SUPPLEMENT to SERVICE MANUAL SECTION PAGE
Contents
1. 30 4 HUBER EGR CIRCUIT MUSSO SPORT 1A 34 MUSSO SPORTS GND Sol Valve Exhanst Gas Recirculation Modulator EGR Modulator Water Sensor Temp Lift Sensor EGR Valve TPS RPM Signal TCU 5 6204 r g o m 69 m E wam E EIS E RE MEE E E E E nS E E S 1 1 eo a Fu 1 I o W m A iS d l Bf I a gt gt 1 io xTM 1 0 i P I Lo iS i S 2 E DRESSES iar 1 1 1 9 ik ikoni ANT c i m G 1 1 n PN amp 2 So o fe 1 q 1 1 1 1 1 1 i 1 m m 1 5 se 1 T i 0 SM A sr st fe 5 110 gt s ai 2 5 m m pi Dw o or samai o2 1 i 1 1 m m m 1 cQ c E 1 i 1 5 j D x ted 0 i q oc oc i oc i 1 A 55 Si Ze L A me p LT 001 QN k g E it Lo i 312. SUPPLEMENT INFORMATION MUSSO SPORTS 1A 35 CONNECTOR NUMBER X CONNECTING WIRING HARNESS CONNECTOR POSITION C103 2Pin White Main Engine Inside The Engine Room Fuse Block C105 8Pin Black Engine Engine Beside Pre Heating Unit DSL MUSSO SPORT C108 16Pin Black Genertor Engine Under The Air Cleaner Housing DSL N Turbo C901 16Pin Black Main T M Upper The T C M T C902 12Pin Black Main T M Upper The T C A T 5201 Black Main Behind The Cluster G204 Main Upper The Huber EGR b CONNECTOR IDENTIFICATION SYMBOL amp PIN NUMBER POSITION a Waa 0000 0000 101 W H MAIN W H MAIN C102 W H ENGINE C901 C902 W H T M 28 27 26 6 HUBER EGR CONTROL UNIT SUPPLEMENT MUSSO SPORTS SUPPLEMENT TO SERVICE MANUAL ISSUED BY INTERNATIONAL A S SSANGYONG MOTOR CO LTD 150 3 CHILGOI DONG PYUNGTAEK SI GYEONGGI DO 459 711 KOREA TELEPHONE 82 31 610 1400 FACSIMILE 82 31 610 3733
3. o 10 to ae oe F16 15A RY GW C351 l a L C361 lasta L 10 10 G BR GW 25122 nn CARNE Um dcs 2 1 E DEM AG Auto i Antenna roy 1 dd 7 UT ed 777777 LY GY 1 2 1 Contact 1 1 Coil GY LY 2 1 I Audio SIG Remote B i F Control i ES Switch EENE Driver 4 3 BW B Contact Br C101 48 B A S Horn Relay B 2 2 9 TE 99 43 93 GND SUPPLEMENT MUSSO SPORTS 1 33 INFORMATION CONNECTOR NUMBER CONNECTING WIRING HARNESS CONNECTOR POSITION C101 21Pin Colorless Main Engine Inside The Engine Room Fuse Block C103 2Pin White Main Engine Inside The Engine Room Fuse Block C351 22Pin Blue Main Driver Door Upper The I P Fuse Block C361 22Pin White Main Co Driver Door Inside Co Driver Side Cowl Panel 201 Black Main Behind The Cluster 202 Black Main Under Right The Audio G203 Main Right The I P Fuse Block b CONNECTOR IDENTIFICATION SYMBOL amp PIN NUMBER POSITION MEE siete es 12 fafa N 112 3 415 lt 61 7 8 9110 101 103 51 W H MAIN W H MAIN W H DRIVER DOOR VIKE PORADI 12 C361 TWEETER W H CO DRIVER DOOR SUPPLEMENT
4. 2 1 GW LY RG G Y 2 10 8 EG v 5 Hazard Switch 425 1 uster G Cluster Y A o 6 203 I G 206 E Blinker G Unit C101 4 B 4 69 YW FRT LH ane LE T 15 1 OM 7 Turn Signal rondes G 2 C904 Lamp C905 Head Lamp DD p FRT RH 6 905 B B 3 2 Turn Signal 3 2 _ 20 E MO Lamp izi eps eas Head Lamp Cluster A i 09 i i 09 1 4 1 4 RR RH Turn Signal Turn Signal Lamp Lamp B B B Tail Lamp Tail Lamp 3 M C905 B 5904 6303 31 G204 G201 G101 G101 G301 G102 G204 GND SUPPLEMENT INFORMATION MUSSO SPORTS 1A 29 CONNECTOR NUMBER CONNECTING WIRING HARNESS CONNECTOR POSITION C101 21Pin Colorless Main Engine Inside The Engine Room Fuse Block C103 2Pin White Main Engine Inside The Engine Room Fuse Block C108 16Pin Black Engine Main Under The Coolant Reservoir Tank C206 Colorless Main Floor Inside Co Driver Side Cowl Panel C904 10Pin Black Floor FRAME Behind The Left FRAME C905 12Pin Black FRAME DECK Behind The Left FRAME 101 Black Main Inside The Engine Room Fuse Block G101 Engine Behind The Left Lamp G102 Engine Behind The Right Head Lamp G201 Main Right The I P Fuse Block G204 Main Upper The ECM G301 Floor Center The Left B Pillar b CONNECTOR ID
