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ELECTRICAL SYSTEM

SECTION

EL

When you read wiring diagrams:


I Read GI section, HOW TO READ WIRING DIAGRAMS.
When you perform trouble diagnoses, read GI section, HOW TO FOLLOW FLOW CHART IN
TROUBLE DIAGNOSES and HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL
INCIDENT.

CONTENTS
PRECAUTIONS ...............................................................2
Supplemental Restraint System (SRS) AIR
BAG (4WD models) ...................................................2
Supplemental Restraint System (SRS) AIR
BAG (2WD models) ...................................................2
HARNESS CONNECTOR................................................3
Description ...................................................................3
STANDARDIZED RELAY ................................................4
Description ...................................................................4
POWER SUPPLY ROUTING ...........................................6
Schematic ....................................................................6
Wiring Diagram - POWER - ........................................7
Fuse ...........................................................................15
Fusible Link................................................................15
Circuit Breaker Inspection .........................................15
GROUND DISTRIBUTION.............................................16
BATTERY .......................................................................20
How to Handle Battery ..............................................20
Battery Test and Charging Chart...............................23
Service Data and Specifications (SDS).....................27
STARTING SYSTEM .....................................................28
Wiring Diagram - START -.........................................28
Trouble Diagnoses.....................................................29
Construction...............................................................30
Removal and Installation ...........................................34
Magnetic Switch Check .............................................34
Pinion/Clutch Check ..................................................34
Brush Check ..............................................................34
Yoke Check................................................................35
Armature Check.........................................................35
Assembly ...................................................................36
Service Data and Specifications (SDS).....................37
CHARGING SYSTEM ....................................................38
Wiring Diagram - CHARGE -.....................................38
Trouble Diagnoses.....................................................40
Construction...............................................................42
Removal and Installation ...........................................43

Disassembly...............................................................44
Rotor Check...............................................................44
Brush Check ..............................................................44
Stator Check ..............................................................45
Diode Check ..............................................................46
Assembly ...................................................................47
Service Data and Specifications (SDS).....................48
COMBINATION SWITCH...............................................49
Combination Switch/Check........................................49
Replacement..............................................................51
HEADLAMP ...................................................................52
Wiring Diagram - H/LAMP -.......................................52
Trouble Diagnoses.....................................................56
Bulb Replacement .....................................................57
Bulb Specifications ....................................................57
Aiming Adjustment .....................................................57
Low Beam..................................................................58
EXTERIOR LAMP..........................................................59
Parking, License and Tail Lamps/Wiring Diagram
- TAIL/L - ....................................................................59
Stop Lamp/Wiring Diagram - STOP/L -.....................61
Back-up Lamp/Wiring Diagram - BACK/L - ...............62
Turn Signal and Hazard Warning
Lamps/Schematic ......................................................63
Turn Signal and Hazard Warning Lamps/Wiring
Diagram - TURN - .....................................................64
Turn Signal and Hazard Warning Lamps/Trouble
Diagnoses ..................................................................67
Combination Flasher Unit Check...............................67
Bulb Specifications ....................................................68
INTERIOR LAMP ...........................................................69
Illumination/Wiring Diagram - ILL - ............................69
Interior and Spot Lamps/Wiring Diagram INT/L - ........................................................................73
Bulb Specifications ....................................................75
METER AND GAUGES .................................................76
Combination Meter ....................................................76

CONTENTS
Speedometer, Tachometer, Temp. and Fuel
Gauges/Schematic.....................................................80
Speedometer, Tachometer, Temp. and Fuel
Gauges/Wiring Diagram - METER -..........................81
Unified Control Meter System Description ................87
Meter/gauge Operation and Odo/Trip Meter
Segment Check in Diagnosis Mode ..........................87
Flexible Print Circuit (FPC)........................................88
Trouble Diagnoses.....................................................89
Electrical Components Inspection .............................94
WARNING LAMPS ........................................................96
Schematic ..................................................................96
Wiring Diagram - WARN - .........................................97
Electrical Components Inspection ...........................107
WARNING BUZZER ....................................................108
Wiring Diagram - BUZZER -....................................108
Electrical Components Inspection ...........................109
WIPER AND WASHER................................................110
System Description..................................................110
Front Wiper and Washer/Wiring Diagram WIPER -...................................................................112
Trouble Diagnoses...................................................119
Wiper Installation and Adjustment ...........................120
Washer Nozzle Adjustment .....................................121
Washer Tube Layout ...............................................121
Wiper Linkage..........................................................122
HORN, CIGARETTE LIGHTER AND CLOCK ............123
Wiring Diagram - HORN - .......................................123
REAR WINDOW DEFOGGER.....................................125
Wiring Diagram - DEF -...........................................125
Electrical Components Inspection ...........................126
Filament Check........................................................126
Filament Repair .......................................................127
AUDIO ..........................................................................128
Wiring Diagram - AUDIO -.......................................128
Trouble Diagnoses...................................................133
AUDIO ANTENNA .......................................................134
Manual Antenna.......................................................134

(Contd)

Power Antenna/Wiring Diagram - P/ANT -..............135


Power Antenna ........................................................136
POWER DOOR MIRROR ............................................138
Wiring Diagram - MIRROR - ...................................138
POWER WINDOW .......................................................140
System Description..................................................140
Schematic ................................................................142
Wiring Diagram - WINDOW - ..................................143
Trouble Diagnoses...................................................151
POWER DOOR LOCK.................................................152
System Description..................................................152
Wiring Diagram - D/LOCK -.....................................153
Trouble Diagnosis ....................................................155
LOCATION OF ELECTRICAL UNITS.........................159
Engine Compartment...............................................159
Passenger Compartment.........................................160
HARNESS LAYOUT ....................................................162
Outline......................................................................162
How to Read Harness Layout .................................163
Main Harness...........................................................164
Engine Room Harness ............................................174
Engine Control Harness ..........................................182
Engine Harness .......................................................184
Alternator Harness...................................................187
Instrument Harness .................................................188
Room Lamp Harness...............................................189
Chassis Harness and Tail Harness .........................190
Front Door Harness (LH side) .................................191
Front Door Harness (RH side) ................................192
Rear Door Harness..................................................193
SUPER MULTIPLE JUNCTION (SMJ)..................Foldout
Terminal Arrangement........................................Foldout
FUSE AND FUSIBLE LINK...................................Foldout
Terminal Arrangement........................................Foldout
CONTROL UNITS/JOINT CONNECTOR (J/C).....Foldout
Terminal Arrangement........................................Foldout

WIRING DIAGRAM REFERENCE CHART


COOLING FAN ............................................................................................................... LC SECTION
ECCS, IGNITION SYSTEM, QUICK-GLOW SYSTEM ................................................. EC SECTION
ANTI-LOCK BRAKE SYSTEM ...................................................................................... BR SECTION
SRS AIR BAG ............................................................................................................ RS SECTION
HEATER AND AIR CONDITIONER .............................................................................. HA SECTION

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

PRECAUTIONS
Supplemental Restraint System (SRS) AIR
BAG (4WD models)
The Supplemental Restraint System Air Bag, used along with a seat belt, helps to reduce the risk or severity of injury to the driver in a frontal collision. The Supplemental Restraint System consists of an air bag module (located in the center of the steering wheel), a diagnosis sensor unit, warning lamp, wiring harness and
spiral cable. Information necessary to service the system safely is included in the RS section of this Service
Manual.
WARNING:
I To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed
by an authorized NISSAN dealer.
I Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system.
I Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses are covered with yellow insulation either just before the
harness connectors or for the complete harness, for easy identification.

Supplemental Restraint System (SRS) AIR


BAG (2WD models)
The Supplemental Restraint System Air Bag, used along with a seat belt, helps to reduce the risk or severity of injury to the driver in a frontal collision. The Supplemental Restraint System consists of an air bag module (located in the center of the steering wheel), a diagnosis sensor unit, warning lamp and spiral cable. Information necessary to service the system safely is included in the RS section of this Service Manual.
WARNING:
I To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed
by an authorized NISSAN dealer.
I Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system.
I Do not use electrical test equipment on any circuit related to the SRS.

EL-2

HARNESS CONNECTOR
Description
HARNESS CONNECTOR

GI

I All harness connectors have been modified to prevent accidental looseness or disconnection.
I The connector can be disconnected by pushing or lifting the locking section.
CAUTION:
Do not pull the harness when disconnecting the connector.

MA
EM

[Example]

LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

SEL769D

EL-3

IDX

STANDARDIZED RELAY
Description
NORMAL OPEN, NORMAL CLOSED AND MIXED TYPE RELAYS
Relays can mainly be divided into three types: normal open, normal closed and mixed type relays.

SEL881H

TYPE OF STANDARDIZED RELAYS


1M

.................... 1 Make

2M

.................... 2 Make

1T

.................... 1 Transfer

1M1B .................... 1 Make 1 Break

SEL882H

EL-4

STANDARDIZED RELAY
Description (Contd)
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX
SEL661TA

EL-5

POWER SUPPLY ROUTING


Schematic

HEL884

EL-6

POWER SUPPLY ROUTING


Wiring Diagram POWER
BATTERY POWER SUPPLY IGNITION SWITCH IN ANY POSITION

GI

Gasoline engine

MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL885

EL-7

POWER SUPPLY ROUTING


Wiring Diagram POWER (Contd)
Gasoline engine

HEL886

EL-8

POWER SUPPLY ROUTING


Wiring Diagram POWER (Contd)
BATTERY POWER SUPPLY IGNITION SWITCH IN ANY POSITION
Diesel engine

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL887

EL-9

POWER SUPPLY ROUTING


Wiring Diagram POWER (Contd)
Diesel engine

HEL888

EL-10

POWER SUPPLY ROUTING


Wiring Diagram POWER (Contd)
ACCESSORY POWER SUPPLY IGNITION SWITCH IN ACC OR ON

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL889

EL-11

POWER SUPPLY ROUTING


Wiring Diagram POWER (Contd)
IGNITION POWER SUPPLY IGNITION SWITCH IN ON OR START

HEL890

EL-12

POWER SUPPLY ROUTING


Wiring Diagram POWER (Contd)
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL891

EL-13

POWER SUPPLY ROUTING


Wiring Diagram POWER (Contd)

HEL892

EL-14

POWER SUPPLY ROUTING


Fuse
a. If fuse is blown, be sure to eliminate cause of problem
before installing new fuse.
b. Use fuse of specified rating. Never use fuse of more than
specified rating.
c. Do not partially install fuse; always insert it into fuse
holder properly.
d. Remove fuse for ELEC B if vehicle is not used for a long
period of time.

GI
MA
EM
LC

SEL954JA

Fusible Link

GEL186

A melted fusible link can be detected either by visual inspection or


by feeling with finger tip. If its condition is questionable, use circuit
tester or test lamp.
CAUTION:
I If fusible link should melt, it is possible that critical circuit
(power supply or large current carrying circuit) is shorted.
In such a case, carefully check and eliminate cause of
problem.
I Never wrap outside of fusible link with vinyl tape. Important: Never let fusible link touch any other wiring harness,
vinyl or rubber parts.

EC
FE
CL
MT
TF
PD
FA
RA

Circuit Breaker Inspection


For example, when current is 30A, the circuit is broken within 8 to
20 seconds.
Circuit breakers are used in the following systems.
I Power window
I Power door lock

BR
ST
RS
BT

SBF284E

HA

IDX

EL-15

GROUND DISTRIBUTION
EARTH
M1/M54

CONNECT TO
ACCESSORY RELAY (In fuse block)
AIR BAG DIAGNOSIS SENSOR UNIT (4WD
models)
ASHTRAY ILLUMINATION
BLOWER RELAY (In fuse block)
CHECK CONNECTOR (NA engine)

CONN. NO.
M14

EL-POWER

M110

RS-SRS

M34
M14
M12

EL-ILL
EL-POWER
EC-CHOKE

CHECK CONNECTOR (Z engine)


CIGARETTE LIGHTER SOCKET

M13
M37

EC-CHOKE
EL-HORN

COMBINATION FLASHER UNIT


DOOR LOCK TIMER
FAN SWITCH ILLUMINATION (Except for
Australia)
FAN SWITCH ILLUMINATION (For Australia)
FAN SWITCH (Except for Australia)
FAN SWITCH (For Australia)
FRONT WIPER AMPLIFIER
(RHD models without KA engine and LHD models)
FRONT WIPER AND WASHER SWITCH
FRONT WIPER MOTOR
(RHD models without KA engine and LHD models)
FUEL FILTER SWITCH (LHD models with diesel
engine)
FUEL PUMP CONTROL MODULE
FUEL RETURN CONTROL SOLENOID VALVE
(LHD models with NA engine)

M15
M51

EL-TURN
EL-D/LOCK

M403

HA-HEATER

M40
M404
M39

HA-HEATER EL-ILL
EC-FIPOT HA-HEATER
HA-HEATER

M220

EL-WIPER

M28

EL-WIPER

M221

EL-WIPER

M259

EL-WARN

M22

EC-FPCM

M257

EC-F/RTN

M29

EC-GLOW

EC-PLA

M30

EC-GLOW

EC-PLA

M253

EC-GLOW

M256
M41

EC-GLOW
EL-TURN

IACV-FICD SOLENOID VALVE (KA engine)


IGNITION RELAY (In fuse block)
POWER WINDOW RELAY

M203
M14
M9

EC-FICD HA-A/C
EL-POWER
EL-WINDOW

REAR WINDOW DEFOGGER SWITCH


SEAT BELT SWITCH

M42
M109

EL-DEF
EL-WARN

SPIRAL CABLE (2WD models with air bag)


FRONT WIPER AMPLIFIER (RHD models with
KA engine)
FRONT WIPER MOTOR (RHD models with KA
engine)
COMBINATION METER (4WD WARNING
LAMP)
COMBINATION METER (ABS WARNING
LAMP)
COMBINATION METER (AIR BAG WARNING
LAMP)
COMBINATION METER (CLOCK ILLUMINATION)
COMBINATION METER (DIGITAL CLOCK)

