solenoid SSANGYONG MUSSO 2003 Repair Manual

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

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-23
MANUAL TRANSMISSION1 Main Wiring Connector ......................Diesel E/G
2 Main Wiring Connector ..................Gasoline E/G
3 Main Wiring Connector .........................Gasoline
(E32, E23) E/G
4 Back Up Switch 5 Oil Pressure Switch
6 Start Motor Solenoid
7 Micro Switch
8 Speed Sensor (Turbo Diesel Engine Only)

9A-24 BODY WIRING SYSTEM
AUTOMATIC TRANSMISSION (BENZ)1 Main Wiring Connector
2 Start Lock Switch
3 Automatic Transmission Change Over Valve
4 Transmission Overload Protection Switch ...........................Gasoline E/G 5 Oil Pressure Switch
6 Start Solenoid
7 Micro Switch
....................................... Diesel E/G
8 Speed Sensor .......................... T urbo Diesel E/G

BODY WIRING SYSTEM 9A-25
AUTOMATIC TRANSMISSION (BTRA)1 Main Wiring Connector
2 Main Wiring Connector
3 Transmission
4 Transmission Lever
5 Oil Pressure Switch ............................Diesel E/G6 Start Motor Solenoid
7 Throttle Position Sensor
....................Diesel E/G
8 Speed Sensor .......................... T urbo Diesel E/G
9 Inhibitor Switch

MUSSO-SPORTS 1A-3
SUPPLEMENT
HUBER EGR
SYSTEM DESCRIPTION The following chart shows the relationship between the input and the output in Huber EGR control unit. Compared to traditional system that only operates theEGR valve with RPM sensor and Micro switch, the HuberEGR control unit bring big differences that of traditionalsystem on the functions.
Input Signal
RPM sensor (CPS)
EGR valve lift sensor
Throttle position sensor (TPS) - M/T
Shift lever position
Throttle position sensor (TPS)
Vehicle speed sensor(VSS) Basic input signal for EGR operation Engine cold or hot signal
Position signal of EGR valve that is triggered by vacuum modulator 1 Transfer the engine load signal to the control unit directly (manual transmission)
TCU (A/T)
EGR
Control
Unit
Coolant temperature sensor (CTS)
Solenoid valve (Control forvacuum modulator 2)
If the control unit determines it is in no-load sharp accel- eration mode after analyzing the input signals, this conver- sion type switch reduces the fuel consumption by cutting off the intake air pressure from
fuel injection ALDA and gen- erating the vacuum pressure. In no-load sharp acceleration
mode, Duty Control ( continu- ous precise control) is acti- vated according to the varia- tions of the input signals when the solenoid valve generates the vacuum pressure in ALDA.
Vacuum modulator 2
The opening value of the modulator is precisely con- trolled by input signals and programmed MAP, and the opening value of EGR valve is also changed by the varia- tions of vacuum pressure to EGR valve. The changed opening value is transferred to the control unit as input signal.
Vacuum modulator 1
TCU in automatic transmission equipped vehicle transfers the information such as driving conditions and speeds into the EGR control unit. EGR control unit uses the shift lever position and vehicle speed as important information for operating the solenoid valve during no-load sharp acceleration mode. In manual transmission, the signal of vehicle speed is transferred into the EGR control unit directly.
Clutch switch
In manual transmission, the clutch switch is the one of core elements to determine driving condition. Output Signal
EGR Control Unit

1A-4 MUSSO-SPORTS
SUPPLEMENT
from vacuum pump
EGR valve
EGR control unit
KAA5A020
KAA5A020
KAA5A020
KAA5A020 EGR COMPONENTS EGR Unit
1. Location: behind passenger's side panel
2. Arrangement: 81-pin connector
3. Integrated self-diagnostic function (Scan-100: not
fixed)
4. Part number For automatic transmission: 28800-07100 For manual transmission: 28800-07000
Vacuum Modulator
1. Location: in front of intake manifold
2. Continuous precise control with the signals from EGR unit (PWM-Pulse With Modulation Control)
3. Rated voltage: 12 V
4. Operating voltage: 8 ~ 16 V
5. Resistance (at 20 °C): 15.4 ± 0.7
6. Operating range of vacuum (Duty control)


 Vacuum modulator 1: 0 ~ 600 mbar


 Vacuum modulator 2: 300 ~ 600 mbar
7. Modulator control


 Vacuum modulator 1: for controlling EGR valve


 Vacuum modulator 2: for controlling no-load sharp
acceleration (ALDA control)
not used connector
Vacuum modulator 1
(for controlling EGR valve)Vacuum modulator 2
(for controlling ALDA)
from vacuum pump
Vacuum modulator 1
Vacuum modulator 2
Solenoid valve
ALDAIntake
manifold
EGR control unit

1A-6 MUSSO-SPORTS
SUPPLEMENT
Coolant Temperature Sensor (CTS)
1. Location: on cylinder block
2. Coolant temperature MAP (4 Stages) T0: 10 ~ 24 °C
T1: 25 ~ 40 °C
T2: 41 ~ 61 °C
T3: above 61 °C
3. If the EGR system is normally defective while engine is cold (or during warming up), it may be caused by incorrect input signal of the coolant temperaturesensor.
4. Resistance between pin 1 and pin 4 of the connector 20 °C: 2250 ± 159.0
50 °C: 836 ± 41.5
80 °C: 321 ± 15.0
120 °C: 113 ± 7.2
KAA5A040 KAA5A060
KAA5A060Solenoid Valve
1. This valve is used in no-load sharp acceleration mode.
2. Solenoid valve (Normal Open type)


 Normal: Solenoid valve opens, then intake
manifold pressure will operate ALDA.


 No-load sharp acceleration mode: Solenoid valve
closes, then vacuum pressure operate ALDA.
3. Operating voltage: approx. 12 V
4. Resistance: approx. 22.4 ± 1.4
5. Check the connections in each passage when supplying or cutting off the operating voltage.
The valve passage to ALDA will be changed when the battery voltage is supplied through EGR control unit.
Changed to ALDA (1 to 3) or vacuum from intake manifold
Changed to ALDA (2 to 3) from modulator 2 (Refer to exhaust gas control mode with no-load sharp acceleration)
TPS sensorSolenoid valve
Intake manifold
ALDAEGR control unit
3
12
Vacuum modulator 2
2
1
3
300
OHM
+-

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.

MUSSO-SPORTS 1A-11
SUPPLEMENT
Install the vacuum tester into out- let port of solenoid valve, andcheck whether the negative pres-sure is generated in no-load sharpacceleration mode or not, and readthe changes of vacuum pressurewithin specified ranges.
YES
In solenoid valve, check whether the vacuum pressure is generated between inlet port and outlet port. When the power is supplied, does the solenoid valve close and the intake boost pressure cut off to complete the vacuum circuit?
NO
Replace the vacuum hose in the range.
Install the vacuum tester into out- let port of solenoid valve, andcheck whether the negative pres-sure is generated in no-load sharpacceleration mode or not, and readthe changes of vacuum pressurewithin specified ranges.
YES
Check whether the vacuum pressure is generated between outlet port of solenoid valve and inlet port of ALDA. Is the approx. -300 ~ 650 mbar of negative pressure generated in no-load
sharp acceleration mode?
NO
Replace the vacuum hose in the range.