5. 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 directiv Clutch switch In manual transmission the clutch switch is the one of core elements to determine driving condition EGR Control Unit Output Signal Solenoid valve Control for vacuum modulator 2 Ifthe 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 Vacuum modulator 2 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 1 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 SUPPLEMENT 1 4 MUSSO SPORTS not used connector KAA5A020 Vacuum modulator 2 for controlling ALDA 22 T KAA5A020 Vacu
6. gate inside and then remove pannel 3 Remove the wiring connector of tail lamp 4 Remove the wiring and grommet which is linked with tail gate 5 Remove left and right hinge of tail gate 6 Remove the assembly of tail gate 5 020 5 020 5 020 5 020 MUSSO SPORTS 1A 19 LATCH OF TAIL GATE AND ROD ASSEMBLV 1 Remove the inside pannel of tail gate 2 After pushing the lower section linking with rod which is connected with latch of tail gate remove rod from the latch 3 Release the fixing bolt 2 EA of latch tail gate 4 Simultaneousiv remove the latch of tail gate and rod 5 Install the reverse order of removal SUPPLEMENT 1 20 MUSSO SPORTS OUT SIDE HANDLE TAIL GATE AND LATCH ACTUATOR 1 Remove the inside handle of tail gate KAASA020 2 Remove the fixing bolt 2 EA of latch actuator of tail gate 3 Remove the outside handle of tail gate KAASA020 SUPPLEMENT MUSSO SPORTS 21 COMPONENTS LOCATOR EXTERIOR BODV PANNEL IE SECTION A A TA mt SEGTION 1 1 13 SECTION 9 PNL Deck Side OTR 12 PNL Deck W House INR 10 PNL Deck Side INR 13 PNL Deck 11 RR Wheel Guard SUPPLEMENT 1 22 MUSSO SPORTS PANNEL 00 1 Front Upper Rail 4 No2 Railof Roof Center 2 FrontLower Rail 5 RoofPannel 3
7. 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 SUPPLEMENT 1 14 MUSSO SPORTS KAASA020 nergy gt KAASA020 KAASA020 SUPPLEMENT Removal and Installation of Rear Combi Lamp 1 After pulling the tailgate release fixing bolt of the tail lamp assembly 2 Carefully remove the tail lamp assembly 3 Remove the wiring connector of tail lamp 4 Installation should follow the removal procedure in the reverse order 5 020 LLI ot bal sd Sanyo 5 020 5 020 5 020 MUSSO SPORTS 1A 15 Removal and Installation of Luggage Deck Preceding work Removal of tail lamp assembly 1 After removing the tail lamp assembly release upper two screw and one lower Screw of the side bumper cover 2 Carefully remove the cover of bumper side Note Due to the opposite fixing section of the cover screw of bumper side is the locking fastener so it is fragile part careful r
8. according to the accelerator pedal positions If the vacuum pressure cannot be generated or changed the vacuum modulator should be replaced NO Is the vacuum modulator 1 operated properly e 5 the vacuum pressure varied between 0 and 600 mbar 5 constant vacuum pressure generated in constant engine speed YES v Is the vacuum pressure properly generated in the vacuum line between vacuum modulator 1 and EGR valve Replace the vacuum line between vacuum modulator 1 and EGR valve with new one YES Check the EGR valve for leaks and sticking MUSSO SPORTS 1A 9 Condition at idling Remove the vacuum modulator 1 and vacuum line to the direction of vacuum pump then install vacuum tester Remove the vacuum hose from outlet port to the direction of vac uum pump of vacuum modulator Connect the tester and check whether vacuum pressure change or not when the engine rpm changes Install the tester into Inlet port of EGR valve and check whether the vacuum pressure changes or not when engine rpm changes 1 Start the engine then remove EGR valve hose with idling If the valve disk snaps into position EGR valve operates properly 2 Install the T connector into inlet port of EGR valve then connects the manual vacuum pump and the vacuum tester in each connection 3 Generate 700 mbar of vacuum pressure with manual vacuum pump If EGR will n