M26

RS-SRS

F20

EL-WIPER

F21

EL-WIPER

N6

EL-WARN

N6

BR-ABS

EL-WARN

N5

RS-SRS

EL-WARN

N6

EL-ILL

GLOW CONTROL UNIT


(TD engine except for cold areas and QD
engine)
GLOW CONTROL UNIT (TD engine for cold
areas)
GLOW RELAY-1 (LHD models with diesel
engine)
GLOW RELAY-2 (TD engine for cold areas)
HAZARD SWITCH

COMBINATION METER (FUEL GAUGE)


COMBINATION METER (HIGH BEAM INDICATOR)
COMBINATION METER (ODO/TRIP METER
ILLUMINATION)

CELL CODE

EL-BUZZER

EL-ILL

EL-HORN

N6

EL-HORN

N5

EL-METER

N5

EL-H/LAMP

N6

EL-ILL

EL-16

HA-A/C

EL-ILL

HA-A/C

GROUND DISTRIBUTION
EARTH
M1/M54

M33/M207
(LHD models
with KA
engine)

CONNECT TO
COMBINATION METER (TURN LH INDICATOR)
COMBINATION METER (TURN RH INDICATOR)
COMBINATION METER (UNIFIED METER
CONTROL UNIT)
COMBINATION METER (WATER TEMP.
GAUGE)
COMBINATION METER (METER ILLUMINATION)
DOOR MIRROR REMOTE CONTROL SWITCH
INTERIOR LAMP (Single cab)
SPOT LAMP
FUEL TANK GAUGE UNIT (With electric fuel
pump)
FUEL TANK GAUGE UNIT (With mechanical
fuel pump)
LICENSE PLATE LAMP LH (With step bumper)
LICENSE PLATE LAMP LH (Without step
bumper)
LICENSE PLATE LAMP RH (With step bumper)
LICENSE PLATE LAMP RH (Without step
bumper)
REAR COMBINATION LAMP LH (BACK-UP)
(A-chassis models, and except for Australia and
China)
REAR COMBINATION LAMP LH (BACK-UP)
(For Australia and China except A-chassis models)
REAR COMBINATION LAMP LH (TAIL AND
STOP) (A-chassis models, and except for
Australia and China)
REAR COMBINATION LAMP LH (TAIL AND
STOP) (For Australia and China except Achassis models)
REAR COMBINATION LAMP LH (TURN SIGNAL) (A-chassis models, and except for
Australia and China)
REAR COMBINATION LAMP LH (TURN SIGNAL) (For Australia and China except A-chassis
models)
REAR COMBINATION LAMP RH (BACK-UP)
(A-chassis models, and except for Australia and
China)
REAR COMBINATION LAMP RH (BACK-UP)
(For Australia and China except A-chassis models)
REAR COMBINATION LAMP RH (TAIL AND
STOP) (A-chassis models, and except for
Australia and China)
REAR COMBINATION LAMP RH (TAIL AND
STOP) (For Australia and China except Achassis models)
REAR COMBINATION LAMP RH (TURN SIGNAL) (A-chassis models, and except for
Australia and China)
REAR COMBINATION LAMP RH (TURN SIGNAL) (For Australia and China except A-chassis
models)
LOCK KNOB SWITCH
POWER WINDOW MAIN SWITCH (Double cab)
POWER WINDOW MAIN SWITCH (Single cab)
CONDENSER
DISTRIBUTOR (POWER TRANSISTOR)
ECM (ECCS CONTROL MODULE)

CONN. NO.

CELL CODE

GI

N6

EL-TURN

N6

EL-TURN

N5

EC-VSS

N5

EL-METER

N6

EL-ILL

N3
R4
R3
C3

EL-MIRROR
EL-INT/L
EL-INT/L
EC-FPCM EC-F/PUMP
EL-WARN

C4

EL-METER

T7

EL-TAIL/L

T6

EL-TAIL/L

T3

EL-TAIL/L

T5

EL-TAIL/L

T8

EL-BACK/L

T9

EL-BACK/L

T8

EL-TAIL/L

EL-STOP/L

T9

EL-TAIL/L

EL-STOP/L

T8

EL-TURN

T9

EL-TURN

T1

EL-BACK/L

T2

EL-BACK/L

T1

EL-TAIL/L

EL-STOP/L

RS

T2

EL-TAIL/L

EL-STOP/L

BT

T1

EL-TURN

T2

EL-TURN

D8
D5
D6
M210
M214
M32

EL-D/LOCK
EL-WINDOW
EL-WINDOW
EC-IGN/SG
EC-IGN/SG
EC-MAIN

EC-GLOW

EL-METER

MA
EM
LC

EL-METER

EC

EL-WARN

FE
CL
MT
TF
PD
FA
RA
BR

EL-17

ST

HA

EL-D/LOCK
EL-D/LOCK

IDX

GROUND DISTRIBUTION
EARTH
M208
(LHD models
with KA
engine)

E6/E39

CONNECT TO
DATA LINK CONNECTOR FOR CONSULT
DISTRIBUTOR (CAMSHAFT POSITION
SENSOR)
ECM (ECCS CONTROL MODULE)
SHIELD WIRE (CAMSHAFT POSITION
SENSOR)
SHIELD WIRE (MASS AIR FLOW SENSOR)
SHIELD WIRE (THROTTLE POSITION
SENSOR)
SHIELD WIRE (HEATED OXYGEN SENSOR)
DATA LINK CONNECTOR FOR CONSULT
(With ABS)
ABS ACTUATOR ASSEMBLY
BRAKE FLUID LEVEL SWITCH
COOLING FAN MOTOR
FRONT COMBINATION LAMP LH (PARKING)
(Except for Australia and China)
FRONT COMBINATION LAMP LH (PARKING)
(For Australia and China)
FRONT COMBINATION LAMP LH (TURN SIGNAL) (Except for Australia and China)
FRONT COMBINATION LAMP LH (TURN SIGNAL) (For Australia and China)
FRONT COMBINATION LAMP RH (PARKING)
(Except for Australia and China)
FRONT COMBINATION LAMP RH (PARKING)
(For Australia and China)
FRONT COMBINATION LAMP RH (TURN SIGNAL) (Except for Australia and China)
FRONT COMBINATION LAMP RH (TURN SIGNAL) (For Australia and China)
FUEL FILTER SWITCH (RHD models with diesel engine)
FUEL RETURN CONTROL SOLENOID VALVE
(RHD models with NA engine)
GLOW RELAY (RHD models with diesel engine)
HEADLAMP LH
HEADLAMP RH
IACV-FICD SOLENOID VALVE (Diesel engine)
ISC-FI POT CONTROL SOLENOID VALVE
POWER ANTENNA
SHIELD WIRE (FRONT WHEEL SENSOR LH)
SHIELD WIRE (FRONT WHEEL SENSOR RH)
SIDE TURN SIGNAL LAMP LH
SIDE TURN SIGNAL LAMP RH
THERMOSWITCH
TRIPLE-PRESSURE SWITCH
VACUUM CONTROL SOLENOID VALVE

CONN. NO.
M11

EC-MIL/DL

ALTERNATOR (Gasoline engine)

E211

NEUTRAL POSITION SWITCH


POWER STEERING OIL PRESSURE SWITCH
(RHD 2WD models with KA engine and LHD
models)
POWER STEERING OIL PRESSURE SWITCH
(RHD 4WD models with KA engine)
SHIELD WIRE (REAR WHEEL SENSOR LH)
(4WD models)
SHIELD WIRE (REAR WHEEL SENSOR RH)
(4WD models)
SHIELD WIRE (REAR WHEEL SENSOR) (2WD
models)

M214

EC-CMPS

M32

EC-MAIN

M214

EC-CMPS

M204

EC-MAFS

M302

EC-TPS

E3

EC-HO2S

M11

BR-ABS

E4
E2
E24

BR-ABS
EL-WARN
LC-COOL/F

E11

EL-TAIL/L

E12

EL-TAIL/L

E11

EL-TURN

E12

EL-TURN

E27

EL-TAIL/L

E28

EL-TAIL/L

E27

EL-TURN

E28

EL-TURN

E5

EL-WARN

E40

EC-F/RTN

E44
E13
E26
E37
E37
E46
E15
E31
E1
E45
E18
E25
E20

E220

EC-GLOW
EL-H/LAMP
EL-H/LAMP
HA-A/C
EC-FIPOT HA-A/C
EL-P/ANT
BR-ABS
BR-ABS
EL-TURN
EL-TURN
LC-COOL/F HA-A/C
LC-COOL/F HA-A/C
EC-IDLE
EC-CHOKE EC-FPCM
EL-WARN
EC-PNP/SW

E208

EC-PST/SW

E207

EC-PST/SW

C5

BR-ABS

C5

BR-ABS

C6

BR-ABS

EL-18

CELL CODE

HA-A/C

EL-BUZZER

EL-CHARGE

GROUND DISTRIBUTION
EARTH
F7/F52
(RHD models
with KA
engine)
F8
(RHD models
with KA
engine)

A1 (Diesel
engine)
R54

CONNECT TO
CONDENSER
DISTRIBUTOR (POWER TRANSISTOR)
ECM (ECCS CONTROL MODULE)
DATA LINK CONNECTOR FOR CONSULT
DISTRIBUTOR (CAMSHAFT POSITION
SENSOR)
ECM (ECCS CONTROL MODULE)
SHIELD WIRE (CAMSHAFT POSITION
SENSOR)
SHIELD WIRE (MASS AIR FLOW SENSOR)
SHIELD WIRE (THROTTLE POSITION
SENSOR)
ALTERNATOR
ENGINE COOLANT TEMPERATURE SENSOR
REAR WINDOW DEFOGGER

CONN. NO.
F10
F14
F51
M11

EC-IGN/SG
EC-IGN/SG
EC-MAIN
EC-MIL/DL

CELL CODE

F14

EC-CMPS

F51

EC-MAIN

F14

EC-CMPS

F4

EC-MAFS

F102

EC-TPS

A7
A11
R53

EC-PLA EL-CHARGE
EC-GLOW
EL-DEF

GI
MA
EM
LC
EL-WARN

EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

EL-19

BATTERY
CAUTION:
If it becomes necessary to start the engine with a booster battery and jumper cables,
a. Use a 12-volt booster battery.
b. After connecting battery cables, ensure that they are
tightly clamped to battery terminals for good contact.
c. Never add distilled water through the hole used to check
specific gravity.

How to Handle Battery


METHODS OF PREVENTING OVER-DISCHARGE

MEL040F

The following precautions must be taken to prevent over-discharging a battery.


I The battery surface (particularly its top) should always be kept
clean and dry.
I The terminal connections should be clean and tight.
I At every routine maintenance, check the electrolyte level.
This also applies to batteries designated as low maintenance
and maintenance-free.
I

When the vehicle is not going to be used over a long period of


time, disconnect the negative battery terminal.

Check the charge condition of the battery.


Periodically check the specific gravity of the electrolyte. Keep
a close check on charge condition to prevent over-discharge.

MEL041F

MEL042F

CHECKING ELECTROLYTE LEVEL


WARNING:
Do not allow battery fluid to come in contact with skin, eyes,
fabrics, or painted surfaces. After touching a battery, do not
touch or rub your eyes until you have thoroughly washed your
hands. If acid contacts eyes, skin or clothing, immediately
flush with water for 15 minutes and seek medical attention.

EL-20

BATTERY
How to Handle Battery (Contd)
I
I

Remove the cell plug using a suitable tool.


Add distilled water up to the MAX level.

GI
MA
EM
LC

MEL043F

SULPHATION
A battery will be completely discharged if it is left unattended
for a long time and the specific gravity will become less than
1.100. This may result in sulphation on the cell plates.
To determine if a battery has been sulphated, note its voltage and current when charging it. As shown in the figure, less
current and higher voltage are observed in the initial stage of
charging sulphated batteries.
A sulphated battery may sometimes be brought back into service by means of a long, slow charge, 12 hours or more, followed by a battery capacity test.
SEL709E

EC
FE
CL
MT

SPECIFIC GRAVITY CHECK


1. Read hydrometer and thermometer indications at eye level.

TF
PD
FA
RA

MEL042FA

BR
ST
RS
BT
HA

IDX

EL-21

BATTERY
How to Handle Battery (Contd)
2. Convert into specific gravity at 20C (68F).
Example:
I When electrolyte temperature is 35C (95F) and specific gravity of electrolyte is 1.230, converted specific gravity at 20C
(68F) is 1.240.
I When electrolyte temperature is 0C (32F) and specific gravity of electrolyte is 1.210, converted specific gravity at 20C
(68F) is 1.196.

SEL007Z

EL-22

BATTERY
Battery Test and Charging Chart
GI

Chart I

MA

VISUAL INSPECTION
I Check battery case for cracks or bends.
I Check battery terminals for damage.
I If the difference between the max. and min. electrolyte level in cells is within 10 mm (0.39 in), it is OK.

EM

OK

NG

Replace
battery.

CHECKING SPECIFIC GRAVITY


Refer to Specific Gravity Check.

LC
EC

Below 1.100

1.100 - 1.220

Above 1.220

FE
CL

SLOW CHARGE
Refer to A: Slow
Charge.

Ready for
use

OK

NG

Replace
battery.

Ready for use

QUICK CHARGE
Refer to C: Quick Charge.
I Time required: 45 min.

OK

Ready for use

CAPACITY TEST
Refer to Chart II.

ST

CAPACITY TEST
Refer to Chart II.

RA
BR

FA
H

CHECKING SPECIFIC
GRAVITY
Refer to Specific Gravity
Check.

RECHARGE
Refer to C: Quick Charge.
I If battery temperature rises above 60C (140F), stop
charging. Always charge battery when its temperature
is below 60C (140F).

OK

PD

Ready for use


I Mount battery again and
check loose terminals.
Also check other related
circuits.

CAPACITY TEST
Refer to Chart II.

NG

NG

CAPACITY TEST
Refer to Chart II.

TF

OK

OK

CAPACITY TEST
Refer to Chart II.

QUICK CHARGE
Refer to C: Quick Charge.

STANDARD CHARGE
Refer to B: Standard
Charge.

MT

H
H

NG

Replace
battery.

RS
BT
HA

NG

Ready for Replace


use
battery.
* STANDARD CHARGE is recommended if the vehicle is in storage after charging.

