Isuzu TF series Electrical Body and chasys

WORKSHOP MANUAL TF SERIES

ELECTRICAL-BODY AND CHASSIS

SECTION 8

International Service & Parts Tokyo, Japan

NOTICE

Before using this Workshop Manual to assist you in performing vehicle service and maintenance operations, it is recommended that you carefully read and thoroughly understand the information contained in Section - 0 “GENERAL INFORMATION”.

All material contained in this Manual is based on the latest product information available at the time of publication. All rights are reserved to make changes at any time without prior notice.

INDEX ELECTRICAL-BODY AND CHASSIS

SECTION 8


TABLE OF CONTENTS PAGE Genera Gen erall Infor Informa matio tion n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–

1

Notes No tes for Wor Workin king g on Ele Electr ctrica icall Items Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–

2

Symbols Sym bols and Abbr Abbrevia eviation tions. s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–

8

Symbols. Symb ols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–

8

Abbre Ab brevia viatio tions ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–

9

Parts for for Electrical Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 10 Wiring Wirin g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 10 Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 12 Fusible Fusi ble Link Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 12 Circuit Circu it Breaker Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 13 Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 13 Diode Diod e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 14 Connecto Conn ectorr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 15 Battery Batt ery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 16 Reading Read ing the the Circui Circuitt Diagram Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 19 Main Data and Specifications. Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 21 Bulb Spe Specifica cification tions s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 21 Relay Rela y and Fuse Box Box,, Fuse Box Loca Location tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 23 Fuse and Fusib Fusible le Link Link Locatio Location-1 n-1 (Relay (Relay and and Fuse Fuse Box) Box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 27 Fuse and Fusib Fusible le Link Link Locatio Location-2 n-2 (Relay (Relay and and Fuse Fuse Box) Box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 28 Fuse and Circu Circuit it Breaker Breaker Loca Location tion (Fus (Fuse e Box) Box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 29 Relay Location-1 Location-1 (Relay (Relay and Fuse Fuse Box). Box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 31 Relay Rela y Locatio Location-2 n-2 (Relay (Relay and Fuse Fuse Box Box – 6VD1) 6VD1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 32 Relay Location-3 Location-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 33 Diode Diod e Locatio Location-1 n-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 34 Diode Location-2 Location-2 (6VD1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 35 Fuse Block Circu Circuit it . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 36 Reference Table of of Fuse, Fusible Fusible Link and and Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 40


Ground Gro unding ing Point Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 48 Referen Reference ce Table Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 48 Location. Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 52 Main Cable Cable Harness Harness Routing Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 55 System System Repair Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 63 Start Start and Charging Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 63 Engine Control Control Module Module (ECM) (ECM) and Fuel Pump. Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 80 Emission Emission Control Control System. System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8– 96 QOS Syste System m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–102 8–102 Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–108 Hazard Warning Flasher, Turn Signal Light, Back Up Light, Horn and Stop Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–138 Dome Light, Light, Spot Light Light and Warning Warning Buzzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–165 Windshie Windshield ld Wiper Wiper and Washer Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–178 8–178 Overdrive Off (A/T) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–194 Transmission Transmission Control Control Module Module (TCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–197 Meter, Warning Warning Light Light and Indicator Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–200 Heater and and Air Conditioning Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–257 Power Door Door Lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–267 Power Power Window Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–278 8–278 Audio, Clock and and Cigarette Cigarette Lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–298 Power Door Door Mirror Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–306 Rear Defogger Defogger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–318 Radiator Level Control Control Warning Warning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–327 Connector Connector List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–330

ELECTRICAL-BODY AND CHASSIS 8–1

GENERAL INFORMATION The body and chassis electrical system operates on a twelve volt power supply with negative ground polarity. The main harness consists of the engine harness, the instrument harness, the body harness, and the chassis harness. The harnesses use a split corrugated tube to protect the wires from the elements. Wire size is determined by current flow, circuit length, and voltage drop. All wires have color-coded insulation. Wire color-codes are shown shown in the circuit diagrams. diagrams. This makes it easier to trace circuits and and to make the proper connections. Each circuit consists of the following: 1. 2. 3. 4.

Power sourc Power source e - The batter battery y and the the altern alternato atorr Wires - To carry electr electrical ical curre current nt throug through h the circu circuit it Fuses - To prot protect ect the the circuit circuit agains againstt current current overl overload oad Relays - To protect protect voltage voltage drop drop between between the battery battery and the the circuit circuit parts and to to protect protect the switch switch points against burning 5. Swi Switch tches es - To open open and and clos close e the circ circuit uit 6. Load - Any device, device, such such as a light or a motor, motor, which which converts converts the the electrical electrical current current into useful useful work work 7. Grou Ground nd - To To allow allow the curre current nt to flow flow back back to the the power power source source

8–2 ELECTRICAL-B ELECTRICAL-BODY ODY AND CHASSIS CHASSIS

NOTES FOR WORKING ON ELECTRICAL ITEMS

Positive cable

Ground cable

BATTERY CABLE Disconnecting the Battery Cable

1. All swit switche ches s should should be be “OFF” “OFF” positi position on.. 2. Discon Disconnec nectt the batt battery ery gro ground und cable. cable. 3. Discon Disconnec nectt the batt battery ery posi positiv tive e cable. cable.

D08RV758

CAUTION: It is important that the battery ground cable be disconnected first. Disconnecting the battery positive cable first can result in a short circuit.

Connecting the Battery Cable

Follow the disconnecting procedure in the reverse order to connect the battery cables. CAUTION: Clean the battery terminal and apply light coat of grease to prevent terminal corrosion.

CONNECTOR HANDLING Disconnecting the Connectors 1

Some connectors have a tang lock to hold the connectors together during vehicle operation. Some tang locks are released by pulling them towards you 1. Other tang locks are released by pressing them forward 2. Determine which type of tang lock is on the connector being handled.

2

D08RV879

Firmly grasp both sides (male and female) of the connector. Release the tang lock and carefully pull the two halves of the connector apart. Never pull on the wires to separate the connectors. connectors. This will result in wire breakage.

OK

NO

D08RV839

ELECTRICAL-BODY AND CHASSIS 8–3 Connecting the Connectors

Firmly grasp both sides (male and female) of the connector. Be sure that the connector pins and pin holes match. Be sure that both sides of the connector are aligned with each other. Firmly but carefully push the two sides of the connector together until a distinct click is heard.

BAD

GOOD D08RV672

Connector Inspection

Use a circuit tester to check the connector for continuity. Insert the test probes from the connector wire side.

D08RV673

CAUTION Never insert the circuit tester test probes into the connector open side to test the continuity. Broken or open connector terminals will result.

D08RV674

Waterproof Connector Inspection

1

It is not possible to insert the test probes into the connector wire side of a waterproof connector. Use one side of a connector 1 with its wires cut to make the test. Connect the test connector to the connector 2 to be tested. Connect the test probes to the cut wires to check the connector continuity.

2

D08RV841

Connector Pin Removal

4

Connector Housing Tang Lock Type 1. Inse Insert rt a sle slend nder er shaf shaftt 3 into the connector housing open end 4. 2. Push Push the the tan tang g loc lock k 5 up (in the direction of the arrow in the illustration). Pull the wire 6 with pin 7 free from the wire side of the connector.

5

3

7

6

D08RV844

8–4 ELECTRICAL-BODY AND CHASSIS Pin Tang Lock Type 8

6

1. Insert a slender shaft 3 into the connector housing open end 4. 2. Push the tang lock 8 flat (toward the wire side of the connector). Pull the wire 6 with pin 7 free from the wire side of the connector.

3 7

4

D08RV843

Connector Pin Insertion 8

1. Check that the tang lock 8 is fully up. 2. Insert the pin 7 from the connector wire side 9. Push the pin in until the tang lock closes firmly. 3. Gently pull on the wires 6 to make sure that connector pin is firmly set in place.

6

9 7

D08RV842

Fuse Replacement

The replacement fuse must have the same amperage specification as the original fuse. Never replace a burn out fuse with a fuse of a different amperage specification. Doing so can result in an electrical fire or other serious circuit damage.

Parts Handling

Be careful for parts handling and any part should not be dropped or thrown, otherwise short circuit or disorder may result.

D08RV704

Wiring Harness

1. When assembling the parts, be careful not to bite or wedge the wiring harness. 2. All electrical connections must be kept clean and tight.

D08RV705


3. Use a grommet or guard tube to protect the wiring harness from contacting a sharp edge or surface.

NO

OK

D08RV836

4. Position the wiring harness with enough clearance from the other parts and guard the wiring harness with a vinyl tube to avoid direct contact.

NO

Vinyl tube

OK Clip

D08RV837

5. The wiring harness between engine and chassis should be long enough to prevent chafing or damage due to various vibrations.

NO OK D08RV838

8–6 ELECTRICAL-BODY AND CHASSIS

SPLICING WIRE Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing “seam ripper” (available from sewing supply stores) to cut open the harness. If the harness has a black plastic conduit, simply pull out the desired wire. Cut the wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 1-1/2” (40 mm) away from other splices, harness branches, or connectors. Strip the insulation When replacing a wire, use a wire of the same size as the original wire. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat the procedure on a new section of wire. The two stripped wire ends should be equal in length.

Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included with your clips. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the two stripped wire ends and hold them between your thumb and forefinger. Then, enter the splice clip under the stripped wires and hold it in place.

Over lap bare wires

Splice clip

D08RV676

•

wing of clip touching former

•

•

Open the crimping tool to its full width and rest one handle on a firm flat surface. Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the back of the splice clip touches the wings of the clip. Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes.

Back of clip centered on anvil D08RV678

Before crimping the ends of the clip, be sure that: • The wires extend beyond the clip in each direction. • No strands of wire are cut loose, and • No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires.

Splice clip

Align tool with edge of clip to crimp ends of splice

D08RV677

ELECTRICAL-BODY AND CHASSIS 8–7 Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer’s instructions for the solder equipment you are using.

D08RV679

Good (Rolled)

Bad (Flagged)

Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness.

D08RV680

If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape.

D08RV681


SYMBOLS AND ABBREVIATIONS SYMBOLS Symbol

Meaning of Symbol

Symbol

Meaning of Symbol

Fuse

Bulb

Fusible link

Double filament bulb

Fusible link wire

M

Motor

Switch

Variable resistor Rheostat

Switch

Coil (inductor), solenoid, magnetic valve

Switch (Normal close type)

Contact wiring

+

–

Relay

Battery

Diode

Connector

Electronic Parts

Light emitting diode

Resistor

Reed switch

Speaker

Condenser

Buzzer

Horn

Circuit breaker

Vacuum switching valve


ABBREVIATIONS Abbreviation A

Meaning of Abbreviation Ampere (S)

Abbreviation LH

Meaning of Abbreviation Left hand

ABS

Anti-lock brake system

LWB

Long wheel base

ASM

Assembly

MPI

Multiport fuel injection

AC

Alternating current

M/T

Manual transmission

A/C

Air conditioner

OD

Over drive

ACC

Accessories

OPT

Option

A/T

Automatic transmission

QOS

Quick on start

CARB

Carburetor

RH

Right hand

C/B

Circuit breaker

RR

Rear

CSD

Cold start device

DIS

Direct ignition system

RWAL SRS

Supplemental restraint system

EBCM

Electronic brake control module

ECGI

Electronic control gasoline injection

STD

Standard

ECM

Engine control module

SW

Switch

ECU

Electronic control unit

SWB

Short wheel base

EFE

Early fuel evaporation

TCM

Transmission control module

4A/T

4-speed automatic transmission

3A/T

3-speed automatic transmission

4X4

Four-wheel drive

FL

Fusible link

FRT

Front

H/L

Headlight

IC

Integrated circuit

IG

Ignition

kW

kilowatt

ST

Rear wheel anti-lock brake system

V VSV W WOT W/ W/O

Start

Volt Vacuum switching valve Watt (S) Wide open throttle With Without


PARTS FOR ELECTRICAL CIRCUIT

WIRING Wire Color All wires have color-coded insulation. Wires belonging to system’s main harness will have a single color. Wires belonging to a system’s sub-circuits will have a colored stripe. Striped wires use the following code to show wire size and colors.

Single color

Example: 0.5 G / R

Colored stripe

Red (Stripe color) D08RV840

Green (Base color) Wire size (0.5 mm2) Abbreviations are used to indicate wire color within a circuit diagram. Refer to the following table.

Wire Color-Coding

Color-Coding

Meaning

Color-Coding

Meaning

B

Black

BR

Brown

W

White

LG

Light green

R

Red

GR

Grey

G

Green

P

Pink

Y

Yellow

LB

Light blue

L

Blue

V

Violet

O

Orange

ELECTRICAL-BODY AND CHASSIS 8–11 Distinction of Circuit by Wire Base Color

Base color

Circuits

Base color

B

Starter circuit and grounding circuit

Y

W

Charging circuit

R

Lighting circuit

G

Signal circuit

Circuits Instrument circuit

L,O, BR, LG, GR, P, LB, V

Other circuits

Wire Size

Outside diameter

Wire size is specified with the metric gauge system. The metric gauge system gives the wire size in cross sectional area measured in square millimeters.

Cross sectional area D08RV683

Wire Size Specifications

Normal size

Cross sectional area (mm2)

Outside diameter (mm)

Allowable current (A)

0.3

0.372

1.8

9

0.5

0.563

2.0

12

0.85

0.885

2.2

16

1.25

1.287

2.5

21

2

2.091

2.9

28

3

3.296

3.6

37.5

5

5.227

4.4

53

8

7.952

5.5

67

15

13.36

7.0

75

20

20.61

8.2

97


Normal

FUSE

Blown

D08RV684

Normal

Fuses are the most common form of circuit protection used in vehicle wiring. A fuse is a thin piece of wire or strip of metal encased in a glass or plastic housing. It is wired in series with the circuit it protects. When there is an overload of current in a circuit, such as a short of a ground, the wire or metal strip is designed to burn out and interrupt the flow of current. This prevents a surge of high current from reaching and damaging other components in the circuit. Determine the cause of the overloaded before replacing the fuse. Never replace a blown fuse with a fuse of a different amperage specification. Doing so can result in an electrical fire or other serious circuit damage. A blown fuse is easily identified.

FUSIBLE LINK

Blown

The fusible link is primarily used to protect circuits where high amounts of current flow and where is would not be practical to use a fuse. For example, the starter circuit. When a current overload occurs, the fusible link melts open and interrupts the flow of current so as to prevent the rest of the wiring harness from burning. Determine the cause of the overload before replacing the fusible link. The replacement fusible link must have the same amperage specification as the original fusible link. Never replace a blown fusible link with fusible link of a different amperage specification. Doing so can result in an electrical fire or other serious circuit damage. A blown fusible link is easily identified.

Fusible Link Specifications

Type

Rating

Case Color

Maximum Circuit Current (A)

Connector

30A

Pink

15

Connector

40A

Green

20

Bolted

50A

Red

25

Bolted

60A

Yellow

30

Bolted

80A

Black

40


CIRCUIT BREAKER The circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. The reset knob pops out when the circuit is open. Push the reset knob in place to restore the circuit after repairing it. Push

RELAY LOAD

Battery and load location may require that a switch be placed some distance from either component. This means a longer wire and a higher voltage drop 1. The installation of a relay between the battery and the load reduces the voltage drop 2. Because the switch controls the relay, amperage through the switch can be reduced.

LOAD

RELAY

1

2

D08RV709

Relay Specifications and Configurations Name/ Color

Rated voltage/ Coil resistance

12V Approx. 90Ω 1T Minimum (MR5C)/ operating Black voltage: 7V at 25°C(77°F) 12V Approx. 90Ω 1T Minimum (MR5C)/ operating Brown voltage: 10.5V at 25°C(77°F)

Internal circuit

1

3

4

3

2 5

1

2

4

5

060RV005

* Relay contact shown in the wiring diagram indicates condition before actuation.


DIODE Diode Specifications and Configurations

SHAPE

MARK/ COLOR

THERE SHOULD BE CONTINUITY IN CHECKING EITHER A OR B WHEN A CIRCUIT TESTER IS CONNECTED WITH DIODE TERMINAL

CONSTRUCTION

TERMINAL NO. CONNECTION PATTERN

BLACK

A B

TERMINAL NO.

CONNECTION PATTERN

A B

2

1

+

–

–

+

3

2

–

+

–

+

+ – –

+

1

BLACK

TERMINAL NO.

CONNECTION PATTERN

A B

3

2

–

+

–

+

+ – –

+

BLACK

TERMINAL NO.

4

3

4

1

2 +

–

A

3 2

1

+

– B

+ +

BLACK

–

+

–

CONNECTION PATTERN

1

+

– –

Maximum Rating (Temp.=25°C)

Items

Rating

Peak reverse voltage

400V

Transient peak reverse voltage

500V

Average output current

1.5A

Working ambient temperature

–30°C~80°C

Storage temperature

–40°C~100°C

Remarks

Temp.=40°C


CONNECTOR The connector pin shape determines whether the connector is male or female. The connector housing configuration does not determine whether a connector is male or female.

Female connector

Connector pin shape

Male connector D08RV685

The symbol illustrated in the figure is used as connector in the circuit of this section.

Female side connector

Male side connector D08RV710

5

Connector is identified with a number.

1

W-38

W-38

4

0.5R/L

W-38

SHIFT LOCK 6

0.85W/L

W-38

7

Connector number

W-38

D08RV711

5

The applicable terminal number is shown for each connector.

1

W-38

W-38

4

0.5R/L

W-38

SHIFT LOCK 6

0.85W/L

W-38

7

Terminal number

W-38

D08RV712

Female side connector

Male side connector

1

2

3

4

4

3

2

1

5

6

7

8

8

7

6

5

Connector terminal numbers are clearly shown. Male side connector terminal numbers are in sequence from upper right to lower left. Female side connector terminal numbers are in sequence from upper left to lower right. NOTE: For those connectors on which specific terminal numbers on symbols are shown, the terminal numbers or symbols are used in the circuit diagram, irrespective of the above rule.

Terminal number D08RV713


BATTERY

1 2

Inspection

3 D08RV944

1. Check the battery terminals 1 for corrosion. 2. Check the battery cables 2 for looseness. 3. Check the battery case 3 for cracks and other damage. 4. Check the battery electrolyte level. If the electrolyte level is excessively low, the battery must be replaced. 5. If the battery has a built-in hydrometer, perform the following steps: 1) Carefully clean the battery upper surface. 2) Check the hydrometer. The hydrometer design will vary with the battery manufacturer. Refer to the illustration shown on the battery.

Battery Replacement

1

2

1. Disconnect the battery ground cable 1. 2. Disconnect the battery positive cable 2. 3. Remove the battery clamp 3. 4. Remove the battery

3 D08RV945

Caution: It is important that the battery ground cable be removed first. Removing the battery positive cable first can result in a short circuit.

Jump Starting the Engine with a Booster Battery

The following description assumes that you are using a booster battery mounted on a second vehicle. The listed steps (with some minor modifications) are also applicable if you are using a naked booster battery or special battery charging equipment.

ELECTRICAL-BODY AND CHASSIS 8–17 Caution: Never push or tow the vehicle in an attempt to start it. Extensive damage to the emission system and other vehicle parts will result. (only catalytic converter vehicle) Treat both the discharged battery and the booster battery with great care when using jumper cables. Carefully follow the procedure outlined below. Always be aware of the dangers of sparking. Failure to follow the following procedure can result in: a. Serious personal injury, especially to your eyes. b. Extensive property damage from a battery explosion, battery acid discharge, or electrical fire. c. Extensive damage to the electronic components of both vehicles. Do not use a 24 volt booster battery. Serious damage to the vehicle’s electrical system and electronic components will result. Jump Starting Procedure

1. Set the parking brake on both vehicles. 2. If one or both vehicles is equipped with an automatic transmission, place the selector lever in the “PARK” position. If one or both vehicles is equipped with a manual transmission, place the gear shift in the “NEUTRAL” position. 3. Turn off the ignition on both vehicles. 4. Turn off all vehicle lights and accessories. 5. Check the built-in hydrometer on the discharged battery (If so equipped). If there is no hydrometer indication abandon the jump start procedure. 6. Be sure that the two vehicles are not touching. Attach the end of one jumper cable to the booster battery positive terminal. 7. Attach the other end of the same cable to the discharged battery positive terminal. 8. Once again, check that the booster battery has a 12volt rating. 9. Attach one end of the remaining booster cable to the booster battery negative terminal. 10. Attach the other end of the booster cable to a solid ground (such as the air conditioner compressor mounting bracket or the alternator mounting bracket) in the engine room of the vehicle with the discharged battery. Be sure that the ground connection is at least 500 mm (20 in) from the discharged battery.

8–18 ELECTRICAL-BODY AND CHASSIS Caution: Do not attach the booster cable to the discharged battery negative terminal.

11. Start the engine of the vehicle with the booster battery. Check that all unnecessary electrical accessories are off. 12. Start the engine of the vehicle with the discharged battery. 13. Remove the jumper cables in the reverse order to which they were attached. Caution: Be absolutely sure to remove the negative jumper cable from the vehicle with the discharged battery first.


READING THE CIRCUIT DIAGRAM In this manual, each system has its own parts location illustration and circuit diagram. And connector configurations used in the circuit diagram are shown at the end of this manual. PARTS LOCATION: The parts location shows the location of the connectors 1 and the harnesses 2 used in the each system. CIRCUIT DIAGRAM: The circuit diagram shows the power supply 3, the load or loads 4 and the grounding point(s) 5. CONNECTOR LIST: The connector configuration shows each connector’s number 6, configuration 7 and the pin numbers 8.

PARTS LOCATION

B-23 B-24 B-32

H-6 H-7

C-39 H-4 C-10 C-11

H-5

C-2

F-1 E-44 C-38 C-41 C-51 C-37

H-8 C-36 R-4

C-28 E-45 E-46 E-19

E-36 E-1

E-2

C-52

C-53 C-54 H-15 H-9

2

1 D08RV910


CIRCUIT DIAGRAM MAIN 80A

15BR

+

P-2

P-1

3

B 3

P-5

_ R 3 5B/Y

EB-12 15A TAIL, ILLUMI.

Y / B 0 3

R 3 5

P-7

P-10

FRAME

ENG.

B / R 5 8 . 0

2 X-1

X-1

B / R 5 8 . 0

RELAY; LIGHTING

X-1

2

X-1 1

5 X-2

X-2

4

RELAY; TAIL

W / R 3 X-2 EB-8 10A H/LAMP-LH

5(A/T)

0.85G/R

0.5R/L

1(M/T)

G / R 5 8 . 0

H-8

W / R 5 . 0

1 C-42

3

H L T H G I L D A E H

4

4

T H B-23 G I L R M A O E T B A C H I G D B-23 I N H I

C-26

C - 26

C - 26

1

2

C-19

C - 19

C - 19

1

4(M/T)

R / G 5 8 . 0

L / R 3 . 0

2

8 . 0

OFF

B / R 5 . 0

R / G 5 8 . 0

B / R 5

Y / R 5 8 . 0

H-8

R / G 5 8 . 0

LIGHTINGSW (COMBINATIONSW)

5

11(A/T)

B / R 5 8 . 0

8 C-42

3

H R T H G I L D A E H

B / R 5 . 0 Y / R 5 8 . 0

1

Y / G 5 . 0

0.5R/W

W / R 5 8 . 0

X-2 4

EB-9 10A H/LAMP-RH

0.85R/B

4

5

C-57

C-57

W S T C E L E S T / A

C-42 7

(W/O TACHOMETER)

3

R E V E L T C E L E S T / A

C-58

C-58 1

C-57 6

11 T H G I B-24 L R M A O E T B A H C I G D I N B-24 H I

B / R 5 8 . 0

Y / R 5 8 . 0

12 13 C-42

15

B 5 8 . 0

14

C-42

C-42

B 5 . 0

DIMMER PASSINGSW (COMBINATIONSW) LOW

HIGH

B 5 . 0

PASS

C-42 16

B 2

5

FENDER-LH

2B

C-2

FENDER-RH

1.25B

C-36

D08RV823

CONNECTOR LIST

CONNECTOR LIST No.

B-1

Connector face

1 4

2 5

No.

3 6

B-11

Connector face

NOT USED

6 7

8 B-12

B-2

1

1 2 3

B-3

2 3

1

1

2

2

B-13

B-4

NOT USED

B-14

B-5

NOT USED

B-15

3

1

2

3

4

5

6

1

2

8

9 10 11 12 13 14 15 16

4

NOT USED

5

6

7


MAIN DATA AND SPECIFICATIONS BULB SPECIFICATIONS This illustration is based on LHD

DOME LIGHT

SIDE TURN SIGNAL LIGHT

SPOT LIGHT

REAR TURN SIGNAL LIGHT

HEADLIGHT

BACK UP LIGHT CLEARANCE LIGHT

FRONT TURN SIGNAL LIGHT

TAIL&STOP LIGHT REAR COMBINATION LIGHT

LICENSE PLATE LIGHT

D08RV911

Bulb No.

Rated Power V-W

Number of Bulbs

Lens Color

H4

12–60/55

2

White

R2

12–45/40

2

White

Front turn signal light

—

12–23

2

Amber

Side turn signal light

W5W

12–5

2

Amber

Rear turn signal light

P21W

12-21

2

Amber

P21/5W

12–21/5

2

Red

Back up light

P21W

12–21

2

White

License plate light

W5W

12–5

1 or 2

White

Clearance light

W5W

12–5

2

White

A/C-Heater control light

—

12–0.7

1

—

Dome light

—

12–10

1

White

Spot light

—

12–5

2

White

Inspection light

—

12–5

1

White

Light Name

Headlight

Tail and stop light

Remarks Halogen


Light Name

Bulb No.

Rated Power V-W

Number of Bulbs

Lens Color

Gasoline Charging engine system Diesel engine

—

14–3.0

1

74

14–1.4

1

Check engine

74

14–1.4

1

W/O Tachometer

158

14–3.4

2

W/Tachometer

74

14–1.4

2

High beam

W/O Tachometer

158

14–3.4

1

W/Tachometer

74

14–1.4

1

Low fuel

W/O Tachometer

—

14–3.0

1

W/Tachometer

74

14–1.4

1

74

14–1.4

1

Red

74

14–1.4

1

Red

158

14–3.4

1

Turn signal

Red

Red

Gasoline (MPI) engine

Green

Blue

Amber

Indicator/ Oil pressure Warning light Brake system 4WD

Remarks

W/O Tachometer

Green W/Tachometer

74

14–1.4

1

Overdrive off

74

14–1.4

1

Amber

A/T

Glow

74

14–1.4

1

Amber

Diesel engine

Sedimenter

74

14–1.4

1

Red

Diesel engine

Seat belt

—

14–2.0

1

Red

Saudi Arabia

Oil temperature

74

14–1.4

1

Red

Gasoline engine (Saudi Arabia)

Timing belt

74

14–1.4

1

Red

4JA1-T engine (RHD models)

Diff. lock

74

14–1.4

1

Green

South Africa


RELAY AND FUSE BOX, FUSE BOX LOCATION LHD-1

RELAY & FUSE BOX

FUSE BOX

D08RV924


RELAY AND FUSE BOX, FUSE BOX LOCATION LHD-2 (6VD1)

FUSE BOX

D08RW613

D08RW522

Relay and fuse box

Fuse box

D08RW555

ELECTRICAL-BODY ELECTRICAL-BODY AND CHASSIS 8–25

RHD-1

RELAY & FUSE BOX FUSE BOX

D08RV925

8–26 ELECTRIC ELECTRICAL-BO AL-BODY DY AND AND CHASSIS CHASSIS

RHD-2 (6VD1)

FUSE BOX

D08RW614

D08RW522

Fuse box

Relay and fuse box

D08RW554


FUSE AND FUSIBLE LINK LOCATION-1 (RELAY AND FUSE BOX) RELAY & FUSE BOX

EB-17

EB-18 EB-16 EB-15 EB-15

EB-19

EB-1 EB-1 EB-2 EB-2 EB-3 EB-4 EB-5 EB-6 EB-7

EB-8 EB-8 EB-9 EB-9 EB-10 EB-10 EB-11 EB-11 EB-12 EB-12 EB-13 EB-13 EB-14 EB-14

FUSE

D08RV811

Engine model

4Z Series

NO.

4ZD1 (MPI)

4ZE1 (MPI)

4J Series

4JA1 (South Africa)

EB-1

15A HAZARD

15A HAZARD

15A HAZARD

15A HAZARD

15A HAZARD

EB-2

10A HORN

10A HORN

10A HORN

10A HORN

10A HORN

EB-3

—

—

—

—

—

EB-4

20A BLOWER

20A BLOWER

20A BLOWER

20A BLOWER

20A BLOWER

EB-5

10A AIR CON.

10A AIR CON.

10A AIR CON.

10A AIR CON.

10A AIR CON.

EB-6

—

—

10A (RR FOG)

—

—

EB-7

—

10A O2 SENS SENSOR OR 10A 10A (O2 SENS SENSOR OR)) 10A 10A (CHA (CHARG RGE) E)

—

EB-8

10A H/ H/LAMP-LH

10A H/ H/LAMP-LH 10A H/ H/LAMP-LH

10A H/ H/LAMP-LH

10A H/ H/LAMP-LH

EB-9

10A H/LAMP-RH

1 0 A H /L A M P - R H 1 0 A H /L A M P - R H

1 0 A H /L A M P - R H

10A H/LAMP-RH

EB-10

—

—

—

—

—

EB-11

10A STOP

10A STOP

10A STOP

10A STOP

10A STOP

EB-12

15A TAIL

15A TAIL

15A TAIL

15A TAIL

15A TAIL

15A ECM

15A ECM

EB-13 EB-14

—

10A 10A AUT AUTO O CHOK CHOKE E 20A 20A FUE FUEL L PUMP PUMP 20A 20A FUE FUEL L PUMP PUMP

—

—

—

—

FUSIBLE LINK Engine model NO.

4Z Series

4ZD1 (MPI)

4ZE1 (MPI)

4J Series

4JA1 (South Africa)

EB-15

40A IGN. B1

40A IGN. B1

40A IGN. B1

40A IGN. B1

40A IGN. B1

EB-16

80A MAIN

80A MAIN

100A MAIN

100A MAIN

80A MAIN

50A GLOW

50A GLOW

EB-17

—

— —

—

EB-18

30A (EFE)

EB-19

40A IGN IGN.. B2, POW POWER ER 40A IGN IGN.. B2, POW POWER ER 40A IGN IGN.. B2, POW POWER ER 40A IGN IGN.. B2, POW POWER ER 40A IGN IGN.. B2, POWER POWER

30A(H/LAMP WASHER)

—

—


FUSE AND FUSIBLE LINK LOCATION-2 (RELAY AND FUSE BOX) RELAY & FUSE BOX

5 1 B E

6 1 B E

0 2 B E 9 1 B E 8 1 B E 7 1 B E

0 1 2 3 4 8 - 9 - 1 - 1 - 1 - 1 - 1 B B B B B B E E E B E E E E 1 - 2 - 3 - 4 - 5 - 6 - 7 B B B B B B B E E E E E E E

FUSE

D08RW523

Engine model

6VD1

NO.

EB-1

15A HAZARD

EB-2

10A HORN

EB-3

20A BLOWER

EB-4

10A A/C

EB-5

—

EB-6

15A FUEL PUMP

EB-7

10A O2 SENSOR

EB-8

10A H/LAMP-LH

EB-9

10A H/LAMP-RH

EB-10

10A STOP LAMP

EB-11

10A TAIL

EB-12

10A TCM

EB-13

10A ECM

EB-14

20A ECM

FUSIBLE LINK Engine model NO.

6VD1

EB-15

40A IGN. B1

EB-16

100A MAIN

EB-17

40A IGN. B2

EB-18

30A RR DEF

EB-19

30A COND FAN


FUSE AND CIRCUIT BREAKER LOCATION (FUSE BOX) LHD FUSE BOX

B-31

CB-1

CB-5

CB-9

CB-13

CB-17

CB-21

CB-2

CB-6

CB-10

CB-14

CB-18

CB-22

CB-3

CB-7

CB-11

CB-15

CB-19

CB-23

CB-4

CB-8

CB-12

CB-16

CB-20

CB-24

D08RV926

FUSE

No.

Capacity

Indication on label

CB-1

10A

STARTER

CB-13

15A

(RR DEFOG.)

CB-2

—

—

CB-14

10A

DOME LIGHT

CB-3

15A

ENGINE-1

CB-15

20A

(DOOR LOCK)

CB-4

10A

ENGINE-2

CB-16

—

—

CB-5

—

—

CB-17

—

—

CB-6

—

—

CB-18

—

—

CB-7

15A

METER

CB-19

15A

AUDIO

CB-8

20A

FRONT WIPER

CB-20

15A

CIGAR

CB-9

—

—

CB-21

—

—

CB-10

—

—

CB-22

—

—

CB-11

15A

BACK UP, TURN

CB-23

—

—

CB-12

10A

(SEAT HEATER)

CB-24

—

—

CIRCUIT BREAKER

No.

Capacity

Indication on label

B-31

30A

(POWER WINDOW)

No.

Capacity

Indication on label


RHD FUSE BOX

CB-21

CB-17

CB-13

CB-9

CB-5

CB-1

CB-22

CB-18

CB-14

CB-10

CB-6

CB-2

CB-23

CB-19

CB-15

CB-11

CB-7

CB-3

CB-24

CB-20

CB-16

CB-12

CB-8

CB-4

B-31

D08RV927

FUSE

No.

Capacity

Indication on label

CB-1

10A

STARTER

CB-13

15A

(RR DEFOG.)

CB-2

—

—

CB-14

10A

DOME LIGHT

CB-3

15A

ENGINE-1

CB-15

20A

(DOOR LOCK)

CB-4

10A

ENGINE-2

CB-16

—

—

CB-5

15A

METER

CB-17

—

—

CB-6

20A

FRONT WIPER

CB-18

—

—

CB-7

—

—

CB-19

15A

AUDIO

CB-8

—

—

CB-20

15A

CIGAR

CB-9

—

—

CB-21

—

—

CB-10

—

—

CB-22

—

—

CB-11

15A

CB-23

—

—

CB-12

—

CB-24

—

—

BACK UP, TURN —

CIRCUIT BREAKER

No.

Capacity

Indication on label

B-31

30A

(POWER WINDOW)

No.

Capacity

Indication on label


RELAY LOCATION-1 (RELAY AND FUSE BOX) RELAY & FUSE BOX

X-1

X-2

X-3

X-5

X-7

X-9

X-4

X-6

X-8

X-10

D08RV807

RELAY Engine model NO.

4Z Series

4ZD1 (MPI)

4ZE1 (MPI)

4J Series

4JA1 (South Africa)

X-1

RELA RELAY; Y; LIGH LIGHTI TING NG RELA RELAY; Y; LIGH LIGHTI TING NG RELA RELAY; Y; LIGH LIGHTI TING NG

RELA RELAY; Y; LIGH LIGHTI TING NG RELA RELAY; Y; LIGH LIGHTI TING NG

X-2

RELAY; TAIL

RELAY; TAIL

RELAY; TAIL

RELAY; TAIL

RELAY; TAIL

X-3

RELAY; HE HEATER

RELAY; HE HEATER

RELAY; HE HEATER

RELAY; HE HEATER

RELAY; HE HEATER

X-4

RELAY; HORN

RELAY; HORN

RELAY; HORN

RELAY; HORN

RELAY; HORN

X-5

RELAY; CHARGE

RELAY; CHARGE

(RELAY; OD OFF)

RELAY; CHARGE

X-6

RELA RELAY; Y; STAR STARTE TER R RELA RELAY; Y; STAR STARTE TER R RELA RELAY; Y; STAR STARTE TER R

X-7

(RELAY (RELAY;; THER THERMO) MO) (RELAY (RELAY;; THER THERMO) MO) (RELAY (RELAY;; THER THERMO) MO) (RELAY (RELAY;; THER THERMO) MO) (RELAY (RELAY;; THER THERMO) MO)

X-8

—

X-9

—

X-10

(RELAY; EFE HEATER)

—

RELAY; ST. CUT

— —

RELAY; FUEL PUMP PUMP RELAY; FUEL PUMP PUMP (RELAY; CSD) RELA RELAY; Y; ECM ECM MAIN MAIN RELAY RELAY;; ECM ECM MAIN MAIN

—

— RELAY; STARTER RELAY; ST. CUT (RELAY; CSD) —


RELAY LOCATION-2 (RELAY AND FUSE BOX - 6VD1) RELAY & FUSE BOX

X-26

X-27

X-23

X-24

X-25

X-20

X-21

X-22

X-17

X-18

X-19

X-15

X-16

D08RW524

RELAY Engine model NO.

6VD1

X-15

RELAY; HEATER

X-16

RELAY; A/C COMP

X-17

RELAY; HORN

X-18

RELAY; ECM MAIN

X-19 X-20 X-21

— RELAY; TAIL —

X-22

RELAY; THERMO

X-23

RELAY; HEAD LAMP

X-24

RELAY; STARTER

X-25

RELAY; COND FAN

X-26

RELAY; FUEL PUMP

X-27

—


RELAY LOCATION-3 (LHD) C-3

Relay;Intermittent C-10

C-11

Relay;Starter C-5

C-6

C-7

Relay;Glow

B-8

Relay;Power window B-7

Relay;Rear defogger B-5

Key,light and seat belt remind buzzer C-45

Flasher unit B-8

Relay:Power window (6VD1)

B-7

Relay:Rear defogger (6VD1)

D08RW552

(RHD) C-45

Flasher unit

C-3

Relay;Intermittent

B-8

Relay;Power window (6VD1) B-7 Relay;Rear defogger (6VD1)

B-8

Relay;Power window B-7

Relay;Rear defogger B-5

Key,light and seat belt remind buzzer

C-5

C-6

C-7

Relay;Glow C-10

C-11

Relay;Starter

D08RW553

RELAY

Connector No.

Relay Engine model

C-3

C-5 C-6 C-7

WINDSHIELD INTERMITTENT

GLOW



4Z Series 4J Series 6VD1

C-10

C-11

B-7

B-8

STARTER

RR DEFOGGER

POWER WINDOW

—

—

















—

—






DIODE LOCATION-1 RELAY & FUSE BOX

1 1 X 2 1 X 3 1 X 4 1 X

D08RV812

FUSE BOX (LHD)

B-29

FUSE BOX (RHD)

B-30

B-30

D08RV928

D08RV929

DIODE

Connector No. Usage Engine model

X-11

X-12

RELAY; RELAY; A/C ECM MAIN THERMO

B-29

X-13

X-14

B-29

B-30

—

FUEL PUMP

—

DOME LIGHT

4Z Series



—

—



—



4J Series

—



—

—

—




DIODE LOCATION-2 (6VD1) RELAY & FUSE BOX

9 2 X

8 2 X

D08RW525

FUSE BOX (LHD)

B-29

FUSE BOX (RHD)

B-30

B-30

D08RV928

DIODE

Connector No.

X-28

X-29

6VD1



—

4J Series

—

—

Usage Engine model

B-29

D08RV929


FUSE BLOCK CIRCUIT GASOLINE ENGINE EXCEPT 4ZE1 (MPI) ENGINE AC GENERATOR

B L

CHARGE WARNING LIGHT

+

MAIN 80A 15A

HAZARD 10A

_

HORN RELAY;TAIL IGN B1 40A

TAIL LIGHT 15A 10A

STOP LIGHT RELAY;HEATER 20A

BLOWER 10A

AIR CON.

10A

AUTO CHOKE RELAY;CHARGE

STARTER SW

B2

15A

CIGAR

OFF ACC

15A

IG2

15A

AUDIO BACK UP,TURN

ST B1

10A

IG1

ENGINE-2

15A

ENGINE-1 15A

METER 20A

FRONT WIPER RELAY;STARTER C 10A

STARTER

B

30A

POWER WINDOW 15A IGN B2 40A

RR DEFOG

10A

DOME LIGHT 20A

DOOR LOCK

RELAY;EFE HEATER

EFE 30A

EFE HEATER FUSE; ENGINE-2 10A 15A

ECM

RELAY; FUEL PUMP

O2SENSOR

20A

FUEL PUMP

RELAY; LIGHTING 10A 10A

HEAD LIGHT

D08RVA12


4ZE1 (MPI) ENGINE

AC GENERATOR

IG B L 15A

HAZARD

+

10A

MAIN 100A

HORN CHARGE WARNING LIGHT

RELAY;TAIL

_

TAIL LIGHT 15A 10A

STOP LIGHT

IGN B1 40A

RELAY;HEATER 20A

BLOWER 10A

AIR CON.

RELAY;ST CU T

STARTER SW

B2

15A

CIGAR

OFF ACC

15A

IG2

15A

AUDIO BACK UP,TURN

ST B1

10A

IG1

ENGINE-2

15A

ENGINE-1 15A

METER 20A


STARTER

B

(AT)

30A


RR DEFOG

10A

DOME LIGHT 20A

15A

ECM

DOOR LOCK

RELAY; FUEL PUMP

20A

FUEL PUMP

RELAY; LIGHTING 10A 10A

HEAD LIGHT

D08RVA13


6VD1 (ECM) ENGINE A/C GENERATOR IG B L

CHARGE WARNING TAIL LAMP

10A MAIN 100A

10A

RELAY;HEATER

STOP LAMP

20A

BLOWER MOTOR

10A

A/C

IGN. 40A

15A

STARTER SW B2 B1

OFF ACC IG2 ST IG1

CIGAR LIGHTER

15A

AUDIO,MIRROR

15A

BACK UP,TURN

10A

ENGINE

15A

(IG.COIL)

15A

METER,WARNING

20A

FT WIPER&WASHER C

10A

B

STARTER

RELAY STARTER COND FAN 30A

RELAY;COND.FAN CONDENSOR FAN TRIPLE PRESSURE SW 20A RELAY;P/WINDOW

P/WINDOW RR 20A

P/WINDOW FT

15A ILGN.B 40A

RR DEFOG

10A

ROOM LAMP AUDIO(B)

20A

RR DEF 30A

DOOR LOCK 10A

RR DEF RELAY;FUEL

RELAY;RR DEF

O2 SENSOR 15A

FUEL PUMP

ECM 20A ECM

ECM 10A TCM 10A

RELAY;ECM TCM

10A 10A

HEAD LIGHT

RELAY;LIGHT 15A 10A

HAZARD HORN D08RW526


DIESEL ENGINE 4JA1

AC GENERATOR

S B

4JB1

10A S B

+

L IG

MAIN 100A

15A

_

HAZARD 10A

HORN IGN B1 40A

RELAY;TAIL TAIL LIGHT 15A 10A

STOP LIGHT

RELAY;HEATER 20A

BLOWER 10A

AIR CON.

CHARGE WARNING LIGHT

RELAY;CHARGE

STARTER SW

B2

15A

CIGAR

OFF ACC

15A

IG2

15A

AUDIO BACK UP,TURN

ST B1

10A

IG1

ENGINE-2

15A

ENGINE-1 15A

METER 20A


STARTER

B

30A


RR DEFOG

10A

DOME LIGHT 20A

DOOR LOCK

RELAY;GLOW

GLOW 50A

GLOW PLUG FUSE; ENGINE-2 RELAY; LIGHTING 10A 10A

HEAD LIGHT

D08RVA14


REFERENCE TABLE OF FUSE, FUSIBLE LINK AND CIRCUIT BREAKER GASOLINE ENGINE FUSE (Relay and fuse box)

Fuse No.