9. 101 21Pin Colorless Main Engine Inside The Engine Room Fuse Block C206 Colorless Main Floor Inside Co Driver Side Cowl Panel C904 10Pin Black Floor FRAMME Behind The Left FRAME C905 12Pin Black FRAME DECK Behind The Left FRAME C906 2Pin Black DECK DECK LID Behind The Left DECK LID 101 Black Main Inside The Engine Room Fuse Block G101 Engine Behind The Left The Lamp G102 Engine Behind The Right Head Lamp G201 Main Right The I P Fuse Block G301 Floor Center The Left B Pillar b CONNECTOR IDENTIFICATION SYMBOL amp PIN NUMBER POSITION 29595 C101 C206 C904 C905 W H MAIN W H MAIN W H FLOOR W H DECK EH Ivi 17275 17275 208 208 906 LICENCE TAIL LAMP W H DECK LAMP HEAD LAMP DI 1 2 3 4 5 6 7 8 9 10 1 12 3 14 15 t6 17 t8 19 20 LI RGGI SEE 39 40 gt lt 41 42 43 144 45 1461474 CLUSTER MULTI FUNCTION SWITCH SUPPLEMENT 1 32 MUSSO SPORTS 3 AUDIO CIRCUIT 30 15C 58 31 ILL Ef10 FRT LH FRT LH FRT RH FRT RH F4 80A 10A Tweeter Speaker Tweeter Speaker 10A Ef8 4 tee WE 60A Ccio1 s 2 1 1 2 2 RY R BrB BrW BrW 2 poke LY S202 R S201 alee F17 07774 6 L
10. ENTIFICATION SYMBOL amp PIN NUMBER POSITION C101 C905 W H DECK 1 2 JB3IBA 5 86 7 8 9 10 LI c12 MULTI FUNCTION SWITCH ME C103 C108 C904 W H MAIN W H ENGINE W H FLOOR 22 000 Ble 099 999 51817181910 HEAD LAMP TAIL HAZARD LAMP SWITCH LI 112 14 15 16 7 9 toft t 13 14 15 16 17 18 19 20 DI EJEJEREJEJEIEJEJEIE 13 144 45 1464748 CLUSTER SUPPLEMENT 1 30 MUSSO SPORTS 2 POSITION LAMP TAIL LAMP LICENCE PLATE LAMP CIRCUIT 30 Muti Function Switch C4 31 Ef2 80A 58 ILL Efi 10A T 0 0 101 R 1 5 BrR GW A 8 C904 2 B VC C101 C101 Y 4 G1 01 GW GW Stics Gw 49 C203 45 906 q C206 4 C904 1 1 ERE edili E NEEN Position Position GW 1 Licence Lamp C904 Lamp Plate Lam t 09 11 9 N C905 09 09 1 1 7791777770 905 5 Tail Lamp Tail Lamp RR LH RR RH Wied 3 iw C905 C905 905 B B B 2 C904 76904 rg C904 201 42101 6201 102 G301 301 GND SUPPLEMENT INFORMATION MUSSO SPORTS 1A 31 CONNECTOR NUMBER WIRING HARNESS CONNECTOR POSITION C
11. Nol Railof Roof Center 6 Rear Roof Rail SUPPLEMENT RAIL MUSSO SPORTS 1A 23 Jk SECTION B B SECTION C C se 3 SECTION A A 6 KAASA300 G N C Pannel of Pillar Inner Reinforce C Pillar Outer Pannel C Pannel of Pillar Outer Front Center Outer Pannel Outer Pannel of Front Wheel House Outer Pannel of Front Center Inner Pannel of Wheel House Outer Pannel of Front Wheel House Side Outer of Pannel Deck Side Inner Pannel Deck Rear Wheel Guard Pannel Deck Wheel House Inner Deck Pannel SUPPLEMENT 1 24 MUSSO SPORTS AND UNDER BODY MOUNTINGS 4 4 8 4 41 23 d 6 0 6 lt 22 e 7 10 8 10 amp 10 9 CH 612 For luggage deck mounting KAASA300 3 Body 1 Upper Insulator 15 Body No3 Upper Insulator 4 Lower Insulator 16 Body No1 Wwasher and Tube Assembly 5 Washer and Tube Assembly 19 Body No4 Upper Insulator 6 Washer of Plain Body Mounting 20 Body No4 Wwasher and Tube 7 Bolt 23 Bolt 8 Body No2 Washer and Tube Assembly 24 Deck Mounting Insulator 9 Upper Insulator SUPPLEMENT MUSSO SPORTS 1 25 LUGGAGE DECK 5 13 Reinforce Deck 1 Mounting 14 Deck Floor No3 Member Rear Floor Pannel 2 Deck Floor Pannel 1 15 Reinforce Deck 2 Mounting 16 Nut Holder 17 Nut M10 3 Middle Pannel of Floor 4 middle Pannel of Floor Exten
12. SUPPLEMENT to SERVICE MANUAL MUSSO SPORTS CD SSANGYONG MOTORCO LTD PYUNGTAEK KOREA SECTION PAGE HUBER EGR 1A 3 MAITENANCE AND i REPAIR 8 REMOVAL INSTALLATION 1 17 COMPONENTS LOCATOR 1 21 ELECTRICAL WIRING 44 DIAGRAM Meee SUPPLEMENT HUBER SVSTEM DESCRIPTION The following chart shows the relationship between the input and the output in Huber EGR control unit EGR MUSSO SPORTS 1A 3 Compared to traditional system that only operates the EGR valve with RPM sensor and Micro switch the Huber EGR control unit bring big differences that of traditional svstem on the functions EGR Control Unit Input Signal Basic input signal for EGR operation RPM sensor CPS gt Coolant temperature Engine cold or hot signal sensor CTS Position signal of EGR valve that is triggered by EGR valve lift vacuum modulator 1 b sensor Transfer the engine load signal Throttle position sensor TPS to the control unit directly manualtransmission gt Throttle position sensor TPS TCU A T Shift lever position Vehicle speed sensor VSS 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