EL-23

IDX

BATTERY
Battery Test and Charging Chart (Contd)
I Check battery type and determine the specified current
using the following table.
Fig. 1 DISCHARGING CURRENT
(Load Tester)

Chart II

CAPACITY TEST

Test using battery checker.

Test using load tester.

Follow manufacturers instructions to check and determine


if battery is serviceable.

Read load tester voltage


when specified discharging
current (Refer to Fig. 1.) flows
through battery for 15 seconds.

OK

Ready for use

NG

Go to next
step.

Above 9.6
volts
OK
H

Ready for use

Type

Current (A)

28B19R(L)

90

34B19R(L)

99

46B24R(L)

135

55B24R(L)

135

50D23R(L)

150

55D23R(L)

180

65D26R(L)

195

80D26R(L)

195

75D31R(L)

210

95D31R(L)

240

115D31R(L)

240

95E41R(L)

300

130E41R(L)

330

Below 9.6
volts
NG
H

Go to next
step.

SEL008Z

EL-24

BATTERY
Battery Test and Charging Chart (Contd)
A: SLOW CHARGE

GI
Determine initial charging current from specific gravity referring to Fig. 2.

MA

Fig. 2 INITIAL CHARGING CURRENT SETTING (Slow charge)


H

Below
1.100
H

Below 12 volts or above 15


volts

12 to 15 volts
OK

4.0
(A)

5.0
(A)

7.0
(A)

8.0
(A)

9.0
(A)

10.0
(A)

130E41R(L)

95E41R(L)

115D31R(L)

95D31R(L)

75D31R(L)

80D26R(L)

65D26R(L)

55D23R(L)

50D23R(L)

55B24R(L)

46B24R(L)

34B19R(L)

CONVERTED
SPECIFIC
GRAVITY

28B19R(L)

BATTERY TYPE

I Charge battery.
I Check charging voltage 30 minutes after starting the battery charge.

EM
LC

14.0
(A)

EC

I Check battery type and determine the specified current using the table
shown above.
I After starting charging, adjustment of charging current is not necessary.

FE

Fig. 3 ADDITIONAL CHARGE (Slow charge)

CL

NG

Continue to charge for 12


hours.

Replace battery.

Below 1.150

1.200 - 1.240

Above 1.240

MT

CHECKING SPECIFIC GRAVITY


Refer to Specific Gravity Check.

1.150 - 1.200

Charge for 5
hours at initial charging
current setting.

Charge for 4
hours at initial charging
current setting.

Charge for 2
hours at initial charging
current setting.

TF
PD

Conduct additional charge as per Fig. 3, if necessary.


H

FA

Go to CAPACITY TEST.
H

Go to CAPACITY TEST.

CAUTION:
I Set charging current to value specified in Fig. 2. If charger
is not capable of producing specified current value, set its
charging current as close to that value as possible.
I Keep battery away from open flame while it is being
charged.
I When connecting charger, connect leads first, then turn on
charger. Do not turn on charger first, as this may cause a
spark.
I If battery temperature rises above 60C (140F), stop
charging. Always charge battery when its temperature is
below 60C (140F).

RA
BR
ST
RS
BT
HA

IDX

EL-25

BATTERY
Battery Test and Charging Chart (Contd)
B: STANDARD CHARGE

Fig. 4 INITIAL CHARGING CURRENT SETTING


(Standard charge)

Determine initial charging current from


specific gravity, referring to Fig. 4.

CONVERTED
SPECIFIC
GRAVITY

CHECKING SPECIFIC GRAVITY


Refer to Specific Gravity Check.

130E41R(L)

115D31R(L)

7.0 (A)

8.0
(A)

9.0 (A)

13.0
(A)

1.130 - 1.160

3.0 (A)

4.0 (A)

5.0 (A)

6.0 (A)

7.0
(A)

8.0 (A)

11.0
(A)

1.160 - 1.190

2.0 (A)

3.0 (A)

4.0 (A)

5.0 (A)

6.0
(A)

7.0 (A)

9.0
(A)

1.190 - 1.220

2.0 (A)

2.0 (A)

3.0 (A)

4.0 (A)

5.0
(A)

5.0 (A)

7.0
(A)

95E41R(L)

95D31R(L)

65D26R(L)

55D23R(L)

6.0 (A)

55B24R(L)

5.0 (A)

46B24R(L)

4.0 (A)

34B19R(L)

1.100 - 1.130

28B19R(L)

75D31R(L)

80D26R(L)

Charge battery for 8 hours.

50D23R(L)

BATTERY TYPE

I Check battery type and determine the specified current using the table shown above.
I After starting charging, adjustment of charging current is not necessary.
Fig. 5 ADDITIONAL CHARGE (Standard charge)

Below 1.150

1.150 - 1.200

1.200 - 1.240

Above 1.240

Conduct additional charge as per Fig. 5, if


necessary.
H
H

Go to CAPACITY TEST.

Charge for 3.5


hours at initial
charging current
setting.
H

Charge for 2.5


hours at initial
charging current
setting.

Charge for 1.5


hours at initial
charging current
setting.

Go to CAPACITY TEST.

CAUTION:
I Do not use standard charge method on a battery whose specific gravity is less than 1.100.
I Set charging current to value specified in Fig. 4. If charger is not capable of producing specified
current value, set its charging current as close to that value as possible.
I Keep battery away from open flame while it is being charged.
I When connecting charger, connect leads first, then turn on charger. Do not turn on charger first,
as this may cause a spark.
I If battery temperature rises above 60C (140F), stop charging. Always charge battery when its
temperature is below 60C (140F).

EL-26

BATTERY
Battery Test and Charging Chart (Contd)

CONVERTED SPECIFIC GRAVITY

Charge battery.

Go to CAPACITY TEST.

15 (A)

20 (A)

30 (A)

1.100 - 1.130

2.5 hours

1.130 - 1.160

2.0 hours

1.160 - 1.190

1.5 hours

1.190 - 1.220

1.0 hours

Above 1.220

0.75 hours (45 min.)

130E41R(L)

95E41R(L)

115D31R(L)

95D31R(L)

75D31R(L)

80D26R(L)

65D26R(L)

55D23R(L)

50D23R(L)

55B24R(L)

10 (A)

46B24R(L)

CURRENT [A]

Determine initial charging current setting and charging time from specific gravity, referring to Fig. 6.

34B19R(L)

BATTERY TYPE

28B19R(L)

Fig. 6 INITIAL CHARGING CURRENT SETTING AND CHARGING TIME (Quick


charge)

C: QUICK CHARGE

40
(A)

FE
CL

Australia

Type
Capacity

V-AH

Z24
Option

TF
PD
FA
RA

ST

Middle East

TD27, QD32

MT

BR

Service Data and Specifications (SDS)

Standard

EM

EC

CAUTION:
I Do not use quick charge method on a battery whose specific gravity is less than 1.100.
I Set initial charging current to value specified in Fig. 6. If charger is not capable of producing
specified current value, set its charging current as close to that value as possible.
I Keep battery away from open flame while it is being charged.
I When connecting charger, connect leads first, then turn on charger. Do not turn on charger first,
as this may cause a spark.
I Be careful of a rise in battery temperature because a large current flow is required during quickcharge operation.
If battery temperature rises above 60C (140F), stop charging. Always charge battery when its
temperature is below 60C (140F).
I Do not exceed the charging time specified in Fig. 6, because charging battery over the charging
time can cause deterioration of the battery.

KA24

MA

LC

I Check battery type and determine the specified current using the table shown
above.
I After starting charging, adjustment of charging current is not necessary.

Applied model

GI

TD27
Standard

Option

55D23R

75D31R

95D31R

34B19R

75D31R

95D31R

12-48

12-60

12-64

12-27

12-60

12-64

RS
BT

General areas
Applied model

NA20, Z24
Standard

Type
Capacity

V-AH

KA24
Option

Standard

HA

TD27, QD32
Standard

Option

34B19R

55D23R

75D31R

95D31R

80D26R, 80D26L

12-27

12-48

12-60

12-64

12-55

IDX

EL-27

STARTING SYSTEM
Wiring Diagram START

HEL893

EL-28

STARTING SYSTEM
Trouble Diagnoses
If any abnormality is found, immediately disconnect battery negative terminal.
Starter does not stop.

GI

Replace magnetic switch.

MA
Engine does not start.

EM

Does engine turn by cranking?

Yes

Yes

Does engine turn normally?

No

Check ignition/fuel system.

LC

No (Turns slowly.)

OK

Check battery as follows:


I Charging condition
I Terminal connections
I Terminal corrosion

Repair starter motor.

EC
FE

H NG

q
A
H

Does starter motor turn?

Yes

Yes

Does gear shaft turn?

No

Check pinion clutch.

No

CL
MT

Check reduction gear, armature


and gear shaft.

TF

Check fuse and fusible link.


H

NG

PD
A
q

NG

OK
H

Check starting system wiring.

NG

FA

H
E I Charge battery.
I Repair connections and corrosion of battery terminals.

Repair.

Replace magnetic switch.

Does starter turn under no load by


connecting wires as follows?

RA
BR

OK

Does magnetic switch operation


sound occur?
H

Replace.

OK

Check battery as follows:


I Charging condition
I Terminal connections
I Terminal corrosion

No

ST

Yes

Check condition of pinion and ring


gear mesh.

OK

Yes

RS
E

Replace magnetic switch.

BT

NG

No

I Adjust pinion movement.


I Check pinion moving mechanism.
I Check ring gear.
SEL009Z

EL-29

HA
E

Repair starter motor.

IDX

STARTING SYSTEM
Construction

MEL673EA

SEL600JA

EL-30

STARTING SYSTEM
Construction (Contd)
GI
MA
EM
LC
EC
FE
CL
MT
TF
MEL437H

PD
FA
RA
BR
ST
RS
BT
HA

IDX
MEL158FA

EL-31

STARTING SYSTEM
Construction (Contd)

MEL438H

MEL439H

EL-32

STARTING SYSTEM
Construction (Contd)
GI
MA
EM
LC
EC
FE
CL
MT
TF
MEL440H

PD
FA
RA
BR
ST
RS
BT
HA

IDX
MEL423HA

EL-33

STARTING SYSTEM
Removal and Installation

MEL271H

Magnetic Switch Check


I
I
1.
I

Before starting to check, disconnect battery ground cable.


Disconnect M terminal of starter motor.
Continuity test (between S terminal and switch body).
No continuity ... Replace.

SEL036H

2. Continuity test (between S terminal and M terminal).


I No continuity ... Replace.

SEL038H

Pinion/Clutch Check

SEL630BA

1. Inspect pinion teeth.


I Replace pinion if teeth are worn or damaged. (Also check condition of ring gear teeth.)
2. Inspect reduction gear teeth (If equipped).
I Replace reduction gear if teeth are worn or damaged. (Also
check condition of armature shaft gear teeth.)
3. Check to see if pinion locks in one direction and rotates
smoothly in the opposite direction.
I If it locks or rotates in both directions, or unusual resistance is
evident. ... Replace.

Brush Check
BRUSH
Check wear of brush.
Wear limit length:
Refer to SDS, EL-37.
I Excessive wear ... Replace.

SEL014Z

EL-34

STARTING SYSTEM
Brush Check (Contd)
BRUSH SPRING PRESSURE
Check brush spring pressure with brush spring detached from
brush.
Spring pressure (with new brush):
Refer to SDS, EL-37.
I Not within the specified values ... Replace.

GI
MA
EM
LC

SEL015Z

BRUSH HOLDER
1. Perform insulation test between brush holder (positive side)
and its base (negative side).
I Continuity exists. ... Replace.
2. Check brush to see if it moves smoothly.
I If brush holder is bent, replace it; if sliding surface is dirty, clean.

EC
FE
CL
MT

SEL568B

Yoke Check
Magnet is secured to yoke by bonding agent. Check magnet to see
that it is secured to yoke and for any cracks. Replace malfunctioning parts as an assembly.
CAUTION:
Do not clamp yoke in a vice or strike it with a hammer.

TF
PD
FA
RA

SEL305H

Armature Check
1.
I
2.
I

Continuity test (between two segments side by side).


No continuity ... Replace.
Insulation test (between each commutator bar and shaft).
Continuity exists. ... Replace.

BR
ST
RS
BT

SEL019Z

3. Check commutator surface.


I Rough ... Sand lightly with No. 500 - 600 emery paper.

HA

IDX

SEL020Z

EL-35

STARTING SYSTEM
Armature Check (Contd)
4. Check diameter of commutator.
Commutator minimum diameter:
Refer to SDS, EL-37.
I Less than specified value ... Replace.

SEL021Z

5. Check depth of insulating mold from commutator surface.


I Less than 0.2 mm (0.008 in) ... Undercut to 0.5 to 0.8 mm
(0.020 to 0.031 in)

SEL022Z

Assembly
Apply high-temperature grease to lubricate the bearing, gears and
frictional surface when assembling the starter.
Carefully observe the following instructions.

PINION PROTRUSION LENGTH ADJUSTMENT


Clearance 
With pinion driven out by magnetic switch, push pinion back to
remove slack and measure clearance  between the front edge
of the pinion and the pinion stopper.
Clearance :
Refer to SDS, EL-37.

SEL026Z

EL-36

STARTING SYSTEM
Assembly (Contd)
Movement 
Compare movement  in height of pinion when it is pushed out
with magnetic switch energized and when it is pulled out by hand
until it touches stopper.
Movement :
Refer to SDS, EL-37.

GI
MA
EM
LC

SEL497D

Not in the specified value ... Adjust by adjusting plate.