Capacity

Indication on lable

EB-1

15A

HAZARD

EB-2

10A

HORN

EB-3

20A

BLOWER (6VD1)

20A

BLOWER

Parts (Load) Hazard SW, Flasher unit Horn relay, Horn SW, Horn Blower motor, Blower resistor Blower motor, A/C thermo relay, Blower resistor

10A

AIR CON (6VD1)

A/C thermo relay, A/C comp relay, Condenser fan relay Pressure SW, Electronic thermo, Magnet clutch A/C SW, Triple pressure SW, Fan SW

EB-5

10A

AIR CON

Pressure SW, A/C SW, Electronic thermostat, Fan SW, Magnetic clutch, FICD, A/C thermo relay

EB-6

15A

FUEL PUMP (6VD1)

EB-7

10A

O2 SENSOR

Oxygen sensor (4ZD1 (MPI))

EB-8

10A

H/LAMP-LH

Headlight-LH, High beam indicator light , Dimmer · passing SW

EB-9

10A

H/LAMP-RH

Headlight-RH, Dimmer · passing SW

EB-10

10A

STOP (6VD1)

Stop light SW, Stop light, High mounted stop light

10A

STOP


10A

TAIL (6VD1)

Tail relay, Clearance light, Tail light, License plate light, Illumination controller, Illumination light, Lighting SW

15A

TAIL

Tail relay, Clearance light, Tail light, License plate light, Illumination controller, Illumination lights, Lighting SW

10A

TCM (6VD1)

EB-4

EB-11

EB-12

15A

ECM

10A

ECM (6VD1)

10A

AUTO CHOKE

EB-13

EB-14

Fuel pump

TCM ECM main relay, ECM, Crank angle sensor, Throttle valve SW, VSV; canister (4ZD1 (MPI)), Fuel injector, VSV; pressure regulator ECM Back Up Auto choke (4ZD1 (CARB)), Vent SW valve (4ZD1 (CARB))

20A

FUEL PUMP

Fuel pump relay (4ZD1 (MPI), 4ZE1 (MPI)), Fuel pump (4ZD1 (MPI), 4ZE1 (MPI)), Air regulator (4ZD1 (MPI), 4ZE1 (MPI))

20A

ECM (6VD1)

ECM main relay, Fuel pump relay, ECM, Fuel injector, Idle air control valve

ELECTRICAL-BODY AND CHASSIS 8–41 FUSE (Fuse box)

Fuse No.

Capacity

Indication on lable

Parts (Load)

CB-1

10A

STARTER

CB-2

—

—

—

CB-3

15A

ENGINE-1

Ignition coil, Power SW, Distributor, Engine speed sensor

CB-4

10A

ENGINE-2

ECM main relay, Engine speed sensor, Slow cut solenoid (4ZD1 (CRAB), 4ZE1 (CARB)), Neutral SW (4ZC1 (CARB), 4ZD1 (CARB)), Coasting richer (4ZC1 (CARB), 4ZD1 (CARB)), 2ND SW (4ZD1 (CARB)), TOP-3RD SW (4ZD1 (CARB)), VSV; Air (4ZD1 (CARB)), Clutch SW (4ZD1 (CARB)), Accel SW (4ZD1 (CARB)) Canister duty solenoid valve (6VD1)

CB-5

15A RHD

METER

CB-6

20A RHD

FRONT WIPER

Windshield wiper & washer SW, Windshield wiper motor, Windshield washer motor, Windshield intermittent relay

CB-7

15A LHD

METER

Vehicle speed sensor, Meter gauges, Indicator and warning lights, Engine speed sensor (4ZD1 (CARB)), RR defogger relay, RR defogger SW, Key, light & seat belt remind buzzer (SAUDI ARABIA), Seat belt SW (SAUDI ARABIA)

CB-8

20A LHD

FRONT WIPER

Windshield wiper & washer SW, Windshield wiper motor, Windshield washer motor, Windshield intermittent relay

CB-9

—

—

—

CB-10

—

—

—

CB-11

15A

BACK UP, TURN

CB-12

10A LHD

(SEAT HEATER)

Starter relay, ST. cut relay (4ZE1 (MPI)), ECM

Vehicle speed sensor, Meter gauges, Indicator and warning lights, Overdrive off relay (A/T), Overdrive solenoid (A/T), Overdrive off SW (A/T), Key, light & seat belt remind buzzer (SOUTH AFRICA), RR defogger relay, RR defogger SW, AC generator, Seat belt SW (SOUTH AFRICA) Indicator and warning lights, Power drive and check trans (6VD1 A/T)

Power window relay, FRT power window & door lock SW-driver side, RR power window SW, Radiator level warning buzzer (4ZD1, LHD), Radiator level control unit (4ZD1, LHD), Hazard SW, Flasher unit, Turn signal SW, Back up light SW (M/T), Back up light, Mode SW (A/T) —


Fuse No.

Capacity

Indication on lable

Parts (Load)

CB-13

15A

(RR DEFOG.)

RR defogger relay, RR defogger SW, RR defogger

CB-14

10A

DOME LIGHT

Dome light, Spot light, Door SW, Audio, Clock

CB-15

20A

(DOOR LOCK)

FRT power window & door lock SW-driver side, Door lock SW-driver side, Door lock actuator

CB-16

—

—

—

CB-17

—

—

—

CB-18

—

—

—

CB-19

15A

AUDIO

Door mirror control SW, Mirror, Audio

CB-20

15A

CIGAR

Cigarette lighter, Clock

CB-21

—

—

—

CB-22

—

—

—

CB-23

—

—

—

CB-24

—

—

—

ELECTRICAL-BODY AND CHASSIS 8–43 FUSIBLE LINK (Relay and fuse box)

Fusible link No.

Capacity

Indication on label

EB-15

40A

IGN. B1

EB-16

80A

MAIN

Except 4ZE1 (MPI)

100A

MAIN

4ZE1 (MPI), 6VD1 (ECM) 6VD1 (ECM)

EB-17

40A

IGN. B2

EB-18

30A

(EFE)

30A

RR DEF

40A

IGN. B2, POWER

30A

CONDENSER FAN

EB-19

Remarks

6VD1

6VD1

CIRCUIT BREAKER (Fuse box)

Circuit breaker No.

Capacity

Indication on label

B-31

30A

(POWER WINDOW)

Parts (Load) Power window & door lock SW, Power window motor, Power window relay


DIESEL ENGINE FUSE (Relay and fuse box)

Fuse No.

Capacity

Indication on lable

Parts (Load)

EB-1

15A

HAZARD

EB-2

10A

HORN

EB-3

—

—

EB-4

20A

BLOWER

Blower motor, A/C thermo relay, Blower resistor

EB-5

10A

AIR CON.

Pressure SW, A/C SW, Electronic thermostat, Fan SW, Magnetic clutch, VSV; FICD, A/C thermo relay

EB-6

—

—

EB-7

10A

(CHARGE)

EB-8

10A

H/LAMP-LH

Headlight-LH, High beam indicator light , Dimmer · passing SW

EB-9

10A

H/LAMP-RH

Headlight-RH, Dimmer · passing SW

EB-10

—

—

EB-11

10A

STOP


EB-12

15A

TAIL

Tail relay, Clearance light, Tail light, License plate light, Illumination lights, Lighting SW, Illumination controller

EB-13

—

—

—

EB-14

—

—

—

Hazard SW, Flasher unit Horn relay, Horn SW, Horn —

— AC generator, Charge relay

—

ELECTRICAL-BODY AND CHASSIS 8–45 FUSE (Fuse box)

Fuse No.

Capacity

Indication on lable

Parts (Load)

CB-1

10A

STARTER

CB-2

—

—

CB-3

15A

ENGINE-1

CSD relay, Fuel cut solenoid, Thermo SW, CSD solenoid, AC generator, Charge relay

CB-4

10A

ENGINE-2

QOS-II control unit, Glow relay

CB-5

15A RHD

METER

CB-6

20A RHD

FRONT WIPER

CB-7

15A LHD

METER

CB-8

20A LHD

FRONT WIPER

CB-9

—

—

—

CB-10

—

—

—

CB-11

15A

BACK UP, TURN

CB-12

10A LHD

(SEAT HEATER)

CB-13

15A

(RR DEFOG.)

RR defogger relay, RR defogger SW, RR defogger

CB-14

10A

DOME LIGHT

Dome light, Spot light, Door SW, Audio, Clock

CB-15

20A

(DOOR LOCK)

FRT power window & door lock SW-driver side, Door lock SW-driver side, Door lock actuator

CB-16

—

—

—

CB-17

—

—

—

CB-18

—

—

—

CB-19

15A

AUDIO

QOS-II control unit, Starter relay, ST. cut relay (4JA1 -SOUTH AFRICA) —

Vehicle speed sensor, Meter gauges, Indicator and warning lights, QOS-II control unit, RR defogger relay, RR defogger SW, Key, light & seat belt remind buzzer (SOUTH AFRICA), Seat belt SW (SOUTH AFRICA) Windshield wiper & washer SW, Windshield wiper motor, Windshield washer motor, Windshield intermittent relay Vehicle speed sensor, Meter gauges, Indicator and warning lights, QOS-II control unit, RR defogger relay, RR defogger SW, Key, light & seat belt remind buzzer (SAUDI ARABIA), Seat belt SW (SAUDI ARABIA) Windshield wiper & washer SW, Windshield wiper motor, Windshield washer motor, Windshield intermittent relay

Power window relay, FRT power window & door lock SW-driver side, RR power window SW, Hazard SW, Flasher unit, Turn signal SW, Back up light SW, Back up light —

Door mirror control SW, Mirror, Audio


Fuse No.

Capacity

Indication on lable

Parts (Load)

CB-20

15A

CIGAR

CB-21

—

—

—

CB-22

—

—

—

CB-23

—

—

—

CB-24

—

—

—

Cigarette lighter, Clock

ELECTRICAL-BODY AND CHASSIS 8–47 FUSIBLE LINK (Relay and fuse box)

Fusible link No.

Capacity

Indication on label

Remarks

EB-15

40A

IGN. B1

EB-16

80A

MAIN

4JA1 (SOUTH AFRICA)

100A

MAIN

Except 4JA1 (SOUTH AFRICA)

EB-17

50A

GLOW

EB-18

—

EB-19

40A

— IGN. B2, POWER

CIRCUIT BREAKER (Fuse box)

Circuit breaker No.

Capacity

Indication on label

B-31

30A

(POWER WINDOW)

Parts (Load) Power window & door lock SW, Power window motor, Power window relay


GROUNDING POINT REFERENCE TABLE (GASOLINE ENGINE – LHD)

Connector No.

Cable harness

Location

Parts (Load)

Body-RH

Fan SW, FRT power window & door lock SWpassenger side, Key, light & seat belt remind buzzer (SAUDI ARABIA)

B-28

Body-LH

Turn signal indicator light, Illumination light (Meter, Heater & A/C control panel, Cigarette lighter, RR defogger SW, Audio, Hazard SW), FRT power window & door lock SW-driver side, RR power window SW, Power window relay, Door mirror control SW, RR defogger, RR defogger SW, Door lock SW-driver side, Audio, Clock, Cigarette lighter, High mounted stop light, Seat belt SW (SAUDI ARABIA)

B-37

Body-RR

Fuel pump

B-9

Body harness

Fender-RH

Heater relay, Dimmer·passing SW, Lighting SW, Charge relay, Idle SW (4ZE1), Accel SW (4ZC1, 4ZD1), Engine speed sensor, EFE heater, Starter relay, Radiator level sensor, Radiator level control unit, Windshield intermittent relay, Windshield wiper motor, Side turn signal light-RH

C-36

Fender-LH

Vehicle speed sensor, Speed warning buzzer (SAUDI ARABIA), Speedometer, Fuel tank unit, 4WD SW, Brake fluid level SW, Tachometer (W/Tachometer), Fuel gauge, Clearance light, Seat belt SW (SAUDI ARABIA), Windshield washer motor, Flasher unit, Side turn signal light-LH, FRT turn signal light, Engine coolant temperature gauge (W/Tachometer)

C-81

Engine-RH

Crank angle sensor, Data link connector, ECM, ECM main relay, Oxygen sensor (4ZD1 (MPI))

E-5

Engine

C-2

Engine room harness

E-72 E-73

Engine harness

Common chamber-LH

E-74

F-3

Common chamber-RH

Chassis harness

Frame

Air regulator, FICD (4ZD1 (MPI)) Data link connector, ECM, Crank angle sensor Ignition coil, ECM Ignition coil, ECM, MAF sensor shield, Cam angle sensor shield, Throttle position sensor shield Tail light, License plate light, Back up light, RR turn signal light, Stop light, Fuel pump

ELECTRICAL-BODY AND CHASSIS 8–49 (GASOLINE ENGINE – RHD)

Connector No.

Cable harness

Location

Parts (Load)

Body-LH

Fan SW, FRT power window & door lock SWpassenger side, RR power window SW, Key, light & seat belt remind buzzer (SOUTH AFRICA)

B-28

Body-RH

Illumination light (Meter, Heater & A/C control panel, Cigarette lighter, Ashtray, RR defogger SW, Audio, Hazard SW), Illumination controller, Turn signal indicator light, FRT power window & door lock SW-driver side, Power window relay, Door mirror control SW, RR defogger, RR defogger SW, Door lock SW-driver side, Audio, Clock, Cigarette lighter

B-37

Body-RR

Fuel pump

B-9

Body harness

Fender-RH

Vehicle speed sensor, 4WD SW, Brake fluid level SW, Heater relay, Dimmer·passing SW, Lighter SW, Overdriver off SW (4ZE1, A/T), Charge relay, Idle SW (4ZE1), Accel SW (4ZC1, 4ZD1), Engine speed sensor, Starter relay, Windshield intermittent relay, ST. cut relay (4ZE1, A/T), Windshield wiper motor, Flasher unit, Side turn signal light-RH, Mode SW (4 ZE1, A/T)

C-36

Fender-LH

Speedometer, Fuel tank unit, Tachometer (W/Tachometer), Engine coolant temperature gauge (W/Tachometer), Fuel gauge, Clearance light, Seat belt SW (SOUTH AFRICA), Windshield washer motor, Side turn signal light-LH, FRT turn signal light

C-81

Engine-RH

Crank angle sensor, Data link connector, ECM, Fuel pump relay, ECM main relay

E-5

Engine

C-2

Engine room harness

E-72 E-73

Engine harness

Common chamber-LH

E-74

F-3

Common chamber-RH

Chassis harness

Frame

FICD (4ZD1 (MPI)), Air regulator

Data link connector, ECM, Crank angle sensor shield Ignition coil, ECM Ignition coil, ECM, TCM, Mode SW, MAF sensor shield, Cam angle sensor shield Throttle position sensor shield Tail light, License plate light, Fuel pump, Stop light, RR turn signal light, Back up light

8–50 ELECTRICAL-BODY AND CHASSIS (DIESEL ENGINE – LHD)

Connector No.

Cable harness

B-9

Location

Parts (Load)

Body-RH

Fan SW, FRT power window & door lock SWpassenger side, Key, light & seat belt remind buzzer (SAUDI ARABIA)

Body-LH

Turn signal indicator light, Illumination light (Meter, Heater & A/C control panel, Cigarette lighter, RR defogger SW, Audio, Hazard SW), FRT power window & door lock SW-driver side, RR power window SW, Door mirror control SW, RR defogger, RR defogger SW, FRT door lock SW-driver side, Audio, Clock, Cigarette lighter, High mounted stop light, Power window relay, Seat belt SW (SAUDI ARABIA)

Fender-RH

Vehicle speed sensor, 4WD SW, Tacho sensor, Heater relay, VSV; FICD, Dimmer·passing SW, Lighting SW, QOS-II control unit, Starter relay, Charge relay, Windshield wiper motor, Windshield intermittent relay, Side turn signal light-RH

Fender-LH

Speedometer, Fuel tank unit, Fuel filter SW, Brake fluid level SW, Tachometer (W/Tachometer), Engine coolant temperature gauge (W/Tachometer), Fuel gauge, Clearance light, Seat belt SW (SAUDI ARABIA), Windshield washer motor, Side turn signal light-LH, FRT turn signal light, Flasher unit

Body harness B-28

C-2

Engine room harness

C-36

F-3

Chassis harness

Frame

Tail light, License plate light, Stop light, RR turn signal light, Back up light

ELECTRICAL-BODY AND CHASSIS 8–51 (DIESEL ENGINE – RHD)

Connector No.

Cable harness

B-9

Location

Parts (Load)

Body-LH

Fan SW, FRT power window & door lock SWpassenger side, RR power window SW, Key, light & seat belt remind buzzer (SOUTH AFRICA)

Body-RH

Turn signal indicator light, Illumination light (Meter, Heater & A/C control panel, Cigarette lighter, Ashtray, RR defogger SW, Audio, Hazard SW), Illumination controller, FRT power window & door lock SW-driver side, Power window relay, Door mirror control SW, RR defogger, RR defogger SW, FRT door lock SW-driver side, Audio, Clock, Cigarette lighter

Body harness B-28

C-2

Fender-RH

Vehicle speed sensor, 4WD SW, Brake fluid level SW, Tacho sensor, Heater relay, VSV; FICD, Dimmer·passing SW, Lighting SW, QOS-II control unit, Starter relay, Charge relay, Windshield intermittent relay, Windshield wiper motor, ST. cut relay (4JA1, SOUTH AFRICA), Side turn signal light-RH, Flasher unit

Fender-LH

Speedometer, Fuel tank unit, Fuel filter SW, Tachometer (W/Tachometer), Engine coolant temperature gauge (W/Tachometer), Fuel gauge, Timing belt warning light, Fuel filter SW, Clearance light, Seat belt SW (SOUTH AFRICA), Windshield washer motor, Side turn signal light-LH, FRT turn signal light

Engine room harness

C-36

F-3

Chassis harness

Frame

Tail light, License plate light, Stop light, RR turn signal light, Back up light


LOCATION F-3

B-28 (RHD) B-9

(LHD)

D08RVA15

QOS-II control unit

D08RV762

C-36

B-9

(RHD)

B-28 (LHD)

D08RVA16

D08RV761

C-2 P-6

Battery D08RV765

D08RV763


P-10 D08RV759

P-9

D08RW537

E-72 E-73

P-8 D08RW535

D08RW538

E-74 P-7

D08RW536

D08RW533


B-37

D08RW534


MAIN CABLE HARNESS ROUTING (LHD)

DOME LIGHT HARNESS BODY HARNESS

H-8 P-2

C-2

P-1 C-36

H-6 H-7 H-11 H-12

H-13

P-5 B-9

P-10

H-1

B-28

H-10

(DIESEL)

H-9

P-7

ENGINE ROOM HARNESS BATTERY NEGATIVE CABLE BATTERY POSITIVE CABLE

D08RVA55

8–56 ELECTRICAL-BODY AND CHASSIS (LHD)

COMBINATION LIGHT HARNESS REAR DOOR HARNESS-RH

FRONT DOOR HARNESS-RH

CHASSIS HARNESS

H-4(DIESEL) H-5(GASOLINE) H-1(GASOLINE) H-2

H-8

H-16 F-3

H-17

H-14

H-13 H-15

REAR DOOR HARNESS -LH

B-28

H-19 H-20 H-10

H-9

H-6 H-7 H-11 H-12

FRONT DOOR HARNESS -LH REAR BODY HARNESS

ENGINE ECGI HARNESS

ENGINE & TRANSMISSION HARNESS(DIESEL) TRANSMISSION HARNESS(GASOLINE)

D08RVA56

ELECTRICAL-BODY AND CHASSIS 8–57 (LHD-6VD1)


ENGINE HARNESS

H-8

C-2 P-1 H-6 H-11 H-12 H-28

C-36 H-13

P-5 B-9

B-28

H-22

H-20 H-24 H-25

H-10 H-34


TRANS MISSION HARNESS

D08RW561

8–58 ELECTRICAL-BODY AND CHASSIS (LHD-6VD1)

COMBINATION LIGHT HARNESS REAR DOOR HARNESS-RH


H-8

CHASSIS HARNESS

H-16 F-3

H-17

H-14

H-13 H-15


B-28 H-32 H-10

H-34

H-6 H-11 H-12 H-28

FRONT DOOR HARNESS -LH REAR BODY HARNESS

D08RW562

ELECTRICAL-BODY AND CHASSIS 8–59 (RHD)


H-6 H-7 H-11 H-12 P-2

C-2

P-1 C-36 H-8

H-10

P-5 B-28

H-13 P-10

B-9

H-1

(DIESEL)

H-9

P-7


D08RVA57

8–60 ELECTRICAL-BODY AND CHASSIS (RHD)

REAR DOOR HARNESS-RH CHASSIS HARNESS


H-1(GASOLINE) H-2

H-6 H-7 H-11 H-12

COMBINATION LIGHT HARNESS

H-16 F-3

H-17

H-14

H-8 H-10 H-15


B-9

H-19 H-20 H-13

H-9

FRONT DOOR HARNESS-LH

REAR BODY HARNESS ENGINE ECGI HARNESS

ENGINE & TRANSMISSION HARNESS(DIESEL) TRANSMISSION HARNESS(GASOLINE)

D08RVA58

ELECTRICAL-BODY AND CHASSIS 8–61 (RHD-6VD1)


ENGINE HARNESS H-6 H-7 H-11 H-12 P-2

P-1

C-2

B-28

C-36

H-26 H-27

H-10

P-5

H-13 B-9 H-20 H-24 H-25

H-34

ENGINE ROOM HARNESS

BATTERY NEGATIVE CABLE

H-22 H-23 H-38

BATTERY POSITIVE CABLE

TRANSMISSION HARNESS

D08RW559

8–62 ELECTRICAL-BODY AND CHASSIS (RHD-6VD1)

REAR DOOR HARNESS-RH CHASSIS HARNESS


H-6 H-7 H-11 H-12

COMBINATION LIGHT HARNESS

H-16 F-3

H-17

H-14

H-26 H-27 H-10 H-15


B-9

H-32 H-13

H-34

FRONT DOOR HARNESS-LH

REAR BODY HARNESS

D08RW560


SYSTEM REPAIR START AND CHARGING PARTS LOCATION (GASOLINE ENGINE – LHD)

RELAY & FUSE BOX (X-3,X-5,X-6) P-2

H-8

C-2

P-1 H-7 P-5

P-3

H-1

C-47 C-48

C-41

P-4 P-10

P-7

D08RVA17


PARTS LOCATION (6VD1 GASOLINE ENGINE-LHD)

RELAY & FUSE BOX (X-15,X-24)

H-8

P-12 H-36 P-11 P-6

P-8

H-6

P-9 C-41 H-37

H-28 P-3 P-4

P-5

P-1 P-10 P-7

D08RW546


PARTS LOCATION (6VD1 GASOLINE ENGINE-RHD)

H-6 H-7

RELAY & FUSE BOX (X-15,X-24,X-28) H-36 P-12 P-11

C-41

P-6 P-8

H-25 P-9

E-74 M-25

P-3 H-37 P-5

P-1

P-10

H-23

P-4

P-7

D08RW547


PARTS LOCATION (GASOLINE ENGINE – RHD)

RELAY & FUSE BOX (X-3,X-5,X-6,X-8) H-6 H-7 P-2

C-2

P-1

C-80

P-5 H-1

P-3

C-48

C-47

P-4 P-10

P-7

D08RVA19


PARTS LOCATION (DIESEL ENGINE – LHD)

RELAY & FUSE BOX (X-3,X-5) P-2

H-8

C-2

P-1 C-10 C-11

P-5

H-7 C-41

C-47 C-48 P-4 P-10

P-3

H-1 P-7

D08RVA18


PARTS LOCATION (DIESEL ENGINE – RHD)

RELAY & FUSE BOX (X-3,X-5,X-6,X-8) H-6 H-7 P-2

C-2

P-1 C-10 C-11

P-5

C-41 C-47

C-48 P-3

P-4

P-10 H-1 P-7

D08RVA20


CIRCUIT DIAGRAM (GASOLINE ENGINE EXCEPT 4ZE1 (MPI) ENGINE)

8W

STARTER SW

15B/R

+

MAIN 80A

OFF ACC

IGN.B2 40A

1

3W

P-2

C-41 IGN.B1 40A

P-1

3W/B

3 C-41

B2

IG2

B1

IG1

ST

P-5

C-41 2

_

L / W 2

Y / B 0 2

(RHD)

W 8

B 3 4

H-7

3 H-7

5B/Y

L / W 2

P-7 FRAME

P-10

CB-1 10A STARTER

ENG.

C-47

W / B 5 . 0

B (RHD)

AC GENERATOR L

3W/B

C-48

B 0 2

1 4 H-8

13 H-6

L / W 5 8 . 0

W / B 5 . 0

B 3 5 X-6

2

X-5

X-6 1

X-5 4

X-3

1

4

2

RELAY; HEATER

X-3

H-1

STARTER

X-3

X-3 1

1 3B/W

B 5 . 0

B 5 . 0

EB-5 10A A/C

W / L 2

M

4

R / L 3

EB-4 20A BLOWER

R O T O M R E W O L B

C-2

X-5

B 3 5

P-4

P-3

2 X-5

5

W / B 3

C

0.85W/L

B 3 X-6

B

1

RELAY; CHARGE

X-6

RELAY; STARTER

FENDER-RH

G N I N ) R R A E T E W E M G ( R T A H H G I C L

R B 5 . 0

B 5 . 0

W S E R U S S E R P

1.25B

D08RV935


CIRCUIT DIAGRAM (4ZE1 (MPI) GASOLINE ENGINE)

STARTER SW

15B/R

+

MAIN 100A

OFF ACC

IGN.B2 40A

1

3W

P-2

C-41 IGN.B1 40A

P-1

3

3W/B

C-41

B2

IG2

B1

IG1

ST

P-5

6

4 3B/R

C-41

3B/R

H-7

CB-5 15A METER

C-41 2

_

L / W 2

Y / B 0 2

H-7

5B/Y

10

L / W 2

P-7 FRAME

W 8

Y 5 8 . 0

3

H-6

B 3

P-10

Y 5 8 . 0

CB-1 10A STARTER

ENG.

3 C-48

C-47

IG

B

W / B 5 . 0

AC GENERATOR 13 H-6

L

B 0 2

C-48 2

L / W 5 8 . 0

3B

0.85W/L

W / B 5 . 0

B 3

5 5

2

X-6

X-3

2

RELAY; HEATER

X-3

X-6 CHARGE WARNING LIGHT(METER)

RELAY; STARTER X-3 X-6

X-6

1

4

W / B 3

X-3 1

4

R / L 3 W / B 5 . 0

EB-4 20A BLOWER

EB-5 10A A/C

1 P-4

H-1

B

W / L 2

) T / A ( R / R B 5 . 0

STARTER

1 C-80

1 C

P-3

3B/W

) T / M ( B 5 . 0

MODE SW

2


R B 5 . 0

O / W 5 . 0

W S E R U S S E R P

X-8

5 X-8

C-80 4

M X-8

RELAY;ST CUT

X-8

4

B 5 . 0

FENDER-RH

C-2

B 5 . 0

3

B 5 . 0

1.25B

D08RV934


CIRCUIT DIAGRAM (6VD1 GASOLINE ENGINE-LHD)

15B/R

+

EB-16 100A MAIN

P-6

STARTER SW OFF ACC

EB-17 40A IGN B-2

1

3W

P-11

P-1

3

3W/B

C-41

EB-15 40A IGN B-1

P-5

8 B2

C-41

IG2

C-41

ST B1

6 3B/Y

H-28

6

IG1

3B/Y

CB-11 15A BUCK TURN

4 3B/R

C-41

3B/R

H-28

CB-4 10A ENGINE

C-41 2

_

L / W 2

4

5B

B 5

Y / L 5 8 . 0

W 5 8 . 0 18

H-28

H-8

Y / B 0 3

W 8 14

H-8

Y / L 5 8 . 0 2

L / W 2

H-36 P-7

P-8

FRAME BODY

B 3

P-10

Y / L 5 8 . 0

CB-1 10A STARTER

ENG.

W / B 5 . 0

W 5 8 . 0

2

H-37

P-9

IG

B

AC GENERATOR

13 H-8

L

B 0 2

H-37

L / 1 W 5 8 . 0 1

3B

H-36

L / W 5 8 . 0

W / B 5 . 0

B 3

5 2

5

X-24

X-15

2

RELAY; HEATER

15

X-15

H-8

X-15

CHARGE WARNING LIGHT(METER)

X-24


X-24

1

1

3

W / B 3

4

R / L 3

EB-3 20A BLOWER

EB-4 10A A/C

1 P-4

P-12

W / L 2

STARTER

B

) T / M ( B 5 . 0

1 C

P-3

3B/W


R B 5 . 0

W S E R U S S E R P

O / W 5 . 0

M

FENDER-RH

C-2

1.25B

D08RW544


CIRCUIT DIAGRAM (6VD1 GASOLINE ENGINE-RHD)

STARTER SW

P-6

15B/R

+

EB-16 100A MAIN

OFF ACC

EB-17 40A IGN B-2

1

3W

P-11

8 B2

C-41

P-1

B1

C-41

P-5

3B/Y

H-7

6

IG1

EB-15 40A IGN B-1

6 3B/Y

C-41

ST

3

3W/B

IG2

CB-11 15A BUCK TURN

4 3B/R

C-41

3B/R

H-7

CB-4 10A ENGINE

C-41 2

_

L / W 2

Y / L 5 8 . 0

W 5 8 . 0 3

5B

B 5

2

H-7 H-6

Y / B 0 3

W 8 19

H-6

Y / L 5 8 . 0 2

L / W 2

H-36 P-7

P-8

FRAME BODY

B 3

P-10

Y / L 5 8 . 0

CB-1 10A STARTER

ENG.

W / B 5 . 0

W 5 8 . 0

2

H-37

P-9

IG

B

AC GENERATOR

13 H-6

R / B 0 2

L H-37

L / 1 W 5 8 . 0 1

3B

H-36

L / W 5 8 . 0

W / B 5 . 0

B 3

5 5

2 X-24

X-15

2

RELAY; HEATER

X-15

3

H-6

X-24


X-24 3

1

W / B 3

3

1

4

CHARGE WARNING LIGHT(METER) (B-23 13)

R / L 3

EB-3 20A BLOWER

X-28 X-28

X-15

1

EB-4 10A A/C

1 P-4

P-12 STARTER

B

X-28 ECM

H-23

1 P-3

R B 5 . 0

2

15

C

W / L 2

3B/W 5 M-25

) T / M ( B 5 . 0


W S E R U S S E R P

O / W 5 . 0

MODE SW

M

M-25 8 7 H-23

7 H-25 COMMON CHAMBER:LH

E-74

FENDER-RH

C-2

1.25B

D08RW545


CIRCUIT DIAGRAM (DIESEL ENGINE – LHD)

8W

W 3

STARTER SW

15B/R

+

MAIN 100A

OFF ACC

IGN.B2 40A

1

3W

P-2

C-41 IGN.B1 40A

P-1

3W/B

3 C-41

B2

IG2

B1

IG1

EB-7 10A CHARGE

ST

6 C-41

2 3B/R

3B/R

H-7

CB-3 15A ENGINE-1 P-5

C-41 2

_

G / W 5 8 . 0

L / W 2 Y / B 0 3

4 H-7

G / W 5 8 . 0

L / W 2

P-7

P-10

5

H-7

5B/Y

FRAME

) 1 B J 4 ( W / B 5 2 . 1

) 1 A J 4 ( W 3

W 8

0.85W/G

CB-1 10A STARTER

ENG.

1 3

W / B 5 . 0

2

C-48

C-48

IG

S

C-47 B

AC GENERATOR 4 H-8

L

R B 0 3

C-48 1

CHARGE WARNING LIGHT(METER) 3B

W / B 5 . 0

B 3 1 C-10

L / W 5 8 . 0

1 C-11

2 X-5

L / W 5 8 . 0

B 3

RELAY; CHARGE

C-11

2

5

X-5

RELAY; STARTER

C-10

R / W 5 8 . 0

X-5

2

3

X-5

X-5 1

4

W / B 5 5 1 P-4

X-3

2

RELAY; HEATER

X-3

H-1 STARTER

B

X-3

X-3 1

C

P-3

R / L 3

3B/W

B 5 . 0

EB-4 20A BLOWER


FENDER-RH

C-2

B 5 . 0

EB-5 10A A/C

W / L 2

M

4

R B 5 . 0

B 5 . 0

B 5 . 0

W S E R U S S E R P

1.25B

D08RV931


CIRCUIT DIAGRAM (DIESEL ENGINE – RHD)

8W

W 3

STARTER SW

15B/R

+

MAIN 100A

OFF ACC

IGN.B2 40A

1

3W

P-2

C-41 IGN.B1 40A

P-1

3W/B

3 C-41

B2

IG2

B1

IG1

EB-7 10A CHARGE

ST

6 C-41

4 3B/R

3B/R

H-7

) 1 B J 4 ( W / B 5 2 . 1

CB-3 15A ENGINE-1 P-5

C-41 2

_

G / W 5 8 . 0

L / W 2

Y / B 0 3

3 H-7

P-10

1

G / W 5 8 . 0

L / W 2

P-7

W 8

H-6

5B/Y

FRAME

) 1 A J 4 ( W 3

0.85W/G

CB-1 10A STARTER

ENG.

1 3

W / B 5 . 0

2

C-48

C-48

IG

S

C-47 B

AC GENERATOR 13 H-6

R B 0 3

L C-48 1

CHARGE WARNING LIGHT(METER) 3B

W / B 5 . 0

B 3 1 C-10

L / W 5 8 . 0

1 C-11

2 X-5

L / W 5 8 . 0

B 3

RELAY; CHARGE

C-11

2

5

X-5

RELAY; STARTER

C-10

R / W 5 8 . 0

X-5

2

3

X-5

X-5 1

4

W / B 5 5

1 P-4

X-3

H-1

2

RELAY; HEATER

X-3

STARTER

B

X-3

X-3 1

C

P-3

3B/W

R / L 3

B 5 . 0

EB-4 20A BLOWER


FENDER-RH

C-2

B 5 . 0

EB-5 10A A/C

W / L 2

M

4

R B 5 . 0

B 5 . 0

B 5 . 0

W S E R U S S E R P

1.25B

D08RV932


CIRCUIT DIAGRAM (4JA1 DIESEL ENGINE – SOUTH AFRICA)

STARTER SW

15B/R

+

MAIN 80A

OFF ACC

IGN.B2 40A

1

3W

P-2

C-41 IGN.B1 40A

P-1

3W/B

3 C-41

B2

IG2

B1

IG1

ST

P-5

6

4 3B/R

C-41

3B/R

H-7

CB-3 15A ENGINE-1

C-41 2

_

L / W 2

Y / B 0 3

G / W 5 8 . 0

3 H-7

W 8

5B/Y

1

L / W 2

P-7 FRAME

H-6

W 3

P-10

G / W 5 8 . 0

CB-1 10A STARTER

ENG.

2

1

C-48

C-47

C-48

IG

B

S

W / B 5 . 0

AC GENERATOR 13 H-6

R B 0 3

L C-48 3

3B

L / W 5 8 . 0

3B

0.85W/L

W / B 5 . 0

B 3

5 5

2

X-6

X-3

2

RELAY; HEATER

X-3

X-6 CHARGE WARNING LIGHT(METER)


X-6 1

4

W / B 3

X-3 1

4

R / L 3 W / B 5 . 0

EB-4 20A BLOWER

EB-5 10A A/C

1 P-4

H-1

B

1 C

P-3

3B/W

R B 5 . 0

W / L 2

STARTER

B 5 . 0 2


O / W 5 . 0

W S E R U S S E R P 5

X-8

X-8

M X-8

RELAY;ST CUT 4

B 5 . 0

FENDER-RH

C-2

X-8 3

0.5B

1.25B

D08RV933


REMOVAL AND INSTALLATION

STARTER SWITCH Removal 1. Steering Lock Assembly • Refer to Section 3B” STEERING COLUMN” for steering lock assembly removal steps. 2. Starter Switch

730RS005

Installation

Follow the removal procedure in the reverse order to install the starter switch.


INSPECTION AND REPAIR

STARTER SWITCH 1

2

3

4

5

6

7

8

Switch Connections

C-41

Starter switch key position LOCK

Terminal No.

Removed

OFF ACC 730RV001

ON START

Inserted

1 (B2)

4 (ACC)

8 (IG2)

2 (ST)

3 (B1)

6 (IG1)

8–78 ELECTRICAL-BODY AND CHASSIS Charge relay (Diesel engine) X-5

Check continuity between the relay terminals. 1

3 – 5 . . . . . . . . . . . . . . 1 – 5 . . . . . . . . . . . . . .

3

4

Continuity No continuity

3

2 5

1

2

4

(When battery voltage is applied between 2 and 4) 3 – 5 . . . . . . . . . . . . . . 1 – 5 . . . . . . . . . . . . . .

No continuity Continuity

5

060RV005

Charge relay (Gasoline engine except 4ZE1 (MPI)) X-5


1 – 5 . . . . . . . . . . . . . .

3

No continuity

3

(When battery voltage is applied between 2 and 4)

5

1

1 – 5 . . . . . . . . . . . . . .

2

4

4 2

Continuity

5

060RV005

Starter relay (Gasoline engine), Heater relay X-3

X-6 1

Check continuity between the relay terminals. 1 – 5 . . . . . . . . . . . . . .

3

No continuity

3


5

1

1 – 5 . . . . . . . . . . . . . .

2

4

4 2

Continuity

5

060RV005

St. cut relay X-8


3 – 5 . . . . . . . . . . . . . .

3

Continuity

3


5

1

3 – 5 . . . . . . . . . . . . . .

2

4

4 2

No continuity

5

060RV005

Starter relay (Diesel engine) C-10

C-11

Check continuity between the relay terminals.

a – b . . . . . . . . . . . . . . No continuity b

c a c

a

b

(When battery voltage is applied between c and d)

a – b . . . . . . . . . . . . . . Continuity

d d

060RV006

ELECTRICAL-BODY AND CHASSIS 8–79 Starter relay (Gasoline engine 6VD1) X-24 1

5


2

1 – 2 . . . . . . . . . . . . . . 2

1

5

3

3 D08RW599

Continuity

(When battery voltage is applied between 3 and 5) 1 – 2 . . . . . . . . . . . . . .

No continuity


ENGINE CONTROL MODULE (ECM) AND FUEL PUMP PARTS LOCATION (LHD)

RELAY & FUSE BOX (X-9,X-10,X-11)

F-3 H-8

F-2

E-11

E-14 E-16

C-82 C-81 C-41

E-10

H-15

E-8 E-9 E-13

H-19 H-20 E-5

E-6

E-7 E-12

C-84

H-6 H-7 C-86 C-87

C-91

C-83 H-9

D08RVA21


PARTS LOCATION (6VD1-LHD)


H-8

F-2

C-2

C-90

B-23

P-12 P-11

B-24

B-37

C-36 H-6 H-15

C-41

H-28 C-102

B-9

H-20 H-24 H-25

H-22

E-61 E-72 E-73 E-57 E-51 E-74 E-55

M-7

E-60

E-53

E-52 E-62 E-8 E-7

E-6

E-9

E-58

E-56

E-69 E-59

E-70 E-68 E-67 E-66 E-65 E-64

E-54

E-63 E-2

H-20 H-24 H-25

ENGINE HARNESS

D08RW550


PARTS LOCATION (RHD)

RELAY & FUSE BOX (X-6,X-9,X-10,X-11,X-14)

H-6 H-7

C-82

F-3 C-84

H-19 H-20

F-2

C-85 C-41

E-14

E-16

E-11

H-2

C-81

C-86 C-87 E-10

E-5 P-11 P-12

E-6

H-8 H-15 E-8 E-9 E-13

C-83

E-7 E-12

H-9

D08RVA22


PARTS LOCATION (6VD1-RHD)

H-6 H-7

RELAY & FUSE BOX (X-18,X-24,X-26,X-28)

F-2

C-2 B-23 B-24

C-90 P-12 C-36

C-41

P-11

B-37 H-26

C-102 H-15 M-25 B-28 H-20 H-25

H-22 H-23

M-17

E-61 E-72 E-73 E-57 E-51 E-74 E-55

E-60

E-53

E-52 E-62 E-8 E-7

E-6

E-9

E-58

E-56

E-69 E-59

E-70 E-68 E-67 E-66 E-65 E-64

E-54

E-63

H-20 H-25

E-2

ENGINE HARNESS

D08RW551


CIRCUIT DIAGRAM (4ZD1 (MPI) GASOLINE ENGINE)

NAIN 80A

15B/R

+

IGM. B2 40A

P-2 IGN.B1 40A

P-1

OFF ACC

1

3W

H-7

0.5 B/W

2

IG2 ST

3 B1

C-41

CB-1 10A STATER

2W/L

C-41

B2

C-41

3W/B

4

2W/L

STARTER SW

6

IG1

2

3B/R

C-41

CB-3 15A ENGINE-1

3B/R

0.85 W/G

H-7

P-5

CB-4 10A ENGINE-2

_

0.5L/Y 14

Y / B 0 2

H-8 5B/Y

5 . Y 0 / L

EB-13 15A ECM

3W

0.85W/L

1

X-11 DIODE

P-10

P-7

ENG.

FRAME X-11

5

V 5 . 0

2 2

X-10

X-10

X-10

X-10

1

4

RELAY; ECM MAIN

0.5R

0.85R

9

7

H-19

H-20

B / G 5 . 0

R / L 5 2 . 1

2

2

E-11

E-11

E-11

6

Y 3 / G 5 8 . 0 8

W / B 5 . 0 1

H-20

H-20

H-20

G 5 . 0

W 5 . 0

B 5 . 0

1

) 4 ( P M ; U Y P A L L E E U R F

4 1 B E E S U F

CRANK ANGLE SENSOR E-11

0.5R

E-16 THROTTLE VALVE SW E-16

4

7

3

Y / B 5 2 . 1

O 5 . 0

4

20

21

R 5 8 . 0

1

W / L 5 . 0 11

Y / L 5 . 0 10

H-19

H-19

R / G 3 . 0

Y / L 3 . 0

15

R 5 8 . 0

E-16

4

14

1

B-86

C-86

C-87

C-86

C-87

C-86

C-86

C-86

A7

B7

C4

B8

D4

A4

B1

A1

ENGINE CONTROL MODULE B5

A3

C-86

C-86

18

B / G 5 . 0

B 5 . 0

D11

C2

C-87

C-87

C-87

3

Y / B 5 . 0

1 DATA LINK CONNECTOR

C11

11

B 5 2 . 1

22

B 5 2 . 1

D2

A2

C-87

C-86

2

R / B 5 2 . 1

13

R / B 5 2 . 1

B13 C-86

2

G / B 5 2 . 1

B 5 . 0

26

G / B 5 2 . 1

2

C-84

C-84

C-84 3

B 5 2 . 1

R / B 5 2 . 1

G / B 5 2 . 1

B 5 . 0

ENGINE

C-81

D08RV938


4 0.5B/W

H-8

5 0.85W/G

0.85W/G

H-7

16 H-20

L / Y 5 . 0

1

T H G I L R O T A C I D N I N O I T C ) N R U E F T L E A M M (

W / B 5 . 0

E-14 IGNITION COIL

E-14 0.85R

2

H-19

0.5R

1

R 5 8 . 0

L / R 5 . 0

Y / R 5 . 0

W / R 5 . 0

R 5 . 0

FUEL INJECTOR

R O T U B I R T S I D

L 5 . 0

1

1

1

1

E-7

E-8

E-9

No.1

No.2

No.3

No.4

E-6

E-7

E-8

E-9

B 2 / W 5 . 0 2

R 2 / W 5 . 0 7

L 2 / W 5 . 0 6

H-19

H-19

H-19

H-19

W 5 . 0

B / W 5 . 0

2

3

13

12

R / W 5 . 0

25

3 E-10 POWER SW

E-6

W 5 . 0

R 5 8 . 0

) 1 ( O M R E H T ; Y A L E R

L / W 5 . 0

1

R O T A L U G E R E R U S S E R P ; V S V

1 C-82

3

R E T S I N A C ; V S V

C-82

3

E-10

H-6

C-82 E-10

Y 5 . 0

2 4

C-82

H-19

O / B 5 . 0

Y / R B 5 . 0

4

2

E-5

Y 5 . 0

R / G L 5 . 0

W / G 5 . 0

G 5 . 0

ENGINE 24

8

23

1

16

22

5

C-86

C-86

C-86

C-86

C-86

C-86

C-87

C-87

C-86

C-86

A13

A12

B12

B11

A8

B10

C1

D5

B9

A5

ENGINE CONTROL MODULE D9

C6

D3

D10

D8

D6

C8

C7

C5

C-87

C-87

C-87

C-87

C-87

C-87

C-87

C-87

C-87

20

6

14

R 3 . 0

G 5 . 0

21

19

8

W / R B 5 . 0

B 3 . 0

W 3 . 0

17

7

W / B 5 . 0 8

H-19 2

Y / G 5 . 0

C-91 OXYGEN SENSOR

C-83 C-91

B 1 / L 5 8 . 0 7 B E E S U F C-81

16 H-19

W 5 . 0

B 5 . 0 7

2

ENGINE

5

C-91

HI

4 C-83

3 C-83 LO

2 E-12 HI

1

H-6

E-12 LO

4

B 5 8 . 0

G / B 5 2 . 1

AIR FLOW SENSOR

ECT SENSOR

R O S N E S ) D R E E E T P E S M E ( L C I H E V

D08RV939


CIRCUIT DIAGRAM (4ZE1 (MPI) GASOLINE ENGINE)

NAIN 100A

15B/R

+

IGM. B2 40A

P-2 IGN.B1 40A

P-1

OFF ACC

1

3W

H-7

0.5 B/W

2

IG2 ST

3 B1

C-41

CB-1 10A STATER

2W/L

C-41

B2

C-41

3W/B

3

2W/L

STARTER SW

6

IG1

C-41

4

3B/R

CB-3 15A ENGINE-1

3B/R

0.85 W/G

H-7

P-5

CB-4 10A ENGINE-2

_

0.5L/Y 19

Y / B 0 2

H-6 5B/Y

5 . Y 0 / L

EB-13 15A ECM

3W

0.85W/L

1

X-11 DIODE

P-10

P-7

ENG.