13. d Lift Sensor 1 EGR valve output signals from EGR unit controls the vacuum modulator 1 through step 1 to step 16 precisely accordingly the opening value of EGR valve willbe changed Lift sensor potentiometer EGR unit converts the position of EGR valve into electrical signal to detect the opening value of the valve Lift sensor In addition to this compensates the opening value of EGR valve bv controlling the vacuum modulator 1 when there are some differences between the output signal from vacuum modulator 1 and the input value of potentiometer from EGR valve If the closing or opening value EGR valve is different from the output value due to the carbon and paticle material in exhaust gas the opening value of EGR valve is compensated bv adjusted the vacuum level of vacuum modulator Measured EGR valve opening value Step Vacuum Valve opening Output mbar value mm voltage V 1 370 0 2 approx 1 7 2 1 2 690 approx 6 0 9 6 11 6 1 The opening value of the valve is the internal moving distance of EGR valve bv vacuum pressure The valve starts to move when the vacuum pressure reaches approximately 370 mbar If the EGR valve is fully opened the moving distance will be 6 mm due to 690 hpa of vacuum pressure The output voltage may vary according to the battery voltage in vehicles These values have been c
14. emove this one 3 After releasing four fixing bolt of rear bumper and then remove the bumper 4 Remove the wiring of tail lamp and the operation cable of fuel filler SUPPLEMENT 1 16 MUSSO SPORTS 5 Release the front fixing bolt mounting of luggage deck 6 Release the rear fixing bolt mounting of luggage deck f Ek i Cross Member lt J 1 B 71 Xx KAASA020 Note In order for other materials not to enter into fuel filler and breather UE KAA5A020 7 Due to removal of luggage deck check if damage happen on the harness and other parts and then remove the luggage deck 8 Install the reverse order of removal KAASA020 SUPPLEMENT MUSSO SPORTS 1A 17 REMOVAL AND INSTALLATION TAIL GATE Preceding repair remove trim cover of tail gate KAASA300 1 Hinge Assembly of Tail Gate 4 Fixing Bolt of Tail Gate Stopper 2 Fixing Bolt of Tail Gate Hinge 5 Latch of Tail Gate and Rod Assembly 3 Stopper of Tail Gate Removal 1 After pulling the tail gate release fixing bolt of left tail gate and right tail gate Notice While stopper fixing bolt of tail gate is released not released completely put this one on the hole of installation 5 020 SUPPLEMENT 1 18 MUSSO SPORTS KAA5A020 KAA5A020 KAA5A020 SUPPLEMENT 2 After pulling the tail gate release fixing screw of tail
15. id valve ON OFF control KAASA060 SUPPLEMENT 1 8 MUSSO SPORTS MAINTENANCE AND REPAIR VACUUM PUMP AND VACUUM LINE This diagnosis procedure checks for vacuum leaks and actuator s operation while performing the actual control of EGR unit through vacuum lines in vacuum pump The following special service tools should be used for this procedure 201589132100 Vacuum Tester 001589732100 Manual Vacuum Pump KAASA2PO KAA5A2Q0 Multi Tester KAA5A2R0 VACUUM LINE TEST Check the EGR system when the vehicle produces excessive exhaust gas Check the vacuum lines for leaks and blocks Ifthere are not any faults check the actuators controlled by EGR control unit Install the tester in position according to the vacuum circuit diagram To prevent personal injury beware of moving parts of engine SUPPLEMENT Test Step 1 EGR operating range between vacuum pump and EGR valve NO Check whether the vacuum pressure can be generated between vacuum modulator 1 and vacuum line vacuum pump side Vacuum leaks from vacuum line NO Is the vacuum pressure of 900 mbar generated YES Vacuum modulator 1 has a problem in power supplying system Check the battery voltage can be supplied to vacuum modulator 1 through EGR control unit With the battery voltage supplied check the vacuum pressure can be changed