EC
FE
CL
MT

SEL633BA

Service Data and Specifications (SDS)


TF

STARTER
M3T70381 M3T29482D S114-348A S114-295B M0T60081A M2T52882
Type

MITSUBISHI

HITACHI

MITSUBISHI

Non-reduction

KA24

S14-205

HITACHI

4WD

NA20, Z24
Standard

System voltage

S13-327

PD

Reduction

2WD
Applied model

S114-459

KA24

Z24

Option

2WD

4WD

TD27

QD32

Standard

FA
RA

12

No-load
Terminal voltage

11.5

11.0

11.5

Current

Less than 60

Less than
90

Less than 100

Revolution

rpm

More than 6,500

Minimum diameter of commutator


mm (in)

31.4 (1.236)

Minimum length of brushmm (in)

11.5 (0.453)

Brush spring tension

N (kg, lb)

Clearance  between pinion


front edge and pinion stopper
mm (in)

0.5 - 2.0
(0.020 - 0.079)

6,000

39.0 (1.535)
12.0
(0.472)

11.0
(0.433)

17.7 - 21.6 13.7 - 17.7


(1.8 - 2.2, (1.4 - 1.8,
4.0 - 4.9)
3.1 - 4.0)

13.7 - 25.5
(1.4 - 2.6, 3.1 - 5.7)

Clearance between bearing


metal and armature shaftmm (in)

Movement  in height of pinion assembly


mm (in)

7,000

More than
2,500

3,000

3,900

28.8
(1.134)

31.4
(1.236)

29.0
(1.142)

7.0 (0.276)

11.5
(0.453)

11.0
(0.433)

11.8 - 23.5
(1.2 - 2.4,
2.6 - 5.3)

16.7 - 21.6 15.7 - 19.6


(1.7 - 2.2, (1.6 - 2.0,
3.7 - 4.9)
3.5 - 4.4)

Less than 0.2 (0.008)

0.3 - 2.5
(0.012 0.098)

1.3 - 2.0
(0.051 0.079)
0.5 - 2.0
(0.020 - 0.079)

*: Not include the current of the magnet switch circuit

EL-37

BR

11.0
Less than
160

Less than
160*

More than
4,000

More than
4,100

35.5 (1.398)

ST
RS

9.0 (0.354)

11.0
(0.433)

BT

28.4 - 34.3
(2.9 - 3.5,
6.4 - 7.7)

HA

0.3 - 1.5
(0.012 - 0.059)

0.3 - 2.0
(0.012 0.079)

IDX

CHARGING SYSTEM
Wiring Diagram CHARGE
GASOLINE ENGINE

HEL894

EL-38

CHARGING SYSTEM
Wiring Diagram CHARGE (Contd)
DIESEL ENGINE

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL895

EL-39

CHARGING SYSTEM
Trouble Diagnoses
Before conducting an alternator test, make sure that the battery is fully charged. A 30-volt voltmeter and suitable test probes are necessary for the test. The alternator can be checked easily by referring to the Inspection Table.
I Before starting, inspect the fusible link.
I Use fully charged battery.

GASOLINE ENGINE MODELS

Ignition switch
ON

Warning lamp
OFF

Disconnect connector (S, L) and


ground L harness side.

Check the following:


I Warning
lamp bulb
I Fuse for
warning lamp

Warning lamp
OFF

Warning lamp
ON

Damaged IC
regulator.
Replace.

Warning lamp
ON

Engine start.
Engine speed:
1,500 rpm

Warning lamp
ON

Warning lamp
OFF

OK

Check the following:


I Drive belt
I Fuse for S terminal
I Connector (S, L terminal) connection

Engine idling

Warning lamp
OFF

OK

More than
15.5V

Damaged IC
regulator.
Replace.

No generation

Field circuit is
open.

Warning lamp
ON
Engine speed:
1,500 rpm
(Measure B
terminal voltage)

Warning lamp: CHARGE warning lamp in combination meter

Note:
I If the inspection result is OK even though the charging system is malfunctioning, check the B terminal connection. (Check the tightening torque.)
I When field circuit is open, check condition of rotor coil, rotor slip ring and brush. If necessary,
replace faulty parts with new ones.

Malfunction indicator
The IC regulator warning function activates to illuminate CHARGE warning lamp, if any of the following
symptoms occur while alternator is operating:
I Field circuit is open.
I Excessive voltage is produced.

EL-40

CHARGING SYSTEM
Trouble Diagnoses (Contd)
DIESEL ENGINE MODELS

Ignition switch
ON

Warning lamp
OFF

Disconnect connector (S, L) and


ground L harness side.

Warning lamp
OFF

Warning lamp
ON

Check the following:


I Warning
lamp bulb
I Fuse for
warning lamp

GI

Damaged IC
regulator.
Replace.

EM
LC

Warning lamp
ON

Engine idling

Warning lamp
OFF

MA

Warning lamp
ON

Check the following:


I Drive belt
I Field circuit

Engine speed: 1,500 rpm


(Measure B terminal voltage)

More than
15.5V

13 - 15V

Check the following:


I Fuse for S
terminal
I Open circuit
for S terminal
I IC regulator
OK

EC
FE
CL
MT
TF

Warning lamp: CHARGE warning lamp in combination meter

Note:
I If the inspection result is OK even though the charging system is malfunctioning, check the B terminal connection (check the tightening torque).
I When field circuit is open, check condition of rotor coil, rotor slip ring and brush. If necessary,
replace faulty parts with new ones.

PD
FA
RA
BR
ST
RS
BT
HA

IDX

EL-41

CHARGING SYSTEM
Construction

MEL441H

MEL383I

EL-42

CHARGING SYSTEM
Construction (Contd)
GI
MA
EM
LC
EC
FE
CL
MT
TF
MEL443H

PD
FA
RA

Removal and Installation


CAUTION:
I Start service operation after removing the negative terminal from the battery.
I Also remove the undercover, if equipped, before servicing.

BR
ST
RS
BT
HA

IDX

MEL444H

EL-43

CHARGING SYSTEM
Removal and Installation (Contd)
CAUTION:
I Start service operation after removing the negative terminal from the battery.
I Also remove the undercover, if equipped, before servicing.

MEL445H

Disassembly
REAR COVER
CAUTION:
Rear cover may be hard to remove because a ring is used to
lock outer race of rear bearing. To facilitate removal of rear
cover, heat just bearing box section with a 200W soldering
iron.
Do not use a heat gun, as it can damage diode assembly.
SEL032Z

REAR BEARING
CAUTION:
I Do not reuse rear bearing after removal. Replace with a
new one.
I Do not lubricate rear bearing outer race.

Rotor Check
1. Resistance test
Resistance: Refer to SDS, EL-48.
I Not within the specified values ... Replace rotor.
2. Insulator test
I Continuity exists. ... Replace rotor.
3. Check slip ring for wear.
Slip ring minimum outer diameter:
Refer to SDS, EL-48.
I Not within the specified values ... Replace rotor.
SEL033Z

Brush Check
1.
I
2.
I

Check smooth movement of brush.


Not smooth ... Check brush holder and clean.
Check brush for wear.
Replace brush if it is worn down to the limit line.

SEL631DA

EL-44

CHARGING SYSTEM
Stator Check
1. Continuity test
I No continuity ... Replace stator.

GI
MA
EM
LC

SEL108E

2. Ground test
I Continuity exists. ... Replace stator.

EC
FE
CL
MT

SEL109E

TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

EL-45

CHARGING SYSTEM
Diode Check
MAIN DIODES
I
I

Use an ohmmeter to check condition of diodes as indicated in chart below.


If any of the test results is not satisfactory, replace diode assembly.
Ohmmeter probes
Positive !

Negative @

Positive diode plate

Diode terminals

Diode terminals

Positive diode plate

Negative diode plate

Diode terminals

Diode terminals

Negative diode plate

Diodes check (Positive side)

Diodes check (Negative side)

Judgement
Diode conducts in only one
direction.
Diode conducts in only one
direction.

SEL039Z

EL-46

CHARGING SYSTEM
Assembly
RING FITTING IN REAR BEARING
I

Fix ring into groove in rear bearing so that it is as close to the


adjacent area as possible.
CAUTION:
Do not reuse rear bearing after removal.

GI
MA
EM
LC

SEL044Z

REAR COVER INSTALLATION


1. Fit brush assembly, diode assembly, regulator assembly and
stator.
2. Push brushes up with fingers and install them to rotor.
Take care not to damage slip ring sliding surface.

EC
FE
CL
MT

SEL048Z

TF
PD
FA
RA

SEL049Z

BR
ST
RS
BT
HA

IDX

EL-47

CHARGING SYSTEM
Service Data and Specifications (SDS)
ALTERNATOR
A5TA0676A

A7T03171A

A5T05472A

LR160-727C

LR160-728C

Type
MITSUBISHI

HITACHI
Z24

Applied model

NA20

Nominal rating

V-A

KA24

12-70

Standard

Option*

12-35

12-70

Ground polarity

TD27, QD32
12-60

Negative

Minimum revolution under noload


(When 13.5V is applied)
rpm

Hot output current

A/rpm

Regulated output voltage

Less than 1,300


More than
19/1,300
More than
50/2,500
(When 14V is
applied)

More than
27.5/2,500
(When 14V is
applied)

Less than 1,000


More than
14/1,300
More than
44/2,500
(When 14V is
applied)

14.1 - 14.7

Minimum length of brush

5.0 (0.20)

6.0 (0.236)

4.6 - 5.8 (470 - 590, 16.58 - 20.81)

1.0 - 3.43 (102 - 350, 3.60 - 12.34)

22.1 (0.870)

26.0 (1.024)

mm (in)
Brush spring pressure
N (g, oz)
Slip ring minimum outer diameter
mm (in)
Rotor (Field coil) resistance

More than 17/1,300


More than 48/2,500
More than 57/5,000
(When 13.5V is applied)

2.5 - 2.9

2.6 - 3.1

*: Models with power steering and air conditioner

EL-48

2.5 - 2.9

2.58

COMBINATION SWITCH
Combination Switch/Check
LHD MODELS

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL896

EL-49

COMBINATION SWITCH
Combination Switch/Check (Contd)
RHD MODELS

HEL897

EL-50

COMBINATION SWITCH
Replacement
For removal and installation of spiral cable, refer to RS section
[Installation Air Bag Module and Spiral Cable, SUPPLEMENTAL RESTRAINT SYSTEM (SRS)].
I Each switch can be replaced without removing combination
switch base.

GI
MA
EM
LC

MEL304D

To remove combination switch base, remove base attaching


screw.

EC
FE
CL
MT

MEL326G

Before installing the steering wheel, align the steering wheel


guide pins with the screws which secure the combination switch
as shown in the left figure.

TF
PD
FA
RA

SEL151V

BR
ST
RS
BT
HA

IDX

EL-51

HEADLAMP
Wiring Diagram H/LAMP
LHD MODELS

HEL898

EL-52

HEADLAMP
Wiring Diagram H/LAMP (Contd)
LHD MODELS

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL899

EL-53

HEADLAMP
Wiring Diagram H/LAMP (Contd)
RHD MODELS

HEL900

EL-54

HEADLAMP
Wiring Diagram H/LAMP (Contd)
RHD MODELS

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL901

EL-55

HEADLAMP
Trouble Diagnoses
Symptom
LH headlamps do not operate.

Possible cause
1. Bulb
2. Grounds
3. 15A fuse

E6

and

E39

1. Bulb
2. Grounds
3. 15A fuse

E6

1. Check bulb.
2. Check grounds E6 and E39 .
3. Check 15A fuse (No. 32 , located in fusible link and

fuse box). Verify battery positive voltage is present


8 of lighting switch.
at terminal q
4. Check lighting switch.

4. Lighting switch
RH headlamps do not operate.

Repair order

and

E39

1. Check bulb.
2. Check grounds E6 and E39 .
3. Check 15A fuse (No. 31 , located in fusible link and

fuse box). Verify battery positive voltage is present


5 of lighting switch.
at terminal q
4. Check lighting switch.

4. Lighting switch
LH high beams do not operate, but 1. Bulbs
LH low beam operates.
2. Open in LH high beams circuit
3. Lighting switch
LH low beam does not operate, but 1. Bulb
LH high beam operates.
2. Open in LH low beam circuit
3. Lighting switch
RH high beams do not operate, but 1. Bulbs
RH low beam operates.
2. Open in RH high beams circuit
3. Lighting switch
RH low beam does not operate, but 1. Bulb
RH high beam operates.
2. Open in RH low beam circuit
3. Lighting switch
High beam indicator does not work. 1. Bulb
2. Grounds M1 and M54
3. Open in high beam circuit

EL-56

1. Check bulbs.
2. Check R/L wire between lighting switch and LH headlamps for an open circuit.
3. Check lighting switch.
1. Check bulb.
2. Check R/G wire between lighting switch and LH headlamp for an open circuit.
3. Check lighting switch.
1. Check bulbs.
2. Check R/Y wire between lighting switch and RH headlamps for an open circuit.
3. Check lighting switch.
1. Check bulb.
2. Check R/B wire between lighting switch and RH headlamp for an open circuit.
3. Check lighting switch.
1. Check bulb in combination meter.
2. Check grounds M1 and M54 .
3. Check R/L wire between lighting switch and combination meter for an open circuit.

HEADLAMP
Bulb Replacement
The headlamp is a semi-sealed beam type which uses a replaceable halogen bulb. The bulb can be replaced from the engine compartment side without removing the headlamp body.
I Grasp only the plastic base when handling the bulb. Never
touch the glass envelope.
1. Disconnect the battery cable.
2. Disconnect the harness connector from the back side of the
bulb.
3. Pull off the rubber cap.
4. Push and raise retaining pin to loosen it.
5. Remove the headlamp bulb carefully. Do not shake or rotate
the bulb when removing it.
6. Install in the reverse order of removal.
CAUTION:
Do not leave headlamp reflector without bulb for a long period
of time. Dust, moisture, smoke, etc. entering headlamp body
may affect the performance of the headlamp. Remove headlamp bulb from the headlamp reflector just before a replacement bulb is installed.

GI
MA
EM
LC
EC
FE
CL
MT

GEL187

Bulb Specifications

TF

Item

Wattage (W)

Semi-sealed beam
High/Low

60/55

Aiming Adjustment
When performing headlamp aiming adjustment, use an aiming
machine, aiming wall screen or headlamp tester. Aimers should be
in good repair, calibrated and operated in accordance with respective operation manuals.
If any aimer is not available, aiming adjustment can be done as
follows:
For details, refer to the regulations in your own country.
a. Keep all tires inflated to correct pressures.
b. Place vehicle and tester on one and same flat surface.
c. See that there is no-load in vehicle (coolant, engine oil
filled up to correct level and full fuel tank) other than the
driver (or equivalent weight placed in drivers position).

PD
FA
RA
BR
ST
RS
BT
HA

IDX

EL-57

HEADLAMP
Low Beam
1. Turn headlamp low beam on.
2. Use adjusting screws to perform aiming adjustment.
I First tighten the adjusting screw all the way and then make
adjustment by loosening the screw.