FRAME X-11

5

V 5 . 0

2 2

X-10

X-10

X-10

X-10

1

4

RELAY; ECM MAIN

0.5R

0.85R

9

7

H-19

H-20

B / G 5 . 0

R / L 5 2 . 1

2

2

E-11

E-11

E-11

6

Y 3 / G 5 8 . 0 8

W / B 5 . 0 1

H-20

H-20

H-20

G 5 . 0

W 5 . 0

B 5 . 0

1

4

7

E-16

4 1 B E E S U F

CRANK ANGLE SENSOR E-11

0.5R

THROTTLE VALVE SW E-16 3

Y / B 5 2 . 1

4

20

R 5 8 . 0

E-16 1

W / L 5 . 0 11

Y / L 5 . 0 10

H-19

H-19

R / G 3 . 0

Y / L 3 . 0

15

R 5 8 . 0

4

14

1

B-86

B-86

C-87

C-87

C-86

C-86

C-86

A7

B7

C4

D4

A4

B1

A1

ENGINE CONTROL MODULE

0.5BR/Y 8 H-8

B 5 . 0

B9

A3

C-86

C-86

Y 22 / R B 5 . 0 Y / R B 5 . 0

D11

C2

C-87

C-87

C-87

3

Y / B 5 . 0

1

T H N I G O L I T C R N O T ) U A R E F I C L T A D E N M M I (

C11

11

B 5 2 . 1

22

B 5 2 . 1

D2

A2

C-87

C-86

2

R / B 5 2 . 1

13

R / B 5 2 . 1

B13 C-86

2

G / B 5 2 . 1

B 5 . 0

26

G / B 5 2 . 1

2

C-84

C-84

DATA LINK CONNECTOR

C-84 3

B 5 2 . 1

R / B 5 2 . 1

G / B 5 2 . 1

B 5 . 0

ENGINE

C-81

D08RV936


13

0.5B/W

0.5B/W

H-6

2

1

0.85W/G

0.85W/G

H-6

X-6 RELAY; STARTER X-6 4

R / R B 5 . 0

16 H-20

0.5BR/R

L / Y 5 . 0

) 1 ( W S E D O M

1 E-14 IGNITION COIL

E-14 0.85R

2

L 5 . 0

1 H-19

0.5R

1 E-6

1 E-7

No.1

E-6 2

W 5 . 0

3

No.2

E-10

1 E-8

No.3

1 E-9

No.4

E-8

E-9

B 2 /

R 2 /

W 5 . 0 7

L 2 / W 5 . 0 6

H-19

H-19

W 5 . 0 2 H-19

W 5 . 0

B / W 5 . 0

12

R / W 5 . 0

25

L / W 5 . 0

T H N I G O L I T C R N O T ) U A R E F I L C T A D E M N M I (

W / B 5 . 0

POWER SW

E-7

H-19

13

3

L / R 5 . 0

Y / R 5 . 0

W / R 5 . 0

R 5 . 0

FUEL INJECTOR

R O T U B I R T S I D

) 1 ( O M R E H T ; Y A L E R

1

R O T A L U G E R E R U S S E R P ; V S V

1

E-10

C-82

H-8

2

O / B 5 . 0

4 H-19

C-82

8

E-10

Y 5 . 0

E-5

Y 5 . 0

G 5 . 0

Y / R B 5 . 0

2

ENGINE 24

8

1

16

17

22

5

C-86

C-86

C-86

C-86

C-86

C-87

C-87

C-86

C-86

C-86

A13

A12

B12

B11

A8

C1

D5

B4

B9

A5

ENGINE CONTROL MODULE C8

C7

D9

C3

D3

D10

D8

D6

C5

C -8 -87

C-8 7

C-87

C-87

C-87

C-87

C-87

C-87

C-87

8

W / R B 5 . 0

7

20

3

W / B 5 . 0 8

H-19

Y / G 5 . 0

14

R 3 . 0 16

H-19

W / B 5 . 0

21

19

5

B 3 . 0

W 3 . 0

R 5 . 0

G 5 . 0

17

W 5 . 0

B 5 . 0 11 2

E-12 HI

1 E-12

4 C-85

3 C-85

2 C-85

LO

ECT SENSOR

2 C-83 HI

CO ADJUSTER

4 C-83

3

H-6

C-83 LO

AIR FLOW SENSOR

R O S N E S ) D R E E E T P E S M E ( L C I H E V

D08RV937


CIRCUIT DIAGRAM (4ZD1 (MPI) GASOLINE ENGINE) 15B/R

+

3W

P-2

P-1 EB-14 20A FUEL PUMP

P-5

_

EB-13 15A ECM

Y / B 5B/Y 0 2

P --1 10

P --7 7

) 1 G I ( W S R E T R A T S

Y / B 5 2 . 1

ENG. FRAME FRAME

V 5 . 0 5

2

X-10

X-10 RELAY; ECM MAIN

1.25B/Y

X-10

X-10

1

4

) 4 C ( M C E

Y / B 5 2 . 1

R 5 8 . 0

5 X-9

2 X-9

RELAY; FUEL PUMP X-9

R 1 / B 5 2 . 1

1.25B/R

R / B 5 2 . 1 17

R / B 5 2 . 1

EB-7 10A OXYGEN SENSOR

H-8

X-9 4

G / B 5 . 0

O 5 . 0

) 8 B ( M C E

R / B 5 2 . 1

5 H-19

1

) 1 ( N R E O G S Y N X E O S

H-9

G / Y 5 2 . 1

R / B 5 2 . 1 1

2

E-13

H-15

R / B 5 2 . 1

AIR REGULATOR

2

E-13 F-2

2

G 5 . 0

G / B 5 2 . 1

FUEL PUMP

M F-2 1

ENGINE

E-5

FRAME

F-3

ENGINE

C-81

1.25B

1.25B

D08RV940


CIRCUIT DIAGRAM (4ZE1 (MPI) GASOLINE ENGINE) 15B / R

+

P-2

P-1 P-5

_ Y / B 5B/Y 0 2

P- 10

W 3

P- 7

ENG. FRAME

) T S ( W S R E T R A T S

) L ( R O T A R E N E G C A

G N I N ) R R A E T E W E M G ( R T A H H G I C L

L / W 5 8 . 0

W / B 5 . 0 13

EB-14 20A FUEL PUMP

H-6

B / W 5 . 0

Y / B 5 2 . 1

3

H-6

L / W 5 8 . 0

0.85W/L

4

3

X-14

X-14 DIODE

1.25B / Y

) 4 C ( M C E

Y / B 5 2 . 1

X-14

X-14

2

1

W 5 . 0

5 X-9

2 X-9

Y 5 . 0

RELAY; FUEL PUMP X-9

X-9

R / 1 B 5 2 . 1

4

R / B 5 2 . 1 1

R / B 5 2 . 1

2 H-2

1 H-2

H-8

R / B 5 2 . 1

5 H-19

1

R / B 5 2 . 1 1

2

E-13

H-15

G / B 5 . 0

1 P-12

1 P-11 OIL PRESSURE SW

R / B 5 2 . 1

AIR REGULATOR

B L 5 . 0

Y 5 . 0

H-9

G / Y 5 2 . 1

2

E-13 F-2

2 FUEL PUMP

G 5 . 0

T E H G R I U L S G S N E I R N P R L I A O W

M F-2 1

ENGINE

E-5

FRAME

F-3

ENGINE

C-81

1.25B

1.25B/G

D08RV930


CIRCUIT DIAGRAM (6VD1 GASOLINE ENGINE-LHD) 2 STARTER SW

8B/R

+

3W

B2

C-41

P-1

ST B1

C-41

B 5

6

IG1

2

3B/R

C-41

CB-3 15A IGN. COIL

3B/R

CB-4 10A ENGINE

P-10

P-8

P-7

ENG

BODY

FRAME

5 H-28

0.85W/G

0.85L/Y 14

2W

EB-14 20A ECM

2W

EB-13 10A ECM

5B

0.5B/W

0.85Y

0.85W/G

H-28

EB-15 40A IGN B1

_

B 0 3

CB-7 15A METER GAUGE

IG2

3

3W/B

4

0.5B/W H-8

1

P-11

P-5

CB-1 10A STARTER

2W/L

H-28

OFF ACC

EB-17 40A IGN B2

EB-16 100A MAIN

4

2W/L

C-41

H-8 3R/G

Y / L 5 8 . 0

0.85 B/Y 2

3

9

0.85 R/W X-18

X-18

H-20 RELAY; ECM MAIN

X-18

X-18

1

5

3R/L

Y / L 8 . 0

13

W 3

L / R 8 . 0

1

E-6

5

2 X-26

FUEL INJECTOR

L R 8 . 0

0.5G/W

2 H-20


L / B 2

36

37

34

E-61

E-61

E-61

E-61

FP

B

B

BB

2

O / G 5 . 0

4

H-8

L / B 2 2

36

OX1

OX1 GND

E-61

E-61

0.85 R/L

17

P 5 . 0

21

L 5 . 0

12

H-22

H-20

1 2

E-52

E-9 2

E-51

E-52 H-20

2

2

2

R / G 5 . 0

G 5 . 0

B / G 5 . 0

Y / G 5 . 0

R E-66 E T S I N A C ; V S V E-66

4

L / R 5 7 . 0

L / B 5 2 . 1

3

H-20

4

34

5

4

F-2

M-17

E-61

E-60

E-61

E-61

INJ1

INJ2 INJ3

INJ4

INJ5 INJ6

SOF

CP

IGS

E C M CASE E-60

E-60

4

POWG

PSPS

VSS

VCC1

TPS

SE1

E-60

E-61

E-61

E-61

E-61

E-61

37

R / B 8 . 0

33

R / B 0 . 1

30

Y / G 5 . 0

G N I W R S E E E R T S U R S E S E R W O P P

2

M-17

B 1 5 2 . 1 1 H-15

P 5 . 0 M-17

M-17

3

G 1 / B 5 7 . 0 1

10 H-22

B 5 . 0

B-37

0.8B/R

32

H-22

27

26

39 0.5G 0.5L

H-20

W 5 . 0

0.8GR 0.8G

7

H-6

5 H-25

W 3 . 0

3 8

R O B-23 S N E S D E E P S R A B-23 C

11 H-6

H-25

) R E T E M (

5

B 5 . 0 B 5 2 . 1

R / B 8 . 0

W 5 . 0

5

1

R O S N E S 2 O

33

E-60

5

L 5 . 0

15

28

E-61

22

8

35 E-60

E-64

2

F-2

L / R 8 . 0

E-61

H-22

M

R / L 5 . 0

E-60

L 5 . 0

H-15

E-72

E-8

1 E-51

L / R 8 . 0 19

COMMON CHAMBER

E-7

1 E-9

1

W / G 5 . 0

3B/R

BODY - RR

1 E-8

2

4

R / B 3

P M U P L E U F

1 E-7

0.8LY

X-26

1

EB-6 15A FUEL PUMP

0.8R/L

R / L 5 . No.1 No.2 No.3 No.4 No.5 No.6 0

E-6

W / R 8 . 0

1.25 R/L

1 R/G

1

H-20

P M X-26 U P L E U F ; Y A L X-26 E R

H-20

L / R 8 . 0

L G 5 . 5 . 0 0 0.8GR

R G 8 . 0

L 8 . 0

G 8 . 0

1 E -6 8

2 E -6 8

3 E -6 8

) ) 5 6 C ( C ( M M C C T T

(T.P.S)

L / R B 8 . 0

E-73 0.8BR/L

COMMON CHAMBER

E-74

FENDER - LH

C-36

1.25B

D08RW532


0.5B/W

X-24

X-24

X-24

X-24

5 3B 2 0.85Y

0.5B 3 3B/W

STARTER:C

P-12

1

RELAY; STARTER

C-2

FUSE MAIN

G / W 5 8 . 0

16

11

C -1 02

C -1 02

9

2

6

C -1 02

C -1 02

C -1 02

4

5

C -1 02

C-102

L / B 5 . 0

L / B 5 . 0

16 H-20

2

1.0W/G

E K I C N E G H N C E

1.0W/G

G / W 0 . 1

1.0W/G

) 6 1 D ( M C T

P O T S E S U F

B-24

) 8 C ( M C T

G / B 5 . 0

G 5 . 0

B-24 1.0W/G

1.0W/G

9

0.8R/L I.A.C.V (Idle Air Control Valve)

0.8R/L 2

2

2

2

2

Y / R B 3 . 0

2

E-53

E-54

E-55

E-56

E-57

E-58

COIL 1

COIL 2

COIL 3

COIL 4

COIL 5

COIL 6

A

3

B

H-6 E-53

E-53

1

E-54

3

Y / B 0 . 1

L / R B 8 . 0

L / R B 0 . 1

1

E-55

3

E-55

1

E-56

3

L / R B 0 . 1

Y / B 0 . 1

L / R 5 . 0

B / R 5 . 0

R 5 . 0

6

E-54

32

7

E-56 1

E-57 3

E-57 1

E-58 3

L / R B 0 . 1

Y / B 0 . 1

Y / R 5 . 0

W / R 5 . 0 31

8

Y / R B 5 . 0

E-58

1

3

E-70

E-70

3

L 2 / R 8 . 0

14 H-20

Y / B 8 . 0

G / R 5 . 0 30

9

E -6 1

E -6 0

E-61

E-60

E-61

E-60

E-61

POWG

IGN1

IGN2

IGN3

IGN4

IGN5

IGN6

Y / R B 5 . 0

Y / B 8 . 0 7

8

E-60

E-60

ECUG

13

16

5

W / L 8 . 0 17

E-61

E-61

E-61

E-61

MIL

IAC1

IAC3

IAC4

IAC2

J1850

CAM

CAG

V CC2

CA

PM

SE2

CLT

E-61

E-60

E -6 0

E -6 0

E-60

E-60

E-60

E-61

Y / B 8 . 0

L / R 8 . 0

B / Y 8 . 0

L 8 . 0

24

23

20

Y 8 . 0

B / Y 8 . 0

G 8 . 0 L / R 8 . 0

0.8GR 0.8G

H-24

2

/ R L G R 8 . B . 0 8 0

21

L / R 5 8 . 0

H-24

4

1 E-67

3 E-63

I.A.T

1 E-63

2 E-63

MAF SENSOR

1 E-62

3 E-62

2 E-62

CAM ANGLE SENSOR

E-74

  

E-72

E-73

C-36

1 E-59

3 E-59

CRANK ANGLE SENSOR

6 COMMON CHAMBER

2 E-59

0.8BR/L

E-61

31

B / G 5 . 0

H-20

3

11

TW70 TACHO E-61

35

12

R / B 5 . 0

R B 5 . 0

Y 5 . 0

E-61

10

Y / B 8 . 0

3

7

H-25 1

H-25

2 C-90

H-20

6

B / Y 5 8 . 0

G 5 8 . 0

C-90

H-20

6

L / R B 5 B 2 8 . . 0 1

R / B 5 . 0 H-8

R / G 8 . 0 2

TMO

E-61

11

B / R B 5 . 0

R / L 8 . 0

ACR

25 E-61

B / Y 8 . 0

H-24

L / R 8 . 0

22

38 E-61

E-61

25

G / B 5 . 0

G 5 . 0

14

MAF

28

1 H -24

E-61

TA

20

3 H-20

6

E-60

B / Y 8 . 0

FENDER:LH

E-70

AC RELAY

19

COMMON CHAMBER

4

E-70

B / L 8 . 0

E C M

E-67

E-70

1

R / L 8 . 0

L 8 . 0

18

E-70

1 C-90

2 E-69

1 E-69

MAP SENSOR COOLANT TEMP. SENSOR

) 2 ( R O S S E R P M O C C / A : Y A L E R

) 1 ( O M R E H T C / A : Y A L E R

) 8 ( N N O C M C T

) 0 3 ( N N O C M C T

7

) 3 ( B N N O C R E T E M : O H C A T

0.8B/R

0.8B/Y

1.25B

D08RW531


CIRCUIT DIAGRAM (6VD1 GASOLINE ENGINE-RHD) 2 STARTER SW

8B/R

+

3W

B2

C-41

P-1

ST B1

C-41

B 5

6

IG1

4

3B/R

C-41

CB-3 15A IGN. COIL

3B/R

CB-4 10A ENGINE

P-10

P-8

P-7

ENG

BODY

FRAME

1 H-6

0.85W/G

0.85L/Y 19

2W

EB-14 20A ECM

2W

EB-13 10A ECM

5B

0.5B/W

0.85Y

0.85W/G

H-7

EB-15 40A IGN B1

_

B 0 3


IG2

3

3W/B

13

0.5B/W

H-6

1

P-11

P-5

CB-1 10A STARTER

2W/L

H-7

OFF ACC

EB-17 40A IGN B2

EB-16 100A MAIN

3

2W/L

C-41

H-6 3R/G

Y / L 5 8 . 0

0.85 B/Y 2

3

9

0.85 R/W X-18

X-18

H-20 RELAY; ECM MAIN

X-18

X-18

1

5

3R/L

Y / L 8 . 0

13

W 3

L / R 8 . 0

1

1

H-20

5

2 X-26

FUEL INJECTOR

L R 8 . 0

0.5G/W

2 H-20


L / B 2

36

37

34

E-61

E-61

E-61

E-61

FP

B

B

BB

2

O / G 5 . 0

4

H-6

L / B 2 2

36

OX1

OX1 GND

E-61

E-61

0.85 R/L

11

P 5 . 0

21

L 5 . 0

12

H-22

H-20

1 2

E-52

E-9 2

E-51

E-52 H-20

2

2

2

R / G 5 . 0

G 5 . 0

B / G 5 . 0

Y / G 5 . 0

R E-66 E T S I N A C ; V S V E-66

4

L / R 5 7 . 0

L / B 5 2 . 1

3

H-20

4

34

5

4

F-2

M-17

E-61

E-60

E-61

E-61

INJ1

INJ2 INJ3

INJ4

INJ5 INJ6

SOF

CP

IGS

E C M CASE E-60

E-60

4

POWG

PSPS

VSS

VCC1

TPS

SE1

E-60

E-61

E-61

E-61

E-61

E-61

37

R / B 8 . 0

33

R / B 0 . 1

30

Y / G 5 . 0

G N I W R S E E E R T S U R S E S E R W O P P

2

M-17

B 1 5 2 . 1 1 H-15

P 5 . 0 M-17

M-17

3

G 1 / B 5 7 . 0 1

10 H-22

B 5 . 0

B-37

0.8B/R

32

H-22

27

26

39 0.5G 0.5L

H-20

W 5 . 0

0.8GR 0.8G

20

H-26

5 H-25

W 3 . 0

3 8

R O B-23 S N E S D E E P S R A B-23 C

5 H-26

H-25

) R E T E M (

5

B 5 . 0 B 5 2 . 1

R / B 8 . 0

W 5 . 0

5

1

R O S N E S 2 O

33

E-60

5

L 5 . 0

15

28

E-61

22

8

35 E-60

E-64

2

F-2

L / R 8 . 0

E-61

H-22

M

R / L 5 . 0

E-60

L 5 . 0

H-15

E-72

E-8

1 E-51

L / R 8 . 0 19

COMMON CHAMBER

E-7

1 E-9

1

W / G 5 . 0

3B/R

BODY - RR

E-8

2

4

R / B 3

P M U P L E U F

1

E-7

0.8LY

X-26

1

EB-6 15A FUEL PUMP

0.8R/L

R / L 5 . No.1 No.2 No.3 No.4 No.5 No.6 0

E-6

W / R 8 . 0

1.25 R/L

1 R/G 1

E-6

P M X-26 U P L E U F ; Y A L X-26 E R

H-20

L / R 8 . 0

L G 5 . 5 . 0 0 0.8GR

R G 8 . 0

L 8 . 0

G 8 . 0

1 E -6 8

2 E -6 8

3 E -6 8

) ) 5 6 C ( C ( M M C C T T

(T.P.S)

L / R B 8 . 0

E-73 0.8BR/L

COMMON CHAMBER

E-74

FENDER - LH

C-36

1.25B

d08RW529


0.5B/W

X-24

5 3B 2

0.5B/W

X-24

3B/W

X-24

X-24

0.85Y

1

3 STARTER:C

P-12

1

3

RELAY; STARTER

4

X-28 0.5BR/Y

X-28

X-28

H-23

2

1.25BR/Y 15

M-25

5

M-25

B 5 2 . 1

MODE SW

X-28

FUSE MAIN

Y / B 5 . 0

G / W 5 8 . 0

16

11

C -1 02

C -1 02

9

2

6

4

C -1 02

C -1 02

C -1 02

C -1 02

5 C-102

H - 25

H-20

E K I C N E G H N C E

1.0W/G

1.0W/G

) 8 C ( M C T

L / B 5 . 0

G / B 5 . 0

G 5 . 0

B-24 1.0W/G

1.0W/G

9

0.8R/L I.A.C.V (Idle Air Control Valve)

0.8R/L 2

2

2

2

2

Y / R B 3 . 0

2

E-53

E-54

E-55

E-56

E-57

E-58

COIL 1

COIL 2

COIL 3

COIL 4

COIL 5

COIL 6

E-53

1

E-54

3

Y / B 0 . 1

L / R B 0 . 1

1

E-55

3

E-55

1

E-56

3

L / R B 0 . 1

Y / B 0 . 1

L / R 5 . 0

B / R 5 . 0

R 5 . 0

6

E-54

32

7

E-56 1

E-57 3

E-57 1

E-58 3

L / R B 0 . 1

Y / B 0 . 1

Y / R 5 . 0

W / R 5 . 0 31

8

1

3

Y / B 5 . 0

E-70

E-70

3

H-20

Y / B 8 . 0

30

9

E -6 1

E -6 0

E-61

E-60

E-61

E-60

E-61

POWG

IGN1

IGN2

IGN3

IGN4

IGN5

IGN6

Y / R B 5 . 0

Y / B 8 . 0 7

8

E-60

E-60

ECUG

29

13

16

E-70

5

W / L 8 . 0 17

E-61

E-61

E-61

E-61

E-61

MIL

INH

IAC1

IAC3

IAC4

IAC2

J1850

CAM

CAG

VCC2

CA

PM

SE2

CLT

E-61

E-61

E-60

E -6 0

E -6 0

E-60

E-60

E-60

E-61

B / Y 8 . 0

Y / B 8 . 0

L / R 8 . 0

B / Y 8 . 0

L 8 . 0

24

23

20

Y 8 . 0

B / Y 8 . 0

G 8 . 0 L / R 8 . 0

0.8GR 0.8G

H-25

9

/ R L G R 8 . B . 0 8 0

21

L / R 5 8 . 0

H-25

10

1 E-67

3 E-63

I.A.T

1 E-63

2 E-63

MAF SENSOR

1 E-62

3 E-62

2 E-62

CAM ANGLE SENSOR

E-74

  

E-72

E-73

C-36

1 E-59

3 E-59

CRANK ANGLE SENSOR

6 COMMON CHAMBER

2 E-59

0.8BR/L

E-61

31

B / G 5 . 0

H-20

11

11

TW70 TACHO E-61

35

12

R / B 5 . 0

R B 5 . 0

Y 5 . 0

E-61

10

Y / B 8 . 0

3

7

H-25 1

H-25

2 C-90

H-20

6

B / Y 5 8 . 0

G 5 8 . 0

C-90

H-20

6

L / R B 5 B 2 8 . . 0 1

R / B 5 . 0 H-6

R / G 8 . 0 2

TMO

E-61

11

B / R B 5 . 0

R / L 8 . 0

ACR

25 E-61

B / Y 8 . 0

H-25

L / R 8 . 0

22

38 E-61

MAF

25

G / B 5 . 0

G 5 . 0

14

TA

28

2 H-25

E-61

E-60

20

3 H -20

6

AC RELAY

19

FENDER:LH

4

E-70

B / L 8 . 0

E C M

E-67

E-70

1

R / L 8 . 0

L 8 . 0

18

E-70

L 2 / R 8 . 0

14

G / R 5 . 0

B

H-25

Y / R B 5 . 0

E-58

A

4

13

H-26

COMMON CHAMBER

) 6 1 D ( M C T

P O T S E S U F

B-24

G / W 0 . 1

L / B 5 . 0

2

1.0W/G

L / R B 8 . 0

B 5 8 . 0 7

16

E-53

7

H-23

1 C-90

2 E-69

1 E-69

MAP SENSOR COOLANT TEMP. SENSOR


) 1 ( O M R E H T C / A : Y A L E R

) 8 ( N N O C M C T

) 0 3 ( N N O C M C T

16

) 3 ( B N N O C R E T E M : O H C A T

0.8B/R

0.8B/Y

1.25B

D08RW530



FUEL PUMP Removal

1. Remove the fuel tank. Refer to the “ENGINE” Section of this Manual. 2. Loosen the screws 1. 1

042RV002

3. Raise the fuel pump assembly 2 from the fuel tank.

2

042RV001

Installation

Follow the removal procedure in the reverse order to install the fuel pump. Pay close attention to the important points mentioned in the following paragraphs.

Rubber Seal

Be absolutely sure that the fuel pump rubber seal is correctly seated. Connector

Be absolutely sure that the fuel pump connector is securely connected. This will prevent a poor contact and an open circuit.



Fuel pump relay X-9


1 – 5 . . . . . . . . . . . . . .

3

No continuity

3


5

1

1 – 5 . . . . . . . . . . . . . .

2

4

4 2

Continuity

5

060RV005

ECM main relay X-10


1 – 5 . . . . . . . . . . . . . .

3

No continuity

3


5

1

1 – 5 . . . . . . . . . . . . . .

2

4

4 2

Continuity

5

060RV005

ECM main relay X-18 1

5


2

1 – 2 . . . . . . . . . . . . . . 2

1

5

3

3 D08RW599

No continuity

(When battery voltage is applied between 3 and 5) 1 – 2 . . . . . . . . . . . . . .

Continuity


EMISSION CONTROL SYSTEM PARTS LOCATION (LHD)


B-23

H-8

C-2 H-5 C-61

C-60 C-72 C-62

C-70 C-66 C-68

H-6 H-7 C-40

C-77 M-13 C-41 M-14

M-1 M-2 M-3 M-4

C-78

C-74

D08RVA23



RELAY & FUSE BOX (X-5)

H-6 H-7

C-2 H-5 C-61 C-78

C-60

C-40 C-66 C-68

C-77 C-41

M-13 M-14

D08RVA24


CIRCUIT DIAGRAM (GASOLINE ENGINE W/O EFE HEATER) STARTER SW OFF ACC

15B/R

+

IGN.B1 40A P-2

B2

IG2

B1

IG1

ST

3 3W/B

C-41

6 C-41

2 3B/R

H-7

3B/R CB-4 10A ENGINE-2

P-1

Y / L 5 . 0

P-5

_

H-8

Y / B 0 2

P-7

P-10

FRAME

ENG.

B / W 3


19

3

1 X-5

(RHD) 5

H-7

H-6

Y / L 5 . 0

1 H-6

(4ZC1,4ZD1)

Y / L 5 . 0

6

H-5

L / W 5 8 . 0

X-5

G / W 5 8 . 0

(RHD) 14

5B/Y

CB-3 15A ENGINE-1

Y / L 5 8 . 0

Y / L 5 . 0

1

G / W 5 8 . 0

M-13

2

NEUTRAL SW

X-5

G / W 5 . 0

RELAY; CHARGE M-14

B 5 . 0

1

P / L 5 8 . 0

C-66 X-5

SLOW CUT SOLENOID (4ZE1)

X-5

5

4

B 5 . 0

B 3

1

1 C-60

2

IGNITION COIL

H-5

(CARBURETOR)

C-66

C-60

P / L 5 . 0

3

2

1

R / B 5 . 0

4 C-66 COASTING RICHER (CARBURETOR)

G / R 5 . 0

EB-14 10A AUTO CHOKE

2

R C-60 O T U B I R T S I D C-60

R / B 5 . 0

C-66 3

0.5R/G

L 5 . 0 2 C-78

2

7

1

C-78

B 5 . 0

C-78

ENGINE SPEED SENSOR

C-66 C-78

C-78

AUTO CHOKE 4

(CARBURETOR)

6

(4ZC1,4ZD1)

W / L 5 . 0

W / L 5 . 0

2 C-77 CLUTCH SW

1

B 5 . 0

C-61 IDLE SW (4ZE1)

C-77

L 5 . 0

C-61

1

1 2

C-40 ACCEL. SW

B 5 . 0

C-40

B 5 . 0 FENDER-RH

C-2

2

1.25B

D08RV941


CIRCUIT DIAGRAM (GASOLINE ENGINE W/ EFE HEATER) STARTER SW

15B/R

+

MAIN 80A

OFF ACC

EFE 30A

P-2 IGN B1 40A

P-1

B2

IG2

B1

IG1

ST

3 3W/B

C-41

P-5

_

5B/Y

C-41

Y / B 0 2

P-7

P-10

FRAME

ENG.

B / W 3

2 H-7


R / B 3 CB-4 10A ENGINE-2

3

1 X-5

CB-3 15A ENGINE-1

G / W 5 8 . 0

Y / L 5 . 0 14

L / W 5 8 . 0

X-5

6

R / B 3

H-8

2

Y / L 5 . 0

R 2

X-5 RELAY; CHARGE

Y / L 5 . 0

X-5

5

6

H-5

B 5 . 0 X-5

4

Y / L 5 8 . 0

Y / L 5 . 0

1

M-13

B 5 . 0

B 3

5

H-7

NEUTRAL SW

G / W 5 8 . 0 G / W 5 . 0

M-14 1

1

C-74 VSV; AIR

EB-14 10A AUTO CHOKE

SLOW CUT SOLENOID

C-74

2 X-10

E V ) C-66 L R A O V T E W S R U T B N R E A V C (

4 C-66

2 2

ACCEL. SW

B 5 . 0

R / B 5 . 0

C-40 1 X-10

L 5 . 0

X-10

4

1

Y 5 . 0

G L 5 . 0

R / L 5 . 0

1 C-77

1

W C-62 S O M R E H T E F E

1

R / B 5 . 0

C-40 RELAY; EFE HEATER

2

E ) R K O T O E H R C U O B T R U A A C (

C-60

X-10

L 5 . 0

2


IGNITION COIL

P / L 5 . 0

3

Y / L 5 . 0

5

C-60

H-5 C-66

2

L 5 . 0

1

1

2

(CARBURETOR)

0.5L

L 5 . 0

P / L 5 8 . 0

C-66

CLUTCH SW

B / R 2 C-77 2 2

R E T A E H E F E

W / L 5 . 0

C-72 3 C-78

2 C-78

7

4

C-78

C-78

1 C-78

C-72 1

ENGINE SPEED SENSOR

C-78 6

B 2

B 5 . 0

FENDER-RH

C-2

1.25B

D08RV943


CIRCUIT DIAGRAM (4ZD1 GASOLINE ENGINE – SAUDI ARABIA) STARTER SW OFF ACC

15B/R

+

IGN.B1 40A P-2

B2

IG2

B1

IG1

ST

3 3W/B

C-41

6 C-41

3B/R

H-7

2

3B/R

P-1

CB-4 10A ENGINE-2

R / B 3

P-5

CB-3 15A ENGINE-1

G / W 5 8 . 0

Y / L 5 . 0

_

14 5B/Y

Y / B 0 2

P-7

P-10

FRAME

ENG.

CB-7 15A METER

B / W 3


H-8

Y / L 5 . 0

Y / L 5 . 0 6

Y 5 8 . 0

H-5

Y / L 5 8 . 0

L / W 5 8 . 0 3 X-5

1 X-5

2

7

B 5 . 0

OIL TEMPERATURE WARNING LIGHT (METER)

X-5

P / L 5 8 . 0

B 3

9

G / W 5 8 . 0

W S D R 3 P O T

G / W 5 . 0 M-4

1

1

1 C-60

0.85L/P

H-5

Y / R B 3 . 0

C-60

P / L 5 . 0

2


2

4

B 5 . 0

1 M-3

M-2 B-24

5

1

W S D N 2

B-23 RELAY; CHARGE

X-5

0.85L/Y

M-1

X-5

5

H-7

2

1

R / B 5 . 0

4 C-66 COASTING RICHER (CARBURETOR)

3 H-6 EB-14 10A AUTO CHOKE

R / B 5 . 0

C-66 3

Y / R B 3 . 0 L 5 . 0 3

2

C-78

2

B 5 . 0

1

C-78

C-78

G / R 5 . 0

ENGINE S PEED SENSOR

ENGINE SPEED S ENS OR

C-66 C-78

C-78

AUTO CHOKE 5

(CARBURETOR)

6

G / Y 5 . 0

2 C-77 1

C-70

CLUTCH SW

B 5 . 0

OIL TEMPERATURE SENSOR

C-77

L 5 . 0

1

1 C-40 ACCEL. SW

C-40

B 5 . 0 FENDER-RH

C-2

2

1.25B

D08RV942



Charge relay X-5


3 – 5 . . . . . . . . . . . . . . 1 – 5 . . . . . . . . . . . . . .

3

4

Continuity No continuity

3

2 5

1

2

4

(When battery voltage is applied between 2 and 4) 3 – 5 . . . . . . . . . . . . . . 1 – 5 . . . . . . . . . . . . . .

No continuity Continuity

5

060RV005

EFE heater relay X-10


1 – 5 . . . . . . . . . . . . . .

3

No continuity

3


5

1

1 – 5 . . . . . . . . . . . . . .

2

4

4 2

5

060RV005

Continuity


QOS SYSTEM PARTS LOCATION (LHD)

RELAY & FUSE BOX (X-9) B-24

H-8 C-2 H-4 C-5,C-6 C-7

H-6 H-7 C-41

E-49

E-41 E-50

C-46

E-37

D08RVA25



RELAY & FUSE BOX (X-9) C-5 C-6 C-7

B-24

H-6 H-7 C-2

H-4

C-41

E-49

E-41 E-50

E-37

D08RVA26


CIRCUIT DIAGRAM (LHD) MAIN 100A

15B/R

+

IGN B2 40A

3W

IGN B1 40A

3W/B

P-2

P-1 3

P-5

_

5B/Y

1

C-41

GLOW 50A

C-41

STARTER SW

Y / B 0 3

1 B

2 B

1 G I

F F O C C T 2 G S I A

C-41

P-7

P-10

FRAME

ENG.

C-41

6

2

4

H-7

W / R 5

H-7

R / B 3

CB-3 15A ENGINE-1

14 H-8

C-5

CB-7 15A METER

G / W 5 8 . 0

Y / L 5 . 0

1

L / W 2

3B/R

CB-4 10A ENGINE-2

2

5

GLOW INDICATOR LIGHT (METER)

0.85W/G 6

C-7

C-7

1

1

1

L / O 3 . 0

FUEL CUT SOLENOID 5

1

C-46

C-46

H-4 QOS-II CONTROL UNIT C-46

G / W 5 8 . 0

G / W 5 8 . 0 2

3

X -9

W / B 5 . 0

H-6

E-37

L / B 5 . 0

H-8

L / O 3 . 0

G / W 5 8 . 0

Y / B 5 8 . 0

1

R / B 5

4

8

C-6

16

B-24

H-4

RELAY; GLOW

5B/R

W / B 5 . 0

B-24

G / W 5 8 . 0

2

CB-1 10A STARTER

Y 5 8 . 0

H-7

Y / L 5 . 0

0.5L/Y

2

L / W 2

R / B 3

7

4

C-46

C-46

QOS-II CONTROL UNIT C-46

5

6

X-9 RELAY; CSD

E-49 GLOW PLUG

X-9 4

V 5 . 0

0.5V

X-9 3

B / W 5 8 . 0 9 H-4

8

B / W 5 8 . 0 1

H-4

V 5 . 0

B 5 . 0

E-50 CSD SOLENOID

1 E-41 THERMO SW

FENDER-RH

C-2

D08RV959


CIRCUIT DIAGRAM (RHD) MAIN 100A

15B/R

+

IGN B2 40A

3W

IGN B1 40A

3W/B

P-2

P-1 3

P-5

_

5B/Y

GLOW 50A

P-10

FRAME

ENG.

C-41

STARTER SW

Y / B 0 3

P-7

1

C-41

1 B

2 B

1 G I

F F O C 2 T G C S I A

C-41 6

C-41 2

L / W 2

R / B 3 4

3

H-7

W / R 5

H-7

R / B 3 CB-4 10A ENGINE-2

CB-3 15A ENGINE-1

19 H-6

1 C-5

CB-5 15A METER

G / W 5 8 . 0

Y / L 5 . 0

2

1

GLOW INDICATOR LIGHT (METER)

0.85W/G 6

C-7

C-7

14

1

1

L / O 3 . 0

FUEL CUT SOLENOID 5

1

C-46

C-46

H-4 QOS-II CONTROL UNIT C-46

G / W 5 8 . 0

G / W 5 8 . 0 2

3

X -9

W / B 5 . 0

H-6

E-37

L / B 5 . 0

H-6

L / O 3 . 0

G / W 5 8 . 0

Y / B 5 8 . 0

1

R / B 5

13

8

C-6

16

B-24

H-4

RELAY; GLOW

5B/R

W / B 5 . 0

B-24

G / W 5 8 . 0

2

CB-1 10A STARTER

Y 5 8 . 0

H-6

Y / L 5 . 0

0.5L/Y

L / W 2

3B/R

7

4

C-46

C-46

QOS-II CONTROL UNIT C-46

5

6

X-9 RELAY; CSD

E-49 GLOW PLUG

X-9 4

V 5 . 0

0.5V

X-9 3

B / W 5 8 . 0 9 H-4

8

B 5 . 0

B / W 5 8 . 0 1

H-4

V 5 . 0

E-50 CSD SOLENOID

1 E-41 THERMO SW

FENDER-RH

C-2

D08RV960



Glow relay C-5

C-6

a

C-7


a – b . . . . . . . . . . . . . . No continuity

c a

(When battery voltage is applied between c and d)

b

a – b . . . . . . . . . . . . . . Continuity c b

d

d

060RV007

CSD relay X-9


3 – 5 . . . . . . . . . . . . . .

3

Continuity

3


5

1

3 – 5 . . . . . . . . . . . . . . No continuity

2

4

4 2

5 060RV005


MEMO


LIGHTING PARTS LOCATION (LHD)

T-6

T-3


T-1

F-3 B-23

B-24

B-19 B-15 C-2

H-17

B-16 C-36

H-6

C-42 B-14 C-18 C-19

B-20 C-26

B-28

H-15

C-27 H-9

D08RVA28


PARTS LOCATION (6VD1-LHD)

T-6

T-3


B-23

B-24

B-19 B-15 C-2

T-1

H-17

B-16 C-36

H-6

C-42 B-14

B-37

C-18 C-19

B-20 C-26

B-28

H-15

C-27 H-34

D08RW566



T-6

T-3


B-23

F-3

B-24 B-16 B-15 B-14

B-33 C-2

C-36 B-19 B-11

C-42 B-28

C-18 C-19

T-1

B-20

H-17

H-8

H-15 C-26

C-27 H-9

D08RVA27


PARTS LOCATION (6VD1-RHD)

T-6

T-3


B-23

B-24 B-16 B-15 B-14

B-33 C-2

B-28

C-18 C-19

C-42

T-1

C-36 B-19 B-11

B-20 H-15 C-26

H-17

H-26

B-37

C-27

H-34

D05RW565


CIRCUIT DIAGRAM (LHD) MAIN 80A OR 100A

15B/R

+

P-2

P-1

B 3

P-5 _

5B/Y

R 3

Y / B 0 3


R 3 5

P-7

P-10

FRAME

ENG.

B / R 5 8 . 0

2 X-1

X-1

RELAY; LIGHTING

X-1

B / R 5 8 . 0 2

X-1 1

5 X-2

X-2

4

RELAY; TAIL

W / R 3 X-2 EB-8 10A H/LAMP-LH 0.5R/W

W / R 5 8 . 0


C- 26

1

1 C-42

3 T H G I B-23 L R M A O E T B A C H I G I D B-23 H N I

3 C-26

C -2 6

G / R 5 8 . 0

W / R 5 . 0

2


Y / R 5 8 . 0

B / R 5 8 . 0

8 C-42

3

LIGHTING SW (COMBINATION SW) C -1 9

C- 19

1

R / G 5 8 . 0

L / R 3 . 0

2

H-6

B / R 5 . 0

R / G 5 8 . 0

B / R 5 8 . 0

Y / R 5 8 . 0

12

0.85G/R

C-19

4

B / R 5 . 0

1

Y / G 5 . 0

0.5R/L

2 H-6

X-2 4

EB-9 10A H/LAMP-RH

OFF 0.85R/B

C-42 7

1 H 1 H L R T C-27 T C-18 H H G G I I L L E E C C N N A A R R A C-27 A C-18 E E L 2 L 2 C C

(W/O TACHOMETER)


B / R 5 8 . 0

Y / R 5 8 . 0

12

13 C-42

15

14

C-42

C-42

B 5 8 . 0

B 5 . 0

B 5 . 0

DIMMER PASSING SW (COMBINATION SW) LOW

HIGH

PASS

C-42 16

B 2

C-2

FENDER-RH FENDER-LH

C-36

2B 1.25B

D08RV964


(W/O TACHOMETER)

13 B-24

R E T E M

B-24 14

5 0.85G/R

H-6

0.85G/R

R / G 5 8 . 0 19 H-9

R / G 5 8 . 0

3

H-15

R / G 5 8 . 0

R / G 5 8 . 0

R / G 5 8 . 0

R / G 5 8 . 0

3

13

H-17

B-24 R / G 5 8 . 0

R / G 5 8 . 0 3

H L T H G I L L I A T

T-1

H R T H G I L L I A T

B-24 T H G I L E T A L P E S N E C I L

T-6

T-6

T-1

2

B 5 . 0

B-23

14

15

T-3

B 5 . 0

B 5 . 0

L E N A P L O R 2 T N B-19 O C C / A D B-19 N 1 A R E T A E H B 5 . 0

R / G 5 8 . 0

R E T 2 H G I B-20 L E T T E R B-20 A G 1 I C

W 6 S R E B-15 G G O F E B-15 D R 2 R

B 5 . 0

B 5 . 0

R / G 5 8 . 0

R / G 5 8 . 0

11

O B-14 I D U A B-14

3

W S B-16 D R A Z A B-16 H

3

B 5 . 0

1

B 5 . 0

T-3 1

4

4

B-23

R E T E M

R / G 5 . 0 3

14

R / G 5 8 . 0

B 5 . 0

B 5 8 . 0 4 H-17

FRAME

BODY-LH

F-3

0.85B

B-28

D08RV965


CIRCUIT DIAGRAM (6VD1-LHD) EB-16 100A MAIN

15B/R

+

P-11

P-1

B 3

P-5 _

5B/Y

R 3

Y / B 0 3


R 2 2

B / R 5 8 . 0

5

X-23 X-23

P-7

P-10

FRAME

ENG.