16. in no load sharp acceleration mode check whether the negative pressure may vary within specified ranges If there are not any vacuuming or if the negative pressure will not be varied replace the modulator with new one NO 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 YES v Replace the vacuum hose in the range 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 SUPPLEMENT YES Condition 1 At idling monitor the changes of boost pressure while changing the accelerator pedal position slowly 2 Remove the inlet port from ALDA on fuel injection pump then install the pressure tester At idling install the pressure tester into inlet port of vacuum modulator 2 and read the negative pressure specified value approx 900 mbar on tester Install the vacuum tester into outlet port of vacuum modulator and check whether the negative pressure is generated or not in no load sharp acceleration mode Install the vacuum tester into inlet port of solenoid valve and check whether the negative pressure is generated in no load sharp accel eration mode or not and read the changes of vacuu
17. istance approx 22 4 1 4 Q 5 Check the connections in each passage when supplying or cutting off the operating voltage IN 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 MUSSO SPORTS 1A 7 Throttle Position Sensor TPS 1 EGR unit receives TPS signal from TCU A T or input signal from pin 61 of EGR unit M T The load value of engine is important signal because Huber EGR system make EGR valve operate in extended range except no load sharp acceleration mode 2 Resistance check e Disconnect the TPS sensor connector from fuel injection pump and measure the entire resistance between pin 1 and pin 4 Specified value 5 20 96 e Measure the resistance between 1 and 2 at no load and full load Approx 10 20 of full resistance at no load Approx 70 85 of full resistance at full load 3 Voltage check e The supplied voltage to TPS from EGR unit for M T or TCU for A T is approx 5 V 0 60 0 2 V at no load 3 85 0 3 V at full load VACUUM LINE Installation of modulator and vacuum line on vehicle EGR vacuum modulator 1 F A control vacuum modulator opening value control opening value control que DL E d F A control soleno
18. m pressure within specified ranges YES Replace the vacuum hose in the range 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 VES Replace the vacuum hose in the range 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 MUSSO SPORTS 1 11 Install the vacuum tester into out let port of solenoid valve and check whether the negative pres sure is generated in no load sharp acceleration mode or not and read the changes of vacuum pressure within specified ranges Install the vacuum tester into out let port of solenoid valve and check whether the negative pres sure is generated in no load sharp acceleration mode or not and read the changes of vacuum pressure within specified ranges SUPPLEMENT 1 12 MUSSO SPORTS 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 KAA5A020 3 Remove pin of con
19. nector 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 Installtemporary 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 KAA5A020 SUPPLEMENT 5 020 MUSSO SPORTS 1A 13 VACUUM 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 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 assembiv 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