GEL188

Adjust headlamps so that main axis of light is parallel to


center line of body and is aligned with point P shown in
illustration.
I Figure to the left shows headlamp aiming pattern for driving on right side of road; for driving on left side of road,
aiming pattern is reversed.
I Dotted lines in illustration show center of headlamp.
H:
Horizontal center line of headlamps
WL: Distance between each headlamp center
L:
5,000 mm (196.85 in)
C:
65 mm (2.56 in)

SEL254I

EL-58

EXTERIOR LAMP
Parking, License and Tail Lamps/Wiring
Diagram TAIL/L

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL902

EL-59

EXTERIOR LAMP
Parking, License and Tail Lamps/Wiring
Diagram TAIL/L (Contd)

HEL903

EL-60

EXTERIOR LAMP
Stop Lamp/Wiring Diagram STOP/L
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL904

EL-61

EXTERIOR LAMP
Back-up Lamp/Wiring Diagram BACK/L

HEL905

EL-62

EXTERIOR LAMP
Turn Signal and Hazard Warning Lamps/
Schematic

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL906

EL-63

EXTERIOR LAMP
Turn Signal and Hazard Warning Lamps/Wiring
Diagram TURN

HEL907

EL-64

EXTERIOR LAMP
Turn Signal and Hazard Warning Lamps/Wiring
Diagram TURN (Contd)
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL908

EL-65

EXTERIOR LAMP
Turn Signal and Hazard Warning Lamps/Wiring
Diagram TURN (Contd)

HEL909

EL-66

EXTERIOR LAMP
Turn Signal and Hazard Warning Lamps/
Trouble Diagnoses
Symptom
Turn signal and hazard warning
lamps do not operate.

Turn signal lamps do not operate


but hazard warning lamps operate.

Possible cause

GI

Repair order

1. Check hazard switch.


1. Hazard switch
2. Refer to combination flasher unit check.
2. Combination flasher unit
3. Open in combination flasher unit 3. Check wiring to combination flasher unit for open circuit.
circuit
1. Check 7.5A fuse (No. 3 , located in fuse block).
Turn ignition switch ON and verify battery positive
voltage is present at terminal q
2 of hazard switch.
2. Hazard switch
2. Check hazard switch.
3. Turn signal switch
3. Check turn signal switch.
4. Open in turn signal switch circuit 4. Check G wire between combination flasher unit and
turn signal switch for open circuit.

MA
EM

1. 7.5A fuse

Hazard warning lamps do not oper- 1. 10A fuse


ate but turn signal lamps operate.
2. Hazard switch
3. Open in hazard switch circuit
Front or side turn signal lamp LH
or RH does not operate.

1. Bulb
2. Grounds

E6

and

Rear turn signal lamp LH or RH


does not operate.

1. Bulb
2. Grounds

M1

and

LH and RH turn indicators do not


operate.
LH or RH turn indicator does not
operate.

1. Check 10A fuse (No. 5 , located in fuse block).


Verify battery positive voltage is present at terminal
q
3 of hazard switch.
2. Check hazard switch.
3. Check G wire between combination flasher unit and
hazard switch for open circuit.

LC
EC
FE
CL
MT

E39

1. Check bulb.
2. Check grounds

E6

and

E39

M54

1. Check bulb.
2. Check grounds

M1

and

M54

1. Ground

1. Check grounds

M1

and

M54

1. Bulb

1. Check bulb in combination meter.

TF
PD
FA

Combination Flasher Unit Check


I
I

Before checking, ensure that bulbs meet specifications.


Connect a battery and test lamp to the combination flasher unit,
as shown. Combination flasher unit is properly functioning if it
blinks when power is supplied to the circuit.

RA
BR
ST
RS

SEL122E

BT
HA

IDX

EL-67

EXTERIOR LAMP
Bulb Specifications
Item

Wattage (W)

Headlamp (Semi-sealed beam)


High/Low

60/55

Front combination lamp


Front turn signal lamp

21

Parking lamp

Side turn signal lamp

Rear combination lamp


Turn signal lamp

21

Stop/Tail lamp

21/5

Back-up lamp

21

License plate lamp


Step bumper

10

Standard bumper

EL-68

INTERIOR LAMP
Illumination/Wiring Diagram ILL
LHD MODELS

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL910

EL-69

INTERIOR LAMP
Illumination/Wiring Diagram ILL (Contd)
LHD MODELS

HEL911

EL-70

INTERIOR LAMP
Illumination/Wiring Diagram ILL (Contd)
RHD MODELS

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL912

EL-71

INTERIOR LAMP
Illumination/Wiring Diagram ILL (Contd)
RHD MODELS

HEL913

EL-72

INTERIOR LAMP
Interior and Spot Lamps/Wiring Diagram
INT/L

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL914

EL-73

INTERIOR LAMP
Interior and Spot Lamps/Wiring Diagram
INT/L (Contd)

HEL915

EL-74

INTERIOR LAMP
Bulb Specifications
Item
Interior lamp
Spot lamp

Wattage (W)
10
8

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

EL-75

METER AND GAUGES


Combination Meter
EXCEPT FOR THE MIDDLE EAST (With tachometer)

HEL990

EL-76

METER AND GAUGES


Combination Meter (Contd)
EXCEPT FOR THE MIDDLE EAST (Without tachometer)

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL991

EL-77

METER AND GAUGES


Combination Meter (Contd)
FOR THE MIDDLE EAST (With tachometer)

HEL992

EL-78

METER AND GAUGES


Combination Meter (Contd)
FOR THE MIDDLE EAST (Without tachometer)

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL993

EL-79

METER AND GAUGES


Speedometer, Tachometer, Temp. and Fuel
Gauges/Schematic

HEL994

EL-80

METER AND GAUGES


Speedometer, Tachometer, Temp. and Fuel
Gauges/Wiring Diagram METER

GI

LHD MODELS

MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL995

EL-81

METER AND GAUGES


Speedometer, Tachometer, Temp. and Fuel
Gauges/Wiring Diagram METER (Contd)
LHD MODELS

HEL996

EL-82

METER AND GAUGES


Speedometer, Tachometer, Temp. and Fuel
Gauges/Wiring Diagram METER (Contd)
LHD MODELS

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL920

EL-83

METER AND GAUGES


Speedometer, Tachometer, Temp. and Fuel
Gauges/Wiring Diagram METER (Contd)
RHD MODELS

HEL997

EL-84

METER AND GAUGES


Speedometer, Tachometer, Temp. and Fuel
Gauges/Wiring Diagram METER (Contd)
RHD MODELS

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL998

EL-85

METER AND GAUGES


Speedometer, Tachometer, Temp. and Fuel
Gauges/Wiring Diagram METER (Contd)
RHD MODELS

HEL923

EL-86

METER AND GAUGES


Unified Control Meter System Description
UNIFIED CONTROL METER

GI

Speedometer, odo/trip meter, tachometer, fuel gauge and water


temperature gauge are controlled totally by control unit combined
with speedometer.

MA
EM
LC

Meter/gauge Operation and Odo/Trip Meter


Segment Check in Diagnosis Mode

EC

DIAGNOSIS FUNCTION
I
I

Odo/trip meter segment can be checked in diagnosis mode.


Meters/gauges can be checked in diagnosis mode.

FE
CL
MT

HOW TO ALTERNATE DIAGNOSIS MODE

SEL110V

1. Turn ignition switch to ON and change odo/trip meter to TRIP


A or TRIP B.
2. Turn ignition switch to OFF.
3. Turn ignition switch to ON when pushing odo/trip meter switch.
4. Confirm that trip meter indicates 000.0.
5. Push odo/trip meter switch more than three times within 5 seconds.
6. All odo/trip meter segments should be turned on.
NOTE: If some segments are not turned on, speedometer (unified meter control unit) with odo/trip meter should be
replaced.
At this point, the unified control meter is turned to diagnosis
mode.

TF
PD
FA
RA
BR
ST
RS
BT

7. Push odo/trip meter switch. Indication of each meter/gauge


should be as shown left during pushing odo/trip meter switch if
it is no malfunctioning.
NOTE: It takes about 1 minute for indication of fuel gauge to
become stable.

HA

IDX

SEL163V

EL-87

METER AND GAUGES


Meter/gauge Operation and Odo/Trip Meter
Segment Check in Diagnosis Mode (Contd)

SEL164V

Flexible Print Circuit (FPC)


Tachometer, fuel gauge and water temperature gauge are connected with unified meter control unit (speedometer) by Flexible
Print Circuit (FPC) connector. When replace or remove and install
unified control unit (speedometer), disconnect and connect FPC
connector according to the following steps.

DISCONNECT
1. Open connector cover.
2. Release connector lock by holding both ends of it and pulling it
up.
3. Disconnect FPC by pulling it up.

SEL109V

CONNECT
1. Insert FPC into connector and lock connector pushing FPC
downward.
2. Check secure connection of FPC.
3. Check continuity of check land terminals for secure connection
of FPC.
Resistance: 0
4. Close connector cover.

SEL162V

EL-88

METER AND GAUGES


Trouble Diagnoses
PRELIMINARY CHECK

GI

CHECK-IN

MA
H

Can Diagnosis mode


be activated? Refer to
Meter/Gauge Operation and Odo/Trip Meter
Segment Check in
Diagnosis Mode,
EL-87.

No

Do meter warning
lamps operate?

Yes

No

Check the screws


securing speedometer
and FPC.
(The screws are
located behind the
combination meter. For
details refer to EL-94.)

Can Diagnosis mode


be activated?
G

No

Yes

EM
LC
EC

Yes
H

FE

Check power supply


and ground circuit.
Refer to POWER SUPPLY AND GROUND
CIRCUIT CHECK,
EL-91.

CL
MT

Check meter/gauge
operation in Diagnosis
mode.

TF

PD
H

Malfunction is indicated
in Diagnosis mode.

No malfunction is indicated in Diagnosis


mode.

Check the following:


I FPC connector connection
Refer to Flexible
Print Circuit (FPC),
EL-88.
I Screws securing the
malfunctioning meter/
gauge
(The screws are
located behind the
combination meter.
For details refer to
EL-94.)

SYMPTOM CHART 2
Refer to EL-90.

Replace speedometer
(unified meter control
unit).

FA
RA
BR
ST

NG

RS
BT
HA

OK
H

SYMPTOM CHART 1
Refer to EL-90.

Reconnect FPC connector and check continuity between


check land terminals and/or repair malfunctioning part.
Refer to FLEXIBLE PRINT CIRCUIT (FPC), EL-88.

EL-89

IDX

METER AND GAUGES


Trouble Diagnoses (Contd)
Before starting trouble diagnoses below, perform PRELIMINARY CHECK, EL-89.

SYMPTOM CHART 1 (MALFUNCTION IS INDICATED IN DIAGNOSIS MODE)


Symptom
Speedometer and/or odo/trip
meter indicate(s) malfunction
in Diagnosis mode.

Possible causes

Repair order

I Speedometer (Unified meter control unit)

I Replace speedometer (unified meter control unit).

I Meter/Gauge
I Speedometer (Unified meter control unit)

1. Check resistance of meter/gauge indicating malfunction. If


the resistance is NG, replace the meter/gauge. Refer to
METER/GAUGE RESISTANCE CHECK, EL-94.
2. If the resistance is OK, replace speedometer (unified meter
control unit).

Multiple meter/gauge indicate


malfunction in Diagnosis
mode.
One of tachometer/fuel gauge/
water temp. gauge indicates
malfunction in Diagnosis
mode.

SYMPTOM CHART 2 (NO MALFUNCTION IS INDICATED IN DIAGNOSIS MODE)


Symptom
Speedometer and odo/trip
meter are malfunctioning.

Possible causes

Repair order

1. Sensor
- Speedometer, Odo/Trip meter
2. FPC connector
3. Speedometer (Unified meter control unit)

Multiple meter/gauge are malfunctioning. (except


speedometer, odo/trip meter)

1. FPC connector

One of tachometer/fuel gauge/


water temp. gauge is malfunctioning.

1. Sensor/Engine revolution signal


- Tachometer

2. Speedometer (Unified meter control unit)

- Fuel gauge
- Water temp. gauge
2. FPC connector
3. Speedometer (Unified meter control unit)

EL-90

1. Check vehicle speed sensor.


INSPECTION/VEHICLE SPEED SENSOR (Refer to EL-92.)
2. Check FPC connector. Refer to FLEXIBLE PRINT CIRCUIT
(FPC), EL-88.
3. Replace speedometer (unified meter control unit).
1. Check FPC connector. Refer to FLEXIBLE PRINT CIRCUIT
(FPC), EL-88.
2. Replace speedometer (unified meter control unit).
1. Check the sensor for malfunctioning meter/gauge.
INSPECTION/ENGINE REVOLUTION SIGNAL (Refer to
EL-92.)
INSPECTION/FUEL TANK GAUGE (Refer to EL-93.)
INSPECTION/THERMAL TRANSMITTER (Refer to EL-93.)
2. Check FPC connector. Refer to FLEXIBLE PRINT CIRCUIT
(FPC), EL-88.
3. Replace speedometer (unified meter control unit).

METER AND GAUGES


Trouble Diagnoses (Contd)
POWER SUPPLY AND GROUND CIRCUIT CHECK
Power supply circuit check

GI

Terminals

SEL165V

Ignition switch position


@

OFF

ACC

ON

q
38

Ground

Battery
voltage

Battery
voltage

Battery
voltage

q
29

Ground

0V

0V

Battery
voltage

If NG, check the following.


I 7.5A fuse [No. 6 , located in fuse block (J/B)]
I 10A fuse [No. 1 , located in fuse block (J/B)]
I Harness for open or short between fuse and combination meter

MA
EM
LC
EC
FE
CL
MT

Ground circuit check


Terminals

Continuity

q
26 - Ground

Yes

TF
PD
FA
RA

SEL166V

BR
ST
RS
BT
HA

IDX

EL-91

METER AND GAUGES


Trouble Diagnoses (Contd)
INSPECTION/VEHICLE SPEED SENSOR
CHECK VEHICLE SPEED SENSOR
OUTPUT.
1. Remove vehicle speed sensor from
transmission.
2. Check voltage between combination
meter terminals q
8 and q
10 while quickly
turning speed sensor pinion.
Voltage: Approx. 0.5V

OK

Vehicle speed sensor is


OK.

