
"A24" TCM
"A23"
TOD
"A11"
"16"
Cluster
Immobilizer C211
14
SIG
SIG SIG
5V
Read
910 1213
12
11
34
56
71 4
8
FUEL
GANGE
321
654