RELAY; LIGHTING

X-23

5

X-23

1

B / R 5 8 . 0 2

X-20 X-20

3

RELAY; TAIL


3

EB-9 10A H/LAMP-RH

0.5R/W

H-6

W / R 5 8 . 0


C- 26

1

1 C-42

11 T H G I B-24 L R M A O E T B A H C I G DB-24 I H N I

3 C-26

C- 26

G / R 5 8 . 0

W / R 5 . 0

2


Y / R 5 8 . 0

B / R 5 8 . 0

8 C-42

3

LIGHTING SW (COMBINATION SW) C- 19

C -1 9

1

R / G 2

L / R 3 . 0

2

H-6

B / R 5 . 0

R / G 5 8 . 0

B / R 5 8 . 0

Y / R 5 8 . 0

12

2G/R

C-19

12

B / R 5 . 0

1

Y / G 5 . 0

0.5R/L

2

X-20

OFF 0.85R/B

C-42 7


(W/O TACHOMETER)

11 T H G I B-24 L R M A O E T B A C H I G I D H N I B-24

B / R 5 8 . 0

Y / R 5 8 . 0

12

13 C-42

15

14

C-42

C-42

B 5 8 . 0

B 5 . 0

B 5 . 0


HIGH

PASS

C-42 16

B 2

C-2

FENDER-RH FENDER-LH

C-36

2B 1.25B

D08RW577


(W/O TACHOMETER)

13 B-24

R E T E M

B-24 14

5 0.85G/R

H-6

0.85G/R

R / G 5 8 . 0 3 H-15

R / G 5 8 . 0 R / G 5 8 . 0

3 H-17

R / G 5 8 . 0

13 B-24 R / G 5 8 . 0

R / G 5 8 . 0 3


T-1


B-24 T H G I L E T A L P E S N E C I L

T-6

T-6

T-1

B 5 . 0

B-23

2

B-23

14

15

T-3

B 5 . 0

B 5 . 0

L E N A P L O R 2 T N B-19 O C C / A D B-19 N 1 A R E T A E H B 5 . 0

R / G 5 8 . 0

R / G 5 8 . 0


W 6 S R E B-15 G G O F E B-15 D R 2 R

B 5 . 0

B 5 . 0

R / G 5 8 . 0

R / G 5 8 . 0

11

O B-14 I D U A B-14

3


3

B 5 . 0

1

B 5 . 0

T-3 1

4

4

14

R E T E M

R / G 5 . 0 3

R / G 5 8 . 0

B 5 . 0

B 5 8 . 0 4 H-17

B 5 8 . 0

1

H-15

CHASSIS

B-37

BODY-LH

B-28

1.25B

D08RW578


CIRCUIT DIAGRAM (RHD) MAIN 80A OR 100A

15B/R

+

P-2

P-1

B 3

P-5 _

5B/Y

R 3

Y / B 0 3


R 3 5

P-7

P-10

FRAME

ENG.

B / R 5 8 . 0

2 X-1

X-1

RELAY; LIGHTING

X-1

B / R 5 8 . 0 2

X-1 1

5 X-2

X-2

4

RELAY; TAIL

W / R 3 X-2 EB-8 10A H/LAMP-LH 0.5R/W

W / R 5 8 . 0


C -2 6

1

1 C-42

3 T H G I B-23 L R M A O E T B A C H I G I D B-23 H N I

3 C-26

C- 26

G / R 5 8 . 0

W / R 5 . 0

2


Y / R 5 8 . 0

B / R 5 8 . 0

LIGHTING SW (COMBINATION SW) C -1 9

C- 19

R / G 5 8 . 0

R / G 5 8 . 0

L / R 3 . 0

2

B / R 5 8 . 0

Y / R 5 8 . 0

H-8

B / R 5 . 0

8 C-42

3

1

3

0.85G/R

C-19

4

B / R 5 . 0

1

Y / G 5 . 0

0.5R/L

9 H-8

X-2 4

EB-9 10A H/LAMP-RH

OFF 0.85R/B

C-42 7


(W/O TACHOMETER)


B / R 5 8 . 0

Y / R 5 8 . 0

12

13 C-42

15

14

C-42

C-42

B 5 8 . 0

B 5 . 0

B 5 . 0


HIGH

PASS

C-42 16

B 2

C-2

FENDER-RH FENDER-LH

C-36

2B 1.25B

D08RV962


(W/O TACHOMETER)

13 B-24

R E T E M

B-24 14

4 0.85G/R

H-8

0.85G/R

R / G 5 8 . 0

19 H-9

R / G 5 8 . 0

R / G 5 8 . 0 3

R / G 5 8 . 0 13

B-24

R / G 5 8 . 0 14

B-23

H-15

R / G 5 8 . 0

R E T E M 3

H-17

R / G 5 8 . 0

R / G 5 8 . 0

R / G 5 8 . 0



T-1

T-1

B-23

14

15

T-6

T-6 4

4

B 5 . 0

T 2 H G I T-3 L E T A L P E S N E T-3 C I L 1

B 5 . 0

1 B-33

3 B-33

B-33

4

2

H-17

B 5 . 0

BODY-RH

B-28

1

R / G 5 8 . 0

W 6 S R E B-15 G G O F E B-15 D R 2 R

B-14 O I D U A

R / G 5 8 . 0

11

B-14 3

3


1

G / R 5 . 0

B 5 8 . 0

F-3

2

Y A B-11 R T H S A B-11

R / G 5 8 . 0

0.5B

ILLUMINATION CONTROLLER

FRAME


R / G 5 8 . 0

R / G 5 . 0 3

3

B-24

L E N A P L O R 2 T N B-19 O C C / A D B-19 N 1 A R E T A E H

R / G 5 8 . 0

) R E L L O R T N O C N O I T A N I M U L L I O / W (

0.85B

1.25B

D08RV963


CIRCUIT DIAGRAM (6VD1-RHD) EB-16 100A MAIN

15B/R

+

P-11

P-1

B 3

P-5 _

5B/Y

R 3

Y / B 0 3

EB-11 10A TAIL

R 2 2

P-7

P-10

FRAME

ENG.

B / R 5 8 . 0

5

X-23 X-23 RELAY; LIGHTING

X-23

5

X-23

1

B / R 5 8 . 0 2

X-20 X-20

3

RELAY; TAIL


3

EB-9 10A H/LAMP-RH

0.5R/W


W / R 5 . 0

C- 26

1

1 C-42

T 11 H G I B-24 L R M A O E T B A C H I G DB-24 I N H I

3 C-26

C -2 6

G / R 5 8 . 0

H-26

W / R 5 8 . 0

2


Y / R 5 8 . 0

B / R 5 8 . 0

B / R 5 . 0

8 C-42

3

LIGHTING SW (COMBINATION SW) C-1 9

C- 19

1

R / G 5 8 . 0

R / G 2

L / R 3 . 0

2

B / R 5 8 . 0

Y / R 5 8 . 0

15 H-26

2G/R

C-19

12

B / R 5 . 0

1

Y / G 5 . 0

0.5R/L

4

X-20

OFF 0.85R/B

C-42 7

1 H 1 H L R T C-27 T C-18 H H G G I I L L E E C C N N A A R R A C-27 A C-18 E E L L 2 2 C C

(W/O TACHOMETER)


B / R 5 8 . 0

Y / R 5 8 . 0

12

13 C-42

15

14

C-42

C-42

B 5 8 . 0

B 5 . 0

B 5 . 0


HIGH

PASS

C-42 16

B 2

C-2

FENDER-RH FENDER-LH

C-36

2B 1.25B

D08RW579


(W/O TACHOMETER)

13 B-24

R E T E M

B-24 14

14 0.85G/R

H-26

0.85G/R

R / G 5 8 . 0

R / G 5 8 . 0

3

R / G 5 8 . 0

R / G 5 8 . 0

H-15 13 B-24

R / G 5 8 . 0

14 B-23

R E T E M

3 H-17

B-24

R / G 5 . 0 R / G 5 8 . 0

R / G 5 8 . 0


T-1

T-1

14

15

T-6

T-6 4

4

B 5 . 0

T 2 H G I T-3 L E T A L P E S N E T-3 C I L 1

B 5 . 0

1 B-33

3 B-33

B-33

4

2

H-17

B 5 . 0

1

H-15 B-37

BODY-RH

B-28

1

R / G 5 8 . 0

W 6 S R E B-15 G G O F E B-15 D R 2 R

O B-14 I D U A

R / G 5 8 . 0

11

B-14 3

3


1

G / R 5 . 0

B 5 8 . 0

CHASSIS

2

Y A B-11 R T H S A B-11

R / G 5 8 . 0

0.5B

ILLUMINATION CONTROLLER

B 5 8 . 0


R / G 5 8 . 0

R / G 5 . 0 3

3


B-23

L E N A P L O R 2 T N B-19 O C C / A D B-19 N 1 A R E T A E H

R / G 5 8 . 0

) R E L L O R T N O C N O I T A N I M U L L I O / W (

1.25B

1.25B

D08RW580


TROUBLE SHOOTING HEADLIGHT 1.

Both the headlights (high and low beam) do not light Checkpoint

Ground point contact (C-2)

Trouble Cause

NG

Countermeasure

Poor ground point contact

Repair the wiring

NG

Poor switch contact or sw faulty

Repair or replace the combination switch

NG

Poor relay contact or relay faulty

Reinstall or replace the lighting relay

Open circuit between battery positive terminal and lighting relay

Repair open circuit

Open circuit between lighting relay and lighting switch

Repair open circuit or connector contact

Open circuit

Repair open circuit

OK Combination switch continuity

OK

Lighting relay

OK Voltage between 5 X-1 - ground and 2 X-1 - ground

NG

OK Voltage between 1 C-42 ground

NG

OK Wiring continuity between 7 C-42 - C-2 and 16 C-42 - C-2

NG

ELECTRICAL-BODY AND CHASSIS 8–121 2.

High or low beam does not light on both headlights Checkpoint

Dimmer · passing switch continuity

Trouble Cause

NG

Countermeasure

Poor switch contact or switch faulty


Open circuit between headlight and dimmer · passing switch


OK Voltage between 13 C-42 - ground and 15 C-42 - ground

3.

NG

RH (or LH) high and low beam does not light

Fuse No. EB-8 (10A) or No. EB-9 (10A) (Relay and fuse box) (No. EB-9 RH, No. EB-8: LH)

NG

Poor installation or blown fuse

Reinstall or replace fuse No. EB-8 or No. EB-9

NG

Blown filament or air leakage

Replace the headlight bulb

NG

Open circuit and/or poor connector contact

Repair or replace the wire and/or connector

OK Headlight connector continuity

OK Wiring continuity between connector 3 C-19 -fuse No. EB-9 or 3 C-26 -fuse No. EB-8

4.

High or low beam does not light on one headlight (RH or LH)

Headlight connector continuity

NG

Blown filament

Replace the headlight assembly

Open circuit between headlight and dimmer · passing switch


OK Wiring continuity between headlight and dimmer · passing switch

NG

8–122 ELECTRICAL-BODY AND CHASSIS 5.

Headlight does not go out Checkpoint

Lighting relay continuity between connector 1 X-1 - 5 X-1 (Should be no continuity)

Trouble Cause

NG

Countermeasure

Relay point fused

Replace the lighting relay

Switch point fused or faulty

Replay the combination switch

Switch point fused or faulty


Short circuit

Repair short circuit between 4 X-1 - 1 C-42 and 4 X-1 - 14 C-42

Lens dirty

Clean the light lens

Bulb filament faulty

Replace the headlight bulb

Poor ground point contact

Repair the wiring

OK Lighting switch continuity between connector 1 C-42 - 7 C-42 when switch is OFF (Should be no continuity)

NG

OK Dimmer · passing switch continuity between connector 14 C-42 - 16 C-42 when switch is not operating (Should be no continuity)

NG

OK Check if headlight goes out when connector C-42 is disconnected

6.

NG

Insufficient headlight brightness

Headlight lens

NG

OK

Headlight bulb

NG

OK Dimmer · passing switch wire continuity between connector 16 C-42 - C-2

NG


Passing light does not function when dimmer switch is operated Checkpoint

Dimmer switch

Trouble Cause

NG

Countermeasure

Poor switch point contact

Repair or replace the dimmer switch

Open circuit

Repair open circuit between 4 X-1 - 14 C-42

OK Voltage between 14 C-42 - ground (Should be battery voltage present)

8.

NG

Headlight beam does not change when dimmer switch is operated

Dimmer switch

NG

Loose beam lever or foreign material in switch

Repair or replace the dimmer switch


TAIL LIGHT, LICENSE PLATE LIGHT, CLEARANCE LIGHT AND ILLUMINATION CONTROLLER 1.

All lights do not light Checkpoint

Fuse No. EB-12 (15A, Relay and fuse box)

Trouble Cause

NG

Countermeasure

Poor fuse contact or blown

Reinstall or replace the fuse No. EB-12

NG

Poor switch point or connector contact


NG

Poor relay contact or relay faulty

Reinstall or replace the tail relay

NG

Bulb burned out or poor connector contact

Replace the bulb or repair connector contact

NG

Open circuit or poor connector contact


OK Lighting switch continuity between connector 8 C-42 - 7 C-42 OK

Tail relay

2.

Tail light does not light

Tail light bulb continuity

OK Continuity between connector 3 T-6 - 4 T-6 (RH) or 3 T-1 - 4 T-1 (LH)


License plate light does not light Checkpoint

License plate light bulb continuity

Trouble Cause

Countermeasure

NG



NG



NG



OK Continuity between connector 1 T-3 - 2 T-3

4.

Clearance light does not light

Clearance light bulb continuity

5.

Illumination controller does not operate

Disconnect the illumination controller connector (Light should be dim)

NG

Short circuit

Repair short circuit or replace the wire

Loose knob or faulty controller

Repair knob installation or replace the controller

OK Turn the illumination controller knob (Brightness should change)

NG



HEADLIGHT Removal

1. Remove the radiator grille center bolt.

D08RV753

2. Use a screwdriver to raise the clip and release the lock. Place a clean rag beneath the screwdriver tip to protect the body painted surfaces. 3. Remove the radiator grille.

D08RV754

4. Remove the headlight rim.

D08RV855

5. Disconnect the headlight connector. 6. Remove the headlight.

D08RV856



HEADLIGHT (RECTANGULAR TYPE) Removal

1. Remove the radiator grille center bolt.

D08RV753

2. Use a screwdriver to raise the clip and release the lock. Place a clean rag beneath the screwdriver tip to protect the body painted surfaces. 3. Remove the radiator grille.

D08RV754

4. Remove the side screws.

D08RV859

5. Remove the top screw.

D08RV860


6. Remove the clearance light.

D08RW563

7. Remove the headlight screws.

D08RW557

8. Disconnect the headlight connector. 9. Remove the headlight.

D08RW564

ELECTRICAL-BODY AND CHASSIS 8–129 Installation

Follow the removal procedure in the reverse order to install the headlight. Pay close attention to the important points mentioned in the following paragraphs.

Connector

Be absolutely sure that the headlight connector is securely connected. This will prevent a contact and an open circuit.

LIGHTING SWITCH Removal

1. Remove the steering wheel 1. Refer to the “STEERING” Section of this manual. 2. Remove the Instrument panel lower cover 2. 3. Remove the steering column cover 3. 3

1

2 D08RV888

4. Disconnect the connector. 5. Remove the lighting switch from the steering shaft.

D08RV747

Installation

Follow the removal procedure in the reverse order to install the lighting switch. Pay close attention to the important points mentioned in the following paragraphs.

8–130 ELECTRICAL-BODY AND CHASSIS Connector

Be absolutely sure that the lighting switch connector is securely connected. This will prevent a poor contact and an open circuit.

Wire Harness

Do not pinch the wire harnesses between the cluster and the meter hood during the cluster installation procedure. Wire damage will result.

CLEARANCE LIGHT Removal

1. Remove the radiator grille. removal procedure.)

(Refer to headlight

2. Remove the side screws.

D08RV859

3. Remove the top screw.

D08RV860

4. Turn the socket counterclockwise to disconnect it from the clearance light housing. 5. Pull the bulb from the socket.

D08RV861


Follow the removal procedure in the reverse order to install the clearance light. Pay close attention to the important points mentioned in the following paragraphs.

Connector

Be absolutely sure that the clearance light connector is securely connected. This will prevent a poor contact and an open circuit.

LICENSE PLATE LIGHT

1

Removal

2

1. Loosen the screws 1. 2. Remove the lens cover 2 and the lens 3. 3. Pull the bulb to remove it. 3

D08RV834

Installation

Follow the removal procedure in the reverse order to install the license plate light. Pay close attention to the important points mentioned in the following paragraphs.

Bulb

Be absolutely sure that the license plate light bulb is correctly installed. This will prevent a poor contact and an open circuit.


HEADLIGHT BEAM SWITCH Removal

1. Remove the steering wheel 1. Refer to the “STEERING” Section of this manual. 2. Remove the Instrument panel lower cover 2. 3. Remove the steering column cover 3. 3

1

2 D08RV888

4. Disconnect the connector. 5. Remove the headlight beam switch (lever) from the steering shaft.

D08RV747

Installation

Follow the removal procedure in the reverse order to install the headlight beam switch (lever). Pay close attention to the important points mentioned in the following paragraphs.

Connector

Be absolutely sure that the headlight beam switch connector is securely connected. This will prevent a poor contact and an open circuit.

Wire Harness

Do not pinch the wire harnesses between the cluster and the meter hood during the cluster installation procedure. Wire damage will result.


ILLUMINATION CONTROLLER Turning the illumination controller knob upward increases the brightness of each illumination light, turning it downward decreases its brightness.

825RS032

1. Instrument panel cluster assembly

Removal 1. Instrument Panel Cluster Assembly • Refer to Section 10 “BODY” for instrument panel cluster assembly removal steps. 2. Illumination Controller • Disconnect the switch connector. • To remove the switch, push the lock from the back side of the cluster assembly.

2. Illumination controller 825RV104

Installation

To install, follow the removal procedure in the reverse order.

Connector

Be absolutely sure that the illumination controller connector is securely connected. This will prevent a poor contact and an open circuit.


AIMING OF HEADLIGHT Check and adjust the inflation pressures, clean the headlight lenses, park the vehicle on a level surface and insure that vehicle is at curb weight.

VERTICAL ADJUSTMENT Use a screwdriver for vertical adjustment.

D08RV869

HORIZONTAL ADJUSTMENT Use a screwdriver horizontal adjustment.

D08RV868

VERTICAL ADJUSTMENT Use a screwdriver for vertical adjustment.

D08RW433

HORIZONTAL ADJUSTMENT Use a screwdriver horizontal adjustment.

D08RW434



LIGHTING SWITCH Lighting Switch Connections

C-42

15

1 2 3 7 8 9 10

4 5 6

Terminal SW No. position

16

1

7

8

11 121314

OFF Tail

Switch side

↔ Headlight

825RV068

HEADLIGHT BEAM SWITCH Headlight Beam and Passing Switch Connections

C-42

Terminal No. 15

1 2 3 7 8 9 10

4 5 6

SW position 16

11 121314

At “Dimmer” position Switch side

At “Passing” position

825RV067

HI LO

16

13

15

14

8–136 ELECTRICAL-BODY AND CHASSIS LIGHTING RELAY, TAIL RELAY X-1 1

X-2

Check continuity between the relay terminals. 1 – 5 . . . . . . . . . . . . . . No continuity

3

4

3


5

1

1 – 5 . . . . . . . . . . . . . . Continuity

2

4

2

5

060RV005

X-20 1

5

LIGHTING RELAY, TAIL RELAY (6VD1)

X-23


2

1 – 2 . . . . . . . . . . . . . . No continuity 2

1

5

3

(When battery voltage is applied between 3 and 5) 1 – 2 . . . . . . . . . . . . . . Continuity

3 D08RW599

+

ILLUMINATION CONTROLLER Controller Inspection

–

Check the illumination controller function.

B-33

Illumination controller 3 2 1

825RV107


MEMO


HAZARD WARNING FLASHER, TURN SIGNAL LIGHT, BACK UP LIGHT, HORN AND STOP LIGHT PARTS LOCATION (LHD)

T-1

T-6


F-3 H-8

C-1

B-16 C-2

H-17 C-44 C-36 C-41 C-42

H-4(H-5)

C-21

E-42(M-8) E-43(M-9)

H-6 H-7 H-12 B-28

H-15 C-35

C-45 C-20

C-22

H-9

C-25

D08RW00005



T-6

T-1

RELAY & FUSE BOX H-6 (X-4)

F-3

H-7

C-1

C-41 C-42

C-2

E-42(M-8) E-43(M-9) B-16

H-17

C-80 C-36

C-44

H-8

C-45 H-4 (H-5) C-21

C-35 H-15

B-28

C-20

C-22

H-9

C-25

D08RVA29


CIRCUIT DIAGRAM (LHD) EB-2 10A HORN

3B

0.5G/R

EB-1 15A HAZARD

0.85G

EB-11 10A STOP

3B

STARTER SW

15B/R

+

OFF ACC

IGN B2 40A

3W

P-2

B2

C-41

IG2

C-41

CB-11 15A BACK UP, TURN

6 3B/Y

H-7

3B/Y

0.85W

ST

MAIN 80A OR 100A

P-1

8

1

B1

IG1

P-5

_

5B/Y

FLASHER UNIT

Y / B 0 3

C-45

C-45

2

1

5 / W 8 . 0 R B G 5 . 0

P-7

P-10

FRAME

ENG.

5 / W 8 . 0 R B

W / R B 5 8 . 0

W C-44 S T H G I L P O T S C-44

H-8

5

R 5 . 0

B R / 5 . G 0 5 8 . 0 3

7

B-16

H-8

B-16

C-42

G 5 8 . 0

B-16

B-16

B-16

B-16

B-16

6

4

2

8

1

5

TURN SIGNAL INDICATOR (METER)

B / G 5 8 . 0

W / G 5 8 . 0

B-28

12 H-8

BODY-LH

R 5 . 0 18

5 0.85G/W

H-9

9

H-9 H-6

R 5 . 0

5

W 5 8 . 0

W S D R A Z A H

RH

W / G 5 8 . 0

B / G 5 8 . 0

R B 5 8 . 0

B-16

4

R 2 5 . 0 8

21 H-6

8

H-6

3

1

3

) 1 ( L I A T ; Y A L E R

R B 5 8 . 0

5 / W 8 . 0 R B

C-42

) W W S S L N A I O N T LH G A I S N I N B R M U O C-42 T C (

C-45

R 5 . 0

0.85G/B

13 H-9

9 2 H-12

B / G 5 8 . 0

H-15

R 5 . 0 2 H-17

R 5 . 0

T H 1 G I L L-5 P O T S D E T N U O L-6 M 1 H G B I H 5 . 0

R 5 . 0 2

2

H T-1 L T H G I L P O T T-1 S

H T-6 R T H G I L P O T T-6 S 4

B 5 8 . 0

B 5 2 . 1

B / G 5 8 . 0

R 5 . 0

4

H L 1 T H G I C-35 L L A N G I S N R C-35 U T 2 E D I S

H L 2 T H C-25 G I L L A N G I S N R C-25 U T 1 T R F

H R 2 T H C-22 G I L L A N G I S N R C-22 U T 1 T R F

W / G 5 8 . H 0 R 1 T H G C-1 I L L A N G I S N R C-1 U T 2 E D I S

B 5 . 0

B 5 . 0

B 5 . 0

B 5 . 0

0.5B

3 H-12

B / G 5 8 . 0

W / G 5 8 . 0

4 H-17

B 5 2 . 1 BODY-LH

FRAME

B-28 0.85B F-3

FENDER-LH

C-36

FENDER-RH

C-2

1.25B 1.25B

D08RV968


0.85W

R / G 5 . 0 R / G 5 . 0

18 H-8 2

5

X-4

X-4 RELAY;HORN

W 5 8 . 0 W 5 8 . 0 13

X-4

1

O / G 5 8 . 0

4(MSG)

H-4

X-4

4

H-5 3(MUA)

W 5 8 . 0

W 5 8 . 0 1

W E-42 S T ) H L G I E L S E P I D U ( K C A B E-43

B / O 5 . 0

1

M-9

H-4

O / G 5 8 . 0

H C-20 G I H N R O H

Y 1 / R 5 8 . 0 8(MSG)

Y 1 / R 5 8 . 0 14

1

W C-21 O L N R O H

H-5

Y / 0.85R/Y R 5 8 . 0 19

0.85G/W

O / G 5 8 . 0

1

) M-8 W T S / M T / H W G I E L N P I U L O K S C A A G B (

6(MUA)

H-8

Y / R 5 8 . 0 14

0.85G/B

12 C-42

H-9 6

B / G 5 8 . 0

H-15

W / G 5 8 . 0

6

H-17

B / G 5 8 . H 0 1 L T H T-1 G I L L A N G I S N T-1 R U T 4 R R B 5 8 . 0

FRAME

F-3

5

H-17

Y / R 5 8 . 0

0.85R/Y

5

H L T H G I L P U K C A B

5

H R T H G I L P U K C A B

T-1

T-1 4

B 5 8 . 0

B 5 8 . 0 F-3

H-15

W / G 5 8 . H 0 1 R T H T-6 G I L L A N G I S N T-6 R U T 4 R R 0.5B

HORN SW

Y / R 5 8 . 0 1

H-17

4 H-17

FRAME

Y / R 5 8 . 0 4

5

H-15

T-6

T-6 4

0.5B

4 H-17

0.85B

D08RV969


CIRCUIT DIAGRAM (6VD1-LHD) EB-2 10A HORN

3B

0.5G/R

EB-1 15A HAZARD

0.85G

EB-11 10A STOP

3B

6

STARTER SW IGN B2 40A

15B/R

+

1

P-2

C-41

P-11

B2

IG2

B1

IG1

8 C-41

Y / B 0 3

G 5 . 0

FRAME

ENG.

RH 1


C-42 5

0.85G/W HAZARD SW

W / G 5 8 . 0 9

12 H-8

H-15

B-16 6

W / G 5 8 . 0

6

1 B-16

C-35

2 C-25

2 C-22

C-1

H-8

FT AND SIDE TURN SIGNAL LIGHT RH/LH

H-9

B R / 5 . G 0 5 8 . 0 3

7

B-16

B-16

C-42

B-16

B-16

B-16

B-16

B-16

6

4

2

8

1

5


B / G 5 8 . 0

W / G 5 8 . 0

B-28

12 H-8

BODY-LH 5 0.85G/W

H-9

9

(6VD1) H-6

R 5 . 0

H-8

G 5 8 . 0

R 5 . 0 18

5 H-15

R B 5 8 . 0

5

W 5 8 . 0

W S D R A Z A H

RH

W / G 5 8 . 0

B / G 5 8 . 0

R 5 . 0

4

21 H-6

8

B-16

4

R 2 5 . 0 8

1

3

) 1 ( L I A T ; Y A L E R

R B 5 8 . 0

5

3

) W W S S L N A O N I T LH G A I S N I N B R M U O C-42 T C (

C-45

H-6

C-42

0.85G/B

B / G 5 8 . 0

1

5 W 8 . / 0 R B

3

H-6

C-45

2

5 / W 8 . 0 R B

W / R B 5 8 . 0

C-42

B / G 5 8 . 0

C-45

5 / W 8 . 0 R B

P-10

4

0.85W

FLASHER UNIT

P-7

) W W S S L N A I O N T LH G I A N S I N B R M U O C-42 T C (

H-7

3B/Y

(6VD1)

_

5B/Y


6 3B/Y

ST

MAIN 80A OR 100A

P-1 P-5

3W

(6VD1)

H-28

OFF ACC

R 5 . 0

0.85G/B

13 H-9

9

(6VD1) 2

B / G 5 8 . 0

H-15

H-12

R 5 . 0 2 H-17

R 5 . 0

R 5 . 0

T H 1 G I L L-5 P O T S D E T N U O L-6 M 1 H G I B H 5 . 0

2

2



B 5 8 . 0

B 5 2 . 1

B / G 5 8 . 0

R 5 . 0

4

B / G 5 8 . 0

W / G 5 8 . 0





B 5 . 0

B 5 . 0

B 5 . 0

B 5 . 0

0.5B

3 4

H-12

H-17

B 5 2 . 1 BODY-LH

FRAME

B-28 0.85B F-3

FENDER-LH

C-36

FENDER-RH

C-2

CHASSIS

B-37

1.25B 1.25B 1 H-15 (6VD1) D08RW581


0.85W

R / G 5 . 0 R / G 5 . 0

18 H-8

2(6VD1) 5

2

(6VD1)5

X-4

X-4 RELAY;HORN

W 5 8 . 0

X-17(6VD1)

W 5 8 . 0 13

W 5 8 . 0

X-4 (6VD1)3

4(MSG)

H-4

H-5

X-4

4

1

O / G 5 8 . 0

8 H-22

3(MUA)

W 5 8 . 0

W 5 8 . 0

W 5 8 . 0

1 E-42

W S T ) H L G I E L S E P I U D ( K C A B E-43 Y / 1 R 5 8 . 0 14

1

M-9

Y 1 / R 5 8 . 0 8(MSG)

H-4 0.85G/W

M-8

M-9

6(MUA)

H-8

Y / R 5 8 . 0

0.85G/B

W S T H ) G 1 I L D P V 6 U ( K C A B

B / O 5 . 0

6

Y 1 / R 5 8 . 0 12

B / G 5 8 . 0

W / G 5 8 . 0

6

H-17


H-8

12 C-42

FRAME

F-3

1

H-17

Y / R 5 8 . 0

0.85R/Y

5


5


T-1

T-1

B 5 8 . 0

B 5 8 . 0

HORN SW

4

4 4

F-3

5

W / G 5 8 . H 0 1 R T H T-6 G I L L A N G I S N T-6 R U T 4 R R

H-17

FRAME

0.85R/Y

H-15

Y / R 5 8 . 0

H-17

0.5B

1

W C-21 O L N R O H

Y / R 5 8 . 0 9

14

Y / R 5 8 . 0

5 H-15

1


H-9

H-15

O / G 5 8 . 0

H-22

H-5

Y / 0.85R/Y R 5 8 . 19 0

O / G 5 8 . 0

1

) M-8 W T S / M T / H W G I E L N P I U L O K S C A A G B (

T-6

T-6 4

0.5B

4 H-17

0.85B 1

CHASSIS

B-37

H-15

(6VD1)

D08RW582


CIRCUIT DIAGRAM (RHD) EB-2 10A HORN

3B

0.5G/R

EB-1 15A HAZARD

0.85G

EB-11 10A STOP

3B

STARTER SW

15B/R

+

OFF ACC

IGN B2 40A

3W

1

P-2

B2

C-41

8 C-41


6 3B/Y

H-7

3B/Y

0.85W

ST

MAIN 80A OR 100A

P-1

IG2

B1

IG1

P-5

_

5B/Y

FLASHER UNIT

Y / B 0 3

P-7

P-10

FRAME

ENG.

C-45

C-45

2

1

5 / W 8 . 0 R B G 5 . 0

5 / W 8 . 0 R B

W / R B 5 8 . 0

1

R 5 . 0

5

RH

C-42

B / G 5 8 . 0

R 5 . 0

B-16

B-16

B 5 . 0

H-6

G 5 8 . 0

B-16

B-16

B-16

B-16

B-16

6

4

2

8

1

5

W / G 5 8 . 0

7

R / G 5 8 . 0 3

6

W 5 8 . 0

W S D R A Z A H

2

H-6

R B 5 8 . 0

B-16

4

18

21 H-6

8

H-6

3


3

) 1 ( L I A T ; Y A L E R

R B 5 8 . 0

5 / W 8 . 0 R B

C-42


C-45


B / G 5 8 . 0

W / G 5 8 . 0

B-28

9 BODY-RH

H-6

5 0.85G/W

18

H-9

2

H-9

H-8

R 5 . 0

0.85G/B

13 H-9

9

B / G 5 8 . 0

H-15

R 5 . 0 2 H-17

R 5 . 0

B / G 5 8 . 0

R 5 . 0 2

2



B 5 8 . 0

4

B / G 5 8 . 0

W / G 5 8 . 0





B 5 . 0

B 5 . 0

B 5 . 0

B 5 . 0

0.5B

4 H-17

FRAME

0.85B F-3

FENDER-LH

C-36

FENDER-RH

C-2

1.25B 1.25B

D08RV966


0.85W

R / G 5 . 0 R / G 5 . 0

2 H-6 2

5

X-4

X-4 RELAY;HORN

W 5 8 . 0 W 5 8 . 0 13

X-4

1

O / G 5 8 . 0

4(MSG)

H-4

X-4

4

H-5 3(MUA)

W 5 8 . 0

W 5 8 . 0 1

1

H-4

C-80

B / O 5 . 0

O / G 5 8 . 0

1


C-80 5

1

W C-21 O L N R O H

H-5

Y / 0.85R/Y R 5 8 . 0 12

0.85G/W

) T / A ( W S E D O M

Y 1 / R 5 8 . 0 8(MSG)

Y 1 / R 5 8 . 0 14

O / G 5 8 . 0

2

) M-8 W T S / T M / H W G I E L N P I U L O K S C A A G B ( M-9

W E-42 S T ) H L G I E L S E P I D U ( K C A B E-43

6(MUA)

H-6

Y / R 5 8 . 0 14

0.85G/B

12 C-42

H-9 6

B / G 5 8 . 0

H-15

W / G 5 8 . 0

6

H-17


FRAME

F-3

1

H-17

Y / R 5 8 . 0

0.85R/Y

5


5


T-1

T-1 4

B 5 8 . 0

B 5 8 . 0 F-3

5

W / G 5 8 . H 0 1 R T H T-6 G I L L A N G I S N T-6 R U T 4 R R 0.5B

HORN SW 4

H-15

Y / R 5 8 . 0

H-17

4 H-17

FRAME

Y / R 5 8 . 0

5

H-15

T-6

T-6 4

0.5B

4 H-17

0.85B

D08RV967


CIRCUIT DIAGRAM (6VD1-RHD) EB-2 10A HORN

3B

0.5G/R

EB-1 15A HAZARD

0.85G

EB-11 10A STOP

3B

STARTER SW

15B/R

+

OFF ACC

IGN B2 40A

3W

P-2

B2

C-41

IG2

C-41

_

B1

FLASHER UNIT

Y / B 0 3

C-45

C-45

2

1

5 W 8 . / 0 R B

P-10

FRAME

ENG.

G 5 . 0

5 W 8 . / 0 R B

W / R B 5 8 . 0

3 C-42

1

B / G 5 8 . 0


RH

C-42 5

R 5 . 0

0.85G/W 0.85G/B HAZARD SW

W / G 5 8 . 0 2

H-26

9 H-6

6 B-16

4 B-16

1 C-35

2

2

C-25

C-22

R 5 . 0

1 C-1

6 H-15

W / G 5 8 . 0

FT AND SIDE TURN SIGNAL LIGHT RH/LH

7

B-16

H-6

B-16

C-42

G 5 8 . 0

B-16

B-16

B-16

B-16

B-16

6

4

2

8

1

5


B / G 5 8 . 0

W / G 5 8 . 0

B-28

9 BODY-RH

H-6

5 0.85G/W

18

H-9

2

(6VD1)

H-9

B / G 5 8 . 0

R B / 5 . G 0 5 8 . 0 3

6

W 5 8 . 0

W S D R A Z A H

RH

W / G 5 8 . 0

B / G 5 8 . 0

R B 5 8 . 0

5

2 18

21 H-6

8

B-16

4

H-6

3

) 1 ( L I A T ; Y A L E R

R B 5 8 . 0

5 W 8 . / 0 R B 3

) W W S S L N A O N I T LH G I A N S I N B R M U O C-42 T C (

C-45

H-6

C-42

4

0.85W

IG1

(6VD1)

P-7


H-7

3B/Y

P-11

P-5

5B/Y


6 3B/Y

ST

MAIN 80A OR 100A

P-1

8

1

H-8

R 5 . 0

0.85G/B

13 H-9

9

5

B / G 5 8 . 0

H-15

H-15

R 5 . 0 (6VD1)

2 H-17

R 5 . 0

B / G 5 8 . 0

R 5 . 0 2

2



B 5 8 . 0

4

B / G 5 8 . 0

W / G 5 8 . 0




W / G 5 8 . H 0 R 1 T H G I C-1 L L A N G I S N R C-1 U T 2 E D I S

B 5 . 0

B 5 . 0

B 5 . 0

B 5 . 0

0.5B

4 H-17

FRAME

0.85B F-3

FENDER-LH

C-36

FENDER-RH

C-2

1.25B 1.25B 1

CHASSIS

B-37

(6VD1)

H-15

D08RW583


0.85W

R / G 5 . 0 R / G 5 . 0

2 H-6 (6VD1)5

2(6VD1) 5

2 X-4

X-4 RELAY;HORN

W 5 8 . 0

X-17(6VD1)

W 5 8 . 0 13

W 5 8 . 0

X-4 (6VD1)3

H-4

H-5

1

O / G 5 8 . 0

8

4(MSG)

X-4

4

H-22

3(MUA)

W 5 8 . 0

W 5 8 . 0

W 5 7 . 0

1 E-42

W S T ) H L G I E L S E P I U D ( K C A B E-43 Y / 1 R 5 8 . 0 14

1

) T / A ( W S E D O M

H-4

5

O / G 5 8 . 0

5

) T / A ( W S E D O M

M-25

) 1 D V 6 (

6(MUA)

Y 2 R 5 7 . 0 12

Y R 5 8 . 0

H-15

B / G 5 8 . 0

W / G 5 8 . 0

6

H-17


12

FRAME

F-3

5

H-17

Y / R 5 8 . 0

0.85R/Y

5


5


T-1

T-1 4

B 5 8 . 0

B 5 8 . 0 F-3

HORN SW

H-15

W / G 5 8 . H 0 1 R T H T-6 G I L L A N G I S N T-6 R U T 4 R R

4 H-17

FRAME

0.85R/Y

Y / R 5 8 . 0 1

H-17

0.5B

O L N R O H

C-42

Y / R 5 8 . 0 4

H-15

1

W C-21

12

H-9 5

1


M-25

H-6

Y / R 5 8 . 0 14

6

B / O 5 . 0

O / G 5 8 . 0

H-22

H-5

H-6 0.85G/B

C-80

C-80

Y / 1 R 5 8 . 0 8(MSG)

Y / 0.85R/Y R 5 8 . 0 12

0.85G/W

2

) M-8 W T S / M T / H W G I L E N P I U L O K S C A A ( B G M-9

T-6

T-6 4

0.5B

4 H-17

0.85B 1

CHASSIS

B-37

H-15 (6VD1)

D08RW584


TROUBLE SHOOTING STOPLIGHT AND HIGH MOUNTED STOPLIGHT 1.

One side of stoplight does not light Checkpoint

Stoplight bulb continuity

Trouble Cause

Countermeasure

NG

Burned out bulb or poor connector contact


NG



NG




Reinstall or replace fuse No. EB-11 (10A)

Incorrect the switch installation or adjustment

Adjust the switch installation position

Open circuit or poor connector contact between stoplight switch (or brake switch) and stoplight


OK LHD: Continuity between 8 H-8 - 2 T-1 (LH) (or 2 T-6 (RH)) RHD: Continuity between 18 H-6 - 2 T-1 (LH) (or 2 T-6 (RH)) OK Continuity between F-3 - 4 T-1 (LH) (or 4 T-6 (RH))

2.

Both sides of stoplight do not light

Fuse No. EB-11 (10A, Fuse and Relay box)

NG

OK Stop light switch (or brake switch) function

NG

OK Voltage between 2 T-1 ground or 2 T-6 - ground with brake pedal depressed (Should be battery voltage present)

NG


High mounted stoplight does not light Checkpoint

Grounding point ( B-28 )

Trouble Cause

Countermeasure

NG

Poor grounding point contact

Repair grounding point ( B-28 ) contact

NG

High mounted stoplight malfunction

Repair or replace the high mounted stoplight

NG


Repair an open circuit or connector contact between 1 L-5 - 8 H-8

OK Continuity between 1 L-5 1 L-6

OK Voltage between 1 L-5 ground with brake pedal depressed (Should be battery voltage present)


TURN SIGNAL LIGHT AND HAZARD WARNING LIGHT 1.

Turn signal light does not light on both sides (RH and LH) Checkpoint

Fuse No. CB-11 (15A, Fuse box)

Trouble Cause

NG

Countermeasure

Poor fuse contact or blown fuse

Reinstall or replace fuse No. CB-11 (15A)

Flasher unit malfunction

Replace the flasher unit

NG



NG

Poor switch point contact or faulty switch


OK Short circuit between connector 1 C-45 - 2 C-45 when turn signal switch operates with starter switch in “ON” position (Turn signal light should be ON)

NG

OK Continuity between connector 3 C-45 -ground (Should be continuity) OK Turn signal switch continuity between connector

3 C-42 - 4 C-42 and 3 C-42 - 5 C-42 when turn signal switch operates

2.

Turn signal light does not light on one side (RH or LH)

Turn signal switch continuity

NG



NG



NG



OK (RH) Continuity between 2 C-22 - 5 C-42 ( FRT), 1 C-1 - 5 C-42 (SIDE) 1 T-6 - 5 C-42 (RR) OK (LH) Continuity between 2 C-25 - 4 C-42 (FRT), 1 C-35 - 4 C-42 (SIDE) 1 T-1 - 4 C-42 (RR)


Hazard warning light does not light Checkpoint

Fuse No. EB-1 (15A, Relay and fuse box)

Trouble Cause

NG

Countermeasure


Reinstall or replace the fuse No. EB-1 (15A)

Hazard SW. malfunction

Repair or replace the hazard SW.

Open circuit or poor connector contact between fuse No. EB-1 (15A) – 2 B-16


Burned out bulb

Replace the bulb or repair open circuit

OK

Hazard SW. continuity

NG

OK Voltage between 2 B-16 ground (Should be battery voltage present)

4.

NG

Flashing rate too fast (One side)

Inspect bulb

NG


BACKUP LIGHT 1.

Backup light does not light on one side (RH or LH) Checkpoint

Backup light bulb continuity

Trouble Cause

NG

Countermeasure

Burned out bulb or poor connector contact


Poor ground contact

Repair grounding point contact

OK

Grounding point

2.

NG

Backup light does not light on both sides


NG


Reinstall or replace fuse No. CB-11 (15A)

NG


Repair or replace the switch

NG



OK Back up light switch (mode switch) continuity

OK Voltage between 5 T-1 (5 T-6 ) - ground with starter switch ON and shift lever into reverse position (Should be battery voltage present)


HORN 1.

Both sides of horn do not sound Checkpoint

Fuse No EB-2 (10A, Relay and fuse box)

Trouble Cause

NG

Countermeasure


Reinstall or replace fuse No. EB-2 (10A)

Poor ground contact

Repair the grounding point

Poor relay contact or faulty horn relay

Reinstall or replace the horn relay

Open circuit or poor connector contact between fuse No. EB-2 (10A) and horn relay

Repair open circuit or reconnect the connector

NG


Repair or replace the horn switch

NG



OK

Grounding point

NG

OK

Horn relay

NG

OK Voltage between connector 2 X-4 - ground or 5 X-4 - ground (Should be battery voltage present)

NG

OK Remove steering pad and steering wheel

Horn switch continuity

OK Continuity between 4 X-4 - 12 C-42 1 X-4 - 1 C-20 (1 C-21 )


One side of horn does not blow Checkpoint

Horn continuity between connectors

Trouble Cause

NG

Countermeasure

Faulty horn assembly

Replace the horn assembly


Repair open circuit or reconnect the connector

Discharged battery

Recharge or replace the battery

Stain or foreign material in the horn

Clean and/or remove the foreign material

OK Voltage between 1 C-20 (1 C-21 )- ground with horn switch depressed (Should be battery voltage present)

3.

NG

Insufficient horn volume

Battery condition

NG

OK

Horn

NG



REAR COMBINATION LIGHT Stoplight Removal

1. Open the rear gate. 2. Remove the screws of rear combination light. 3. Remove the rear combination light assembly.

D08RV751

4. Turn the bulb 2 counterclockwise to remove it.

2

D08RV887

Installation

Follow the removal procedure in the reverse order to install the rear combination light. Pay close attention to the important points mentioned in the following paragraphs.

Bulb

Be absolutely sure that each bulb is correctly installed. This will prevent a poor contact and an open circuit.


FRONT TURN LIGHT Removal

1. Remove the front turn light lens. 2. Pull the light housing free.

D08RV862

3. Push the bulb in and turn it counterclockwise to remove it from the light housing.

D08RV863

Installation

Follow the removal procedure in the reverse order to install the front turn light. Pay close attention to the important points mentioned in the following paragraphs.

Bulb

Be absolutely sure that the front turn light bulb is correctly installed. This will prevent a poor contact and an open circuit.


SIDE TURN LIGHT Removal

2

1. Remove the lens 1. • Pull the light/bulb toward you while pushing the light housing in the rear direction of the vehicle to release its lock. • Remove the socket by turning it counterclockwise.

1

2. Pull the bulb 2 to remove it. D08RV750

Installation

Follow the removal procedure in the reverse order to install the side turn light. Pay close attention to the important points mentioned in the following paragraphs.

Bulb

Be absolutely sure that the side turn light bulb is correctly installed. This will prevent a poor contact and an open circuit.


REAR COMBINATION LIGHT Turn Signal Light Removal

1. Open the rear gate. 2. Remove the screws. 3. Remove the rear combination light assembly.

D08RV751

4. Turn the bulb 1 counterclockwise to remove it. 1

D08RV752

Installation


Bulb

Be absolutely sure that the rear combination light bulb is correctly installed. This will prevent a poor contact and an open circuit.