Replace vehicle speed


sensor.

NG
H

NG

CHECK VEHICLE SPEED SENSOR.


Check resistance between vehicle speed
sensor terminals q
1 and q
2 .
Resistance: Approx. 250
OK
H
SEL167V

Check harness or connector between


speedometer and vehicle speed sensor.

SEL118V

INSPECTION/ENGINE REVOLUTION SIGNAL (Models


with tachometer)
Terminals
Engine
Injection

Check item

DC voltage

Carburetor
AC voltage

q
9

Diesel
SEL168V

Explanation

q
26

Higher rpm = Higher voltage


Lower rpm = Lower voltage
Voltage should change with
rpm.

If NG, check the following.


Engine

Check item

Injection

I Harness for open or short and connection

Carburetor

I Harness for open or short and connection


I Resistor etc.

Diesel

I Harness for open or short and connection


I Engine revolution sensor etc.

EL-92

METER AND GAUGES


Trouble Diagnoses (Contd)
INSPECTION/FUEL TANK GAUGE
CHECK GROUND CIRCUIT FOR FUEL
TANK GAUGE UNIT.
Check harness continuity between fuel
tank gauge unit terminal q
3 and ground.
Continuity should exist.

NG

GI
Repair harness or connecE
tor.

MA
EM

OK
H
SEL169V

CHECK GAUGE UNITS.


Refer to FUEL TANK GAUGE UNIT
CHECK (EL-94).

NG

Repair or replace.
Refer to FE section.

LC
EC

OK

FE
H

CHECK HARNESS.
1. Disconnect combination meter connector N4 and fuel tank gauge unit connector.
2. Check harness continuity between combination meter terminal q
7 and fuel
tank gauge unit terminal q
1 .
Continuity should exist.
3. Check continuity between combination
meter terminal q
7 and ground.
Continuity should not exist.

NG

Repair harness or connector.

CL
MT
TF
PD

OK

FA

Fuel tank gauge is OK.

RA

SEL170V

INSPECTION/THERMAL TRANSMITTER
CHECK THERMAL TRANSMITTER.
Refer to THERMAL TRANSMITTER
CHECK (EL-95).

NG

BR

Repair or replace.

ST

OK

RS
H

CHECK HARNESS.
1. Disconnect combination meter connector N4 and thermal transmitter connector.
2. Check harness for open or short
between combination meter terminal q
6
and thermal transmitter terminal q
1 .
3. Check continuity between combination
meter terminal q
6 and ground.
Continuity should not exist.
OK
H

Thermal transmitter is OK.


SEL171V

EL-93

NG

Repair harness or connector.

BT
HA

IDX

METER AND GAUGES


Electrical Components Inspection
METER/GAUGE RESISTANCE CHECK
1. Disconnect FPC connector. Refer to EL-88.
2. Check resistance between installation screws of meter/gauge.
Screws
Tachometer

Fuel/Temp. gauge

Resistance

A-C

A-C

Approx. 70 - Approx. 140

B-D

B-C

Approx. 90 - Approx. 170

SEL172V

SEL173V

FUEL TANK GAUGE UNIT CHECK (With electric fuel


pump)
I For removal, refer to FE section.
Check the resistance between terminals q
1 and q
4 .
Ohmmeter
(+)

()

q
1

q
4

Float position

mm (in)

60 (13-1/4
Imp gal) tank

80 (17-5/8
Imp gal) tank

Resistance
value
()

Full

253 (9.96)

247 (9.72)

Approx. 4 - 6

*2

1/2

130 (5.12)

130 (5.12)

27 - 35

*3

Empty

27 (1.06)

26 (1.02)

78 - 85

*1

*1 and *3: When float rod is in contact with stopper.

GEL189

EL-94

METER AND GAUGES


Electrical Components Inspection (Contd)
FUEL TANK GAUGE UNIT CHECK (With mechanical fuel
pump)
I For removal, refer to FE section.
Check the resistance between terminals q
1 and q
2 .
Ohmmeter
(+)

Float position

()
*1

q
1

q
2

Full

mm (in)

60 (13-1/4
Imp gal) tank

80 (17-5/8
Imp gal) tank

Resistance
value
()

50 (1.97)

247 (9.72)

Approx. 4 - 6

*2

1/2

174 (6.85)

130 (5.12)

27 - 35

*3

Empty

277 (10.91)

26 (1.02)

78 - 85

GI
MA
EM
LC
EC
FE
CL
MT

GEL190

THERMAL TRANSMITTER CHECK


Check the resistance between the terminals of thermal transmitter
and body ground.
Water temperature

Resistance

60C (140F)

Approx. 167 - 211

100C (212F)

Approx. 47 - 53

TF
PD
FA
RA

MEL424F

VEHICLE SPEED SENSOR SIGNAL CHECK


1. Remove vehicle speed sensor from transmission.
2. Turn vehicle speed sensor pinion quickly and measure voltage
a and q
b .
between terminals q

BR
ST
RS
BT

SEL378PA

HA

IDX

EL-95

WARNING LAMPS
Schematic

HEL924

EL-96

WARNING LAMPS
Wiring Diagram WARN
LHD MODELS

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL988

EL-97

WARNING LAMPS
Wiring Diagram WARN (Contd)
LHD MODELS

HEL999

EL-98

WARNING LAMPS
Wiring Diagram WARN (Contd)
LHD MODELS

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL927

EL-99

WARNING LAMPS
Wiring Diagram WARN (Contd)
LHD MODELS

HEL928

EL-100

WARNING LAMPS
Wiring Diagram WARN (Contd)
LHD MODELS

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL929

EL-101

WARNING LAMPS
Wiring Diagram WARN (Contd)
RHD MODELS

HEL930

EL-102

WARNING LAMPS
Wiring Diagram WARN (Contd)
RHD MODELS

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL931

EL-103

WARNING LAMPS
Wiring Diagram WARN (Contd)
RHD MODELS

HEL932

EL-104

WARNING LAMPS
Wiring Diagram WARN (Contd)
RHD MODELS

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL964

EL-105

WARNING LAMPS
Wiring Diagram WARN (Contd)
RHD MODELS

HEL965

EL-106

WARNING LAMPS
Electrical Components Inspection
FUEL WARNING LAMP SENSOR CHECK
I

GI

It will take a short time for the bulb to light.

MA
EM
LC
EC
FE
CL
MT

GEL191

OIL PRESSURE SWITCH CHECK

TF

Oil pressure
kPa (bar, kg/cm2, psi)

Continuity

Engine start

More than 10 - 20
(0.10 - 0.20, 0.1 - 0.2, 1 - 3)

NO

PD

Engine stop

Less than 10 - 20
(0.10 - 0.20, 0.1 - 0.2, 1 - 3)

YES

FA

Check the continuity between the terminals of oil pressure switch


and body ground.
MEL425F

DIODE CHECK
I
I

Check continuity using an ohmmeter.


Diode is functioning properly if test results are as shown in the
figure at left.
NOTE: Specification may vary depending on the type of tester.
Before performing this inspection, be sure to refer to
the instruction manual for the tester to be used.

RA
BR
ST
RS
BT

SEL901F

Diodes for warning lamps are built into the combination meter
printed circuit.

HA

IDX

GEL192

EL-107

WARNING BUZZER
Wiring Diagram BUZZER

HEL933

EL-108

WARNING BUZZER
Electrical Components Inspection
WARNING BUZZER CHECK

GI
MA
EM
LC

GEL208

EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

EL-109

WIPER AND WASHER


System Description
WIPER OPERATION
The wiper switch is controlled by a lever built into the combination switch.
There are two or three wiper switch positions:
I LO speed
I HI speed
I INT (Intermittent wiper models only)
With the ignition switch in the ACC or ON position, power is supplied
I through 20A fuse (No. 16 , located in the fuse block)
I to wiper motor terminal q
4 .
Low and high speed wiper operation
Ground is supplied to wiper switch terminal q
17 through body grounds M1 and M54 .
When the wiper switch is placed in the LO position, ground is supplied
I through terminal q
14 of the wiper switch
2 .
I to wiper motor terminal q
With power and ground supplied, the wiper motor operates at low speed.
When the wiper switch is placed in the HI position, ground is supplied
I through terminal q
16 of the wiper switch
I to wiper motor terminal q
3 .
With power and ground supplied, the wiper motor operates at high speed.
Auto stop operation
With wiper switch turned OFF, wiper motor will continue to operate until wiper arms reach windshield base.
When wiper arms are not located at base of windshield with wiper switch OFF, ground is provided
I from terminal q
14 of the wiper switch
I to wiper motor terminal q
2 , in order to continue wiper motor operation at low speed.
Ground is also supplied
I through terminal q
13 of the wiper switch
I to wiper amplifier terminal q
2 (Intermittent wiper models only)
I through terminal q
7 of the wiper amplifier (Intermittent wiper models only)
5
I to wiper motor terminal q
I through terminal q
6 of the wiper motor, and
I through body grounds M1 and M54 .
4 and q
5 are connected instead of terWhen wiper arms reach base of windshield, wiper motor terminals q
minals q
5 and q
6 . Wiper motor will then stop wiper arms at the PARK position.
Intermittent operation
The wiper motor operates the wiper arms one time at low speed at an interval of approximately 7 seconds.
This feature is controlled by the wiper amplifier.
When the wiper switch is placed in the INT position, ground is supplied
I to wiper amplifier terminal q
1
I from wiper switch terminal q
15
I through body grounds M1 and M54 .
2
I to wiper motor terminal q
I through the wiper switch terminal q
14
I to wiper switch terminal q
13
I through wiper amplifier terminal q
2
I to wiper amplifier terminal q
3
I through body grounds M1 and M54 .
With power and ground supplied, the wiper motor operates at low speed intermittently.

EL-110

WIPER AND WASHER


System Description (Contd)
WASHER OPERATION
With the ignition switch in the ACC or ON position, power is supplied
I through 20A fuse (No. 16 , located in the fuse block)
1 .
I to washer motor terminal q

With intermittent wiper


When the lever is pulled to the WASH position, ground is supplied
2 , and
I to washer motor terminal q
I to wiper amplifier terminal q
6
I from terminal q
18 of the wiper switch
17 of the wiper switch, and
I through terminal q
I through body grounds M1 and M54 .
With power and ground supplied, the washer motor operates.
When the lever is pulled to the WASH position for one second or more, the wiper motor operates at low speed
for approximately 3 times after the lever is released. This feature is controlled by the wiper amplifier in the
same manner as the intermittent operation.

GI
MA
EM
LC
EC

Without intermittent wiper


When the lever is pulled to the WASH position, ground is supplied
I to washer motor terminal q
2
I from terminal q
18 of the wiper switch
I through terminal q
17 of the wiper switch, and
I through body grounds M1 and M54 .
With power and ground supplied, the washer motor operates.

FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

EL-111

WIPER AND WASHER


Front Wiper and Washer/Wiring Diagram
WIPER
LHD MODELS WITH INTERMITTENT WIPER

HEL934

EL-112

WIPER AND WASHER


Front Wiper and Washer/Wiring Diagram
WIPER (Contd)
LHD MODELS WITH INTERMITTENT WIPER

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL935

EL-113

WIPER AND WASHER


Front Wiper and Washer/Wiring Diagram
WIPER (Contd)
LHD MODELS WITHOUT INTERMITTENT WIPER

HEL936

EL-114

WIPER AND WASHER


Front Wiper and Washer/Wiring Diagram
WIPER (Contd)
RHD MODELS WITH INTERMITTENT WIPER

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL937

EL-115

WIPER AND WASHER


Front Wiper and Washer/Wiring Diagram
WIPER (Contd)
RHD MODELS WITH INTERMITTENT WIPER

HEL938

EL-116

WIPER AND WASHER


Front Wiper and Washer/Wiring Diagram
WIPER (Contd)
RHD MODELS WITHOUT INTERMITTENT WIPER

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL939

EL-117

WIPER AND WASHER


Front Wiper and Washer/Wiring Diagram
WIPER (Contd)
RHD MODELS WITHOUT INTERMITTENT WIPER

HEL940

EL-118

WIPER AND WASHER


Trouble Diagnoses
DIAGNOSTIC PROCEDURE 1

GI

SYMPTOM: Intermittent wiper does not operate.


Check whether wiper operates with the
wiper switch at Lo position.

NG

OK

SEL140VB
H

1) Turn front wiper switch to OFF.


2) Disconnect wiper amp. connector.
3) Check voltage between wiper amp. terminal q
2 and ground.
Battery voltage should exist.

NG

OK
H

SEL141VB

CHECK INTERMITTENT SWITCH INPUT


SIGNAL.
Check harness continuity between wiper
amp. terminal q
1 and ground.
Condition of
wiper switch

Continuity

OFF

No

INT

Yes

NG

Check the following.


I 20A fuse (No. 16 ,
located in fuse block)
I Wiper motor
I Wiper switch
I Harness for open or
short

MA

Check the following.


I Wiper switch
I Harness for open or
short between wiper
amp. terminal q
2 and
wiper switch terminal q
13

EC

SEL142VB

Check the following.


I Wiper switch
I Harness for open or
short between wiper
amp. terminal q
1 and
wiper switch terminal q
15
I Ground circuit for front
wiper switch terminal q
17

OK
H

Replace wiper amp.

FE

MT
TF
PD

NG

Check the following.


I 20A fuse (No. 16 ,
located in fuse block)
I Harness for open or
short between wiper
amp. and fuse

FA
RA
BR

OK

CHECK WIPER AMP. GROUND CIRCUIT.


Check harness continuity between wiper
amp. terminal q
3 and body ground.
Continuity should exist.

LC

CL

OK

CHECK WIPER AMP. POWER SUPPLY


CIRCUIT.
Check voltage between wiper amp. terminal q
5 and ground while ignition switch is
ACC.
Battery voltage should exist.

EM

NG

Repair harness or connector.

ST
RS
BT

SEL143VB

HA

IDX

EL-119

WIPER AND WASHER


Trouble Diagnoses (Contd)
DIAGNOSTIC PROCEDURE 2
SYMPTOM: Wiper and washer activate individually but not in
combination.