20. onverted into percentage from battery voltage in each step e Step 1 15 of battery voltage e Step 2 64 of battery voltage SUPPLEMENT 1 6 MUSSO SPORTS KAA5A040 u MS sensor i KAASA060 EGR control unit ALDA I4 3 b e y PIENSURG D7 ae lt gt PA6 GF3D lt 2 2 modulator 2 09 300 OHM Intake manifold KAASA060 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 temperature sensor 4 Resistance between pin 1 and pin 4 of the connector 20 C 2250 159 00 50 C 836 41 50 80 321 15 00 120 113 7 2 Q Solenoid Valve 1 This valve is used in no load sharp acceleration mode 2 Solenoid valve Normal Open type e Normal Solenoid valve opens then intake manifold pressure will operate ALDA e No load sharp acceleration mode Solenoid valve closes then vacuum pressure operate ALDA 3 Operating voltage approx 12 V Res
21. ot open stay vacuum state EGR valve should be replaced due to Sticks of inner valve guide and valve SUPPLEMENT 1 10 MUSSO SPORTS Test Step 2 Exhaust gas control mode with no load sharp acceleration between vacuum pump ALDA NO Before checking the generation of vacuum pressure Check whether the boost pressure from intake manifold can be appliedto ALDA or not in the range beyond no load sharp acceleration mode Check the intake boost pressure by ranges e Boostpressure line between intake manifold and solenoid valve e Boostpressure line between ALDA and solenoid outlet valve If the boost pressure is not within specified value appropriate pressure line should be replaced Check the solenoid valve with the same method in no load sharp acceleration mode NO 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 rom 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 YES Check the voltage supplying and vacuuming Check whether the EGR control unit can supply the battery voltage to vacuum modulator 2 If can
22. sion 5 Reinforce Fuel Sending Cover 6 Reinforce Rear Seat Mounting 18 Deck Floor No4 Member 19 Upper Bracket of Spare tire 20 Lower Bracket Spare Tire LH 7 Reinforce Rear Seat Mounting RH 8 Reinforce Hinge Mounting Deck Back Outer Pannel 22 Reinforce Stopper Mounting 23 Deck Floor Member 21 9 Mounting Member of Body Mounting 10 Reinforce 5 Mounting Deck floor No1 Member 12 Deck floor No2 Member 11 SUPPLEMENT 1 26 MUSSO SPORTS 5 Gate Striker Assembly Tail Gate Latch Assembly Tail Gate Inner Pannel Tail Gate Inner Cover Tail Gate Stopper Assembly OQ G IN SUPPLEMENT ON O gt Tail Gate Hinge Assembly Tail Gate Latch amp Rod Assembly Tail Gate Ccrank Assembly Outside Tailgate Holder Tail Gate Outer Pannel MUSSO SPORTS 1 27 REAR GLASS Component Locator SECTION 2 Rearglass moulding 1 Rearglass 1 28 MUSSO SPORTS ELECTRICAL WIRING DIAGRAM 1 TURN SIGNAL LAMP HAZARD LAMP CIRCUIT 30 BAT 15 IGN 1 58 ILL Ef10 Ef2 10 Ef9 GW 60 aA cri Pe C103 7 1 JA BG T Multi Function Switch n 5202 2 Turn Signal Switch F7 i 4 15 A EA
23. um modulator 1 for controlling EGR valve PN A A Vacuum modulator 1 from vacuum pump 99Ti55 4 7 21903 16 12V 1 EGR control unit KAASA020 Intake manifold 99T 165 4 7 21903 16 12 4 EGR control unit KAASA020 SUPPLEMENT 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 Q 6 Operating range of vacuum Duty control e Vacuum modulator 1 0 600 mbar e Vacuum modulator 2 300 600 mbar 7 Modulator control e Vacuum modulator 1 for controlling EGR valve Vacuum modulator 2 for controlling no load sharp acceleration ALDA control Location of EGR valve KAA5A020 EGR valve arrangement Vacuum lt Connector potentiometer modulator 1 i KAA5A020 Circuit of potentiometer KAA5A020 MUSSO SPORTS 1 5 EGR Valve an
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