TURN SIGNAL SWITCH Removal

1. Remove the steering wheel 1. Refer to the “STEERING” Section of this Manual. 2. Remove the instruments panel lower cover 2. 3. Remove the steering column cover 3. 3

1

2 D08RV888

4. Disconnect the connector. 5. Remove the turn signal switch from the steering shaft.

D08RV747

Installation

Follow the removal procedure in the reverse order to install the turn signal switch (lever). Pay close attention to the important points mentioned in the following paragraphs.

Connector

Be absolutely sure that the turn signal switch connector is securely connected. This will prevent a poor contact and at an open circuit.


REAR COMBINATION LIGHT Back Up Light Removal

1. Open the rear gate. 2. Remove the screws. 3. Remove the rear combination light assembly.

D08RV751

4. Turn the bulb 3 counterclockwise to remove it. 3

D08RV886

Installation


Bulbs

Be absolutely sure that each bulb is correctly installed. This will prevent a poor contact and an open circuit.


HAZARD WARNING FLASHER SWITCH Removal 1. Instrument Panel Cluster Assembly • Refer to Section 10 “BODY” for instrument panel cluster assembly removal steps. 2. Hazard Warning Switch • Disconnect the switch connector. • To remove the switch, push the lock from the back side of the cluster assembly. D08RV893

Installation

To install, follow the removal procedure in the reverse order.

Connector

Be absolutely sure that the hazard warning flasher switch connector is securely connected. This will prevent a poor contact and an open circuit.

BACK UP LIGHT SWITCH Removal

1. Disconnect the connector 1. 2. Remove the back transmission 2.

up

light

switch

from

the

1 2

D08RV867

Installation

Follow the removal procedure in the reverse order to install the back up light switch. Pay close attention to the important points mentioned in the following paragraphs.

8–162 ELECTRICAL-BODY AND CHASSIS Back up Light Switch Threads

Apply liquid gasket to the threaded portion and install the back up light switch.

Connector

Be absolutely sure that the back up light connector is securely connected. This will prevent a poor contact and an open circuit.

HORN Removal

1. Remove the radiator grille. Refer to the “HEADLIGHT” removal procedure. 2. Loosen the horn bolt. 3. Disconnect the horn connector.

D08RV878

Installation

Follow the removal procedure in the reverse order to install the horn. Pay close attention to the important points mentioned in the following paragraphs.

Connector

Be absolutely sure that the horn connector is securely connected. This will prevent a poor contact and an open circuit.


HORN SWITCH Removal

1. Remove the horn pad 1.

1

D08RV870

2. Remove the steering wheel nut 2.

2

3. Remove the steering wheel 3. 4. Remove the horn switch.

3 D08RV871

Installation

Follow the removal procedure in the reverse order to install the horn switch. Pay close attention to the important points mentioned in the following paragraphs. Steering Wheel Nut (2)

Tighten the nut to the specified torque. Steering Wheel Nut Torque

kg·m (lb·ft/N·m)

3.5 ± 0.5 (25.3 ± 3.6/34.3 ± 4.9)



TURN SIGNAL SWITCH Lighting Switch Connections

C-42

Terminal No. 15

1 2 3

4 5 6

7 8 9 10

11 121314

16

SW position

3

4

5

Left Switch side

Turning direction

↔

X

X

Neutral

↔

X

X

Right

HAZARD WARNING FLASHER SWITCH Hazard Warning Flasher Switch Connections

B-16 3

2 1

8 7 6 5 4

Terminal SW No. position ON

Switch side

OFF

4

5

6

7

8

2

1

3


DOME LIGHT, SPOT LIGHT AND WARNING BUZZER PARTS LOCATION (LHD)

L-1 L-2 L-9

L-8 H-8

B-24 R-6

L-3

C-36

B-9

B-5

H-6 H-7 H-11

C-41

R-1

R-3 B-28

H-9 H-21

D08RVA31



L-1 L-2 L-9 H-6 H-7 H-11

L-8

R-6

L-3

C-36

C-41

H-8 R-1 B-5

R-3 B-9

H-9 H-21

D08RVA32


CIRCUIT DIAGRAM (LHD & RHD)

15B/R

+

MAIN 80A OR 100A

IGN.B2 40A

P-2

P-1 P-5

_

5B/Y

(RHD)

W 3 Y / B 0 3

P-7

P - 10

FRAME

ENG.

3

5

H-7

H-7

W 3 CB-14 10A ROOM LAMP

W / R 5 . 0 2 H - 11

W / R 5 8 . 0

0.85 R/W

1

1

L-1

T H G I L E M ON O D

L-9

OFF

T H G I L T O P S

DOOR

L-2 1

G / R 5 8 . 0

0.85 R/G

1 H-11

G / R 5 . 0 15 H-9

G / R 5 8 . 0

G / R 5 8 . 0 1 L- 8

H R W S R O O D R R

G / R 5 8 . 0 1

1

1

L- 3

H L W S R O O D R R

G / R 5 8 . 0

R-6

H R W S R O O D T R F

R-1

H L W S R O O D T R F

D08RV970


CIRCUIT DIAGRAM (LHD – SAUDI ARABIA) STARTER SW

15B/R

+

MAIN 80A OR 100A

OFF ACC

IGN.B2 40A

P-1

1

3W

P-2

C - 41

IG2

B1

IG1

ST

3

3 W/B

P-5

B2

C - 41

6 C - 41

3 B/R

2

3 B/R

H -7

CB-7 15A METER

IGN.B1 40A

_

W 3 5B/Y

Y / B 0 3

P-7

P - 10

FRAME

ENG.

3 H-7

W 3

Y 5 8 . 0 1 1 B E E S U F

CB-14 10A ROOM LAMP

W / R 5 . 0

G 5 . 0

2 H - 11

T 2 H G I L B-24 G N ) I N R R E A T E W M T ( L E B T B-24 A E S 10

5 C-41

W / R 5 8 . 0

) 1 ( L I A T ; Y A L E R

0.85 R/W

1

1

L-1

Y W 5 S ) W 8 . 0 D S N I R E M T E R R A Y T E S K (

C-41 7

5


OFF

H-6

T H G I L T O P S

Y / G 5 . 0

B / R 5 . 0

L-9

17 H-8

R / G 5 8 . 0

DOOR

3 L-2

Y / G 5 . 0

B / R 5 . 0 6

B-5

B-5

4

Y / G 5 . 0 5

B-5

B-5

1

G / R 5 8 . 0

1

KEY,LIGHT AND SEAT BELT REMIND BUZZER

B-5

H-21

B-5

1

2

Y / G 3 . 0

W / B 5 . 0 1 0.85 R/G

1 0.5 R/G

H - 11

B - 30

DIODE

B 5 . 0

2 B - 30

0.5B/W

W / B 5 . 0

G / R 5 . 0 H-9

0.85 R/G

1

H L W S R O O D R R

1

1 L- 8

H R W S R O O D R R

H-9

W / B 5 8 . 0

G / R 5 8 . 0 L- 3

R-3 2

B 5 . 0

1 R-1

R-6


W S T L E B T A E S

1

15

G / R 5 8 . 0

1 R-3


B 2

B 5 . 0

B 2 4 H-9

B 2 BODY-RH

B-9

11 H-9

B 5 8 . 0 11 H-6

BODY-LH

B-28

FENDER-LH

C-36

0.85 B

(W/O POWER WINDOW)

D08RV971


CIRCUIT DIAGRAM (RHD – SOUTH AFRICA) STARTER SW

15B/R

+

MAIN 80A OR 100A

OFF ACC

IGN.B2 40A

3W

P-2

P-1

1 C - 41

IG2

B1

IG1

ST

3

3 W/B

P-5

B2

C - 41

6 C - 41

3 B/R

4

3 B/R

H -7

CB-5 15A METER

IGN.B1 40A

_

W 3 5B/Y

Y / B 0 3

P-7

P - 10

FRAME

ENG.

5 H-7

W 3

1 1 B E E S U F

CB-14 10A ROOM LAMP

W / R 5 . 0

G 5 . 0

2 H - 11

5 C-41

W / R 5 8 . 0

) 1 ( L I A T ; Y A L E R

0.85 R/W

1

1

L-1

Y W 5 S ) W 8 . 0 D S N R I E M T E R R A Y T S E ( K

C-41 7

B / R 5 . 0

L-9 4


OFF

H-8

T H G I L T O P S

11 H-6

R / G 5 8 . 0

DOOR

B / R 5 . 0 3

L-2

6

B-5

B-5

4 B-5

1

G / R 5 8 . 0

KEY,LIGHT AND SEAT BELT REMIND BUZZER

B-5

B-5

1

B-5 5

2

Y / G 3 . 0

W / B 5 . 0 1 0.85 R/G

1 0.5 R/G

H - 11

B - 30

DIODE

B 5 . 0

2 B - 30

0.5B/W

L- 3

H L W S R O O D R R

BODY-LH FENDER-LH

1

1 L- 8

H R W S R O O D R R

B-9 C-36

2

R-1


R-3

R-3 1

R-6


W S T L E B T A E S

H-9

W / B 5 8 . 0

G / R 5 8 . 0 1

1 15

1 H-9

0.85 R/G

Y / G 3 . 0

W / B 5 . 0

G / R 5 . 0 G / R 5 8 . 0

1 H-21

B 2

B 5 . 0 11 H-9

B 5 . 0 B 5 8 . 0

5

H-8 0.85 B

D08RV972


TROUBLE SHOOTING 1.

Dome light does not light Checkpoint

Dome light bulb continuity

Trouble Cause

NG

Countermeasure

Burned out the bulb

Replace the dome light bulb

Switch malfunction

Repair or replace the dome light assembly

NG



NG

Switch malfunction or foreign material in switch

Repair or replace the door switch

Short circuit

Repair short circuit or connector contact

OK

Dome light switch function

NG

OK Continuity between connector 2 H-11 - 1 L-1

2.

Dome light does not go out

Door switch function (Both side)

OK Continuity between connector 1 L-2 -ground when shutting the door (Should be no continuity)

NG



DOME LIGHT Removal

1. Remove the dome light cover free.

D08RV872

2. Pull the bulb to remove it.

D08RV873

Installation

Follow the removal procedure in the reverse order to install the dome light. Pay close attention to the important points mentioned in the following paragraphs.

Bulb

Be absolutely sure that the dome light bulb is correctly installed. This will prevent a poor contact and an open circuit.

8–172 ELECTRICALELECTRICAL-BODY BODY AND CHASSIS CHASSIS

DOOR SWITCH

1 2

Removal

1. Push Push the the door door switc switch h slidin sliding g porti portion on 1 in the direction of the arrow in the illustration. 2. Loos Loosen en the the scr screw ew 2. 3. Pull Pull the the switch switch free free to remove remove it. 4. Discon Disconnec nectt the door door switc switch h connec connector tor..

D08RV874

Installation

Follow the removal procedure in the reverse order to install the spot light. Pay close attention to the important points mentioned in the following paragraphs.

Connector

Be absolutely sure that the door switch connector is securely connected. This will prevent a poor contact and an open circuit.

SPOT LIGHT Removal

1

1. Grasp Grasp the spot spot ligh lightt hou housin sing g 1 with both hands. Pull the housing straight down. This will release the clip.

D08RV875

2. Disc Discon onne nect ct the the conne connecto ctorr 2. 3. Push the bulb bulb in and and turn turn it count counterclo erclockwis ckwise e to remove it.

2

D08RV876


Follow the removal procedure in the reverse order to install the spot light. Pay close attention to the important points mentioned in the following paragraphs. Connector

Be absolutely sure that the spot light connector is securely connected. This will prevent a poor contact and an open circuit. Bulb

Be absolutely sure that the spot light bulb is correctly installed. This will prevent a poor contact and an open circuit.

WARNING BUZZER Removal 1. Dash ash Sid Side e Pan Panel el 2. Warni arning ng Buzz Buzzer er • Disconnect the connector. • Remove the screw.

2. Warning buzzer 1. Dash side panel This illustration is based on LHD 825RV105

Installation

Follow the removal procedure in the reverse order to install the warning buzzer. Pay close attention to the important points mentioned in the following paragraphs.

Connector

Be absolutely sure that the warning buzzer connector is securely connected. This will prevent a poor contact and an open circuit.



L-3

L-8

R -1

R-6

DOOR SWITCH Door Switch Connections

Connector No. SW position

Terminal No.

1

L-3

L-8

R-1

R -6

Body Ground

PUSHED RELEASED 825RV106

R-3

SEAT BELT SWITCH (SAUDI ARABIA, SOUTH AFRICA) Seat Belt Switch Connections

Connector No. 21 Switch side

SW position

Terminal No.

ON (Belt tongue tongue removed) removed) OFF (Belt tongue inserted)

R-3

1

2


WARNING BUZZER (SAUDI ARABIA) Starter Key Tail remind SW relay SW + –

Seat belt warning light

1. Warni Warning ng Buzz Buzzer er Circ Circuit uit

6 4 3 Warning buzzer 2 1

5

Seat belt SW

Door SW (Driver side)

D08RV991

Warning function

Operational conditions The warning light in the meter assembly turned on about 6 seconds from the moment the starter switch is turned on.

Fasten the seat belt

The buzzer sounds for about 6 seconds when the starter switch is turned on with the seat belt switch on (when the seat belt is not used).

Key left in starter switch

The buzzer sounds when both the key remind switch and the FRT door switch-LH are turned on. To stop the sound of the buzzer, turn on the starter switch.

Taillights left on

The buzzer sounds when the starter switch is turned from the “on” to “off” position while the taillights are on.

2. Warning Warning Buzz Buzzer er Harnes Harness s Side Conne Connecto ctorr Circuit Circuit

Disconnect the warning buzzer connector and check continuity and voltage between the warning buzzer harness side connector terminals.

B-5

1

2

3 4 5 6

Harness side

8–176 ELECTRICALELECTRICAL-BODY BODY AND CHASSIS CHASSIS Terminal No.

Wire color

Check item

Connecting terminal

5

G/Y

Seat belt SW

Continuity

5-Ground

Seat belt

3

G/R

Tail relay

3-Ground

Lighting SW “ON”

4

R/B

Key remind SW (Starter SW)

4-Ground

Key

6

Y

Fuse CB-7

6-Ground

Starter SW “ON”

1

B/W

Door SW (FRT-LH)

1-Ground

FRT do door-LH

2

B

Connecting to

Voltage

Continuity

Ground

2-Ground

Standard

Unfasten

Continuity

Fasten

No continuity Approx. 12V

Insert

Approx. 12V

Remove

0V Approx. 12V

Open

Continuity

Close

No continuity

—

Continuity

WARNING BUZZER (SOUTH AFRICA)

Starter SW 6

1. Warni Warning ng Buzz Buzzer er Circu Circuit it

Key remind SW 4

Tail relay

Check condition

Warning buzzer

3 2

5

Seat belt SW

1

Door SW (FRT -LH)

D08RV990

Warning function

Operational conditions

Fasten the seat belt

The buzzer sounds when the starter switch is turned on with the seat belt switch on (when the seat belt is not used).

Key left in starter switch

The buzzer sounds when both the key remind switch and the FRT door switch-LH are turned on. To stop the sound of the buzzer, turn on the starter switch.

Taillights left on

The buzzer sounds when the starter switch is turned from the “on” to “off” position while the taillights are on.

ELECTRICAL-BODY AND CHASSIS 8–177 2. Warning Warning Buzz Buzzer er Harnes Harness s Side Conne Connecto ctorr Circuit Circuit

Disconnect the warning buzzer connector and check continuity and voltage between the warning buzzer harness side connector terminals.

B-5

1

2

3 4 5 6

Harness side

Terminal No.

Wire color

Check item

Connecting terminal

5

G/Y

Seat belt SW

Continuity

5-Ground

Seat belt

3

G/R

Tail relay

3-Ground

Lighting SW “ON”

4

R/B

Key remind SW (Starter SW)

4-Ground

Key

6

Y

Fuse CB-5

6-Ground

Starter SW “ON”

1

B/W

Door SW (FRT-LH)

1-Ground

FRT do door-LH

2

B

Connecting to

Voltage

Continuity

Ground

Check condition

2-Ground

Standard

Unfasten

Continuity

Fasten

No continuity Approx. 12V

Insert

Approx. 12V

Remove

0V Approx. 12V

Open

Continuity

Close

No continuity

—

Continuity

KEY REMIND SWITCH (STARTER SWITCH) 1

2

3

4

5

6

7

8

Switch Connections

C-41

Connector No. Starter switch key position LOCK

Terminal No. Removed

OFF 730RV001

ACC ON START

Inserted

C-41 5

7

8–178 ELECTR ELECTRICALICAL-BODY BODY AND CHAS CHASSIS SIS

WINDSHIELD WIPER AND WASHER PARTS LOCATION (LHD)

H-8

C-2 C-3 C-36 C-17

C-4

H-7

C-41 C-43

D08RVA36



H-6 H-7

C-2 C-3 C-36 C-17

C-4

C-41 C-43

D08RVA35


CIRCUIT DIAGRAM (LHD)

STARTER SW

15B/R

+

ACC

IGN B2 40A

MAIN 80A OR 100A

1

3W

C -41

P-2 IGN B1 40A

P-1

B2

IG2

B1

IG1

ST

3 3W/B

C -41

P-5

2

6 3B/R

C-41

H-7

3B/R

_

5B/Y

P-7

Y / B 0 3

CB-8 20A FRONT WIPER

W / G L 5 8 . 0 20

P - 10

FRAME ENG.

H-8

WINDSHIELD WIPER & WASHER SW (COMBINATION SW)

1

0.85LG/W

C-43 7

WASHER

0.85L/B

C-43 3

0.85LG/W

C-43 4

HI C-43

LOW

5 C-43

INT

W / G L 5 8 . 0

C-43 OFF

Y / L 5 8 . 0

2

L 5 8 . 0

C-43

B / L 5 8 . 0

B / L 5 8 . 0

6

2

R / G L 5 8 . 0

O / L 5 8 . 0

C-4

1 WINDSHIELD WIPER MOTOR

C-4

LO

M

3

C-4

C-4

0.85LG/W

C-4

R / L 5 8 . 0 3

4 C-3

M

W / G L 5 8 . 0

5

C-3

R 1 O T O C-17 M R E H S A W D L E I H C-17 S D 2 N I W

6

HI

6

8

C-3

C-3

7 C-3

RELAY;INTERMITTENT - WINDSHIELD

C-3 2

B 5 2 . 1

B 5 2 . 1

B 3 . 0

FENDER-RH

C-2

FENDER-LH

C-36

1.25B

D08RW576


CIRCUIT DIAGRAM (RHD)

STARTER SW

15B/R

+

ACC

IGN B2 40A

MAIN 80A OR 100A

1

3W

C -41

P-2 IGN B1 40A

P-1

B2

IG2

B1

IG1

ST

3 3W/B

C -41

P-5

4

6 3B/R

C-41

H-7

3B/R

_

5B/Y

Y / B 0 3

P-7

P - 10

FRAME

ENG.

CB-6 20A FRONT WIPER

W / G L 5 8 . 0 4 H-6

WINDSHIELD WIPER & WASHER SW (COMBINATION SW)

1

0.85LG/W

C-43 7

WASHER

0.85L/B

C-43 3

0.85LG/W

C-43 4

HI C-43

LOW

5 C-43

INT

W / G L 5 8 . 0

C-43 OFF

Y / L 5 8 . 0

2

L 5 8 . 0

C-43

B / L 5 8 . 0

B / L 5 8 . 0

6

2

R / G L 5 8 . 0

O / L 5 8 . 0

C-4

1 WINDSHIELD WIPER MOTOR

C-4

LO

M

3

C-4

C-4

0.85LG/W

C-4

R / L 5 8 . 0 3

4 C-3

M

W / G L 5 8 . 0

5

C-3

R 1 O T O C-17 M R E H S A W D L E I C-17 H S D 2 N I W

6

HI

6

8

C-3

C-3

7 C-3

RELAY;INTERMITTENT - WINDSHIELD

C-3 2

B 5 2 . 1

B 5 2 . 1

B 3 . 0

FENDER-RH

C-2

FENDER-LH

C-36

1.25B

D08RV976


TROUBLE SHOOTING WINDSHIELD WIPER 1.

Wiper does not operate at any switch position Checkpoint

LHD: Fuse No. CB-8 (20A) RHD: Fuse No. CB-6 (20A)

Trouble Cause

NG

Countermeasure


Reinstall or replace the fuse No. CB-8 (20A) (RHD: CB-6 (20A))



SW. malfunction

Replace the wiper & washer SW.


Repair grounding point ( C-2 ) contact

Wiper motor malfunction

Replace the wiper motor



OK Voltage between 3 C-43 and the ground (Should be battery voltage present)

NG

OK Continuity in the wiper & washer SW.

NG

OK

Grounding point ( C-2 )

NG

OK 1. Wiper motor function when connecting the motor connector 2 C-4 to the battery (+) terminal, and 3 C-4 to the (–) terminal (Should the wiper motor rotate at a low speed) 2. Wiper motor function when connecting the motor connector 1 C-4 to the battery (+) terminal, and 3 C-4 to the (–) terminal (Should the wiper motor rotate at a high speed)

NG

OK Continuity between 3 C-4 and C-2

NG


Wiper does not operate at “INT” position Checkpoint

Continuity between the wiper & washer SW. connector terminals 3 C-43 and 2 C-43 at the “INT” position

Trouble Cause

NG

Countermeasure

SW. malfunction


NG


Repair grounding point contact

NG



Relay malfunction

Replace the intermittent relay

OK

Grounding point C-2

OK Voltage between the intermittent relay harness side connector terminal 4 C-3 and the ground at the “INT” position (Should be battery voltage present) OK

Intermittent relay function

3.

NG

Wiper does not operate at “LO” position

Wiper motor function 1.Disconnect the wiper & washer SW. connector 2.Turn the starter SW. on 3.Short-circuit between the wiper & washer SW. harness side connector terminals 3 C-43 and 5 C-43 4.Check to see if the wiper motor rotates at a low speed

NG



SW. malfunction


OK Wiper & washer SW. function

NG


Wiper does not operate at “HI” position Checkpoint

Continuity between the wiper & washer SW. connector terminals 3 C-43 and 4 C-43 at the “HI” position

Trouble Cause

NG

Countermeasure







OK Wiper motor function when connecting the motor connector 1 C-4 to the battery (+) terminal, and 3 C-4 to the (–) terminal (Should the wiper motor rotate at a high speed)

NG

OK Continuity between 4 C-43 and 1 C-4

5.

NG

Rotation of the wiper motor does not stop

Continuity in the wiper & washer SW.

NG

SW. malfunction




OK

Wiper motor function

NG


Auto-stop function of the wiper motor does not operate Checkpoint

Continuity between the wiper & washer SW. connector terminals 5 C-43 and 6 C-43 at the “OFF” position

Trouble Cause

NG

Countermeasure





NG


Repair an open circuit or a poor connection of the connectors between the fuse No. CB-8 (20A) (RHD: CB-6 (20A)) and 6 C-4

NG



Relay malfunction

Replace the intermittent relay

OK Wiper motor function 1. Disconnect the wiper motor connector 2. Connect the motor connector 2 C-4 to the battery (+) terminal and 3 C-4 to the (–) terminal, and then change the connection of the battery (+) terminal to the connector 6 C-4 while the motor rotating at a low speed 3. Check to see if the wiper motor stops at the auto stop position when connecting the connector terminals 2 C-4 and 5 C-4 in this condition

NG

OK Voltage between the wiper motor harness side connector terminal 6 C-4 and the ground (Should be battery voltage present) OK Continuity between the intermittent relay harness side connector 6 C-3 and the wiper motor harness side connector 5 C-4 OK

Intermittent relay function

NG


WASHER 1.

Washer motor does not operate Checkpoint

LHD: Fuse No. CB-8 (20A) RHD: Fuse No. CB-6 (20A)

Trouble Cause

Countermeasure


Reinstall or replace the fuse No. CB-8 (20A) (RHD: CB-6 (20A))

SW. malfunction



Repair or an open circuit or a poor connection of the connectors between the fuse No. CB-8 (20A) (RHD: CB-6 (20A)) and 1 C-43

NG


Repair or an open circuit or a poor connection of the connectors between 1 C-17 and 7 C-43

NG


Repair grounding point ( C-36 ) contact

Motor malfunction

Replace the washer motor



NG

OK Continuity between the wiper & washer SW. side connector terminals 1 C-43 and 7 C-43 when the washer button is depressed

NG

OK Voltage between the wiper & washer SW. harness side connector terminal 1 C-43 and the ground (Should be battery voltage present)

NG

OK Voltage between the washer motor harness side connector terminal 1 C-17 and the ground when the washer button is depressed (Should be battery voltage present) OK

Grounding point ( C-36 )

OK Washer motor function when connecting the motor side connector 1 C-17 to the battery (+) terminal, and the connector 2 C-17 to the (–) terminal (Should the washer motor rotate)

NG

OK Continuity between 2 C-17 and C-36

NG



WIPER AND WASHER SWITCH Removal

Refer to the removal steps of the LIGHTING SWITCH (COMBINATION SWITCH) in “LIGHTING” of this section.

825RV068

Installation

Follow the removal procedure in the reverse order to install the wiper and washer switch. Pay close attention to the important points mentioned in the following paragraphs.

Connector

Be absolutely sure that the wiper and washer switch connector is securely connected. This will prevent a poor contact and an open circuit.



Control Switch Connections

Terminal No. SW position

C-43

1 2 3

3

5

4

2

1

Mist

4 5 6

7 8 9 10

6

11 12 13 14

Off

Switch side

INT Lo Hi Wash

Wiper Motor Inspection Connector

3

2

1

6

5

4

825RV084

Low Speed Inspection

1. Clamp the wiper motor in a vise. The moving parts must be clear of the vise. 3

2

1

6

5

4

2. Connect the connector terminals to the battery. Refer to the illustration. 3. Check the wiper motor low speed operation.

825RV081

7

ELECTRICAL-BODY AND CHASSIS 8–189 High Speed Inspection


2

1

6

5

4

2. Connect the connector terminals to the battery. Refer to the illustration. 3. Check the wiper motor high speed operation.

825RV082

Auto-Stop Inspection


2

1

6

5

4

2. Connect the connector terminals to the battery. Refer to the illustration. 3. Check the wiper motor low speed operation. 4. Disconnect the positive battery terminal. This will stop the motor. 825RV081

5. Connect the connector terminals No. 2 and No. 5 with a lead wire. Refer to the illustration. 3

2

1

6

5

4

6. Reconnect the positive battery terminal to connector terminal No. 6. This will restart the motor. Refer to the illustration. 7. Check the auto-stop operation.

825RV080

Washer Motor Inspection

1. Fill the washer tank with washing solution. 2. Disconnect the motor connector. 3. Apply battery connector.

voltage

to

the

4. Check the washer motor operation.

825RV079

washer

motor


WIPER MOTOR AND LINKAGE Removal 2

1. Disconnect the wiper motor connector 1. 2. Remove the wiper motor bracket screws 2.

1 825RV069

3. Disconnect the wiper motor from the wiper linkage at the crank arm 3. 3

825RV070

4. Disconnect the wiper arm nut cap 4.

4

825RV071

5. Remove the wiper arm nut 5. 6. Remove the wiper arm with blade.

5

825RV072

7. Remove the vent cowl cover 6.

6

825RV073


8. Remove the wiper linkage 7 from the access hole. 7

825RV074

Installation

Follow the removal procedure in the reverse order to install the wiper motor and linkage. Pay close attention to the important points mentioned in the following paragraphs.

Wiper Linkage

Take care not to scratch the painted surfaces of the body when installing the wiper linkage to the body. In case crank arm of wiper motor is removed, confirm the position of auto stop prior to reinstall the crank a rm to the wiper motor. Crank Arm Nut Torque

kg·m (lb·ft/N·m)

1.4 ±0.2 (10 ± 1.4/13.7 ± 2.0)

Wiper Blade Position 2

Confirm the auto stop position of wiper motor prior to the installation of the wiper blade and arm.

1

The distance between the vent cowl cover rubber seal 1 and the wiper blade edge 2 is about 45 mm (1.8 in).

825RV075

Wiper Arm Nut

Tighten the wiper arm nut to the specified torque. Wiper Arm Nut Torque

kg·m (lb·ft/N·m)

1.4 ± 0.2 (10 ± 1.4/13.7 ± 2.0)

8–192 ELECTRICAL-BODY AND CHASSIS Windshield Washer Spray

Be sure that the engine hood 1 is completely closed before checking the windshield washer spray adjustment. Windshield Washer Spray Position A

A

mm (in)

Approximately 300 (11.8)

1

825RV076

Connector

Be absolutely sure that the wiper motor connector is securely connected. This will prevent a poor contact and an open circuit.

Note: Windshield wiper arm and blade assembly configurations are different for the right-hand and left-hand side of the vehicle. Be careful not to confuse the right-hand and left-hand side assemblies.

WASHER TANK MOTOR 1

Removal

2

1. Remove the washer tank bolts. 2. Disconnect the connector 1. 3. Disconnect the water hose 2.

825RV077

4. Remove the washer tank motor 3.

3

825RV078


Follow the removal procedure in the reverse order to install the washer tank motor. Pay close attention to the important points mentioned in the following paragraphs. Connector

Be absolutely sure that the washer tank motor connector is securely connected. This will prevent a poor contact and an open circuit.


OVERDRIVE OFF (A/T) PARTS LOCATION


B-24

H-6 H-7

C-58

C-2

C-79

C-41

D08RVA37


CIRCUIT DIAGRAM

STARTER SW

15B/R

+

MAIN 100A

IGN.B2 40A

P-2

OFF ACC

1 3W

C - 41

P-1

IG2

B1

IG1

ST

3

3 W/B

C - 41 P-5

B2

IGN.B1 40A

_

C - 41 6

5B/Y

R / B 3

Y / B 0 2

4 H-7

P-7

P - 10

FRAME

ENG.

R / B 3 CB-5 15A METER

Y 5 8 . 0

0.85Y

10 2

H-6

B-24

Y 5 8 . 0

Y 5 8 . 0

OVER DRIVE OFF INDICATOR LIGHT

B-24

Y 5 8 . 0 5

X -5

8 4

L / O 3 . 0

X-5

RELAY; OVERDRIVE OFF

4 H-6 X-5

X-5

3

W / G 5 8 . 0 1

2

L / O 5 . 0

0.3O/L

C-79

0.85G/R

RELAY;TAIL(1)

OVERDRIVE SOLENOID 2 C-58

3 C-58 OVER DRIVE OFF SW

C-58

C-58

4

B 5 . 0

FENDER-RH

C-2

1

B 5 . 0

2B

D08RV961



OVERDRIVE OFF SWITCH C-58

Overdrive Off Switch Connections

Terminal No. 1

2

3

4

2

4

1

SW position ON OFF

Switch side

OVERDRIVE OFF RELAY X-5 1

Check continuity between the relay terminals. 3 – 5 . . . . . . . . . . . . . . Continuity

3

4

3


5

1

3 – 5 . . . . . . . . . . . . . . No continuity

2

4

2

5

060RV005

3


TRANSMISSION CONTROL MODULE (TCM) PARTS LOCATION (RHD)

H-6 H-7

H-17

B-23 B-24

RELAY & FUSE BOX (X-18) C-2

E-60 E-61

C-95 C-41 C-96

P-11

C-36

C-98

C-102 E-72 C-94

E-68

H-26 M-15

E-74 H-15 H-22 H-23 H-38

M-25 H-20 H-25

M-17 M-7 M-6

D08RW543


CIRCUIT DIAGRAM (6VD1-W/TCM) STARTER SW

+

8B/R

EB-17 EB-16 40A 100A MAIN IGN B-2 P-11

OFF 1

3W C-41

B2

IG2

B1

IG1

6

3B/Y

3B/Y

H-7

ST 3 3W/B

P-5

_

EB-15 40A IGN B-1

B 5

8 C-41

P-1

B 0 3

ACC

5B 2W

C-41

EB-10 10A STOP LIGHT

6 C-41

4 3B/R

3B/R

H-7

CB-11 15A BUCK TURN

0.85W


0.5G

EB-14 20A ECM

0.85R/G

3R/G

EB-12 10A TCM

P-10 ENG

P-8

N I A X-18 M M C E ; Y A L X-18 E R

BODY FRAME

) 6 1 ( R K O T N I C L E A N T N A O D C

1

P M A L P O T S

G 5 . 0

B-44

C-44

R E W O P

L / R 3

B-24

R 5 . 0

R / B 5 . 0 16 H-6

R E T E M O H C A T

A4

D9

D12

D14

C1

D1

C-95

C-95

C-95

C-95

C-95

R B R / 5 . B 0 5 . 0 6 6 H-20

) 2 1 B ( M C E

B 5 . 0

8

7 H-26

W / R 5 . 0

L / O 5 . 0

21

T D16

B 5 8 . 0

P O T S E S U F

C

M C E

7 H-25

B 5 8 . 0

L / R 5 . 0

L / R 5 . 0

10

8

7

C-96

C-95

C-96

C-96

B9

C10

A8

A7

C8

C5

C6

C-95

C-95

C-95

32

8

0.5Y

B / Y 5 . 0

) 8 2 A ( M O E

M

Y 5 . 0

L 5 G 6 5 5 . . 0 0

0.8GR 1

0.8L

H-25

H-25

) 0 1 B (

) 9 1 B ( M C E

L / O 3 . 0

H-26

25 C-95

17

8

W / R 3 . 0

C-96

4

K S C N E A H R C T B-23

R 5 . 0

1

5

H-20

6

30

X-18

R / L 5 . 0

B-24

W S T H G I L P O T S

2

4

X-18

1

2

R 28 / B 5 . 0

3

2

P-7

R O T C 16 11 9 E N N C-102 C-102 C-102 O C K C-102 C-102 N I L 4 5 A T A B B D 5 5 . . 0 0

Y 5 . 0

0.8G

35 E-61

39 E-61

26 E-61

5

27 E-61

ECM

E-60 4

H-25

L 5 . 0

R G 5 . 0

E-61 1

6 E-68

I H B 5 2 . 1

3

H-25

2 E-68

T U O

3 E-68

O L

THROTTLE POSITION SENSOR 0.8B/R

COMMON CHAMBER

E-72

COMMON CHAMBER

E-74

FENDER-RH

C-36

0.8BR/L

D08RW541


2 0.85W

8 0.85W

H-6

0.75W

H-22

RELAY STARTER

5

4

M-25


MODE SW

M-25

M-25

M-25

M-25

M-25

2

8

7

6

3

L / R 5 7 . 0

Y / R 5 8 . 0

5 . 0

12

17

20

) 4 ( L I A T ; Y A L E R

L 5 . 0

1

WC-94 S N W O D K C I K C-94 2

Y / G 5 . 0

2

B 5 . 0

C-2

B 5 8 . 0

1 7 H-25 23

22

21

20

C-95

C-95

C-95

C-95

D7

D6

D5

D4

C7

C14

B3

C16

C15

A9

A2

C12

A3

B11

A12

B12

C-95

C-95

C-96

C-95

C-95

C-96

C-96

C-95

C-96

C-96

C-96

C-96

7

Y / R 5 . 0

14

15

16

G / R 5 8 . 0

R G 5 . 0

L 5 . 0

15

B / R 5 . 0

9

B / Y 5 . 0

2

12

23

12

1

2

5

8

16

13

14

6

H-23

H-38

H-38

H-23

H-23

H-23

H-23

H-23

H-23

Y / R 5 . 0

L 5 . 0

4 M-6

C-98 6

B 5 . 0

D I O N E L O S C C T

G / R 5 7 . 0

R G 5 . 0 5

M-6

3 M-6

R P O S M E N T E S

B / R 5 . 0 1

M-6

2 M-6 (+)

E R C O R T O O F M (-)

ADAPTOR CASE (T/MISSION)

B / Y 5 . 0 2

3

M-7

M-7

Y L P P A D N A B

B / R B 5 . 0

W / R B 5 . 0

G / Y 5 . 0

4 M-7

D I 4 - O 3 N , E 2 - L 1 O S

24

B / R B 5 . 0

W / R B 5 . 0

G / Y 5 . 0

3

12

C-98

1

B 5 . 0

BODY-RH

4

H-23

B / L 5 . 0

W / L 5 . 0

H-23

L / R B 5 . 0

L 5 . 0

P 5 . 0 9

W S C-98 R E T N I W & R E W O P C-98

7

H-23

H-17

D8

C-96

R / L 5 . 0

L 5 . 0

24

C-96

4

H-23

H-15

Y / R 5 8 . 0

C-95

B6

B 5 2 . 1

3

H-23

1

Y / R 5 8 . 0 4

P M A L K C A B

L / R B 5 . 0

B8

2

H-23

M-25

B / L 5 . 0

W / L 5 . 0

1

H-6

B5

R / L 5 . 0

12 L

H-22

L / R B 5 2 . 1

M-25

10

11

H-23

H-23

P 5 . 0

L 5 . 0

1 M-7

D I O N E L O S 3 2

MAIN CASE (T/MISSION)

1

2

M-15

M-15

+

-

MAGNETIC SENSOR

1.25B 0.8BR/L

E-74

D08RW542


METER, WARNING LIGHT AND INDICATOR LIGHT PARTS LOCATION (GASOLINE ENGINE – LHD)

B-24

C-39

M-10 H-20

F-1

B-23

H-8

H-5

C-38

H-2 C-37 M-11 M-12 P-11

E-3

H-6 H-7 C-36

C-41 H-15

R-4 R-3 B-28 H-9 H-21

D08RVA43


PARTS LOCATION (6VD1 GASOLINE ENGINE – LHD)

H-8

B-23

B-24

F-1

C-42 C-41 H-36

C-92

C-37

E-61

C-36 B-37 H-15 H-22

H-37

H-6 H-7

R-4 H-20

M-11 M-12 M-10 H-34 M-16

E-65

D08RW575


PARTS LOCATION (GASOLINE ENGINE – RHD)

H-6 H-7

B-23 B-24

C-38

F-1

C-37

H-5 C-2 (H-18)

C-39

H-20 H-2

C-41

M-10

M-11 M-12

B-28

P-11

E-3

H-15

C-36

H-8

R-4

H-9

D08RVA53


PARTS LOCATION (6VD1 GASOLINE ENGINE – RHD)

H-6 H-7

B-23 B-24 F-1

C-92

C-2

C-41

H-36

C-95.96

C-36 B-37

E-61 C-42

H-26

H-20 H-15

R-4

H-22 M-10 H-37

H-34 M-16

E-65

D08RW574


PARTS LOCATION (DIESEL ENGINE – LHD)

B-23

H-8

F-1 B-24

C-39 C-38

C-2 C-37 C-44 C-41

H-4 H-15 E-45 E-46

E-19 E-36

E-1

C-51 C-52

H-6 H-7 C-36

R-4 R-3 B-28 H-9 H-21

D08RVA42


PARTS LOCATION (DIESEL ENGINE – RHD)

H-6 H-7

B-23 B-24

C-38

F-1

C-37

C-2

C-39

C-41

E-44

B-28 E-19

E-36

E-45 E-46 E-1

H-15 C-51 C-52

C-36

H-8

R-4

H-9

D08RVA50


CIRCUIT DIAGRAM (W/O TACHOMETER – GASOLINE ENGINE (LHD)) STARTER SW OFF

ACC

B2

IG2

B1

IG1

ST 3 C-41

6 C-41

CB-7 15A METER

2 3 B/R

H-7

3 B/R

Y 5 8 . 0

B / W 3

ECM(C5)

Y 5 8 . 0

Y 5 8 . 0

IGN B1 40A

Y 5 8 . 0

7 H-6

W 3 . 0 P-2

1

P-1 P-5 _

Y / B 5B/Y 0 2

P-7

P-10 ENG.

7

B-23

2

B-23

) A I B A R A I D U A S ( Y R 5 E 8 . Z 0 Z U B G N I N R A W D E E P 3(MSG) S

+

FRAME

8

H-8

R / B 5 1

METER

B-24

V/R

L E U F

R E T E M O D E E P S

E G T U N A A G L O E O R C U E T A N R I G E N P E M E T

E ) R U A I T B A A R R E A P I D M E U T A L I S ( O

L I O

E G U A G L E U F

H-5 B-23

2(MUA)

9

B / L 5 . 0

B-24

B-23

6

5

B / Y 5 . 0

9

1

5(MUA)

B / Y 5 . 0

3

M-10

M-10

VEHICLE SPEED SENSOR M-10

T I ) N I U P O M 1 M R D Z E 4 H ( T

E-4

B / Y 5 . 0 1

10

T I N U K N A T L E U F

7 H-15

R / Y 5 . 0

P 5 . 0

F-1

B 5 . 0

B 5 8 . 0

H-6

1 H-2

B L 5 . 0 2

F-1

F-1

9

Y / R B 3 . 0 3

L 5 . 0

P 3 . 0

1

T I N U O M R E H T

3 H-8

H-15

1 C-71

2

1

W P-11 S E R U S S E R P L I O

D E E ) P 3 S ( E R N O I S G N N E E S

3

1

H-15

B 5 . 0 11

1 H-5

B 5 8 . 0

L 3 . 0

H-9

8

H-20

B-24

10

P 3 . 0

R / Y 5 . 0

12

7(MSG)

B-23

16

17

B / Y 5 . 0

H-5

B-23

11

H-9

H-8

B / L 5 . 0

B / L 5 . 0

R / Y 5 . 0

2

H-8

Y 5 8 . 0

B-23

H-9

B 5 8 . 0

0.85 B

11 H-6

FENDER-LH

C-36

1.25B

B 5 8 . 0

D08RV996


W S G W N S I N N R O I A T W A N D I B R A M Z O A C H

'97 TFR/S EXP.-LHD METER(DIE.W/O TACHO)-2


9

H-8

W / G 5 8 . 0

W / G 5 8 . 0 16

B-24

E R U S S E R P L I O

E K A R B

D W 4

B-23

B-24

10

L 3 . 0

R / L 3 . 0

H-8

H-8

B-23

15

16 3

B-23

B-24

L / 13 W 5 8 . 0

12

B / P 3 . 0

18 1

R / L 5 . 0 1

W S D W 4

W E-1 S E R U S S E R P L I O

E-46

B 1 5 . 0 B 5 8 . 0

Y / G 5 . 0

6 H-6

B / P 5 . 0

12

3 W S L C-37 E V E L D I U L F E K C-37 A R 1 B

G / P 5 . 0 2

C-37

1

C-38

W S M U U C A V

G / P 5 . 0 ) 2

C-2

FENDER-LH

C-36

BODY-LH

B-28

N O I T A N I M U L L I

M A E B H G I H

B-24

B-24

12

14

B 5 . 0 12 H-6

DIMMER PASSING SW

R-3

W S T L E B T A E S R-3

16 H-9 1

4 ( W C-39 S E K A R B G N I K R A P

B 5 . 0

B 5 8 . 0

FENDER-RH

13 B-24

1

G / P 5 . 0

H-4

B 5 2 . 1

11 B-24

B 5 8 . 0

0.5 P/G

H-6

E-45 1

R / G 5 8 . 0

B / R 5 . 0

1

2

L 5 . 0

1

1

Y / G 5 . 0

RELAY;CHARGE(5)

H-4 H-4

B-24

10

5 H-6

W / R 5 . 0

B-23

H R N R U T

H L N R U T

2 H-6

H-21

R / L 5 . 0

L 5 . 0

) TIMER A I T B L A E R B A T I A D E U S A S (

E G R A H C

8 B E E S U F

12

H-6

) 1 ( L I A T ; Y A L E R

B 5 2 . 1

G / P 5 . 0 ) 4 4 ( W R-4 S E K A R B G N I K R A P

2

B 5 . 0

1

11 H-9

B 5 8 . 0 H-6

B 2 11

4

B 5 2 . 1

B 5 2 . 1

H-9

B 5 8 . 0 B 2

(W/O POWER WINDOW)

D08RV998


CIRCUIT DIAGRAM (W/O TACHOMETER – GASOLINE ENGINE (RHD)) STARTER SW OFF

ACC

B2

IG2

B1

IG1

ST 3 C-41

6 C-41

CB-5 15A METER

4 3 B/R

H-7

3 B/R

Y 5 8 . 0

B / W 3

ECM(C5)

Y 5 8 . 0

Y 5 8 . 0

IGN B1 40A

Y 5 8 . 0

11 H-6

W 3 . 0 P-2

10

8

H-6

R / B 5 1

7

B-23

2

B-23

METER

B-24

V/R + P-1

L E U F

P-5 _

Y 5 8 . 0

Y / B 5B/Y 0 2

P-7

P-10

FRAME

ENG.