SEL145VB

CHECK WASHER SWITCH INPUT SIGNAL.


1) Turn ignition switch to OFF.
2) Disconnect wiper amp. connector.
3) Check harness continuity between
wiper amp. terminal q
6 and ground.
Condition of
washer switch

NG

Check harness for open or


short between wiper amp.
terminal q
6 and wiper
switch terminal q
18 .

Continuity

OFF

No

ON

Yes

OK
H

Go to DIAGNOSTIC PROCEDURE 1.

NG

Replace wiper amp.

Wiper Installation and Adjustment

SEL543TA

1. Prior to wiper arm installation, turn on wiper switch to operate


wiper motor and then turn it OFF (Auto Stop).
2. Lift the blade up and then set it down onto glass surface to set
the blade center to clearance L1 & L2 immediately before
tightening nut.
3. Eject washer fluid. Turn on wiper switch to operate wiper motor
and then turn it OFF.
4. Ensure that wiper blades stop within clearance L1 & L2.
Clearance L1: 20 - 30 mm (0.79 - 1.18 in)
Clearance L2: 20 - 30 mm (0.79 - 1.18 in)
I Tighten wiper arm nuts to specified torque.
Front wiper: 12.7 - 17.7 Nm (1.3 - 1.8 kg-m, 9 - 13 ft-lb)

Before reinstalling wiper arm, clean up the pivot area as


illustrated. This will reduce possibility of wiper arm looseness.

SEL024J

EL-120

WIPER AND WASHER


Washer Nozzle Adjustment
I

Adjust washer nozzle with suitable tool as shown in the figure


at left.
Adjustable range: 10

GI
MA
EM
LC

GEL013-A

Unit: mm (in)
*1

470 (18.50)

*5

60 (2.36)

*2

215 (8.46)

*6

225 (8.86)

*3

380 (14.96)

*7

255 (10.04)

*4

180 (7.09)

*8

460 (18.11)

*: The diameters of these circles are less than 60 mm (2.36 in).

EC
FE
CL
MT

SEL544TA

TF
PD
FA
RA

SEL845T

Washer Tube Layout

BR
ST
RS
BT

GEL193

HA

IDX

EL-121

WIPER AND WASHER


Wiper Linkage

GEL194

REMOVAL
1.
2.
3.
Be

Remove 4 bolts that secure wiper motor.


Detach wiper motor from wiper linkage at ball joint.
Remove wiper linkage.
careful not to break ball joint rubber boot.

INSTALLATION
I Grease ball joint portion before installation.
1. Installation is the reverse order of removal.

EL-122

HORN, CIGARETTE LIGHTER AND CLOCK


Wiring Diagram HORN
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL941

EL-123

HORN, CIGARETTE LIGHTER AND CLOCK


Wiring Diagram HORN (Contd)

HEL942

EL-124

REAR WINDOW DEFOGGER


Wiring Diagram DEF
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL943

EL-125

REAR WINDOW DEFOGGER


Electrical Components Inspection
REAR WINDOW DEFOGGER SWITCH
Check continuity between terminals when rear window defogger
switch is pushed and released.
Terminals

q
1 -q
2
GEL195

Condition

Continuity

Rear window defogger


switch is pushed

Yes

Rear window defogger


switch is released

No

Filament Check
1. Attach probe circuit tester (in volt range) to middle portion of
each filament.

SEL263

When measuring voltage, wrap tin foil around the top of


the negative probe. Then press the foil against the wire
with your finger.

SEL122R

2. If a filament is burned out, circuit tester registers 0 or 12 volts.

SEL265

EL-126

REAR WINDOW DEFOGGER


Filament Check (Contd)
3. To locate burned out point, move probe to left and right along
filament. Test needle will swing abruptly when probe passes the
point.

GI
MA
EM
LC

SEL266

Filament Repair
REPAIR EQUIPMENT
1.
2.
3.
4.
5.
6.

Conductive silver composition (Dupont No. 4817 or equivalent)


Ruler 30 cm (11.8 in) long
Drawing pen
Heat gun
Alcohol
Cloth

EC
FE
CL
MT

REPAIRING PROCEDURE
1. Wipe broken heat wire and its surrounding area clean with a
cloth dampened in alcohol.
2. Apply a small amount of conductive silver composition to tip of
drawing pen.
Shake silver composition container before use.
3. Place ruler on glass along broken line. Deposit conductive silver composition on break with drawing pen. Slightly overlap
existing heat wire on both sides [preferably 5 mm (0.20 in)] of
the break.
BE540

4. After repair has been completed, check repaired wire for continuity. This check should be conducted 10 minutes after silver
composition is deposited.
Do not touch repaired area while test is being conducted.

TF
PD
FA
RA
BR
ST
RS
BT

SEL012D

5. Apply a constant stream of hot air directly to the repaired area


for approximately 20 minutes with a heat gun. A minimum distance of 3 cm (1.2 in) should be kept between repaired area
and hot air outlet. If a heat gun is not available, let the repaired
area dry for 24 hours.

HA

IDX

SEL013D

EL-127

AUDIO
Wiring Diagram AUDIO
LHD MODELS RADIO WITH 1-SPEAKER

HEL944

EL-128

AUDIO
Wiring Diagram AUDIO (Contd)
LHD MODELS RADIO WITH 2 OR 4-SPEAKERS (Without CD deck)

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL945

EL-129

AUDIO
Wiring Diagram AUDIO (Contd)
LHD MODELS RADIO WITH 4-SPEAKERS (With CD deck)

HEL946

EL-130

AUDIO
Wiring Diagram AUDIO (Contd)
LHD MODELS RADIO WITH 4-SPEAKERS (With CD deck)

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL947

EL-131

AUDIO
Wiring Diagram AUDIO (Contd)
RHD MODELS

HEL948

EL-132

AUDIO
Trouble Diagnoses
Symptom
Radio inoperative (no digital
display and no sound from
speakers).

Possible causes

Repair order

18 , located in fuse block). Turn ignition switch ON and verify battery positive voltage is
present at terminal q
10 of radio.
2. Check radio case ground.
3. Remove radio for repair.

1. 10A fuse

1. Check 10A fuse (No.

2. Poor radio case ground


3. Radio
Radio controls are operational, 1. Radio output
but no sound is heard from
2. Radio
any speaker.

1. Check radio output voltages.


2. Remove radio for repair.

Radio presets are lost when


ignition switch is turned OFF.

2. Radio

1. Check 7.5A fuse (No. 6 , located in fuse block) and verify


battery positive voltage is present at terminal q
6 of radio.
2. Remove radio for repair.

Individual speaker is noisy or


inoperative.

1.
2.
3.
4.

1.
2.
3.
4.

Radio stations are weak or


noisy.

1. Antenna
2. Poor radio ground
3. Radio

1. Check antenna.
2. Check radio ground.
3. Remove radio for repair.

1. Poor radio ground


2. Loose or missing ground bonding straps
3. Ignition condenser or rear window defogger
noise suppressor condenser
4. Alternator
5. Ignition coil or secondary wiring
6. Radio

1. Check radio ground.


2. Check ground bonding straps.
3. Replace ignition condenser or rear window defogger noise
suppressor condenser.
4. Check alternator.
5. Check ignition coil and secondary wiring.
6. Remove radio for repair.

1.
2.
3.
4.

1.
2.
3.
4.

Radio generates static noise


with engine running.

Radio generates static noise


with accessories on (switch
pops and motor noise).

1. 7.5A fuse

Speaker
Radio output
Speaker circuit
Radio

Poor radio ground


Antenna
Accessory ground
Faulty accessory

Check speaker.
Check radio output voltages.
Check wires for open or short between radio and speaker.
Remove radio for repair.

Check radio ground.


Check antenna.
Check accessory ground.
Replace accessory.

MA
EM
LC
EC
FE
CL
MT
TF
PD
FA

SPEAKER INSPECTION
1.
2.
I
3.
I

GI

Disconnect speaker harness connector.


Measure the resistance between speaker terminals q
1 and q
2 .
The resistance should be 2 - 4.
Using jumper wires, momentarily connect a 9V battery between speaker terminals q
1 and q
2 .
A momentary hum or pop should be heard.

RA
BR

ANTENNA INSPECTION

ST

Using a jumper wire, clip an auxiliary ground between antenna and body.
I If reception improves, check antenna ground (at body surface).
I If reception does not improve, check main feeder cable for short circuit or open circuit.

RS

RADIO INSPECTION

BT

All
I
I
I

HA

voltage inspections are made with:


Ignition switch ON or ACC
Radio ON
Radio connected (If removed for inspection, supply a ground to the case using a jumper wire.)

IDX

EL-133

AUDIO ANTENNA
Manual Antenna
LOCATION OF ANTENNA

GEL196

ANTENNA ASSEMBLY REPLACEMENT


1. Remove antenna cover in cowl top.
2. Remove wiper arm and cowl top.

GEL207

3. Loosen nut at antenna bracket.


4. Disconnect antenna feeder cable jack shown in the above illustration.
5. Remove fender protector.
6. Remove the grommet and pull the feeder cable out from fender
inner.
7. Remove antenna assembly and replace with a new one.

GEL197

EL-134

AUDIO ANTENNA
Power Antenna/Wiring Diagram P/ANT
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL949

EL-135

AUDIO ANTENNA
Power Antenna
TROUBLE DIAGNOSES
Symptom
Power antenna does not operate.

Possible causes

Repair order
1. Check 7.5A fuse (No. 6 , located in fuse block). Verify that
battery positive voltage is present at terminal q
1 of power
antenna.
2. Turn ignition switch and radio ON. Verify that battery positive
voltage is present at terminal q
3 of power antenna.
3. Check grounds E6 and E39 .

1. 7.5A fuse

2. Radio signal
3. Grounds

E6

and E39

LOCATION OF ANTENNA

SEL339V

ANTENNA ROD REPLACEMENT


Removal
1. Remove antenna nut and antenna base.

SEL240V

2. Withdraw antenna rod while raising it by operating antenna


motor.

SEL341V

EL-136

AUDIO ANTENNA
Power Antenna (Contd)
Installation
1. Lower antenna rod by operating antenna motor.
2. Insert gear section of antenna rope into place with it facing
toward antenna motor.
3. As soon as antenna rope is wound on antenna motor, stop
antenna motor. Insert antenna rod lower end into antenna
motor pipe.
4. Retract antenna rod completely by operating antenna motor.
5. Install antenna nut and base.

GI
MA
EM
LC
EC
FE
CL
MT

SEL342V

ANTENNA ASSEMBLY REPLACEMENT


1. Remove antenna nut and antenna base.
2. Loosen bolts at antenna bracket and disconnect power antenna
connector.
3. Disconnect antenna feeder cable jack shown in LOCATION
OF ANTENNA.
4. Remove fender protector.
5. Remove the grommet and pull the feeder cable out from fender
inner.
6. Remove antenna assembly and replace with a new one.
SEL240V

TF
PD
FA
RA
BR
ST
RS
BT

SEL340V

HA

IDX

EL-137

POWER DOOR MIRROR


Wiring Diagram MIRROR

HEL950

EL-138

POWER DOOR MIRROR


Wiring Diagram MIRROR (Contd)
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL951

EL-139

POWER WINDOW
System Description
Power is supplied at all times
I from 30A fusible link (Letter b , located in the fusible link and fuse box)
I to circuit breaker terminal q
1
I through circuit breaker terminal q
2
I to power window relay terminal q
3 .
With ignition switch in ON or START position, power is supplied
I through 10A fuse (No. 14 , located in the fuse block)
2 .
I to power window relay terminal q
Ground is supplied to power window relay terminal q
1
I through body grounds M1 and M54 .
The power window relay is energized and power is supplied
I through power window relay terminal q
5
I to power window main switch terminal q
1 ,
5 .
I to power window sub-switch terminal q

MANUAL OPERATION
Driver side door
Ground is supplied
I to power window main switch terminal q
3
I through body grounds M1 and M54 .
WINDOW UP
When the driver side switch in the power window main switch is pressed in the up position, power is supplied
2
I to driver side power window regulator terminal q
I through power window main switch terminal q
9 .
Ground is supplied
I to driver side power window regulator terminal q
1
I through power window main switch terminal q
8 .
Then, the motor raises the window until the switch is released.
WINDOW DOWN
When the driver side switch in the power window main switch is pressed in the down position, power is supplied
I to driver side power window regulator terminal q
1
I through power window main switch terminal q
8 .
Ground is supplied
I to driver side power window regulator terminal q
2
I through power window main switch terminal q
9 .
Then, the motor lowers the window until the switch is released.

Front passenger side door


Ground is supplied
I to power window main switch terminal q
3
I through body grounds M1 and M54 .
NOTE:
Numbers in parentheses are terminal numbers, when power window switch is pressed in the up and down
positions respectively.
MAIN SWITCH OPERATION
Power is supplied
I through power window main switch (q
5 ,q
6 )
4 ,q
3 ).
I to front power window sub-switch (q
The subsequent operation is the same as the sub-switch operation.

EL-140

POWER WINDOW
System Description (Contd)
SUB-SWITCH OPERATION
Power is supplied
I through front power window sub-switch (q
2 ,q
1 )
I to front passenger side power window regulator (q
2 ,q
1 ).
Ground is supplied
I to front passenger side power window regulator (q
1 ,q
2 )
I through front power window sub-switch (q
1 ,q
2 )
I to front power window sub-switch (q
3 ,q
4 )
6 ,q
5 ).
I through power window main switch (q
Then, the motor raises or lowers the window until the switch is released.

Rear door
Rear door windows will raise and lower in the same manner as front passenger side door window.

AUTO OPERATION
The power window AUTO feature enables the driver to open or close the drivers window without holding the
window switch in the respective position.
When the AUTO switch in the main switch is pressed and released, the drivers window will travel to the fully
open or closed position.

GI
MA
EM
LC
EC
FE

POWER WINDOW LOCK

CL

The power window lock is designed to lock operation of all windows except for drivers door window.
When the lock switch is pressed to lock position, ground of the sub-switches in the power window main switch
is disconnected. This prevents the power window motors from operating.

MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

EL-141

POWER WINDOW
Schematic

HEL952

EL-142

POWER WINDOW
Wiring Diagram WINDOW
LHD MODELS

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL953

EL-143

POWER WINDOW
Wiring Diagram WINDOW (Contd)
LHD MODELS

HEL954

EL-144

POWER WINDOW
Wiring Diagram WINDOW (Contd)
LHD MODELS

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL955

EL-145

POWER WINDOW
Wiring Diagram WINDOW (Contd)
LHD MODELS

HEL956

EL-146

POWER WINDOW
Wiring Diagram WINDOW (Contd)
RHD MODELS

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL957

EL-147

POWER WINDOW
Wiring Diagram WINDOW (Contd)
RHD MODELS

HEL958

EL-148

POWER WINDOW
Wiring Diagram WINDOW (Contd)
RHD MODELS

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL959

EL-149

POWER WINDOW
Wiring Diagram WINDOW (Contd)
RHD MODELS

HEL960

EL-150

POWER WINDOW
Trouble Diagnoses
Symptom

Possible cause

Repair order

None of the power windows can be 1. 10A fuse, 30A fusible link and 1. Check 10A fuse (No. 14 , located in fuse block), 30A
fusible link (letter b , located in fusible link and fuse
operated using any switch.
M52 circuit breaker
box) and M52 circuit breaker. Turn ignition switch
ON and verify battery positive voltage is present at
terminal q
1 of power window main switch and terminal
q
5 of sub-switch.
2. Grounds M1 and M54
2. Check grounds M1 and M54 .
3. Check power window relay.
3. Power window relay
4. Open/short in power window 4. Check W wire between power window relay and power
window main switch for open/short circuit.
main switch circuit
Driver side power window cannot be 1. Driver side power window regula- 1. Check harness between power window main switch
and power window regulator for open or short circuit.
tor circuit
operated but other windows can be
2. Driver side power window regula- 2. Check driver side power window regulator.
operated.
tor
Passenger power window cannot be 1. Power window sub-switches
operated.
2. Passenger side power window
regulators
3. Power window main switch
4. Power window circuit

1. Check power window sub-switch.


2. Check passenger side power window regulator.
3. Check power window main switch.
4-1. Check harnesses between power window main
switch and power window sub-switch for open/short
circuit.
4-2. Check harnesses between power window subswitch and power window regulator for open/short
circuit.

Passenger power window cannot be 1. Power window main switch


operated using power window main
switch but can be operated by power
window sub-switch.

1. Check power window main switch.

Driver side power window auto func- 1. Power window main switch
tion cannot be operated using power
window main switch.

1. Check power window main switch.

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

EL-151

POWER DOOR LOCK


System Description
Power is supplied at all times
I through 30A fusible link (Letter b , located in the fusible link and fuse box)
I to circuit breaker terminal q
1
I through circuit breaker terminal q
2
I to door lock timer terminal q
3 .
Ground is supplied to door lock timer terminal q
1 through body grounds M1 and

M54

INPUT
When the door lock & unlock switch (power window main switch) is in LOCKED position, ground signal is
supplied
I to door lock timer terminal q
5
I through door lock & unlock switch terminal q
14
I to door lock & unlock switch terminal q
3
I through body grounds M1 and M54 .
When the door lock & unlock switch (power window main switch) is in UNLOCKED position, ground signal is
supplied
I to door lock timer terminal q
8
I through door lock & unlock switch terminal q
7
I to door lock & unlock switch terminal q
3
I through body grounds M1 and M54 .
Driver side door key cylinder and driver side lock knob are connected to lock knob switch with a rod. When
lock knob switch is in UNLOCKED position, ground signal is supplied
I to door lock timer terminal q
6
I through lock knob switch terminal q
2
I to driver side lock knob switch terminal q
1
I through body grounds M1 and M54 .
When lock knob switch is in LOCKED position, ground signal is interrupted.
Door lock operates according to the conditions of the door lock & unlock switch (power window main switch)
and lock knob switch.

OUTPUT
Unlock
Ground is supplied
I to passenger side door lock actuator, rear door lock actuator LH and RH terminal q
1 (double cab models)
I through door lock timer terminal q
2 .
Power is supplied
I to passenger side door lock actuator, rear door lock actuator LH and RH terminal q
2 (double cab models)
I through door lock timer terminal q
4 .
Then, the doors are unlocked.
Lock
Ground is supplied
I to passenger side door lock actuator, rear door lock actuator LH and RH terminal q
2
I through door lock timer terminal q
4 .
Power is supplied
I to passenger side door lock actuator, rear door lock actuator LH and RH terminal q
1
I through door lock timer terminal q
2 .
Then, the doors are locked.

EL-152

POWER DOOR LOCK


Wiring Diagram D/LOCK
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL961

EL-153

POWER DOOR LOCK


Wiring Diagram D/LOCK (Contd)

HEL962

EL-154

POWER DOOR LOCK


Trouble Diagnosis
SYMPTOM CHART

GI
EL-155

EL-156

None of the doors lock/unlock when operating any switch.

EL-158

Diagnostic procedure 3
(Driver side lock knob switch check)

Diagnostic procedure 2
(Door lock actuator check)

Diagnostic procedure 1
(Door lock and unlock switch check)

SYMPTOM

EL-157

MA

Main power supply and ground circuit check

REFERENCE PAGE

EM
LC
EC
FE
CL

One or more doors are not locked and/or


unlocked.

MT

Door lock and unlock switch does not operate.

TF

Lock knob switch on drivers door does not


operate.

PD
FA

MAIN POWER SUPPLY AND GROUND CIRCUIT CHECK


Main power supply for door lock timer
Terminal

RA
BR

Ignition switch

OFF

ACC

ON

q
3

Ground

Battery
voltage

Battery
voltage

Battery
voltage

ST
RS

SEL154V

BT
Ground circuit for door lock timer
Terminals

Continuity

q
1 - Ground

Yes

HA

IDX
SEL155V

EL-155

POWER DOOR LOCK


Trouble Diagnosis (Contd)
DIAGNOSTIC PROCEDURE 1
(Door lock and unlock switch check)
CHECK DOOR LOCK AND UNLOCK
SWITCH INPUT SIGNAL.
1. Disconnect door lock timer connector.
2. Check continuity between control unit
terminal q
5 or q
8 and ground.
SEL156V

Terminals
q
5 - Ground
q
8 - Ground

Door lock and


unlock switch
condition
Lock
N and Unlock
Unlock
N and Lock

OK

Door lock and unlock


switch is OK.

Replace door lock and


unlock switch.

Continuity
Yes
No
Yes
No

NG
H

CHECK DOOR LOCK AND UNLOCK


SWITCH.
1. Disconnect door lock and unlock switch
connector.
2. Check continuity between power window main switch (Door lock and unlock
switch) terminals.

Condition
Lock
N
Unlock

Terminals
7

3
q

14
q

No continuity
q

OK
H

Check the following.


I Ground circuit for door lock and unlock
switch
I Harness for open or short between door
lock and unlock switch and door lock
timer connector

SEL157V

EL-156

NG

POWER DOOR LOCK


Trouble Diagnosis (Contd)
DIAGNOSTIC PROCEDURE 2
(Door lock actuator check)
CHECK DOOR LOCK ACTUATOR CIRCUIT.
Check voltage for door lock actuator.
Lock knob switch
condition
SEL158V

Lock
Unlock

Terminals
@
q
2
ground
q
4
ground

GI
NG

Replace door lock timer.


(Before replacing control
unit, perform DIAGNOSTIC
PROCEDURE 1.)

Voltage
(V)
Battery
voltage

MA
EM
LC
EC

OK
H

CHECK DOOR LOCK ACTUATOR.


1. Disconnect door lock actuator connector.
2. Apply 12V direct current to door lock
actuator and check operation.
SEL159V

Door lock actuator operation


Unlocked , Locked
Locked , Unlocked

Terminals
! @
q
q
1
2
q
q
2
1

OK

Repair harness between door lock timer


connector and door lock actuator.

NG

Replace door lock actuator.

FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

EL-157

POWER DOOR LOCK


Trouble Diagnosis (Contd)
DIAGNOSTIC PROCEDURE 3
(Driver side lock knob switch check)
CHECK LOCK KNOB SWITCH INPUT
SIGNAL.
Check voltage between door lock timer
terminal q
6 and ground.

SEL160V

Lock knob switch


condition
Lock
Unlock

OK

Driver side lock knob


switch is OK.

Voltage
(V)
Approx. 12
0

NG
H

CHECK LOCK KNOB SWITCH.


1. Disconnect driver side lock knob switch
connector.
2. Check continuity between lock knob
switch terminals.
SEL161V

Terminals
q
1 -q
2

Condition
Locked
Unlocked

Continuity
No
Yes

OK

Check the following.


I Ground circuit for lock knob switch
I Harness for open or short between lock
knob switch and door lock timer

EL-158

NG

Replace lock knob switch.

LOCATION OF ELECTRICAL UNITS


Engine Compartment
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL843

EL-159

LOCATION OF ELECTRICAL UNITS


Passenger Compartment
LHD MODELS

HEL844

EL-160

LOCATION OF ELECTRICAL UNITS


Passenger Compartment (Contd)
RHD MODELS

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL845

EL-161

HARNESS LAYOUT
LHD MODELS

Outline

HEL846

RHD MODELS

HEL847

EL-162

HARNESS LAYOUT
How to Read Harness Layout
GI

Example:
G2

E1

B/6

: ASCD ACTUATOR

MA

Connector color / Cavity

EM

Connector number
Grid reference

LC
The following Harness Layouts use a map style grid to help locate connectors on the drawings:
I Main Harness (Instrument Panel, Engine Compartment)
I Engine Room Harness
I Engine Control Harness
To
1)
2)
3)
4)
5)

use the grid reference


Find the desired connector number on the connector list.
Find the grid reference.
On the drawing, find the crossing of the grid reference letter column and number row.
Find the connector number in the crossing zone.
Follow the line (if used) to the connector.

CONNECTOR SYMBOL
Main symbols of connector (in Harness Layout) are indicated in the below.
Water proof type
Female

FE
CL
MT
TF

Standard type

Connector type
Male

EC

Male

I Cavity: Less than 4


I Relay connector

Female

PD
FA

I Cavity: From 5 to 8
I Cavity: More than 9
I Ground terminal etc.

RA

BR

ST
RS
BT
HA

IDX

EL-163

HARNESS LAYOUT
Main Harness
INSTRUMENT PANEL LHD MODELS

HEL848

EL-164

HARNESS LAYOUT
Main Harness (Contd)
INSTRUMENT PANEL LHD MODELS

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL849

EL-165

HARNESS LAYOUT
Main Harness (Contd)
INSTRUMENT PANEL RHD MODELS

HEL850

EL-166

HARNESS LAYOUT
Main Harness (Contd)
INSTRUMENT PANEL RHD MODELS

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL851

EL-167

HARNESS LAYOUT
Main Harness (Contd)
BODY SIDE LHD MODELS

HEL989

EL-168

HARNESS LAYOUT
Main Harness (Contd)
BODY SIDE RHD MODELS

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL853

EL-169

HARNESS LAYOUT
Main Harness (Contd)
ENGINE COMPARTMENT KA24E ENGINE (LHD models)

HEL854

EL-170

HARNESS LAYOUT
Main Harness (Contd)
ENGINE COMPARTMENT KA24E ENGINE (LHD models)

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL855

EL-171

HARNESS LAYOUT
Main Harness (Contd)
ENGINE COMPARTMENT EXCEPT KA24E ENGINE (LHD models)

HEL856

EL-172

HARNESS LAYOUT
Main Harness (Contd)
ENGINE COMPARTMENT EXCEPT KA24E ENGINE (LHD models)

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL857

EL-173

HARNESS LAYOUT
Engine Room Harness
LHD MODELS GASOLINE ENGINE

HEL858

EL-174

HARNESS LAYOUT
Engine Room Harness (Contd)
LHD MODELS GASOLINE ENGINE

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL859

EL-175

HARNESS LAYOUT
Engine Room Harness (Contd)
LHD MODELS DIESEL ENGINE

HEL860

EL-176

HARNESS LAYOUT
Engine Room Harness (Contd)
LHD MODELS DIESEL ENGINE

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL861

EL-177

HARNESS LAYOUT
Engine Room Harness (Contd)
RHD MODELS GASOLINE ENGINE

HEL862

EL-178

HARNESS LAYOUT
Engine Room Harness (Contd)
RHD MODELS GASOLINE ENGINE

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL863

EL-179

HARNESS LAYOUT
Engine Room Harness (Contd)
RHD MODELS DIESEL ENGINE

HEL864

EL-180

HARNESS LAYOUT
Engine Room Harness (Contd)
RHD MODELS DIESEL ENGINE

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL865

EL-181

HARNESS LAYOUT
Engine Control Harness

HEL866

EL-182

HARNESS LAYOUT
Engine Control Harness (Contd)
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL867

EL-183

HARNESS LAYOUT
Engine Harness
NA AND Z ENGINES

HEL868

EL-184

HARNESS LAYOUT
Engine Harness (Contd)
KA ENGINE

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL870

EL-185

HARNESS LAYOUT
Engine Harness (Contd)
TD AND QD ENGINES

HEL871

EL-186

HARNESS LAYOUT
Alternator Harness
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA

IDX

HEL872

EL-187

HARNESS LAYOUT
LHD MODELS

Instrument Harness

HEL873

RHD MODELS

HEL874

EL-188

HARNESS LAYOUT
LHD MODELS

Room Lamp Harness


GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
HEL875

RHD MODELS

FA
RA
BR
ST
RS
BT
HA

IDX

HEL876

EL-189

HARNESS LAYOUT
Chassis Harness and Tail Harness

HEL877

EL-190

HARNESS LAYOUT
LHD MODELS

Front Door Harness (LH side)


GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
HEL878

RHD MODELS

FA
RA
BR
ST
RS
BT
HA

IDX

HEL879

EL-191

HARNESS LAYOUT
LHD MODELS

Front Door Harness (RH side)

HEL880

RHD MODELS

HEL881

EL-192

HARNESS LAYOUT
LH SIDE

Rear Door Harness


GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
HEL882

RH SIDE

FA
RA
BR
ST
RS
BT
HA

IDX

HEL883

EL-193