E G T U N A A L G O E O R C U E T A N I R E G P N M E E T


L I O

E G U A G L E U F

3(MSG) H-5 B-23

2(MUA)

9

B-24

B-23

6

5

B / Y 5 . 0

B / L 5 . 0 22

12

7(MSG)

1

B / Y 5 . 0

3

M-10

T I ) N I U P O M 1 M E R Z E 4 H ( T

M-10


E-4

B / Y 5 . 0 1

10

L 5 . 0

P 3 . 0 7 H-15

R / Y 5 . 0

P 5 . 0


2

F-1

F-1

B 5 . 0

B 5 8 . 0

F-1

1 H-2

B L 5 . 0 2

1

T I N U O M R E H T

7 H-6

H-15

1 C-71

10

L 3 . 0

H-9

8

H-20

5(MUA)

P 3 . 0

R / Y 5 . 0

B-23

16

17

B / Y 5 . 0

H-5

B-23

11

H-9

H-6

B / L 5 . 0

B / L 5 . 0

R / Y 5 . 0

17

H-6

Y 5 8 . 0

B-23

1


3

1

H-15

B 5 . 0 11

1 H-5

H-9

B 5 8 . 0

B 5 8 . 0

0.85 B

5 H-8

C-2

FENDER-RH FENDER-LH

C-36

0.85 B

D08RV997


W S G W I S N N N O R I A T W A N I D B R A M Z O A C H


2

9

H-8

H-6

W / G 5 8 . 0

W / G 5 8 . 0 16

B-24

E N I G N E K C E H C

B-24

B-24

9

R / L 5 . 0 15

8 H-8

B-24

B / P 5 . 0

R / L 5 . 0

1

11 B-24

13 B-24


M A E B H G I H

B-24

B-24

12

14

B 5 . 0

B 5 8 . 0

0.5 P/G

H-6

R / G 5 8 . 0

B / R 5 . 0

AC GENERATOR(L)

20

4 H-8

W / R 5 . 0

1

H-6

) 9 B ( M C E

5

3 H-8

H-6 5(MSG)

H-5 4(MUA)

R / L 5 . 0 1 M-11

W S D W 4 M-12

B 5 . 0 B 5 8 . 0 H-5

BODY-RH

B-23

L / 13 W 5 8 . 0

12

9 H-8

B-23

H R N R U T

H L N R U T

B-23

15

Y / R B 3 . 0

FENDER-RH

E G R A H C

E K A R B

D W 4

) 1 ( L I A T ; Y A L E R

8 B E E S U F

C-2

1

B / P 5 . 0

3 W S L C-37 E V E L

D I U L F E K C-37 A R 1 B B 5 . 0

1

B 5 2 . 1

G / P 5 . 0

G / P 5 . 0 2

C-37

1

C-38

W S M U U C A V

G / P 5 . 0 ) 2

DIMMER PASSING SW 16 H-9

W ( G / R 5 . 0

1



) R E L L O R T N O C N O I T A N I M U L L I /

1

B 5 2 . 1

B 5 2 . 1

) N 3 ( O R I T E A L L N O I R M T U N L O L I C

1.25 B

B-28

D08RV999


CIRCUIT DIAGRAM (W/O TACHOMETER – DIESEL ENGINE (LHD)) STARTER SW OFF

ACC

B2

IG2

B1

IG1

ST 3 C-41

6 C-41

CB-7 15A METER

2 3 B/R

H-7

3 B/R

Y 5 8 . 0

B / W 3

IGN B1 40A

Y 5 8 . 0

Y 5 8 . 0

Y 5 8 . 0

P-2

1

2

7

H-8

R / B 5 1

METER

B-24

B-23

V/R + P-1

L E U F

P-5 _

Y 5 8 . 0

Y / B 5B/Y 0 3

P-7

P-10

FRAME

ENG.



R E T N E M I D E S

W O L G

E G U A G L E U F

5 H-4 B-23

B-24

B-23

6

5

9

B / L 5 . 0 9

B-23

R / Y 5 . 0 17

B / Y 5 . 0 2

H-8

B-23

11

H-9

16

P 3 . 0

B-24

L / O 3 . 0

10 H-9

B-24

8

1

9

Y / R B 5 . 0

H-6

H-8

B / L 5 . 0

Y 5 8 . 0

11

B / Y 5 . 0

H-4

R / Y 5 . 0 4

H-4

B / L 5 . 0 1

3

E-44

E-44

VEHICLE SPEED SENSOR E-44 2

B / Y 5 . 0 T I N U K N A T L E U F

E-19

C-2

FENDER-LH

P 5 . 0

F-1

Y / R B 5 . 0

2 F-1

F-1

QOS-II CONTROL UNIT(7)

1

WC - 51 S R E T L I F L E U F C - 52 1

3

1

B 5 . 0

B 5 . 0 11

H-4

FENDER-RH

R / Y 5 . 0

H-15

12

5 2 . 1

7 H-15

B 5 . 0

B 5 8 . 0

B 5 8 . 0

8

H-6

H-15

1

1

T I N U O M R E H T

3

P 3 . 0

H-9

B 5 8 . 0

0.85 B

11 H-6

B 5 2 . 1

B 5 8 . 0

C-36

D08RVA03


W S G W I S N N N R O I A T W A N D I B R A M Z O A C H

W S G W I S N N N R O I A T W A N D I B R A M Z O A C H

9

H-8

W / G 5 8 . 0

W / G 5 8 . 0 16

B-24


E K A R B

D W 4

B-23

B-24

10

L 3 . 0

R / L 3 . 0

H-8

H-8

B-23

15

16 3

B-23

B-24

L / 13 W 5 8 . 0

12

B / P 3 . 0

18 1

R / L 5 . 0 1

W S D W 4


E-46

B 1 5 . 0 B 5 8 . 0

Y / G 5 . 0

6 H-6

B / P 5 . 0

12


G / P 5 . 0 2

C-37

1

C-38

W S M U U C A V

G / P 5 . 0 ) 2

C-2

FENDER-LH

C-36

BODY-LH

B-28


M A E B H G I H

B-24

B-24

12

14

B 5 . 0 12 H-6

DIMMER PASSING SW

R-3


16 H-9 1


B 5 . 0

B 5 8 . 0

FENDER-RH

13 B-24

1

G / P 5 . 0

H-4

B 5 2 . 1

11 B-24

B 5 8 . 0

0.5 P/G

H-6

E-45 1

R / G 5 8 . 0

B / R 5 . 0

1

2

L 5 . 0

1

1

Y / G 5 . 0

RELAY;CHARGE(5)

H-4 H-4

B-24

10

5 H-6

W / R 5 . 0

B-23

H R N R U T

H L N R U T

2 H-6

H-21

R / L 5 . 0

L 5 . 0


E G R A H C

8 B E E S U F

12

H-6

) 1 ( L I A T ; Y A L E R

B 5 2 . 1


2

B 5 . 0

1

11 H-9

B 5 8 . 0 H-6

B 2 11

4

B 5 2 . 1

B 5 2 . 1

H-9

B 5 8 . 0 B 2

(W/O POWER WINDOW)

D08RVA05


CIRCUIT DIAGRAM (W/O TACHOMETER – DIESEL ENGINE (RHD)) STARTER SW OFF

ACC

B2

IG2

B1

IG1

ST 3 C-41

6 C-41

CB-5 15A METER

4 3 B/R

H-7

3 B/R

Y 5 8 . 0

B / W 3

Y 5 8 . 0

Y 5 8 . 0

IGN B1 40A

P-2

10

7

H-6

R / B 5 1

Y 5 8 . 0

2

B-23

METER

B-24

V/R + P-1 P-5 _

Y 5 8 . 0

Y / B 5B/Y 0 3

P-7

P-10

FRAME

ENG.

T L E B G N I M I T

L E U F


E G T U N A A G L O E O R C U E T A N R I G E P N M E E T

E G U A G L E U F

R E T N E M I D E S

W O L G

5 H-4 B-23

B-24

B-23

6

5

9

B / L 5 . 0 22

R / Y 5 . 0 17

B / Y 5 . 0

H-6

H-9

H-6

11 H-4

B-23

11

17

B / L 5 . 0

Y 5 8 . 0

B-23

R / Y 5 . 0

B / Y 5 . 0 4

16

P 3 . 0 10 H-9

1

3

E-44

E-44

VEHICLE SPEED SENSOR E-44 2

B / Y 5 . 0 T I N U O M R E H T


E-19

B 5 8 . 0

8

8

7 H-15

R / Y 5 . 0

P 5 . 0

C-2

FENDER-RH FENDER-LH

Y / R B 5 . 0

2 F-1

F-1


1

WC - 51 S R E T L I F L E U FC - 52 1

3

1

B 5 . 0

B 5 . 0 11

H-4

5 2 . 1

F-1

H-15

12

B 5 8 . 0

9

Y / R B 5 . 0

H-8

H-15

B 5 . 0

14

P 3 . 0

1

1

L / O 3 . 0

B-24

8

H-6

H-4

B / L 5 . 0

B-24

H-9

B 5 8 . 0

0.85 B

5 H-8

B 5 2 . 1

B 5 8 . 0

C-36

D08RVA06




2

9

H-8

H-6

W / G 5 8 . 0

W / G 5 8 . 0 16

B-24


B-23

B-24

10

L 3 . 0

R / L 3 . 0

H-6

H-6

R / G 5 8 . 0

W / R 5 . 0 1

11 B-24

13 B-24


M A E B H G I H

B-24

1

B-24

12

14

B / R 5 . 0

RELAY;CHARGE(5) OR AC GENERATOR(L) 20

1

B-24

L / 13

4 H-8

W 5 8 . 0

B / P 3 . 0

R / L 5 . 0

L 5 . 0

B-23

12

9 H-8

B-23

H R N R U T

H L N R U T

B-23

15

15 7

E G R A H C

E K A R B

D W 4

) 1 ( L I A T ; Y A L E R

8 B E E S U F

H-6

H-4

B 5 . 0

B 5 8 . 0

0.5 P/G 5

3 H-8

H-6

2

R / L 5 . 0

H-4

1

L 5 . 0

B / P 5 . 0

E-45

W S D W 4

1


E-46

B 1 5 . 0 B 5 8 . 0

12


B 5 . 0

H-4

B 5 8 . 0 B 5 2 . 1 FENDER-RH BODY-RH

B 5 2 . 1

G / P 5 . 0

G / P 5 . 0 2

C-37

1

C-38

W S M U U C A V

G / P 5 . 0 ) 2

DIMMER PASSING SW 16 H-9 1



1

B 5 2 . 1

B 5 2 . 1

C-2 B-28

D08RVA07


CIRCUIT DIAGRAM (W/ TACHOMETER – GASOLINE ENGINE (LHD)) STARTER SW OFF

ACC

B2

IG2

B1

IG1

ST 3 C-41

6 C-41

CB-7 15A METER

2 3 B/R

3 B/R

H-7

Y 5 8 . 0

B / W 3

ECM(C5)

Y 5 8 . 0

Y 5 8 . 0

IGN B1 40A

7 H-6

W 3 . 0 P-2

1

R / B 5 1

P-1 P-5 _

Y / B 5B/Y 0 2

P-7

P-10 ENG.

2

B-23

METER

B-24

) A I B A R A I D U A S ( Y R 5 E 8 . Z 0 Z U B G N I N R A W D E E P 3(MSG) S

+

FRAME

8

H-8

L E U F


E G T U N A A G L O E O R C U T E A N I R G E N P E M E T

R E T E M O H C A T

E ) R A U I T B A A R R E A P I D M E U T A L ( S I O

L I O

E G U A G L E U F

H-5 B-23

2(MUA)

9

B / L 5 . 0

B-24

B-24

B-23

3

6

5

R / B 5 . 0

9 H-8

7

7(MSG)

12

1

5(MUA)

3

M-10

M-10

VEHICLE SPEED SENSOR

D E E ) P 1 S ( E R O N I S G N N E E S

R / B 5 . 0 15 H-20

L 5 . 0

M-10 2

B 5 8 . 0

B / Y 5 . 0 T I ) N I U P O M 1 M R D E Z 4 H ( T

E-4

B / Y 5 . 0 1

7 H-15

R / Y 5 . 0

P 5 . 0


) I N P O ) I 2 M T I ( L 1 D N I O Z G I C 4 (

F-1

F-1

B 5 . 0

9

Y / R B 3 . 0 3 H-6

1 H-2

B L 5 . 0 2

1

T I N U O M R E H T

B-24

L 5 . 0

P 3 . 0

F-1

3 H-8

H-15

1 C-71

1


D E E ) P 3 S ( E R O N I S G N N E E S

3

1

H-15

B 5 . 0 11

1 H-5

B 5 8 . 0

10

8

H-20

10

L 3 . 0

H-9

R / Y 5 . 0

B-23

16

P 3 . 0

H-9

B / Y 5 . 0

R / B 5 . 0

B-23

11

17

H-8

H-5

B / L 5 . 0

R / Y 5 . 0

2

H-8

B / L 5 . 0

Y 5 8 . 0

B / Y 5 . 0

B-23

H-9

B 5 8 . 0

0.85 B

11 H-6

FENDER-LH

C-36

1.25B

B 5 8 . 0

D08RV993


W S G W N S I N N O R I A T W A N D I B R A M Z O A C H

W S G W N S I N N O R I A T W A N D I B R A M Z O A C H

9

12

H-6

H-8

W / G 5 8 . 0

W / G 5 8 . 0 16

B-24


E K A R B

D W 4

B-24

B-24

9

Y / R B 3 . 0

B-23

15

R / L 5 . 0 3

16


E G R A H C

B-23

B-24

L 13 / W 5 8 . 0

12

B / P 5 . 0

AC GENERATOR(L)

18

5(MSG) H-5 4(MUA)

R / L 5 . 0 1 M-11

W S D W 4 M-12

H-5

FENDER-LH

C-36

BODY-LH

B-28

1.25 B

3 B-23

13 B-24

14 B-23


M A E B H G I H

B-23

B-24

4

B-23

14

1

B / P 5 . 0


B 5 . 0

B 5 8 . 0

Y / G 5 . 0

6 H-6

B 5 8 . 0

1

0.85 G/R

15

B / R 5 . 0

1

0.5 P/G

H-6

B 5 . 0

R / G 5 8 . 0

H-21

R / L 5 . 0

) 9 B ( M C E

5 H-6

W / R 5 . 0

1

Y / G 5 . 0

H-8

H-6

B-24

10

2 H-6

B-23

H R N R U T

H L N R U T

) 1 ( L I A T ; Y A L E R

8 B E E S U F

B 5 . 0

12 H-6

1

G / P 5 . 0

G / P 5 . 0 2

C-37

1

C-38

W S M U U C A V

G / P 5 . 0 ) 2

DIMMER PASSING SW

R-3


16 H-9 1


B 5 . 0

1

B 5 2 . 1 (W/O POWER WINDOW)


2

B 5 . 0

1

11 H-9

B 5 8 . 0 H-6

B 2 11

4

B 5 2 . 1

B 5 2 . 1

H-9

B 5 8 . 0 B 2

D08RV994


CIRCUIT DIAGRAM (W/ TACHOMETER – GASOLINE ENGINE 6VD1 – LHD) STARTER SW OFF

ACC

B2

IG2

B1

IG1

ST 3 C-41

6 C-41

CB-7 15A METER

2 3 B/R

H-7

3 B/R

Y 5 8 . 0

M C E

B / W 3

32 E-61

W 5 . 0 Y 5 8 . 0

IGN B1 40A

5

Y 5 8 . 0

H-20

W 5 . 0

7

H-6

H-8

R / B 5 1

P-1 P-5 _

Y 5 8 . 0

Y / B 5B/Y 0 2

P-7

P-10 ENG.

8

2

B-23

+

FRAME

W 3 . 0

1

P-11

7

METER

B-24

) A I B A R A I D U A S ( R E Z Z U B G N I N R A W D E E P S

L E U F


R E T E M O H C A T

E G T U N A A G L O E O R C U E T A N I R G E N P E M E T

L I O

E G U A G L E U F

H-22 B-23 9

B / L 5 . 0

B-24

B-24

B-23

3

6

5

R / B 5 . 0

9 H-8

11

E-61

M-10

VEHICLE SPEED SENSOR M-10 2

B / Y 5 . 0

M C E

T I N U O M R E H T

10

L 3 . 0 3 H-8 7

8

H-15

L 5 . 0

15

2 H-22

R / Y 5 . 0

1

P 5 . 0


F-1

F-1

F-1

B 5 . 0

B L 5 . 0 2

1

E-65

B 5 8 . 0

1

W M-16 S E R U S S E R P L I O

3

1

H-15

B 5 . 0

6 H-22

B 5 8 . 0

B-23

16

P 3 . 0

H-15

H-20

12 3

M-10

6 H-20

B / L 5 . 0

R / Y 5 . 0

H-6

B / Y 5 . 0

B-23

11

22

R / B 5 . 0

H-22

1

7 H-8

B / L 5 . 0

Y 5 8 . 0

B / Y 5 . 0

B-23

11 B-37

B 5 8 . 0 11 H-6

FENDER-LH

C-36

1.25B

B 5 8 . 0

D08RW572-1




4

5 C-42

C-42

9

12

H-6

H-8

B / G 5 8 . 0

W / G 5 8 . 0 16


B-24

B-24

9

B-23

15

Y / R B 3 . 0

R / L 5 . 0 3

18

3

H-20

H-22

Y / R B 5 . 0

R / L 5 . 0

H-8

W S D W 4 M-12

B 5 8 . 0

1

BODY-RH

B-9

BODY-LH

B-28

2 W S L C-92 E V E L

D I U L F E K C-92 A R 1 B B 5 . 0

B-23

B-24

B-23

14

4

15

B 5 . 0

B 5 . 0

12 H-6

1 H-36

H-34

PASSING SW

1 H-37

G C A W S E R-4 K A R B G N I K R A P

1

B 5 2 . 1

B 5 2 . 1

9

H-22

C-36

H-6

13

M-11

B 5 . 0

6

14 B-23


DIMMER

1

M C E

B / P 5 . 0

13 B-24

M A E B H G I H

B 5 8 . 0

14

E-61

3

0.5 G/R

B / R 5 . 0

15

H-6

R / G 5 . 0

B-23

1

L / W 5 8 . 0

R / L 5 . 0

18

B-24

13

B / P 5 . 0

H-8

Y / R B 5 . 0

B-23

5 H-6

W / R 5 . 0

B-23

H R N R U T

H L N R U T

12

16

H-6

FENDER-LH

E G R A H C

E K A R B

D W 4

2 H-6

1

B-24

) 1 ( L I A T ; Y A L E R

8 B E E S U F

B 5 2 . 1

1.25 B

D08RW571


CIRCUIT DIAGRAM (W/ TACHOMETER – GASOLINE ENGINE (RHD)) STARTER SW OFF

ACC

B2

IG2

B1

IG1

ST 3 C-41

6 C-41

CB-5 15A METER

4 3 B/R

3 B/R

H-7

Y 5 8 . 0

B / W 3

ECM(C5)

Y 5 8 . 0

Y 5 8 . 0

IGN B1 40A

11 H-6

W 3 . 0 P-2

10

8

H-6

R / B 5 1

2

B-23

METER

B-24

+ P-1

L E U F

P-5 _

Y 5 8 . 0

Y / B 5B/Y 0 2

P-7

P-10

FRAME

ENG.


E G T U N A A G L O E O R C U T E A N R I G E P N M E E T

R E T E M O H C A T

L I O

E G U A G L E U F

3(MSG) H-5 B-23

2(MUA)

9

(A/T)

B / L 5 . 0 10

22

H-6

Y 5 8 . 0

H-6

2

3

H-18

H-18

Y 5 . 0

B / L 5 . 0 1

M-10

M-10


5

R / B 5 . 0

B / Y 5 . 0

16

7(MSG)

1

5(MUA)

M-10

17

D E E ) P 1 S ( E R N O I S G N N E E S

15 H-20

L 5 . 0

2

B 5 8 . 0

C-18

B 5 8 . 0

B / Y 5 . 0 T I ) N I U P O M 1 M E R Z E 4 H ( T

E-4

T I N U O M R E H T


) I N P O ) M I 2 T ( I L 1 E N I Z O 4 G C ( I

L 5 . 0 7

H-15

R / Y 5 . 0

P 5 . 0

F-1

1 H-2

B L 5 . 0 2

F-1

F-1

B 5 . 0

7 H-6

P 3 . 0

1

1


3

1

H-15

B 5 . 0 11

H-5

H-9

B 5 8 . 0

C-2

B 5 8 . 0

FENDER-RH

10

H-15

1 C-71

1

B 5 2 . 1

L 3 . 0

H-9

8

1

10

P 3 . 0

R / Y 5 . 0

B / Y 5 . 0

B-23

16

17

12

R / B 5 . 0

B-23

11

H-9

B / Y 5 . 0

R / B 5 . 0

M-10

2

B 5 8 . 0 1

R / Y 5 . 0

H-20

3

M-10

B-23

H-6

H-5


M-10

B-23

6

H-6

B / L 5 . 0

Y 5 8 . 0

B / L 5 . 0 3

B-24

3

22

H-6

B / L 5 . 0

B-24

0.85 B

5 H-8

FENDER-RH

C-2

FENDER-LH

C-36

0.85 B

D08RV992




2

9

H-8

H-6

W / G 5 8 . 0

W / G 5 8 . 0 16

B-24


D W 4

B-24

B-24

9

B-23

15

Y / R B 3 . 0

R / L 5 . 0 15

8 H-8

F F ) O A I E L V A I R R D T S R U E A V ( O

E G R A H C

E K A R B

B-24

B-23

L / 13 W 5 8 . 0

12

B / P 5 . 0

AC GENERATOR(L)

R / G 5 8 . 0

1

3 B-23

0.85 G/R

13

14

B-24

B-23


M A E B H G I H

B-23

B-24

4

B-23

14

15

B 5 . 0

B / R 5 . 0

4

4 H-8

W / R 5 . 0

1

L / O 3 . 0

H-6

B 5 . 0

H-6 20

R / L 5 . 0

) 9 B ( M C E

B-24

8

9 H-8

B-23

H R N R U T

H L N R U T

) 1 ( L I A T ; Y A L E R

8 B E E S U F

B 5 8 . 0

0.5 P/G

H-6

5

3 H-8

H-6 5(MSG) H-5 4(MUA)

R / L 5 . 0 1 M-11

W S D W 4 M-12

B 5 . 0 B 5 8 . 0 H-5

FENDER-RH

C-2

BODY-RH

B-28

1.25 B

1

B / P 5 . 0


B 5 . 0

1

B 5 2 . 1

G / P 5 . 0

G / P 5 . 0 2

C-37

1

C-38

W S M U U C A V

G / P 5 . 0 ) 2

16 H-9

E ) V ( I 2 R W D S R F E F V O O

DIMMER PASSING SW

0. 5R/G

1



B 5 . 0 1

B 5 2 . 1

B 5 2 . 1

N ) O R I T E A L L N I O R M U T L N L I / O C W (

) 3 N ( O R I T E A L L N O I R M T U N L O L I C

D08RV995


CIRCUIT DIAGRAM (W/ TACHOMETER – GASOLINE ENGINE 6VD1 – RHD) STARTER SW OFF

ACC

B2

IG2

B1

IG1

ST 3 C-41

6 C-41

CB-5 15A METER

4 3 B/R

H-7

3 B/R

Y 5 8 . 0

B / W 3

ECM(C5)

Y 5 8 . 0

Y 5 8 . 0

IGN B1 40A

11 H-6

W 3 . 0 P-11

10

8

H-6

R / B 5 1

2

B-23

METER

B-24

+ P-1

L E U F

P-5 _

Y 5 8 . 0

Y / B 5B/Y 0 2

P-7

P-10

FRAME

ENG.

E V I R D R E W O P


R E T E M O H C A T


S N A R T K C E H C

L I O

E G U A G L E U F

7 H-22 B-23 9

B / L 5 . 0 22 H-6

11 H-22

B-23

6

5

R / B 5 . 0

B / Y 5 . 0

16

B-23

11

R / Y 5 . 0

16

M C E T I N U O M R E H T

M-10


H-15

H-15

R / Y 5 . 0

P 5 . 0

15

1

E-65

7


2

F-1

F-1

F-1

8

7

L 5 . 0 C-96

2 H-22

10 C-95

L 5 . 0 1

2

1

B 5 8 . 0

B-24

H-26

H-6

21

H-20

B / Y 5 . 0

10

8 7

8

B-23

6

H-26

B / Y 5 . 0

R / B 5 . 0 6

B-23

L 5 . 0

P 3 . 0

H-6

3

M-10

B-23

17

H-20

B / L 5 . 0 1

B-24

3

H-6

B / L 5 . 0

Y 5 8 . 0

B-24

) T / A 1 D V 6 ( M C T

W M-16 S E R U S S E R P L I O

) T / A 1 D V 6 ( M C T

3

B 5 . 0

B 5 8 . 0

1 6

H-15

H-22

B 5 8 . 0

5

B 5 . 0

H-26 FENDER-LH

C-36

CHASSIS

B-37

0.85 B

D08RW558




4

5 C-42

C-42

B / G 5 8 . 0

W / G 5 8 . 0 2

9

B / G 5 8 . 0

16

E G R A H C

B-24

B-23

9

B-23

Y / R B 3 . 0 13

20

3

H-6

14

B / P 5 . 0

H-20

Y / R B 5 . 0


8 E-61

H-6

B 5 . 0

13 B-24

14 B-23

B-23

B-24

4

B-23

14

B 5 . 0

15

B 5 . 0

15 H-26

L / W 5 8 . 0

G / P 5 . 0

5

H-6

1

DIMMER

H-36

L / W 5 8 . 0

G / P 5 . 0 13 H-34

PASSING SW

T N O C I M U L L I

1 H-37

G / P 5 . 0 1 R-4

M C E

B 5 8 . 0

0.5 G/R


M A E B H G I H

B / R 5 . 0

H-26

Y / R B 5 . 0

3 B-23

1

L / W 5 8 . 0

B / P 5 . 0

R / G 5 8 . 0

1

B-24

13

14 H-26

W / R 5 . 0

B-23

H R N R U T

H L N R U T

12

H-26

W / G 5 8 . 0

B-24

E K A R B

4

H-6

H-26


) 1 ( L I A T ; Y A L E R

1 1 B E E S U F


B 5 2 . 1

B 5 2 . 1 FENDER-RH

C-2

BODY-LH

B-9

D08RW573


CIRCUIT DIAGRAM (W/ TACHOMETER TACHOMETER – DIESEL ENGINE (LHD)) STARTER SW OFF

ACC

B2

IG2

B1

IG1

ST 3 C-41

6 C-41

CB-7 15A METER

2 3 B/R

H-7

3 B/R

Y 5 8 . 0

B / W 3

Y 5 8 . 0

Y 5 8 . 0

IGN B1 40A

P-2

1

2

H-8

R / B 5 1

METER

B-24

+ P-1

L E U F

P-5 _

Y 5 8 . 0

Y / B


5B/Y 0 3

P-7

P-10

FRAME

ENG.

R E T E M O H C A T

E G T U N A A G L E O R O C U T E A N R I G E P N M E E T

R E T N E M I D E S

W O L G

E G U A G L E U F

5 H-4 B-23 9

B / L 5 . 0 9

5

H-8

H-4 11

R / B 5 . 0 1

H-4

B / L 5 . 0

E-36

1

3 E-44

VEHICLE SPEED SENSOR E-44

R O S N E S O H C A T

2

B-23

R / Y 5 . 0 17 2

H-9

B / Y 5 . 0

R / Y 5 . 0 4

H-4

B / Y 5 . 0

C-2

FENDER-RH FENDER-LH

P 3 . 0

B-24

L / O 3 . 0

B-24

8

10 H-9

1

9

Y / R B 5 . 0

H-6

T I N U O M R E H T

3

P 3 . 0 8

E-19

7 H-15

R / Y 5 . 0

P 5 . 0

F-1


Y / R B 5 . 0

2 F-1

F-1

B 5 . 0

0.5 B

H-6

H-15

1


1

WC - 51 S R E T L I F L E U F C - 52 1

3

1

H-15

B 5 . 0

B 5 . 0 11

H-4

B 5 2 . 1

16

H-8

12

B 5 8 . 0

B-23

11

B / Y 5 . 0

1

E-36

2

B 5 8 . 0

B-23

6

R / B 5 . 0 7

B / L 5 . 0

E-44

B-24

R 3 /

B 5 . 0 7

H-8

Y 5 8 . 0

B-24

H-9

B 5 8 . 0

0.85 B

11 H-6

B 5 2 . 1

B 5 8 . 0

C-36

D08RVA00


W S G W I S N N N R O A I T W A N D I B R A M Z O A C H


9

H-8

W / G 5 8 . 0

W / G 5 8 . 0 16

B-24


E K A R B

D W 4

B-23

B-24

10

L 3 . 0

R / L 3 . 0

H-8

H-8

B-23

15

16 3

B-23

B-24

L 13 / W 5 8 . 0

12

B / P 3 . 0

18 1

R / L 5 . 0 1

W S D W 4


E-46

B 1 5 . 0 B 5 8 . 0

Y / G 5 . 0

6 H-6

B / P 5 . 0

12


G / P 5 . 0 2

C-37

1

C-38

W S M U U C A V

G / P 5 . 0 ) 2

C-2

FENDER-LH

C-36

BODY-LH

B-28


B-23

B-24

4

B-23

14

15

B 5 . 0

B 5 . 0

12 H-6

DIMMER PASSING PASSING SW

R-3


16 H-9 1


B 5 . 0

B 5 8 . 0

FENDER-RH

14 B-23

1

G / P 5 . 0

H-4

B 5 2 . 1

13 B-24

M A E B H G I H

B 5 8 . 0

0.5 P/G

H-6

E-45 1

3 B-23

0.85 G/R

B / R 5 . 0

1

2

L 5 . 0

R / G 5 8 . 0

1

1

Y / G 5 . 0

RELAY;CHARGE(5)

H-4 H-4

B-24

10

5 H-6

W / R 5 . 0

B-23

H R N R U T

H L N R U T

2 H-6

H-21

R / L 5 . 0

L 5 . 0

) TIMER A I T L B E A B R A T I A D E U S A S (

E G R A H C

8 B E E S U F

12

H-6

) 1 ( L I A T ; Y A L E R

B 5 2 . 1


2

B 5 . 0

1

11 H-9

B 5 8 . 0 H-6

B 2 11

4

B 5 2 . 1

B 5 2 . 1

H-9

B 5 8 . 0 B 2

(W/O POWER WINDOW)

D08RVA01


CIRCUIT DIAGRAM (W/ TACHOMETER TACHOMETER – DIESEL ENGINE (RHD)) STARTER SW OFF

ACC

B2

IG2

B1

IG1

ST 3 C-41

6 C-41

CB-5 15A METER

4 3 B/R

H-7

3 B/R

Y 5 8 . 0

B / W 3

Y 5 8 . 0

Y 5 8 . 0

IGN B1 40A

P-2

10

2

H-6

R / B 5 1

METER

B-24

+ P-1 P-5 _

Y 5 8 . 0

Y / B


5B/Y 0 3

P-7

P-10

FRAME

ENG.

T L E B G N I M I T

L E U F

R E T E M O H C A T

E G T U N A A G L E O R O C U T E A N R I G E P N M E E T

R E T N E M I D E S

W O L G

E G U A G L E U F

5 H-4 B-23 9

B / L 5 . 0 22

5

H-4

R / B 5 . 0 1

H-4

B / L 5 . 0

E-36

1

3 E-44

VEHICLE SPEED SENSOR E-44

R O S N E S O H C A T

17

H-9

H-6

B / Y 5 . 0

R / Y 5 . 0 4

H-4

B / Y 5 . 0

2

T I N U O M R E H T

E-19

C-2

FENDER-RH FENDER-LH

P 3 . 0 10 H-9

0.5 B

B-24

L / O 3 . 0

B-24

8

14

9

Y / R B 5 . 0

H-6 8

P 3 . 0 8

H-8 7

H-15

H-15

R / Y 5 . 0

P 5 . 0

F-1


Y / R B 5 . 0

2 F-1

F-1

B 5 . 0

1

WC - 51 S R E T L I F L E U F C - 52 1

3

1

H-15

B 5 . 0

B 5 . 0 11

H-4

5 2 . 1

16

1


12

B 5 8 . 0

B-23

11

R / Y 5 . 0 17

1

E-36

2

B-23

B / Y 5 . 0

H-6

11

B 5 8 . 0

B-23

6

R / B 5 . 0 7

B / L 5 . 0

E-44

B-24

R 3 /

B 5 . 0 16

H-6

Y 5 8 . 0

B-24

H-9

B 5 8 . 0

0.85 B

5 H-8

B 5 2 . 1

B 5 8 . 0

C-36

D08RVA02




2

9

H-8

H-6

W / G 5 8 . 0

W / G 5 8 . 0 16

B-24


D W 4

B-23

B-24

10

L 3 . 0

R / L 3 . 0

H-6

H-6

B / P 3 . 0

R / L 5 . 0

L 5 . 0

R / G 5 8 . 0

1

3 B-23

0.85 G/R

13 B-24

14 B-23


M A E B H G I H

B-23

B-24

4

B-23

14

15

B / R 5 . 0 B 5 . 0

B 5 8 . 0

0.5 P/G

H-6

H-4

4 H-8

W / R 5 . 0

1

RELAY;CHARGE(5) OR AC GENERATOR(L) 20

1

B-24

B-23

L 13 / W 5 8 . 0

12

9 H-8

B-23

H R N R U T

H L N R U T

B-23

15

15 7

E G R A H C

E K A R B

) 1 ( L I A T ; Y A L E R

8 B E E S U F

5

B 5 . 0

3 H-8

H-6

2

R / L 5 . 0

H-4

1

L 5 . 0

B / P 5 . 0

E-45

W S D W 4

1


E-46

B 1 5 . 0 B 5 8 . 0

12


B 5 . 0

H-4

B 5 8 . 0 B 5 2 . 1 FENDER-RH BODY-RH

B 5 2 . 1

G / P 5 . 0

G / P 5 . 0 2

C-37

1

C-38

W S M U U C A V

G / P 5 . 0 ) 2

DIMMER PASSING PASSING SW 16 H-9 1



1

B 5 2 . 1

B 5 2 . 1

C-2 B-28

D08RVA04


TROUBLE SHOOTING SPEEDOMETER 1.

Spee Speedo dome meter ter and odome odomete terr do do not not func functio tion n Checkpoint

Check the vehicle speed sensor output (4 pulses/1 rotation)

Trouble Cause

NG

Countermeasure

Vehicle speed sensor malfunction

Replace the vehicle speed sensor


Repair an open circuit in the circuit or a poor connection at the connectors

Speedometer malfunction

Replace th the sp speedometer

OK Continuity between the vehicle speed sensor and the meter, or the fuse (LHD: CB-7 (15A)/RHD: CB-5 (15A)) and the ground

NG

OK Use a meter tester to check the speedometer function

2.

NG

Spee Speedo dome mete terr nee needl dle e flu fluct ctua uate tes s (May be wide fluctuation)

Check the speed sensor output by using the oscilloscope

NG

Vehicle speed sensor malfunction, or open circuit or poor connector contact

Replace the vehicle speed sensor, or repair an open circuit in the circuit or a poor connection at the connectors


NG

Speedometer malfunction



Spee Speedom domete eterr needl needle e jump jumps s errati erratica call lly y Checkpoint

Trouble Cause

Check the vehicle speed sensor output by using the oscilloscope

NG

Countermeasure

Replace the vehicle speed sensor, or repair an open circuit in the circuit or a poor connection at the connectors

Vehicle speed sensor malfunction, or open circuit or poor connector contact


NG

Speedometer ma malfunction


Inspection of a waveform by oscilloscope 1. Connect a resistance of of 1.3 to 5k ohm (1.4W or more) between between the harness side connectors 2 B-24 and 9 B-23 of the meter. B-24

1 2 3 4 5 6 7 8 9

B-23

1 2 3 4 5 6 7

10111213141516

8 9 10 111213141516

2. Install a speedometer tester. 2. Turn on the starter SW. 3. Check the waveform at the time when the vehicle speed is at 60km/h. Normal waveform Approximate battery voltage - 2V 0V 23.6m sec.

2V or less 825RV108

4.

Trip Trip odom odomet eter er does does not not res reset et

Check at other mileage figures given by meter tester (Reset should be made to zero kilometer)

NG

Faulty reset mechanism or worn gear

Replace the speedometer


TACHOMETER 1.

Tach Tachom omete eterr does does not fun functi ction on when when engi engine ne is runn running ing Checkpoint

Pulse between connector 3 B-24 B-24 and the ground ground when engine is running (Should be pulse present)

Trouble Cause

NG

Countermeasure

Tacho sensor malfunction, or open circuit or poor connector contact

Replace the tacho sensor, or repair open circuit or connector contact

Tachometer malfunction

Replace th the ta tachometer

Tachometer malfunction

Replace th the ta tachometer

OK

Tachometer function

2.

NG

Meter eter need needle le fluc fluctu tuat ates es (May be wide fluctuation)

Use a meter tester to check the tachometer function

NG


TEMPERATURE GAUGE AND THERMO UNIT 1.

No temperature indicates at all Checkpoint

Thermo unit continuity between connector 1 E-4 (or 1 C-71 ) and the ground (Diesel engine: 1 E-19 and the ground)

Trouble Cause

NG

Countermeasure

Thermo unit malfunction

Replace the thermo unit

Gauge malfunction

Replace the temperature gauge



OK Gauge function 1. Disconnect the unit connector then connect 3.4W bulb to wire harness side with ground 2. Check indicating point when starter SW. is ON position (Temperature should indicate)

NG

OK Continuity between 1 E-4 (or 1 C-71 ) and 6 B-24 (Diesel engine: 1 E-19 and 6 B-24

2.

NG

Temperature gauge incorrect readings in all ranges

Thermo unit resistance between connector 1 E-4 (or 1 C-71 ) and the ground (Diesel engine: 1 E-19 and the ground) when disconnecting the connector (Specified resistance should indicate)

NG

Thermo unit malfunction

Replace the thermo unit


FUEL GAUGE AND FUEL TANK UNIT 1.

No fuel level indicates at all Checkpoint

Tank unit continuity between connector 1 F-1 and ground

Trouble Cause

NG

Countermeasure

Open circuit inside the tank unit

Replace the tank unit

Gauge malfunction

Replace the fuel gauge



OK Fuel gauge function 1. Disconnect the tank unit connector then connect 3.4W bulb to wire harness side 2. Check indicating point when starter SW. is ON position (Fuel level should indicate)

NG

OK Continuity between connectors 11 B-23 and 1 F-1

2.

NG

Fuel gauge gives incorrect readings in all ranges

Tank unit resistance position with the float at checking points (Specified resistance should indicate)

NG

Tank unit malfunction

Replace the tank unit


WARNING AND INCIDATOR LIGHT 1.

When the parking brake lever is pulled, the indicator light does not light up Checkpoint

Brake indicator light bulb continuity

Trouble Cause

Countermeasure

NG

Bulb burned out or loose contact

Replace or reinstall the bulb

NG

Incorrect SW. adjustment or poor SW. point contact

Adjust or replace the parking brake SW.

NG



NG

Parking brake SW. malfunction

Replace the parking brake SW.

OK Parking brake SW. installation position and function OK Continuity between the parking brake SW. connector 1 C-39 (4x4: 1 R-4 ) and 12 B-23 OK Continuity between the parking brake SW. connector 1 C-39 (4x4: 1 R-4 ) and the ground when the parking brake is operated


Even when the parking brake lever is pulled, the indicator light does not go off Checkpoint

Parking brake SW. installation position and function

Trouble Cause

NG

Incorrect the parking brake SW. adjustment or brake SW. faulty

Countermeasure

Adjust the SW. installation position or replace the parking brake SW.

OK Check to see if the indicator light goes off when the parking brake SW. connector 1 C-39 (4x4: 1 R-4 ) is disconnected

3.

NG

Brake fluid level SW. or vacuum SW. faulty or short circuit

Replace the brake fluid level SW., or vacuum SW., or repair a short circuit between the parking brake SW. connector 1 C-39 (4x4: 1 R-4 ) and 12 B-23 or the brake fluid level SW. connector 3 C-37 and 12 B-23 , or the vacuum SW. connector 1 C-38 and 12 B-23

Oil pressure warning light does not go off while engine is running

Engine oil pressure

NG

Refer to ENGINE Section

Refer to ENGINE Section

Short circuit

Repair a short circuit between 1 P-11 and 10 B-23 (Diesel engine: 1 E-1 and 10 B-23 )

Oil pressure unit (or oil pressure SW) faulty

Replace the oil pressure unit (or the oil pressure SW.)

OK Check to see if the warning light goes off when the oil pressure SW. connector 1 P-11 (Diesel engine: 1 E- 1 ) is disconnected

NG

OK Continuity between the oil pressure SW. connector 1 P-11 (Diesel engine: 1 E-1 ) and the body ground when the engine is operating

NG


Even when the fuel filter is filled with water, the warning light does not light up Checkpoint

Sedimenter warning light bulb continuity

Trouble Cause

NG

Countermeasure

Bulb burned out or loose contact

Replace or reinstall the bulb

SW. malfunction

Replace the fuel filter SW.



OK

Fuel filter SW. function

NG

OK Continuity between the fuel filter SW. harness side connector 1 C-51 and 9 B-24 or 1 C-52 and C-36

5.

NG

Even when the fuel filter is empty, the warning light does not go off

Check to see if the warning light goes off when the fuel filter SW. connectors C-51 and C-52 are disconnected

NG

Short circuit

Repair a short circuit between 1 C-51 and 9 B-24

SW. malfunction

Replace the fuel filter SW.

OK

Fuel filter SW. function

NG



METER ASSEMBLY Removal 1. Instrument Panel Driver Lower Cover • Refer to the removal steps of “INSTRUMENT PANEL” in Section 10 “CAB”. 2. Lower Cluster Assembly • Refer to the removal steps of “INSTRUMENT PANEL” in Section 10 “CAB”.

826RV017

3. Instrument Panel Cluster Assembly • Refer to the removal steps of “INSTRUMENT PANEL” in Section 10 “CAB” 4. Meter Assembly • Remove four screws of the meter assembly. • Disconnect the meter connectors.

Installation

Follow the removal procedure in the reverse order to install the meter. Pay close attention to the important points mentioned in the following paragraphs.

Connector

Be absolutely sure that the meter connectors are securely connected. This will prevent a poor contact and an open circuit.

ELECTRICAL-BODY AND CHASSIS 8–235 Wire Harness

Do not pinch the wire harness between the cluster and the meter hood during the meter assembly installation procedure. Wire damage will result.

METERS AND GAUGES Removal 1. Meter Assembly • Refer to “METER ASSEMBLY” removal steps in this system. 2. Meter Glass 3. Meter Needless • Pull out the tachometer 825RV062

needles

of

speedometer

and

4. Meter Board • Loosen four fixing screws. 5. Meters and Gauges

Installation

To Install, follow the removal steps in the reverse order.

WARNING LIGHT BULB, INDICATOR LIGHT BULB AND ILLUMINATION LIGHT BULB Removal

Turn the bulb socket counterclockwise and pull the bulb out. 3.Bulb 2.Socket & bulb 1.Meter assembly 825RV063

8–236 ELECTRICAL-BODY AND CHASSIS Installation

To Install, follow the removal steps in the reverse order.

FUEL TANK UNIT Removal

1

1. Disconnect the fuel tank unit connector. 2. Loosen the screws 1.

140RV008

3

3. Remove the fuel tank unit 2 from the fuel tank 3.

2

140RV009

Installation

Follow the removal procedure in the reverse order to install the fuel tank unit. Pay close attention to the important points mentioned in the following paragraphs.

Rubber Seal

Be absolutely sure that the fuel tank unit rubber seal is correctly seated. Connector

Be absolutely sure that the fuel tank unit connector is securely connected. This will prevent a poor contact and an open circuit.


VEHICLE SPEED SENSOR (INSTALLED ON THE TRANSMISSION)

This illustration is based on MUA T/M

Removal

1. Disconnect the connector. 2. Remove the vehicle speed sensor body by rotating it.

Speed sensor 826RV043

Installation

To Install, follow the removal steps in the reverse order, noting the following point. Tighten the vehicle speed sensor to t he specified torque. Vehicle Speed Sensor Tightening Torque kg·m (lb·ft/N·m) 2.5 ± 0.5 (18 ± 3.6 / 25 ± 4.9)


INSPECTION AND REPAIR Warning, indicator and illumination light position W/O Tachometer (Gasoline engine) (This illustration is based on the Km/h meter) Engine coolant temperature gauge

Speedometer

Warning light lens

Reset knob

Fuel gauge

Warning light lens

Illumination light

826RV035

ELECTRICAL-BODY AND CHASSIS 8–239 W/O Tachometer (Diesel engine) (This illustration is based on the Km/h meter)

Engine coolant temperature gauge

Speedometer

Warning light lens

Reset knob

Fuel gauge

Warning light lens

Illumination light

826RV036

8–240 ELECTRICAL-BODY AND CHASSIS W/ Tachometer (Gasoline engine) (This illustration is based on the Km/h meter)


Tachometer

Warning light lens

Speedometer

Warning light lens

Fuel gauge

Reset knob

(Tachometer,6VD1)

Illumination light

D08RW556

ELECTRICAL-BODY AND CHASSIS 8–241 W/ Tachometer (Diesel engine) (This illustration is based on the Km/h meter)


Tachometer

Warning light lens

Speedometer

Fuel gauge

T BELT

Warning light lens

Reset knob

Illumination light

826RV032

8–242 ELECTRICAL-BODY AND CHASSIS Meter connector pin arrangement W/O Tachometer (Gasoline engine)

B-24

1 2 3 4 5 6 7 8 9

B-23 1 2 3 4 5 6 7

10 11 12 13 14 15 16

BLACK

8 9 10 11 12 13 14 15 16

WHITE 826RV038

Connector No. Terminal No.

B-24


B-23

1

Ground

1

Turn signal indicator light (right)

2

Ignition

2

—

3

—

3

—

4

—

4

—

5

—

5

6


Ground

6

—

7

—

7

Ignition

8

—

8

Speedometer

9

Speedometer

10

Oil pressure warning light

11

Fuel gauge

12

Brake warning light

13

Charge warning light

9

10

Oil temp. warning light (Saudi Arabia only) Check engine warning light Seat belt warning light (Saudi Arabia only) Diff. lock indicator light (South Africa only)

11

High-beam indicator light (+)

12

High-beam indicator light (–)

13

Illumination light (+)

14

Illumination light (–)

15

4WD indicator light

16

Turn signal indicator light (left)

14

—

15

—

16

Fuel warning light

ELECTRICAL-BODY AND CHASSIS 8–243 Meter connector pin arrangement W/O Tachometer (Diesel engine)

B-24

1 2 3 4 5 6 7 8 9

B-23 1 2 3 4 5 6 7

10 11 12 13 14 15 16

BLACK

8 9 10 11 12 13 14 15 16

WHITE 826RV037


B-24


B-23

1

Ground

1


2

Ignition

2

—

3

—

3

—

4

—

4

—

5

—

5

6 7

Engine coolant temperature gauge —

Ground

6

—

7

Ignition

8

Glow indicator light

8

Speedometer

9

Sedimenter warning light

9

Speedometer

10

Seat belt warning light (Saudi Arabia only) Diff. lock indicator light (South Africa only)

10


11

Fuel gauge

12

Brake warning light

11


13


12


14

—

13


15

—

14


16

15

4WD indicator light

16


Fuel warning light

8–244 ELECTRICAL-BODY AND CHASSIS Meter connector pin arrangement W/ Tachometer (Gasoline engine)

B-24

1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16

B-23 1 2 3 4 5 6 7

BLACK

8 9 10 11 12 13 14 15 16

WHITE 826RV033


B-24


B-23

1

Ground

1


2

Ignition

2

3

Tachometer

3


—

4

—

4


5

—

5

Ground

6

Power drive indicator (6VD1 A/T)

6 7 8 9

10

Engine coolant temperature gauge — O/D off indicator light (Australia: A/T) Check trans warning light (6VD1 A/T) Oil temp. warning light (Saudi Arabia only) Check engine warning light Seat belt warning light (Saudi Arabia only) Diff. lock indicator light (South Africa only)

7

—

8

Speedometer

9

Speedometer

10


11

Fuel gauge

12

Brake warning light

13


14


11

—

15


12

—

16

Fuel warning light

13


14


15

4WD indicator light

16


ELECTRICAL-BODY AND CHASSIS 8–245 Meter connector pin arrangement W/ Tachometer (Diesel engine)

B-24

1 2 3 4 5 6 7 8 9

B-23

10 11 12 13 14 15 16

1 2 3 4 5 6 7

BLACK

8 9 10 11 12 13 14 15 16

WHITE 826RV034


B-24


B-23

1

Ground

1


2

Ignition

2

3

Tachometer

3


—

4

—

4


5

—

5

Ground

6 7

Engine coolant temperature gauge —

6

—

7

—

8

Glow indicator light

8

Speedometer

9

Sedimenter warning light

9

Speedometer

10

Seat belt warning light (Saudi Arabia only) Diff. lock indicator light (South Africa only)

10


11

Fuel gauge

12

Brake warning light

11

—

13


12

—

14


13


15


14


16

Fuel warning light

15

4WD indicator light

16



SPEEDOMETER AND TACHOMETER Speedometer On-Vehicle Inspection

Check the speedometer accuracy with a speedometer tester. Carefully follow the tester manufacturer’s instructions.

km/h meter (Except Saudi Arabia, South Africa)

W/O Tachometer

Indication 20 40 60 80 100 120 140 160

km/h

Permissible Range 17.2–22.8 37.2–42.8 57.2–62.8 77.2–82.8 97.3–103.7 117.3–123.7 137.3–143.7 156.9–164.1

826RV027

km/h meter (Saudi Arabia, South Africa) Indication 20 40 60 80 100 120 140 160

Permissible Range 20–25.6 40–45.6 60–65.6 80–85.6 99.5–105.9 119.5–125.9 139.5–145.9 159.1–166.3

MPH meter

W/O Tachometer

Indication 20 40 60 80 100

km/h

MPH Permissible Range 18.2–21.8 38.2–41.8 58.2–61.8 78.8–82.8 98.5–103.1

826RV039

km/h meter (Except Saudi Arabia, South Africa) W/Tachometer

Indication 20 40 60 80 100 120 140 160 826RV026

Permissible Range 17.5–22.5 37.5–42.5 57.5–62.5 77.5–82.5 97.6–103.4 117.6–123.4 137.6–143.4 157.2–163.8

km/h


km/h meter (Saudi Arabia, South Africa) Indication

km/h

Permissible Range

20 40 60 80 100 120 140 160

20–25 40–45 60–65 80–85 99.8–105.6 119.8–125.6 139.8–145.6 159.4–166

MPH meter

W/O Tachometer

MPH

Indication

Permissible Range

20 40 60 80 100

18.5–21.5 38.5–41.5 58.5–61.5 79.1–82.5 98.9–102.7

826RV040

Speedometer Off-Vehicle Inspection IGN

GND

Remove the speedometer from the meter assembly and measure the resistance and the current consumption between each terminal. Speedometer Resistance Tester terminal

Red (+)

Black (–) Black (–)

Red (+)

Terminal symbol SEN

4P

IGN – GND

IGN

4P – GND

SEN

IGN

GND

SEN

28.8 – 35.2k 4P

GND

30.6 – 37.4k

∞

825RV064

SEN – GND

GND

GND

13.5 – 16.5k

GND ∞

4P

GND ∞

Note: Use the analog type circuit tester (range: x 1k).

Speedometer Current Consumption Terminal symbol

Current consumption

IGN – GND , .

85 ± 15 mA (when 12 ± 1V applied)

Remarks

No signal input

Note: 1. Use the analog type circuit tester. 2. Since the current consumption fluctuates when the source voltage varies, check to be sure that the voltage applied is 12V ± 1V.

8–248 ELECTRICAL-BODY AND CHASSIS Tachometer On-Vehicle Inspection

1. Attach a tune-up tester to the engine. 2. Start the engine. 3. Compare the tachometer reading and the tester reading. If the tachometer indication is outside the permissible range, the tachometer must be replaced. 4.

Gradually increase and decrease the engine speed. Note the movement of the tachometer needle. If the needle movement is sluggish, the tachometer must be replaced.

Gasoline engine (6VD1)

Gasoline engine (6VD1)

Indication 1,000 2,000 3,000 4,000 5,000 6,000 7,000

rpm Permissible Range 900–1060 1820–2070 2820–3120 3820–4180 4820–5180 5820–6180 6820–7180

825RW256

Gasoline engine

Gasoline engine

Indication 1,000 2,000 3,000 4,000 5,000 6,000

rpm Permissible Range 940–1060 1875–2125 2850–3150 3820–4180 4820–5180 5820–6180

821RV121

Diesel engine

Diesel engine

Indication 750 2,000 3,000 4,000 5,000

821RV118

rpm Permissible Range 690–810 1875–2125 2850–3150 3820–4180 4820–5180

ELECTRICAL-BODY AND CHASSIS 8–249 Tachometer Off-Vehicle Inspection

P

Remove the tachometer from the meter assembly and measure the resistance value and the current consumption between each terminal.

IGN

GND 821RV117

Tachometer Resistance Tester terminal

Red (+)


Red (+)

Terminal symbol IGN – GND

P – GND

IGN

GND

GND

23 – 31k

∞

P

IGN

GND ∞

P

GND

24.7 – 33.4k

Note: Use the analog type circuit tester (range: x 1k).

Tachometer Current Consumption Terminal symbol IGN – GND , .

Current consumption 90 ± 15 mA (12 ± 1V when voltage applied)

Remarks

No signal input

Note: 1. Use the analog type circuit tester. 2. Since the current consumption fluctuates as the source voltage varies, check to be sure that the voltage applied is 12V ± 1V.


W/O Tachometer

TEMPERATURE GAUGE AND THERMO UNIT

W/Tachometer

826RV041

Temperature Gauge On-Vehicle Inspection W/Tachometer

1 IGN

Unit

1.

Disconnect the temperature gauge wire connector.

2.

Connect a 3.4 Watt test bulb 1 to the ground. The gauge needle should move the middle part of the gauge

Ground

140RV006

W/O Tachometer Voltage regulator 1 Unit

140RV005

Temperature Gauge Off-Vehicle Inspection

Use a circuit tester to measure the temperature gauge resistance. Temperature Gauge Resistance

Ω

Standard Measuring Point IGN (+) – Ground IGN (+) – UNIT UNIT – Ground VOLTAGE REGULATOR – UNIT

With Tachometer

Without Tachometer

130 82 212

– – –

–

25

ELECTRICAL-BODY AND CHASSIS 8–251 Thermo Unit Inspection 55 or 25 (Including resistance of ammeter)

The thermo unit is thermistor type and must be inspected under the conditions as shown in the left chart.

Ammeter A

DC 7.0V

1. Put the deviation of the galvanometer to 0 by using the variable resistor, switch the thermo unit off and then measure the resistance of the resistor through the bridge.

Galvano meter GA Switch

Variable resistor

Confirm that the resistance is continuously variable in any other points than those shown in the following table.

Bridge 825RV112

2. Dip the thermo unit into 80 – 90°C (176 – 194°F) water and confirm that there is no bubble continuously coming out of inside of the unit. Replace the unit when the result of inspection is found abnormal. Temperature Check condition 7V 55Ω Gauge 7V 25Ω Gauge

W/O Tachometer

Resistance value (Ω)

50°C (122°F)

115°C (239°F)

226.0+33.6 226.0–36.6

26.4+1.71 26.4–2.21

—

26.4+2.68 24.3–3.68

FUEL GAUGE AND TANK UNIT

W/Tachometer

826RV042

Fuel Gauge On-Vehicle Inspection

W/Tachometer

1. Disconnect the fuel gauge wire connector. 2. Connect a 3.4 Watt test bulb 1 to the ground. 1 IGN

Unit Ground

140RV006

The gauge needle should more the middle part of the gauge.


W/O Tachometer

1 IGN

Unit

140RV007

Fuel Gauge Off-Vehicle Inspection

Use a circuit tester to measure the fuel gauge resistance. Fuel Gauge Resistance

Ω

Standard Measuring Point

With Tachometer

Without Tachometer

223

110 (0) 25 110 135 25

IGN (+) – Ground IGN (+) – 7V IGN (+) – UNIT Ground – 7V Ground – UNIT 7V – UNIT

140

Fuel Tank Unit Inspection

F

Measure the fuel tank unit resistance between the connector terminals 1 F-1 and 3 F-1 while shifting the float from “E” to “F” point.

B Base line A

83

1/2

Fuel Tank Resistance C

Level

E 140RV003

F (B) 1/2 (A) E (C)

Float position mm 51.7 49.4 166.9

Standard resistance Ω

17 ± 2.1 45 ± 4.5 120 ± 6.5

ELECTRICAL-BODY AND CHASSIS 8–253 Low Fuel Indicator Light Inspection

1. Disconnect the fuel tank unit wire connector.

2 YL

B

YR

2. Connect between terminal (YL) and (B). 3. Turn the key switch on. Check that the bulb lights. 1

If operation is not correct, remove and check the bulb or circuit.

140RV004

Check level sensor operation B

YL

1. Remove the fuel tank unit. . t t a w 4 . 3

2. Apply battery voltage between terminal (YL) and (B) through a 3.4 watt bulb. Check that the bulb lights. Note: It will take a short time for the bulb light.

3. Submerge the sensor in fuel. Check that the bulb goes out.

Sensor

If operation is not correct, replace the fuel tank unit. 140RV010

BRAKE SYSTEM WARNING LIGHT The brake system warning light comes on while the parking brake is set and the starter key is ON position. Note: The parking brake indicator light circuit is designed to prevent driving of the vehicle with the parking brake on. It does not indicate the condition of the parking brake system.

This illustration is based on the floor type parking brake lever

The parking brake switch is in parallel with the brake fluid switch.

Parking brake lever

Parking brake switch 825RV066

The brake system warning light also comes on when reservoir brake fluid level falls below the specified limit with the parking brake released and the starter switch is ON position.

Level mark Max

Max

Min

Min

330RV001


VEHICLE SPEED SENSOR (INCORPORATED IN THE SPEEDOMETER)

IGN

SEN

Vehicle Speed Sensor Inspection

GND

Remove the speedometer from the meter assembly and measure the resistance value between the terminals.

4P 825RV064

Speed Sensor Resistance Tester terminal

Red (+)


Red (+)

Terminal symbol 4P – GND

4P

GND

13.5 – 16.5k

4P

GND ∞

Note: Use the analog type circuit tester.

MSG T/M (4 4)

VEHICLE SPEED SENSOR (INSTALLED ON THE TRANSMISSION)

MSG T/M (4 2)

The speed sensor is installed on the rear portion of the transmission. The number of pulses generated is four pulses per one rotation of the pinion shaft.

Speed sensor


MUA T/M


ELECTRICAL-BODY AND CHASSIS 8–255 Vehicle Speed Sensor Inspection 3

2

1. Connect the vehicle speed sensor connector 1 M-100 (Diesel engine: 1 E-44 ) to the battery (+) terminal and 2 M-100 (Diesel engine: 2 E-44 ) to the (–) terminal.

1

–

2. Connect a resistance of 1.3K ohm to 5K ohm (1/4 W or more) between connectors 1 M-10 (Diesel engine: 1 E-44 0) and 3 M-10 (Diesel engine: 3 E-44 )

+

Battery 820RV001

CAUTION: Be extremely careful not to connect the battery (+) terminal to the connector 3 M-10 (Diesel engine: 3 E-44 ). This may damage the vehicle speed sensor.

3. Rotate the shaft of the vehicle speed sensor slowly and measure the voltage at the both ends with a digital tester. The voltage, with one rotation of shaft fluctuates four times in the following range: 10 to 14V — 2V or less.

8–256 ELECTRICAL-BODY AND CHASSIS Timing Belt Indicator Light Reset Procedure (4JA1-T Diesel Engine - RHD) W/Tachometer B

A

Masking tape 821RV120

Timing belt must be replaced after 100,000 km of vehicle operation. When the odometer reading reaches 100,000 km, the timing belt indicator light will turn on to remind the driver to change the timing belt. After replacing the timing belt, the timing belt indicator light must be reset to remind the driver to replace the timing belt after the next 100,000 km.

Timing Belt Indicator Light Reset Procedure

1. Remove the masking tape from the hole B. 2. Remove the screw from the hole A and install it to the hole B. 3. Apply new masking tape to the hole A. Note: The above procedure assumes that the timing belt is being replaced for the first time (after 100,000 km). For subsequent reset procedure (at next 100,000 km), hole positions will be the opposite of the above procedure.


HEATER AND AIR CONDITIONING PARTS LOCATION (LHD)


H-8

C-2 H-20 B-2

B-9

B-13

B-1 B-3 C-65 E-2

C-15 E-1

C-49

B-12

E-5

C-24

D08RVA45


PARTS LOCATION (6VD1 – LHD)

RELAY & FUSE BOX (X-15,X-16,X-22,X-25) B-12

B-1

H-8

B-13 B-2

C-2 P-11 B-9

B-3

H-6

C-41 C-28

H-20 C-101

C-93

E-2

C-24

D08RW549




H-7

C-2 H-20 B-13

C-65

B-12

E-1

B-1

H-8

E-2

C-15

B-2 C-49

B-3 E-5

B-9

C-24

D08RVA48


PARTS LOCATION (6VE1 – RHD)

RELAY & FUSE BOX (X-15,X-16,X-22,X-25)

H-6 H-7

B-12

C-2

B-13

C-41

P-11

H-20

H-26

B-1 B-2 B-3 C-101

C-93

B-9

E-2

C-24

D08RW548


CIRCUIT DIAGRAM (GASOLINE ENGINE – LHD) 15B/R

+

MAIN 80A P-2

P-1 P-5

_

5B/Y

Y / B 0 2

RELAY; CHARGE(5)

B 3

B 3 2 X-3

5 X-3 RELAY; HEATER

P-10

P-7 FRAME

ENG. X-3

X-3 4

1

R / L 3

EB-4 20A BLOWER

EB-5 10A AIR CON

R B 5 . 0

W / L 2

0.5BR 1

C-24

B 5 . 0 10

H-8

R B 5 . 0

C-24

H-8

W 2 / G 5 . 0 5

2 RELAY; A/C THERMOSTAT

W / L 2

X-7

1 B-3 BLOWER MOTOR

B-12 1

B-12

2

3

13

H-8

B / G L 5 . 0

G 5 . 0

R / G 5 . 0 1

B-3 B-2

2

B-12

X-7 4

R / G 5 . 0

1

A/C SW

X-7

X-7

M

6

PRESSURE SW

W / L 5 . 0

ELECTRONIC THERMOSTAT

W 5 . 0

3 B-2

B-2 2

B / L 2 W 5 . 0 B 5 2 . 1

G 5 . 0

H-20

B-1 BLOWER RESISTOR

1 FAN SW

3 B -1 6 B -1 4 B -1 1 B -1 FENDER-RH

C-2

BODY-RH

B-9

ENGINE

E-5

G 5 . 0

11

2

2L / R

1.25L / O

0.85LG / B

0.85L / W

B-13

B / G 5 . 0 1

2 B-13

E-2

3

G 5 . 0 1 C-49

B-13 6 B-13 5 B-13

14

G 5 . 0

H-20

B 2

R G 5 . 0 1

) E-1 I P M 1 D Z 4 ( D C I F

1 C-65

D C I F

E-1

MAGNETIC CLUTCH (4ZD1 MPI)

MAGNETIC CLUTCH

2

4 B-13

0.3B

D08RVA08


CIRCUIT DIAGRAM (GASOLINE ENGINE 6VD1 - LHD) STARTER SW EB-16 100A MAIN +

P - 11 P-1

EB-17 40A IGN-B2

EB-15 40A IGN-B1

OFF ACC

8

C-41

B2

IG2

B1

IG1

C-41

3B/Y

H-28

CB-11 15A BACK TURN

18 0.85W

H-8

ST

3 3 W/B

3B/Y

C-41

1 3W

6

W 5 8 . 0

P-5 _

3B 5

B 0 3

B 5

5B

X-15

2 X-15

RELAY; HEATER

P - 10

P-8

P-7

ENG

BODY

FLAM

X-15

R / L 3 EB-4 10A A/C

X-15 1

4

EB-3 10A BLOWER MOTOR

6 0.5BR

H-8

R B 5 . 0

1.25BR

R B 5 2 . 1

R B 5 . 0

1

B-12 4

SW;A/C

5

X-16

5

X-16

B-12

B 5 . 0

RELAY; THERMO

X-16

3

B / W 5 . 0

X-16 2

H-6

B / W 5 . 0

X-22 1

11 H-20

C-24 PRESSURE SW

2

B / W 5 . 0

Y / R 5 . 0

B-3

1

R / G 5 . 0

E-2

) 1 1 B ( M C E

BLOWER MOTOR 13

MAGNET CLUTCH

C-2

1

C-24

1 C-101

W / L 2

) 1 3 ( M C E

2

L / R B 5 . 0

R / R B 5 . 0

C-101

H-8

B / G 2

10 H-20

10 1

W / G 5 . 0

3 TRIPLE PRESSURE SW

X-22 3

L / R B 5 2 . 1

R / R G 5 . 0

19

X-25

X-22

B-12 2

1

W / L 2

2

X-22

RELAY; A/C COMP.

R / L 3

R B 5 2 . 1

R B 5 . 0

M

H-8 B-3

R / G 5 . 0

3

2 1

X-25 B-2

RELAY; CONDENSER FAN

3

0.5W/B X-25

X-25 2

ELECTRONIC THERMO

B-2

B / L 2

B-2 5

2

L 2 0.5W

0.5W

1 C-93 CONDENSER FAN MOTOR

B 5 . 0

2B

W 5 . 0

B-1 2

M

2

B-9

B-13

1 B-13 3

3

C-93

2L/R

B-13

2

6

B 5 2 . 1

6 1.25L

B-13

0.85L/Y

B-13

B-1 1

4 B-13

B-1 4

5 C-2

B-1

0.85L/W

B-1 RESISTER

SW;FAN

D08RW528


CIRCUIT DIAGRAM (GASOLINE ENGINE – RHD) 15B/R

+

MAIN 80A OR 100A P-2

P-1 (4ZE1 MPI) RELAY; CHARGE(5)

P-5

_

5B/Y

Y / B 0 2

AC GENERATOR(L)

B 3

2 X-3

5 X-3

FRAME

2

X-3

5 X-3

RELAY; HEATER

P-10

P-7

L / W 5 8 . 0

B 3

RELAY; HEATER

ENG. X-3

X-3

X-3

4

1

X-3 4

1

R / L 3

EB-4 20A BLOWER

) I P M 1 E Z 4 ( O / W 5 . 0

EB-5 10A AIR CON

R B 5 . 0

W / L 2

0.5BR 1

C-24

B 5 . 0 2

) ; 5 Y ( A T L U E C R T S

H-8

R B 5 . 0

C-24

H-7

W 2 / G 5 . 0 5


W / L 2

X-7

2

BLOWER MOTOR

B-12 1

B-12

2

3

6

H-8

B / G L 5 . 0

G 5 . 0

R / G 5 . 0 1

B-3 B-2

1

B-12

X-7 4

R / G 5 . 0

B-3

1

A/C SW

X-7

X-7

M

7

PRESSURE SW

W / L 5 . 0


W 5 . 0

3 B-2

B-2 2

B / L 2 W 5 . 0 B 5 2 . 1

G 5 . 0

H-20

B-1 BLOWER RESISTOR

1 FAN SW

3 B -1 6 B -1 4 B -1 1 B -1 FENDER-RH

C-2

BODY-LH

B-9

ENGINE

E-5

G 5 . 0

11

2

2L / R

1.25L / O

0.85LG / B

0.85L / W

B-13

B / G 5 . 0 1

2 B-13

E-2

3

G 5 . 0 1 C-49

B-13 6 B-13 5 B-13

14

G 5 . 0

H-20

B 2

R G 5 . 0 1

) E-1 I P M 1 D Z 4 ( D C I F

1 C-65

D C I F

E-1

MAGNETIC CLUTCH (4ZD1 MPI)

MAGNETIC CLUTCH

2

4 B-13

0.3B

D08RVA09


CIRCUIT DIAGRAM (GASOLINE ENGINE 6VD1 – RHD) STARTER SW EB-16 100A MAIN +

P - 11 P-1

EB-17 40A IGN-B2

EB-15 40A IGN-B1

OFF ACC

8

C-41

B2

IG2

B1

IG1

C-41

3B/Y

H-7

CB-11 15A BACK TURN

2 0.85W

H-6

ST

3 3 W/B

3B/Y

C-41

1 3W

6

W 5 8 . 0

P-5 _

3B 5

B 0 3

B 5

5B

X-15

2 X-15

RELAY; HEATER

P - 10

P-8

P-7

ENG

BODY

FLAM

X-15

R / L 3 EB-4 10A A/C

X-15 1

4

EB-3 10A BLOWER MOTOR

17 0.5BR

H-26

R B 5 . 0

1.25BR

R B 5 2 . 1

R B 5 . 0

1

B-12 4

SW;A/C

5

X-16

5

X-16

B-12

B 5 . 0

RELAY; THERMO

X-16

3

B / W 5 . 0

X-16 2

H-26

B / W 5 . 0

X-22 1

11 H-20

C-24 PRESSURE SW

2

B / W 5 . 0

Y / R 5 . 0

B-3

1

R / G 5 . 0

E-2

) 1 1 B ( M C E

BLOWER MOTOR 18

MAGNET CLUTCH

C-2

2

C-24

1 C-101

W / L 2

) 1 3 ( M C E

2

L / R B 5 . 0

R / R B 5 . 0

C-101

H-7

B / G 2

10 H-20

2 1

W / G 5 . 0

3 TRIPLE PRESSURE SW

X-22 3

L / R B 5 2 . 1

R / R G 5 . 0

12

X-25

X-22

B-12 2

1

W / L 2

2

X-22

RELAY; A/C COMP.

R / L 3

R B 5 2 . 1

R B 5 . 0

M

H-26 B-3

R / G 5 . 0

3

1 1

X-25 B-2

RELAY; CONDENSER FAN

3

0.5W/B X-25

X-25 2

ELECTRONIC THERMO

B-2

B / L 2

B-2 5

2

L 2 0.5W

0.5W

1 C-93 CONDENSER FAN MOTOR

B 5 . 0

2B

W 5 . 0

B-1 2

M

2

B-9

B-13

1 B-13 3

3

C-93

2L/R

B-13

2

6

B 5 2 . 1

6 1.25L

B-13

0.85L/Y

B-13

B-1 1

4 B-13

B-1 4

5 C-2

B-1

0.85L/W

B-1 RESISTER

SW;FAN

D08RW527


CIRCUIT DIAGRAM (DIESEL ENGINE – LHD) 15B/R

+

MAIN 100A P-2

P-1 P-5

_

5B/Y

Y / B 0 3

RELAY; CHARGE(5)

L / W 5 8 . 0

B 3

2

X-3

5 X-3 RELAY; HEATER

P-10

P-7 FRAME

ENG. X-3

X-3 4

1

R / L 3

EB-4 20A BLOWER

EB-5 10A AIR CON

R B 5 . 0

W / L 2

0.5BR 1

C-24

B 5 . 0

PRESSURE SW

W / L 5 . 0 10

W 2 / G 5 . 0 5


W / L 2

X-7

B-3 BLOWER MOTOR

X-7 1

B-12

2

3

13

H-8

B / G L 5 . 0

G 5 . 0

R / G 5 . 0 1

B-3 B-2

2

B-12

4

R / G 5 . 0

1 B-12 A/C SW

X-7

X-7 1

M

R B 5 . 0

C-24

H-8

6 H-8


W 5 . 0

3 B-2

B-2 2

B / L 2

W 5 . 0

B 5 2 . 1

0.5G 2 B-1

3 BLOWER RESISTOR

1 FAN SW

3 B -1

2L / R

B-13

X-12

2

DIODE

B-13 1

3

C-49

B-13

X-12 6 B -1 4 B -1 1 B -1 FENDER-RH

C-2

BODY-RH

B-9

FENDER-RH

C-2

1.25L / O

0.85LG / B

0.85L / W

6 B-13

4

O / G 5 . 0

B 2

5

1

B-13 MAGNETIC CLUTCH

4

C-15 VSV; FICD

B-13

C-15 2 1.25B

0.5B

D08RVA10


CIRCUIT DIAGRAM (DIESEL ENGINE – RHD) 15B/R

+


P-1 (4JA1 FOR SOUTH AFRICA) RELAY; CHARGE(5)

P-5

_

5B/Y

L / W 5 8 . 0

Y / B 0 3

AC GENERATOR(L)

B 3

2

X-3

5 X-3

FRAME

2

X-3

5 X-3

RELAY; HEATER

P-10

P-7

L / W 5 8 . 0

RELAY; HEATER

ENG. X-3

X-3

X-3

4

1

X-3 4

1

R / L 3

) A C I R F A H T U O S R O F 1 A J 4 ( O / W 5 . 0

EB-4 20A BLOWER

EB-5 10A AIR CON

R B 5 . 0

W / L 2

0.5BR 1

C-24

B 5 . 0

PRESSURE SW

W / L 5 . 0 2

) ; 5 Y ( A T L U E C R T S

W 2 / G 5 . 0 5


W / L 2

X-7

2

BLOWER MOTOR

B-12 1

B-12

2

3

6

H-8

B / G L 5 . 0

G 5 . 0

R / G 5 . 0 1

B-3 B-2

1

B-12

X-7 4

R / G 5 . 0

B-3

1

A/C SW

X-7

X-7

M

R B 5 . 0

C-24

H-7

7 H-8


W 5 . 0

3 B-2

B-2 2

B / L 2

W 5 . 0

B 5 2 . 1

0.5G 2 B-1

3 BLOWER RESISTOR

1 FAN SW

3 B -1

2L / R

B-13

X-12

2

DIODE

B-13 1

3

C-49

B-13

X-12 6 B -1 4 B -1 1 B -1 FENDER-RH

C-2

BODY-LH

B-9

FENDER-RH

C-2

1.25L / O

0.85LG / B

0.85L / W

6 B-13

4

O / G 5 . 0

B 2

5

1

B-13 MAGNETIC CLUTCH

4

C-15 VSV; FICD

B-13

C-15 2 1.25B

0.5B

D08RVA11


POWER DOOR LOCK PARTS LOCATION (LHD)

H-16

D-18

D-9

H-14

H-7 H-13

D-5

D-14

B-28

D-4 H-10 H-9

D08RVA38



H-16

D-18

D-4 D-5

H-7

H-14

H-10 B-28 D-14

D-9 H-13 H-9

D08RVA39


CIRCUIT DIAGRAM

15B/R

+


W 3

P-1 P-5

(RHD) 3

H-7

_

5B/Y

IGN B2 40A

5 H-7

W 3

Y / B 0 3

CB-15 20A DOOR LOCK P-7

P - 10

FRAME

ENG.

W / G L 5 2 . 1

9

H-10

W / G L 5 2 . 1

9

D-5 6 LOCK

D-5

UNLOCK

D-5

POWER WINDOW AND DOOR LOCK SW-DRIVER

D-5

D-5 4

11 1.25L/Y

8

H-10 10

1.25Y/G

H-10

Y / L 5 2 . 1

D-5 3

5

Y / L 5 2 . 1

G / Y 5 2 . 1

G / Y 5 2 . 1

20 H-9

R / G L 5 2 . 1

12 H-9

W / R 5 2 . 1 6 H-13

5 H-13

Y / L 5 2 . 1

B 2

3

Y / L 5 2 . 1

1

D-4

D-4

K C O L N U

K C O L

G / Y 5 2 . 1

6 H-16

G / Y 5 2 . 1

6

7 H-16

H-14

7 H-14

DOOR LOCK SW

Y / L 5 2 . 1

2 D-9

D-4

4 D-9

Y / L 5 2 . 1

G / Y 5 2 . 1

3 D-18

1 D-18

G / Y 5 2 . 1

3 D-14

1 D-14

2

B 5 . 0 B 2

Y / L 5 2 . 1

G / Y 5 2 . 1

M

M

M

3

H-10

B 2 BODY-LH

B-28

BODY-RH

B-28

FRT DOOR LOCK ACTUATOR -PASSENGER

RR DOOR LOCK ACTUATOR-RH

RR DOOR LOCK ACTUATOR-LH

(RHD)

D08RV734


TROUBLE SHOOTING QUICK CHART FOR CHECK POINTS Check Points Fuse CB-15 (20A) Trouble Mode

1. All the doors do not lock and unlock 2. All the doors do not get locked (or unlocked) 3. Driver’s side door does not get locked (or unlocked)



Power Window & Door Lock Switch

Door Lock Switch

Driver’s side

Driver’s side

Cable Harness Passenger’s side

RR-RH

RR-LH











4. FRT passenger’s side door does not get locked (or unlocked)





5. RR door-RH does not get locked (or unlocked)





6. RR door-LH does not get locked (or unlocked) 7. Door lock does not operate when operating from the driver’s seat side

Door Lock Actuator












All the doors do not lock and unlock Checkpoint


Trouble Cause

NG

Countermeasure


Reinstall or replace the fuse No. CB-15 (20A)

NG



NG



NG



SW. malfunction

Replace the driver’s side power window & door lock SW.

OK


OK Voltage between the driver’s side power window & door lock SW harness side connector terminal 9 D-5 and the ground (Should be battery voltage present) OK Continuity between 5 D-5 and B-28

OK Driver’s side power window & door lock SW. function

2.

NG

All the doors do not get locked (or unlocked)

Continuity between the driver’s side power window & door lock SW harness side connector terminals 6 D-5 and 8 D-5

NG



SW. malfunction

Replace the driver’s side power window & door lock SW.

OK Driver’s side power window & door lock SW. function

NG


Driver’s side door does not get locked (or unlocked) Checkpoint

Door lock SW. function

4.

Replace the door lock SW.

NG

Actuator malfunction

Replace the FRT passenger’s side door lock actuator

NG


Replace the RR door lock actuator-RH

RR door-LH does not get locked (or unlocked)

RR door lock actuator-LH function

7.

SW. malfunction

RR door-RH does not get locked (or unlocked)

RR door lock actuator-RH function

6.

NG

Countermeasure

FRT passenger’s side door does not get locked (or unlocked)

FRT passenger’s side door lock actuator function

5.

Trouble Cause

NG


Replace the RR door lock actuator-LH

Door lock does not operate when operated from the driver’s seat side


NG


NG

SW. malfunction


OK Continuity between the door lock SW. side connector terminals 1 D-4 and 2 D-4 when the SW is locked and between 3 D-4 and 2 D-4 when the SW. is unlocked

Replace the door lock SW.



DRIVER SEAT SIDE POWER WINDOW & DOOR LOCK SWITCH

Switch

Removal

1. Remove the switch by pushing the spring with the tip of a screwdriver. 2. Disconnect the connector.

This illustration is based on 2 doors model 825RV089

Installation

To install, follow the removal steps in the reverse order.

DRIVER’S SIDE DOOR LOCK SWITCH Removal 1. Door Lock ASM • Refer to the removal steps of the DOORS in Section 10 “BODY”.

Door lock switch

2. Door Lock Switch Connector

825RV056

Installation



FRT PASSENGER’S SIDE DOOR LOCK ACTUATOR Removal 1. Door Lock ASM • Refer to the removal steps of the DOORS in Section 10 “BODY”. Door lock actuator 825RV057

2. Door Lock Actuator • Remove the actuator fixing bolts. • Disconnect the door lock link rod. • Disconnect the actuator connector. Installation


RR DOOR LOCK ACTUATOR-LH & RH Removal 1. Door Lock ASM • Refer to the removal steps of the DOORS in Section 10 “BODY”. 2. Door Lock Actuator • Remove the actuator fixing bolts. • Disconnect the door lock link rod. • Disconnect the actuator connector.

Door lock actuator

825RV097

Installation




Driver Seat Side Power Window & Door Lock Switch 1. Harness Side Connector Circuit

D-5

1 2

Check voltage and continuity between the switch harness side connector terminals as shown in the following table.

3 4

5 6 7 8 9 10

Harness side

Terminal No.

Wire color

Connecting to

Check item

3

R/W

Door lock SW (Lock)

3-Ground

Driver seat side door

Lock

Continuity

Unlock

No continuity

4

LG/R

Door lock SW (Unlock)

4-Ground

Driver seat side door

Lock

No continuity

Unlock

Continuity

5

B

Ground

L/Y

Door lock actuator (Lock)

8

Y/G

Door lock actuator (Unlock)

9

LG/W

Fuse CB-15 (20A)

Continuity

Connecting terminal

5-Ground

Check condition

—

Continuity

—

Continuity There is some resistance

8–6

—

Continuity There is some resistance

9- Ground

—

Battery voltage (Approx. 12V)

(Resistance)

6

6–8

Voltage

Standard

( (

) )

8–276 ELECTRICAL-BODY AND CHASSIS 2. Switch Side Connector Circuit D-5

4 3

Remove the switch connector, and check continuity and voltage between the switch connector terminals. (Connect the (+) terminal of the battery to 9 D-5 and the (–) terminal to 5 D-5 .)

2 1

10 9 8 7 6 5

5 D-5 - 6 D-5 . . . . Continuity 5 D-5 - 8 D-5 . . . . Continuity

Switch side

(Then, ground 3 D-5 .) 632RV002

6 D-5 . . . . Current flow for approx. 1 second (Disconnect the ground of 3 D-5 , and ground 4 D-5 .) 8 D-5 . . . . Current flow for approx. 1 second

3. Door Lock Operation Test

After confirming that there is continuity between the switch harness side connector terminals 6 D-5 and 8 D-5 , apply the battery voltage to each of the terminals to conduct the operation test.

D-5 1 2

3 4

When the door lock will not operate, check the door lock actuator for any trouble.

5 6 7 8 9 10

Harness side

Connecting terminals 060RS009

Operation

8 (Y/G)

6 (L/Y)

+

–

Unlock

–

+

Lock

ELECTRICAL-BODY AND CHASSIS 8–277 Driver’s Side Door Lock Switch 1. Switch Side Connector Circuit

D-4

3

2

Check continuity between the switch connector terminals Terminal No.

1

SW position Switch side

1

2

3

Lock Unlock Front Passenger’s Side Door Lock Actuator 1. Actuator Side Connector Circuit

D-9

Apply the battery voltage to the actuator connector terminals to check the operation. 2

1

4

3

Actuator side

When the door lock actuator is checked on the vehicle and there is no continuity, and when the door lock actuator itself is checked and no trouble is found, check the circuit between the door lock actuator and the driver seat side power window & door lock switch for any failure. Connecting terminals

Operation

2

4

+

–

Lock

–

+

Unlock

Rear Door Lock Actuator -LH & RH D-14

D-18

1. Actuator Side Connector Circuit

Apply the battery voltage to the actuator connector terminals to check the operation. 2

1

4

3

Actuator side

When the door lock actuator is checked on the vehicle and there is no continuity, and when the door lock actuator itself is checked and no trouble is found, check the circuit between the door lock actuator and the driver seat side power window & door lock switch for any failure. Connecting terminals

Operation

1

3

–

+

Lock

+

–

Unlock


POWER WINDOW PARTS LOCATION (LHD)

D-16 H-16

D-15

D-10

H-14

B-8

D-1 D-6 B-9

H-13

D-12

C-41 D-11

B-28 D-5

H-10 H-9

D08RVA40



D-16 H-16

D-15

H-7 D-1

H-14

D-5

D-10 B-28

H-10

D-12

C-41 D-11 B-9 D-6

H-13 H-9

D08RVA41



STARTER SW MAIN 80A OR 100A

15B/R

+

OFF ACC

IGN.B2 40A

1

3W

P-2

C - 41

W 3

P - 11 P-5

B1

3

(6VD1)

P - 10 ENG.

6

6 H-7

IG1

H-28 (6VD1)

Y / B 3

H-28 (6VD1)


CIRCUIT BREAKER 30A

Y / B 0 3

P-7

3B/Y

C - 41

3

H-7

_

FRAME

IG2 ST

P-1

5B/Y

8

B2

3W

2G/W

W 5 8 . 0

W 5 . 0 5

2

B-8

B-8 RELAY; POWER WINDOW

B-8

B-8

1

4

2G/R

0.5R/Y

Y / R 5 . 0

R / G 2 R / G 2

3

Y / R 5 . 0

H-9

Y / R 5 . 0

R / G 2

2 H - 34

2

10

H-9

H - 34

(6VD1)

1 H - 34 (6VD1)

(6VD1)

Y / R 5 . 0

1

2

H - 10

1

H - 10

Y / R 5 . 0

2

H - 13

H - 13

R / G 2 R / G 2 3

Y / R 5 . 0

R / G 2

2

9

D-5

DOWN

LOCK

UP

DOWN

D-5

D-5

D - 10

D - 10

R / L 2

W / L 2

2

5

3

D-1

H - 10

M

6

Y / R 5 . 0

R / G 2

B 5 . 0

8 H -16

W / L 2

2

RR POWER WINDOW SW-LH

D - 16

RR POWER WINDOW SW-RH

DOWN D - 12

D - 12

D - 12

D - 16

D - 16

D - 16

D - 16

5

5

6

3

1

5

6

3

1

W / R B 2

R / L 2

UP

B 5 . 0

B 2

DOWN

W / R B 2

R / L 2

B 5 . 0

B 2

4

2

1

1

2

2

1

1

2

H - 13

D - 11

D - 11

H - 14

H - 14

D - 15

D - 15

H - 16

H - 16

M

FRT POWER WINDOW MOTOR-PASSENGER

2

D - 16

UP

B 2

D-6

4

D - 12

D - 12

1

D-6

2

Y / R 5 . 0

D - 10

M B 2

FRT POWER WINDOW MOTOR-DRIVER

R / G 2

D - 12

10

R / L 2

B 2

1

D-1

H - 16

FRT POWER WINDOW AND DOOR LOCK SW-PASSENGER

UP

10

H - 14

4

D - 10

D-5 1

H - 14

2

D -10

FRT POWER WINDOW AND DOOR LOCK SW-DRIVER

3

Y / R 5 . 0

R / G 2

7

D-5

8

B 2

RR POWER WINDOW MOTOR-LH

M B 2

RR POWER WINDOW B 2 MOTOR-RH

B 5 . 0

1 BODY - LH

B - 28

BODY - RH

B-9

2B

H-34

D08RW569

TROUBLE SHOOTING




15B/R

+

OFF ACC

IGN.B2 40A

3W

P-2

C - 41

W 3

P - 11 P-5

B1

P - 10 ENG.

3B/Y

C - 41

6 H-7

IG1

Y / B 3

H-7


CIRCUIT BREAKER 30A

Y / B 0 3

P-7

IG2

5

(6VD1)

_

FRAME

8

B2

ST

P-1

5B/Y

1

3W

2G/W

W 5 8 . 0

W 5 . 0 5

2

B-8

B-8 RELAY; POWER WINDOW

B-8

B-8

1

4

2G/R

0.5R/Y

Y / R 5 . 0

R / G 2 R / G 2

3

Y / R 5 . 0

Y / R 5 . 0

R / G 2

2

H-9

H - 34

2 H-9

10 H - 34

(6VD1)

1 H - 34 (6VD1)

(6VD1)

Y / R 5 . 0

1

2

H - 10

1

H - 10

Y / R 5 . 0

2

H - 13

H - 13

R / G 2 R / G 2 3

8

H - 14

Y / R 5 . 0

R / G 2

2

7

9

D-5

Y / R 5 . 0

DOWN

LOCK

UP

DOWN

D-5

D-5

D - 10

D - 10

R / L 2

W / L 2

2

5

3

D-1

H - 10

2

B - 28

BODY - LH

B-9

FRT POWER WINDOW MOTOR-PASSENGER

RR POWER WINDOW SW-RH

DOWN D - 12

D - 12

D - 12

D - 16

D - 16

D - 16

D - 16

5

5

6

3

1

5

6

3

1

W / R B 2

R / L 2

UP

B 5 . 0

B 2

DOWN

W / R B 2

R / L 2

B 5 . 0

B 2

4

2

1

1

2

2

1

1

2

H - 13

D - 11

D - 11

H - 14

H - 14

D - 15

D - 15

H - 16

H - 16

M B 2

RR POWER WINDOW SW-LH

D - 16

UP

B 2

D-6

2

D - 16

D - 12

1

D-6

M FRT POWER WINDOW MOTOR-DRIVER

BODY - RH

W / L 2

4

D - 12

D - 10

10

R / L 2

B 2

1

D-1

6

Y / R 5 . 0

R / G 2

2

D - 12

FRT POWER WINDOW AND DOOR LOCK SW-PASSENGER

UP

10

4

D - 10

D-5 1

H -16

B 5 . 0

2

D -10

FRT POWER WINDOW AND DOOR LOCK SW-DRIVER

8

H - 16

Y / R 5 . 0

R / G 2

R / G 2

D-5

3

H - 14

M B 2

RR POWER WINDOW MOTOR-LH

M B 2

RR POWER WINDOW B 2 MOTOR-RH

B 5 . 0

2B 1 2B

H - 34

D08RW570


TROUBLE SHOOTING QUICK CHART FOR CHECK POINTS Check Points Trouble Mode

All windows will not operate

Power Window & Power Window Power Window Motor Fuse Circuit Relay; Door Lock Switch Switch Cable CB-11 Breaker Power Driver’s Passenger’s Driver’s Passenger’s Harness (15A) (30A) Window RR-LH RR-RH RR-LH RR-RH Side Side Side Side 











Lock SW does not function Driver’s Window: Window does not operate











One-touch operation for “DOWN” movement will not operate



Window operates in only one direction





Front window on passenger seat side: Window does not operate



Window does not operate when operating the driver’s SW



Window does not operate when operating the passenger’s SW





Window does operate in only one direction when operating the driver’s SW





Window does operate in only one direction when operating the passenger’s seat side SW











Rear window on left (or right) side: Window on left (or right) side does not operate



Window does not operate when operating the driver’s SW



Window does operate in only one direction when operating the driver’s SW



Window does operate in only one direction when operating the RR-LH (or RH) side SW


















All windows do not operate Checkpoint

Fuse CB-11 (15A, Fuse box)

Trouble Cause

NG

Countermeasure


Reinstall or replace the fuse No. CB-11(15A)

Circuit breaker malfunction

Replace the circuit breaker (30A)

NG


Repair grounding points ( B-9 and B-28 ) contact

NG

Power window relay malfunction

Replace the power window relay


Repair an open circuit or a poor connection of the connectors between 3 H-7 (RHD: 5 H-7 ) and 5 B-8


Repair an open circuit or a poor connection of the connectors between 1 B-8 and 2 D-5

OK Circuit breaker (30A, Fuse box) function

NG

OK

Grounding points ( B-9 and B-28 )

OK Power window relay function OK Voltage between the power window relay harness side connector terminal 5 B-8 and the ground (Should be battery voltage present)

NG

OK Voltage between 2 D-5 and the ground (Should be battery voltage present)

NG

OK Voltage between B-28 and the ground

Continued on the next page

NG


Repair an open circuit or a poor connection of the connectors between 5 D-5 and B-28 , or 4 B-8 and B-28

8–284 ELECTRICAL-BODY AND CHASSIS Checkpoint

Trouble Cause

Countermeasure

Continued from the previous page OK Driver seat side power window & door lock SW. function

2.

SW. malfunction

Replace the driver seat side power window & door lock SW.

SW. malfunction


Lock switch does not function

Driver seat side power window & door lock SW. function

3.

NG

NG

Window on the driver’s side does not operate

Driver seat side power window & door lock SW. function

NG

SW. malfunction


Motor malfunction

Replace the driver seat side power window motor



OK 1. Driver seat side power window motor function when connecting the motor connector 2 D-1 to the battery (+) terminal, and 1 D-1 to the (–) terminal (Should the motor rotate in the “UP” direction of the window) 2. Driver seat side power window motor function when connecting the motor connector 1 D-1 to the battery (+) terminal, and 2 D-1 to the (–) terminal (Should the motor rotate in the “DOWN” direction of the window)

NG

OK Continuity between 1 D-5 and 2 D-1 , or 10 D-5 and 1 D-1

NG


Window on the front passenger’s side does not operate Checkpoint

Front passenger’s power window & door lock SW. function

Trouble Cause

NG

Countermeasure

SW. malfunction

Replace the front passenger’s power window & door lock SW.

SW. malfunction


Motor malfunction

Replace the front passenger’s power window motor



OK Driver seat side power window & door lock SW. function

NG

OK 1. Front passenger’s power window motor function when connecting the motor connector 2 D-6 to the battery (+) terminal, and 1 D-6 to the (–) terminal (Should the motor rotate in the “UP” direction of the window) 2. Front passenger’s power window motor function when connecting the motor connector 1 D-6 to the battery (+) terminal, and 2 D-6 to the (–) terminal. (Should the motor rotate in the “DOWN” direction of the window)

NG

OK Continuity between 6 D-10 and 2 D-6 , or 10 D-10 and 1 D-6

NG


Rear window on the left (right) side does not operate Checkpoint

Rear power window SW.LH (RH) function

Trouble Cause

NG

Countermeasure

SW. malfunction

Replace the rear power window SW.-LH (RH)

SW. malfunction


Motor malfunction

Replace the rear power window motor



OK Driver seat side power window & door lock SW. function

NG

OK 1. Rear power window motor-LH (RH) function when connecting the motor connector 2 D-11 (2 D-15 ) to the battery (+) terminal, and 1 D-11 (1 D-15 ) to the (–) terminal (Should the motor rotate in the “UP” direction of the window) 2. Rear power window motor-LH (RH) function when connecting the motor connector 1 D-11 (1 D-15 ) to the battery (+) terminal, and 2 D-11 (2 D-15 ) to the (–) terminal (Should the motor rotate in the “DOWN” direction of the window)

NG

OK Continuity between 5 D-12 and 2 D-11 (5 D-16 and 2 D-15 ), or 6 D-12 and 1 D-11 (6 D-16 and 1 D-15 )

NG



DRIVER SEAT SIDE POWER WINDOW & DOOR LOCK SWITCH (2 DOORS MODEL)

Switch

Removal

1. Remove the switch by pushing the spring with the tip of a screwdriver. 2. Disconnect the connector. This illustration is based on RHD 825RV089

Installation


FRONT PASSENGER’S POWER WINDOW & DOOR LOCK SWITCH (2 DOORS MODEL)

Switch

Removal


Installation



DRIVER SEAT SIDE POWER WINDOW & DOOR LOCK SWITCH (4 DOORS MODEL)

Switch

Removal


Installation


FRONT PASSENGER’S POWER WINDOW & DOOR LOCK SWITCH (4 DOORS MODEL)

Switch

Removal


Installation


REAR POWER WINDOW & DOOR LOCK SWITCH-LH & RH

Switch

Removal

1. Remove the switch by pushing the spring with the tip of a screwdriver. Spring

2. Disconnect the connector.

825RV096



DRIVER SEAT SIDE POWER WINDOW MOTOR

2.Power window motor

Removal

1.Window regulator ASM

1. Window Regulator ASM • Refer to the removal steps of the WINDOW REGULATOR/POWER WINDOW MOTOR in Section 10 “BODY”. 2. Power Window Motor • Loosen the fixing bolts to remove the power window motor from the regulator.

825RV091

Installation


FRONT PASSENGER’S POWER WINDOW MOTOR Removal 1.Window regulator ASM

2.Power window motor

825RV090

1. Window Regulator ASM • Refer to the removal steps of the WINDOW REGULATOR/POWER WINDOW MOTOR in Section 10 “BODY”. 2. Power Window Motor • Loosen the fixing bolts to remove the power window motor from the regulator. Installation



REAR POWER WINDOW MOTOR-LH & RH Removal and Installation

Refer to the “DRIVER SEAT SIDE POWER WINDOW MOTOR” removal and installation steps in this section.



Power Window Relay


B-8 1

1 - 5 . . . . . . . . . . . . . . . . . . . . No continuity

3

4


3

2 5

1

2

4

1 - 5 . . . . . . . . . . . . . . . . . . . . Continuity

5 060RV005

Driver Seat Side Power Window & Door Lock Switch 1. Harness Side Connector Circuit

D-5

1 2

Disconnect the switch connector, and check voltage and continuity between the harness side connector terminals as shown in the following table.

3 4

5 6 7 8 9 10

Harness side

Terminal No.

Wire color

2

G/R

1

L/R

10

L/W

5

B

Connecting to

Check item

Connecting terminal

Check condition

Standard

Starter SW “ON”

Approx. 12V

Power window relay

Voltage

2-Ground

Power window motor

Continuity

1 – 10

—

Continuity

Ground

Continuity

5-Ground

—

Continuity

Front Passenger’s Power Window & Door Lock Switch 1. Harness Side Connector Circuit D-10

1 2

3 4

5 6 7 8 9 10

Harness side

Disconnect the switch connector, and check voltage and continuity between the harness side connector terminals as shown in the following table.

8–292 ELECTRICAL-BODY AND CHASSIS Terminal No.

Wire color

9

G/R

6

L/R

10

L/W

5

B

Connecting to

Check item

Connecting terminal

Check condition

Standard

Starter SW “ON”

Approx. 12V

Power window relay

Voltage

9-Ground

Power window motor

Continuity

6 – 10

—

Continuity

Ground

Continuity

5-Ground

—

Continuity

Rear Power Window Switch-LH & RH D-12

1

1. Harness Side Connector Circuit

D-16

Disconnect the switch connector, and check voltage and continuity between the harness side connector terminals as shown in the following tables.

2

3 4 5 6

Harness side

D-12 (RR–LH) Terminal No.

Wire color

4

G/R

5

L/R

6

BR/W

3

B

Connecting to

Check item

Connecting terminal

Check condition

Standard

Starter SW “ON”

Approx. 12V

Power window relay

Voltage

4-Ground

Power window motor

Continuity

5–6

—

Continuity

Ground

Continuity

3-Ground

—

Continuity

Connecting terminal

Check condition

Standard

Starter SW “ON”

Approx. 12V

D-16 (RR–RH) Terminal No.

Wire color

4

G/R

5

L/R

6

BR/W

3

B

1

B

Connecting to

Check item

Power window relay

Voltage

4-Ground

Power window motor

Continuity

5–6

—

Continuity

Ground

Continuity

3–1

—

Continuity

ELECTRICAL-BODY AND CHASSIS 8–293 Driver Seat Side Power Window Motor 1. Driver Seat Side Power Window & Door Lock Switch Connector Circuit

D-5

1 2

Disconnect the switch connector, apply the battery voltage (12V) to the harness side connector terminals and check operation.

3 4

5 6 7 8 9 10

Connecting terminals

Harness side

10 (L/W)

–

+

DOWN

+

–

UP

2. Driver Seat Side Power Window Motor Connector Circuit

DOWN

Disconnect the switch connector, apply the battery voltage (12V) to the motor side connector terminals and check operation.

M

UP

1

Operation direction

1 (L/R)

2


D-1 Motor side

825RV092

Operation direction

1

2

+

–

DOWN

–

+

UP

8–294 ELECTRICAL-BODY AND CHASSIS Front Passenger’s Power Window Motor 1. Front Passenger’s Power Window Switch & Door Lock Switch Connector Circuit

D-10 1 2

Disconnect the motor connector, apply the battery voltage (12V) to the harness side connector terminals and check operation.

3 4

5 6 7 8 9 10


Harness side

Operation direction

6 (L/R)

10 (L/W)

–

+

DOWN

+

–

UP

2. Front Passenger’s Power Window Motor Connector Circuit DOWN


M

UP

1

2


D-6 Motor side

825RV092

Operation direction

1

2

+

–

DOWN

–

+

UP

ELECTRICAL-BODY AND CHASSIS 8–295 Rear Passenger’s Power Window Motor-LH 1. Rear Power Window Switch-LH Connector Circuit

D-12

1


2

3 4 5 6

Connecting terminals Harness side

Operation direction

5 (L/R)

6 (BR/W)

–

+

DOWN

+

–

UP

2. Rear Power Window Motor-LH Connector Circuit


DOWN M

UP

Connecting terminals 1

2

D-11 Motor side

825RV092

Operation direction

1

2

+

–

DOWN

–

+

UP

8–296 ELECTRICAL-BODY AND CHASSIS Rear Power Window Motor-RH 1. Rear Power Window Switch-RH Connector Circuit

D-16 1


2

3 4 5 6

Connecting terminals Harness side

Operation direction

5 (L/R)

6 (BR/W)

–

+

DOWN

+

–

UP

2. Rear Power Window Motor-RH Connector Circuit


DOWN M

UP

Connecting terminals 1

2

D-15 Motor side

825RV092

Operation direction

1

2

+

–

DOWN

–

+

UP


MEMO


AUDIO, CLOCK AND CIGARETTE LIGHTER PARTS LOCATION (LHD)

D-17 H-16 B-14 D-8 H-14 B-20

H-7 D-3

C-41

D-13

B-10 H-13

B-21

B-22

B-28

H-10 H-9

D08RVA54



D-17 H-16 H-7 C-41

B-14

D-3

H-14 B-10

B-28

B-20

D-8 D-13

B-22

B-21

H-10

H-13 H-9

D08RVA52




15B/R

+

P-2

1

3W

B2

C-41

P-11

3

4

CB-20 15A CIGAR

1 3L

C-41

3L

H-7

ST

H-28

IG1

(6VD1)

H-28 (6VD1)

W 3

Y / B 0 3

CB-14 10A ROOM LAMP

L / R 5 8 . 0

P-10

P-7 FRAME

1.25BR/W

CB-19 15A AUDIO

1

IG2

B1

3

H-7

(6VD1)

_

5B/Y

OFF ACC

W 3

P-1 P-5

IGN B2 40A

ENG.

W / R 5 . 0

0.5R/W

RELAY;TAIL(1)

R / G 5 8 . 0 (W/POWER WINDOW AND DOOR LOCK)

14

4

B-14 AUDIO B-14

B-14

6

L 5 . 0

B-14

B-14

7

W 5 . 0

13 H-10

R G 5 . 0

G 5 . 0

7

H-13

G 5 . 0

R G 5 . 0

2

1 D-3 –

FRT - LH

2 D-8 +

Y 5 . 0

B-14

7

B-14

B-14

7 1

W 5 . 0 4

5

2

R G 5 . 0

G 5 . 0

H-13

G 5 . 0

R G 5 . 0

D-3 +

FRT - RH 2

1

1

2

D-3 –

D-8 +

3

6 H-9

2

H-13

B 5 . 0 W / L 5 . 0

L 5 . 0 4

H-14

W 5 . 0

D -13 +

1

H-10

2

R 5 . 0

9

W / L 5 . 0

H-9 H-10

R 5 . 0

2

L 5 . 0

R G 5 . 0

G 5 . 0

B-14

16

8

1 D-8 –

B-14

15

H-9

H-14 D-3 +

L 5 . 0

8

H-13

B-14

6

8

9 12

B-14

B-14

1

R 5 . 0

R G 5 . 0

G 5 . 0

B-14

16

H-9 H-10

B-14

AUDIO

15

Y 5 . 0

11

B-14

5

H-16

H-16

R 5 . 0

W 5 . 0

1 D-8 –

FRT - RH

FRT - LH

2

D -13 –

D-17 +

RR - LH

1 D-17 –

RR - RH SPEAKER

B 5 2 . 1

BODY-LH

B - 28

D08RW567


1.25 BR/W

W / R B 5 . 0

) 1 ( L I A T ; Y A L E R R / G 5 8 . 0

0.5 R/W

R / G 5 8 . 0 2

R / G 5 . 0 1 B-10

4 B-10 CLOCK B-10 2

3 B-10

B-20

1

R E T H G I L E T T E R A G I C

B-21

B-22 1

B-20 1

B 5 . 0

BODY-LH

B - 28

B 5 . 0

B 5 2 . 1

1.25B

D08RV979




15B/R

+

P-2

1

3W

(6VD1)

B2

IG2

B1

IG1

4

CB-20 15A CIGAR

1 3L

C-41

H-7

3L

5

H-7

_

W 3

Y / B 0 3

CB-14 10A ROOM LAMP

L / R 5 8 . 0

P-10

P-7 FRAME

0.85BR/W

CB-19 15A AUDIO

ST

W 3

P-11

5B/Y

OFF ACC

C-41

P-1 P-5

IGN B2 40A

ENG.

W / R 5 . 0

0.5R/W

RELAY;TAIL(1)

R / G 5 8 . 0 (W/POWER WINDOW AND DOOR LOCK)

14

4

B-14 AUDIO B-14

B-14

6

L 5 . 0

B-14

B-14

7

B-14

16

9 8 H-13

G 5 . 0

R G 5 . 0

G 5 . 0

D-8 +

1 D-8 –

FRT - LH

2 D-3 +

Y 5 . 0

B-14

7

B-14

B-14

W 5 . 0 4

5

7 2

H-13

H-13

G 5 . 0

R G 5 . 0

D-8 +

W 5 . 0

FRT - RH 2 D -13 +

1

H-10

G 5 . 0

R G 5 . 0

1

1

2

D-8 –

D-3 +

6 H-9

2

H-10

W / L 5 . 0

L 5 . 0 4

H-14 2

R 5 . 0

9

W / L 5 . 0

H-9 1

R 5 . 0

2

L 5 . 0

R G 5 . 0

G 5 . 0

B-14

16

8

1 D-3 –

B-14

15

H-9

H-14 2

L 5 . 0

12 13 H-10 H-10

R G 5 . 0

B-14

6

8

W 5 . 0

H-9 7

B-14

B-14

1

R 5 . 0

R G 5 . 0

G 5 . 0

H-13

B-14

AUDIO

15

Y 5 . 0

11

B-14

5

H-16

H-16

R 5 . 0

W 5 . 0

1 D-3 –

3

) R E L L O R T N O C N O I T A N I M U L L I O / W ( B 5 . 0

G / R 5 . 0

) N 3 ( O R I T E L A L N O I R M T U N L O L C I

FRT - RH

FRT - LH

2

D -13 –

D-17 +

RR - LH

1 D-17 –

RR - RH SPEAKER

B 5 2 . 1

BODY-RH

B - 28

D08RW568


0.85 BR/W

) 1 ( L I A T ; Y A L E R

W / R B 5 . 0 0.5 R/W

R / G 5 8 . 0 R / G 5 8 . 0 2

R / G 5 . 0 1 B-10

4 B-10

B-20

3

1

R E T H G I L E T T E R A G I C

B-10

CLOCK B-10 2

B-21

B-22 1

B-20 1

G / R 5 . 0

B 5 . 0

BODY-RH

B - 28

) 3 N ( O R I T E L A L N I O R M T U N L O L I C

) R E L L O R T N O C N O I T A N I M U L L I O / W ( B 5 . 0

B 5 2 . 1

1.25B

D08RV981


TROUBLE SHOOTING CIGARETTE LIGHTER 1.

Lighter does not pop out after being pushed in. It does not become hot. Checkpoint

Audio system (System should receive power)

Trouble Cause

Countermeasure

NG

Poor Fuse No. CB-20 (15A, Fuse box) contact or blown


NG


Replace the lighter

NG



NG



OK Lighter continuity between center part and outer area

OK Voltage between connector 1 B-21 and the ground at starter SW. is ACC position (Should be battery voltage present) OK Continuity between connector 1 B-22 and the ground

2.

Lighter pops out prematurely before becoming hot

Lighter and casing

3.

NG

Deformed lighter or casing

Repair or replace the lighter and/or casing

Deformed lighter and casing

Repair or replace the lighter and/or casing

Lighter becomes too hot

Lighter and casing

NG



AUDIO Refer to Section 9 “ACCESSORIES” for details.

CIGARETTE LIGHTER

1

Removal

1. Remove the lighter 1. 2. Disconnect the connector 2. 3. Loosen the lighter holder 3 nut at the back side. 4. Remove the holder from the bezel.

2 3 D08RV882

Installation

Follow the removal procedure in the reverse order to install the lighter. Pay close attention to the important points mentioned in the following paragraphs.

Connector

Be absolutely sure that the lighter connector is securely connected. This will prevent a poor contact and an open circuit.


POWER DOOR MIRROR PARTS LOCATION (LHD)

D-7 B-26

H-7 C-41 D-2 H-13

B-28

H-10

D08RVA51



D-2 B-26

H-7

H-10 B-28

C-41

D-7

H-13

D08RVA49



15B/R

MAIN 80A OR 100A

IGN.B2 40A

P-2

+ W 3

P-1

_

5B/Y

P-5

1 C-41

Y / B 0 3

P-7

P-10

FRAME

ENG.

B1

B2

STARTER SW

IG1 ST IG2 ACC

C-41

L 3

4 1

H-7

L 3 CB-19 15A AUDIO

L / R 5 8 . 0 L / R 5 . 0

4

B-26

CONTROL SW

RH RV LV RH LH LH

C

B-26 B-26 B-26 B-26 B-26

7 8 5 10 1

B-26 9

B 5 . 0

6 H-10

W / B 5 . 0

5 H-10

V 5 . 0

2

B 5 2 . 1

D-2

G / W 5 . 0

R / B 5 . 0

W / B 5 . 0

4

B / W 5 . 0

W / B 5 . 0

BODY-LH

B-28

MIRROR-LH

2 D-7

1 D-7

3 D-7

T F E L MLR

N W O D

3 H-13

B / W 5 . 0

P U

MUD

T H G I R

9 H-13

V 5 . 0

3

T F E L MLR

10 H-13

D-2

B / W 5 . 0

V 5 . 0

H-10

1 D-2

W / B 5 . 0

P U

MUD

T H G I R

N W O D

MIRROR-RH

D08RV777



15B/R

MAIN 80A OR 100A

IGN.B2 40A

P-2

+ W 3

P-1

_

5B/Y

P-5

1 C-41

Y / B 0 3

P-7

P-10

FRAME

ENG.

B1

B2

STARTER SW

IG1 ST IG2 ACC

C-41

L 3

4 1

H-7

L 3 CB-19 15A AUDIO

L / R 5 8 . 0 L / R 5 . 0

4

B-26

CONTROL SW

RH RV LV RH LH LH

C

B-26 B-26 B-26 B-26 B-26

7 8 5 10 1

B-26 9

B 5 . 0

10 H-13

W / B 5 . 0

9 H-13

D-7

W / B 5 . 0

3 H-13

1 D-7

BODY-RH

B-28

MIRROR-LH

2 D-2

1 D-2

3 D-2

T F E L MLR

N W O D

4 H-10

B / W 5 . 0

P U

MUD

T H G I R

5 H-10

V 5 . 0

3

T F E L MLR

6

W / B 5 . 0

D-7

B / W 5 . 0

V 5 . 0

H-10

B / W 5 . 0

V 5 . 0

2

B 5 2 . 1

G / W 5 . 0

R / B 5 . 0

W / B 5 . 0

P U

MUD

T H G I R

N W O D

MIRROR-RH

D08RV778


TROUBLE SHOOTING QUICK CHART FOR CHECK POINTS Check Points Trouble Mode

1. Mirrors on the both sides do not operate

Fuse CB-19 (15A)

Door Mirror Control Switch





2. Mirror on the left (or right) side does not operate



3. Mirrors on the both sides operate only in the vertical (or horizontal) direction



4. Mirror on the left side operates only in the vertical (or horizontal) direction



5. Mirror on the right side operates only in the vertical (or horizontal) direction



Door Mirror LH

RH

Cable Harness


















TROUBLE SHOOTING DOOR MIRROR CONTROL SWITCH 1.

Mirrors on the both sides do not operate Checkpoint


NG

Trouble Cause

Countermeasure





OK


NG

OK Voltage between the door mirror control SW. harness side connector terminal 4 B-26 and the ground (Should be battery voltage present)

Repair an open circuit or a poor connection of the connectors between the fuse No. CB-19 (15A) and 4 B-26

NG


NG



SW. malfunction

Replace the door mirror control SW.



OK Continuity between the door mirror control SW. harness side connector terminal 9 B-26 and B-28 OK Door mirror control SW. function

NG

OK Continuity between 1 B-26 and 10 H-13 (or 6 H-10 )

NG


Mirror on the left (or right) side does not operate Checkpoint

Door mirror control SW. function

Trouble Cause

NG

Countermeasure

SW. malfunction


NG

Mirror malfunction on the left (or right) side

Repair or replace the door mirror

NG



OK Mirror function on the left (or right) side OK Continuity between [LHD] 1 B-26 and 2 D-2 (1 B-26 and 2 D-7 ) [RHD] 1 B-26 and 2 D-7 (1 B-26 and 2 D-2 )

3.

Mirrors on the both sides operate only in the vertical (or horizontal) direction


4.

NG

SW. malfunction


Mirror on th left side operates only in the vertical (or horizontal) direction


NG

SW. malfunction


Door mirror malfunction




OK

Door mirror function

NG

OK Continuity between [LHD] 8 B-26 and 3 D-2 (10 B-26 and 1 D-2 ) [RHD] 8 B-26 and 3 D-7 (10 B-26 and 1 D-7 )

NG


Mirror on the right side operates only in the vertical (or horizontal) direction Checkpoint


Trouble Cause

NG

Countermeasure

Door mirror control malfunction


Door mirror malfunction




OK

Door mirror function

NG

OK Continuity between [LHD] 7 B-26 and 3 D-7 (5 B-26 and 1 D-7 ) [RHD] 7 B-26 and 3 D-2 (5 B-26 and 1 D-2 )

NG



DOOR MIRROR CONTROL SWITCH

2. Door mirror control switch

Removal 1. Instrument Panel Cluster Assembly • Refer to section 10 “BODY” for instrument panel cluster assembly removal steps. 2. Door Mirror Control Switch • Disconnect the switch connector. • To remove the switch, push the lock from the back side of the cluster assembly.

1. Instrument panel cluster assembly 825RV094

Installation


DOOR MIRROR Removal and Installation

Refer to the DOOR MIRROR in section 10 “BODY”.



Door Mirror Control Switch 1. Switch Side Connector Circuit

B-26

4 3

Check continuity between the switch connector terminals while operating the door mirror control switch as shown in the following table.

2 1

10 9 8

7 6 5

Switch side

Connector No. 4

9

1

8

10

7

5

Switch position 

(Up)



(Down)

Door mirror (RH)  (Left)  (Right)

Door mirror (LH)



(Up)



(Down)

 (Left)  (Right)

2. Harness Side Connector Circuit B-26

1 2

3 4

5 6 7 8 9 10

Harness side

Remove the connector No. B-26 of the mirror control switch and check voltage and continuity of the harness side connector. • When there is no continuity at the terminal No. 5, 7, 8 and 10, it is considered that the circuit with terminal No. 1 (B/W) is defective.

8–316 ELECTRICAL-BODY AND CHASSIS •

Terminal No.

Wire color

1

B/W

4

When there is no continuity at either one of the circuit No. 5, 7, 8, or 10, the motor in the mirror of the circuit or the circuit itself is defective.

Check item

Connecting terminal

LH mirror & RH mirror

Continuity

R/L

Fuse CB-19 (15A)

Voltage

5

V

RH mirror-LH/RH

5–1

—

7

W/B

RH mirror-Up/Down

7–1

—

8

W/G

LH mirror-Up/Down

8–1

—

9

B

Ground

9-Ground

—

10

B/R

LH mirror-LH/RH

10 – 1

—

Connecting to

Continuity

Check condition

Standard

1-Ground

—

No continuity

4-Ground

Starter SW “ACC” position

Approx. 12V

Continuity

Door Mirror B-26

1 2

3 4

1. Door Mirror Control Switch Connector Circuit

Disconnect the switch connector ( B-26 ), apply the battery voltage to the harness side connector terminals and check its function.

5 6 7 8 9 10

Connector No.

Harness side

Terminal No.

Mirror

B-26

10

Right

Left

Operating 8

7

direction

5

1

+

–

Left

–

+

Right

–

+

Up

+

–

Down

+

–

Left

–

+

Right

–

+

Up

+

–

Down

ELECTRICAL-BODY AND CHASSIS 8–317 2. Door Mirror Connector Circuit D-2

1

Disconnect the door mirror connector, apply the battery voltage to the door mirror side connector ( D-2 and D-7 ) terminals and check its function.

D-7

2

3

Door mirror side

Connector No.

3 1

UP LH

M M

RH

2

825RV093

1

D-7

2

3

Up

–

+

Down

+

–

Operation

Down

Terminal No.

D-2

Left

+

–

Right

–

+


REAR DEFOGGER PARTS LOCATION (LHD)

L-7

L-4 B-15

H-7 H-12

C-41 B-28

D08RVA46



L-4

H-7 H-12

L-7

B-15 C-41 B-28

D08RVA47



STARTER SW

15B/R

+

MAIN 80A OR 100A P-2 IGN.B1 40A

P-1

IGN.B2 40A

OFF ACC

3W

IG2

B1

IG1

ST

3 3W/B

C-41

6

_

3B/R

C-41

3

P-5

5B/Y

B2

2

H-7 Y / B 0 3

P-7

P-10

FRAME

ENG.

H-7

W 3

R / B 3

CB-13 15A RR DEF

CB-7 15A METER

Y 5 8 . 0 1.25G/Y

Y 5 . 0 5

2

B-7

B-7

RELAY; RR DEFOGGER

B-7

B-7

1

4

) 1 ( L I A T ; Y A L E R

R / B 5 2 . 1 G / Y 5 . 0

R / B 5 2 . 1 4

3

B-15

B-15

R / G 5 8 . 0

6

B-15

RR DEFOGGER SW

B-15

B-15

5

2

1 H-12

R / B 5 2 . 1

1 L-4

RR DEFOGGER

B 3 . 0

B 5 . 0

L-7 1

B 5 2 . 1

3 H-12

B 5 2 . 1

BODY-LH

B-28

1.25B

D08RV975



STARTER SW

15B/R

+

MAIN 80A OR 100A P-2 IGN.B1 40A

P-1

IGN.B2 40A

OFF ACC

3W

IG2

B1

IG1

ST

3 3W/B

C-41

6

_

3B/R

C-41

5

P-5

5B/Y

B2

4

H-7 Y / B 0 3

P-7

P-10

FRAME

ENG.

H-7

W 3

R / B 3

CB-13 15A RR DEF

CB-5 15A METER

Y 5 8 . 0 1.25G/Y

Y 5 . 0 5

2

B-7

B-7

RELAY; RR DEFOGGER

B-7

B-7

1

4

) 1 ( L I A T ; Y A L E R

R / B 5 2 . 1 G / Y 5 . 0

R / B 5 2 . 1 4

3

B-15

B-15

R / G 5 8 . 0

6

B-15

RR DEFOGGER SW

B-15

B-15

5

2

1 H-12

R / B 5 2 . 1

1 L-4

RR DEFOGGER

B 3 . 0

B 5 . 0

L-7 1

B 5 2 . 1

3 H-12

B 5 2 . 1

BODY-RH

B-28

1.25B

D08RV974


TROUBLE SHOOTING Rear defogger inoperative Checkpoint

LHD: Fuse No. CB-7 (15A, Fuse box) RHD: Fuse No. CB-5 (15A, Fuse box)

Trouble Cause

NG

Countermeasure


Reinstall or replace the fuse No. CB-7 (15A) (RHD: fuse No. CB-5 (15A))



Switch malfunction

Replace the rear defogger switch

Relay malfunction

Replace the rear defogger relay



OK Fuse No. CB-13 (15A, Fuse box)

NG

OK Rear defogger switch function

NG

OK Rear defogger relay function

NG

OK


NG

OK Voltage between 1 L-4 ground when the starter switch and the rear defogger switch are at on position (should be battery voltage present)

Continued on the next page

NG


Repair open circuit or poor connector contact between fuse No. CB-7 (15A) (RHD: fuse No. CB-5 (15A)) and 2 B-7 , fuse No. CB-13 (15A) and 5 B-7 , 1 B-7 and 1 L-4 , 4 B-7 and 4 B-15 or 5 B-15 and B-28

ELECTRICAL-BODY AND CHASSIS 8–323 Checkpoint

Trouble Cause

Countermeasure

Continued from the previous page OK Continuity between 1 L-7 and B-28

NG


Repair open circuit or connector contact between 1 L-7 and B-28

NG

Broken heat wire of rear defogger

Repair heat wire

OK Continuity between rear defogger terminals



REAR DEFOGGER SWITCH

Instrument panel cluster assembly

Removal 1. Instrument Panel Cluster Assembly • Refer to Section 10 “BODY” for instrument panel cluster assembly removal steps. Rear defogger switch

This illustration is based on RHD

2. Rear Defogger Switch • Disconnect the switch connector. • To remove the switch, push the lock from the back side of the cluster assembly.

825RV095

Installation

Follow the removal procedure in the reverse order to install the rear defogger switch.



REAR DEFOGGER SWITCH B-15

Rear Defogger Switch Connections Terminal No.

2

3

1

5

4

6

2

SW position

6 5 4 3

ON OFF Switch side 825RV095

REAR DEFOGGER RELAY Check continuity between the relay terminals.

B-7 1

1 - 5 . . . . . . . . . . . . . . . . . . . . No continuity

3

4

3

2 5

1

2

4

(When battery voltage is applied between 2 and 4) 1 - 5 . . . . . . . . . . . . . . . . . . . . Continuity

5 060RV005

INSPECTION OF REAR DEFOGGER HEAT WIRE Heat wire

•

•

Test probe •

Tin foil

Heat wires are printed on the inner side of glass. To clean, use a soft cloth and wipe horizontally along the wires. Never use glass cleaner or equivalent. When measuring voltage, wind a piece of tin foil around the tip of the negative probe and press the foil against the wire with your finger as shown.

825RV102

(1)

Turn the ignition switch on.

(2)

Turn the defogger switch on.

(3)

Measure the voltage between the three points on the heat wire and the (–) terminal with a voltmeter.

(4)

Check that the voltage becomes smaller from A to B to C.

Grounding side A

B

C

825RV103


(5)

If there is a place where the voltage suddenly changes to 0V, there is a broken wire between there and the power side.

(6)

Move the tester probe from the position where the voltage changes to 0V toward the power side and find where the voltage suddenly increases.

OV

Power side

Broken point

Ground side

825RV101

REPAIR OF BROKEN HEAT WIRE Repair agent

(1)

Clean broken wire tips with white gasoline.

(2)

Place masking tape along both sides of wire to be repaired.

(3)

Thoroughly mix the repair agent (Dupont paste No. 4817 or equivalent).

(4)

Using a fine tip brush, apply a small amount to the wire.

(5)

After a couple of minutes, remove the masking tape.

(6)

Allow to stand at least 24 hours.

Broken wire

Masking tape

825RV099

825RV100


RADIATOR LEVEL CONTROL WARNING SYSTEM PARTS LOCATION (LHD ONLY)

H-8

C-2

H-7 C-76

C-41

C-75

C-73

D08RVA44


CIRCUIT DIAGRAM

STARTER SW

15B/R

+

MAIN 80A P-2

IGN.B2 40A

OFF ACC

3W

1 C - 41

B2

8 IG2

C - 41

3 B/Y

ST

P-1 B1

IG1

6

P-5

H -7

_

5B/Y

Y / B 3

Y / B 0 2

CB-11 15A BACK UP, TURN P-7

P - 10

FRAME

ENG.

W 5 8 . 0 18 H -8

W 5 8 . 0

1 C-76 RADIATOR LEVEL WARNING BUZZER

W 5 8 . 0

C-76 2

R 5 . 0

1

4

C-75

C-75

RADIATOR LEVEL WARNING CONTROL UNIT C-75

C-75

5

6

Y 5 . 0

1 C-73 RADIATOR LEVEL SENSOR

B 5 . 0

C-73 2

B 5 . 0

FENDER-RH

C-2

1.25B

D08RV973


MEMO


CONNECTOR LIST No.

Connector face

No.

B-1

Connector face

B-11

1 4

2 5

3 6

B-2

1

1

2

2

B-12

1 1 2 3

2 3

B-3

B-13

1

1

2

2

B-4

1

2

3

4

5

6

B-14

NOT USED

B-5

1

2

3

4

5

8

9 10 11 12 13 14 15 16

B-15

2

1

3 4 5 6

3

1

B-6

2 4

5

6

B-16

1 2

NOT USED

3

4 5 6 7 8

B-7

B-17 1 2

3

NOT USED

4

5

B-8

B-18 1 2

3

NOT USED

4

5

B-9

B-19

1 2

B-10

B-20

1

1

2

3

4

2

6

7


No.

Connector face

No.

B-21

Connector face

B-31

—

1

B-22

B-32

NOT USED

1

B-23

B-33

1 2 3 4 5 6 7

8 9 10111213141516

1

B-24

2

3

B-34 1 1 2 3 4 5 6 7 8 9

10111213141516

2

B-25

B-35

NOT USED

1

2 3

B-26

B-36

1 2

3 4

5 6 7 8 9 10

B-27

4 3 10 9 8

2 1

1

7 6 5

2

B-37

NOT USED

B-28

B-29

1

2

3

4

1

2

3

4

B-30


No.

Connector face

C-1

No.

Connector face

C-11

1

1

2

2

C-2

C-12

NOT USED

C-3

C-13

1

2

3

4

5

6

7

8

C-4

NOT USED

C-14

1

2

3

4

5

6

C-5

NOT USED

C-15

1

1

C-6

2

C-16

NOT USED

1

C-7

C-17

1

1

2

2

C-8

C-18

NOT USED

1

C-9

2

C-19 1

NOT USED 2

C-10

3

C-20 1 2

1


No.

Connector face

No.

C-21

Connector face

C-37

1 1

2 3

C-22

C-38

2

1

1

2

C-23

C-39 (LHD)

NOT USED

1

C-24

C-39 (RHD) 1 2

C-25

C-40

2

1

1

C-26

2

1 2

C-41 1 2

3

C-27

4

3

2

1

8

7

6

5

2

3

4

6

7

8

C-42 6 5 4

3 2 1

16 1

15 14131211

2

C-28

10 9 8 7

1 2 3

4 5 6

15

16 7 8 9 10

11 121314

C-43

C-34

6 5 4

NOT USED

3 2 1

14131211

C-35

10 9 8 7

C-44

1

2 1

C-36

1 5

2

C-45

1

3 2

1 2

3

7 8 9 10

4 5 6 11 12 13 14


No.

Connector face

No.

C-46

Connector face

C-52 1

2

4

5

3 6

7

C-47

C-53 C-57

NOT USED (GASOLINE) C-47

C-58

1

2

1

1

2

4

3

3

4

(DIESEL) C-48

C-59

NOT USED

1

(GASOLINE) C-48

C-60

1

2 1

3

2

4

(4JA1) C-48

C-60 1 2

1 2

3

(4JA1 FOR SOUTH AFRICA)

(CHINA)

C-48

C-61

1

2

3

1

2

(4JB1) C-49

C-62

1

1

1

C-50

C-63

NOT USED

NOT USED

C-51

C-64

NOT USED


No.

Connector face

No.

C-65

Connector face

C-74

1

C-66

2

C-75

1

2

3

4

C-66

3

2

1

6

5

4

C-76 1 3

2

2

1

4

4

3

1 2

(CHINA) C-67

C-77

NOT USED

1 2

C-68

C-78

1

2

C-69

1

2

4

5

3 6

7

C-78

NOT USED

1

2

4

5

3 6

7

(4ZD1 WITH CATALYSIS CONTROL) C-70

C-79

1

1

C-71

C-80

1

C-72

1

2

3

3

2

1

4

5

6

6

5

4

C-81

1 2

C-73

C-82

1

1

2

3

4

2

2

1

4

3


No.

Connector face

No.

C-83

Connector face

C-93

1

2

3

4

1

C-84

2

C-94 1

1 2 3

2

C-85

C-95

1

2

2

1

3

4

4

3

C1 C2 C3 C4 C5 C6 C7 C8 C9 C10C11C12C13C14C15C16

C-86

D1 D2 D3 D4 D5 D6 D7 D8 D9 D10D11D12D13D14D15D16

C-96

A1

A2

A3

A4

A5

A6

A7

A8

A9 A10 A11 A12 A13

B1

B2

B3

B4

B5

B6

B7

B8

B9

A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 B1

B2 B3

B4

B5

B6

B7

B8 B9 B10 B11 B12

B10 B11 B12 B13

C-87

C-97

1 2 3

1

2

4 5 6

7 8 9 10

C-88

11 12 13 14

C-98

1

NOT USED

3

C-89

2 4

5

6

C-99

1

NOT USED

2

3 4 5 6

C-90

C-100

3

2

1

1 2

C-91

C-101

1 2 3 4

C-92

2

1

4

3

1 3

4 2

C-102

1 2

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16


No.

Connector face

C-103 1 3

4 2

No.

Connector face


No.

Connector face

No.

D-1

Connector face

D-11

2

1

1

2

2

D-2

1

1

2

1

2

D-12

3

2

1

1 1

2

3

D-3

2

3 4 5 6

D-13

1

1

2

2

D-4

D-14

1

2

3

3

2

1

D-5

1 3

2 4

2

1

D-15

1 2

3 4

5 6 7 8 9 10

D-6

D-16

2

1

1

1

2

2

3 4 5 6

D-7

D-17

1 3

2

1

D-8

1

2

3

2

D-18

1 1 3

2

D-9

1 3

2 4

D-10

1 2

3 4

5 6 7 8 9 10

2 4


No.

Connector face

No.

E-1

Connector face

E-10

1

1

2

3

(DIESEL) E-1

E-11

2

1

1

2

1

2

3

4

(GASOLINE WITH MPI) E-2

E-12

1

1

2

1

2

2

1

1

E-3

E-13

E-4

E-14

1

E-5

E-15

E-6

E-16

1

1

2

E-7

2

E-17

1

NOT USED

2

E-8

E-18

1

NOT USED

2

E-9

E-19

1

2

1

3


No.

Connector face

No.

E-20

Connector face

E-47

E-35

NOT USED

NOT USED

E-36

E-48 1

1

2

2

E-37

NOT USED

E-49

1

1

E-38

E-50

E-40

NOT USED

1

1

E-41

E-51

E-42

1

2

1

2

E-52

E-43

E-53

E-44

1

2

3

1

2

3

1

2

3

1

2

3

E-54

1

2

3

E-45

E-55

1

1

E-46

E-56

1

1


No.

Connector face

No.

E-57

Connector face

E-67

1

2

3

1 2

E-58

E-68

1

2

1

3

E-59

2

3

E-69

1

2

3

1 2

E-60

E-70

393735333129272523211917151311 9 7 5

3 1

40383634323028262422201816141210 8 6 4 2

E-61

1

2 3

4

5 6

E-71

2 4 6 8 10121416182022242628303234363840 1 3

5 7

9 111315171921232527293133353739

1

E-62

E-72

1 2

3

E-63

E-73

1

2

3

E-64

4

E-74

1

E-65

1

E-66

1

2


No.

Connector face

No.

F-1

1

2

3

3 2 1

F-2

1

F-3

2

2

1

Connector face


No.

Connector face

No.

H-1

Connector face

H-8 (LHD) 1

1

1

2

3

7

8

8

4 10 17

14 15 16

5

6

11 12 13 18 19 20

6

5

4

10

13 12 11 17

20 19 18

H-2

3

2

1

9

8

7

16 15 14

H-8 (RHD) 1

1

1

2

2

2

5

6

3

4 4 3

H-3

7

8

9 10

2 1

10 9 8

7 6

5

H-9 1 2

NOT USED

4 3

3 4

5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

H-4

2 1

12 11 10 9 8

7 6 5

20 19 18 17 16 15 14 13

H-10 1 5

2 6

3 7

4

4 8

9

9

2 7

1 6

5

14 1 3 1 2 1 1 1 0

10 1 1 1 2 1 3 1 4

15

3 8

16

16

2

1 2

1

15

(WITHOUT POWER WINDOW AND POWER DOOR LOCK) H-5

H-10 1 2 1

2

5

3

6

4

7

8

4

3

2

1

8

7

6

5

3

3

4 5 6 7 8 9 10111213

(4ZC1 AND 4ZD1)

2 1

8 7 6 5 4 13121110 9

(WITH POWER WINDOW AND POWER DOOR LOCK)

H-5

H-11

1

2

3

4

4

3

2

1

5

6

7

8

8

7

6

5

1

1

2

2

(4ZD1 FOR SAUDI ARABIA) H-5

H-12 1

2

3

3

2

1

4

5

6

6

5

4

1

2

2

1 3

3

(4ZE1) H-6

H-13

1 2 3 4 5

6 7 8 9 10

1112131415 16

17 1819202122

10 9 8 7 6

5 4 3 2 1

22 21 20 19 18 17

2

1 2

1615 14 13 1211

1

(WITHOUT POWER WINDOW AND POWER DOOR LOCK) H-7

H-13

(LHD) 1

2

3

4

5

6

3

2

1

6

5

4

1

2

5

6

3 7

8

4

9 10

4 3

2 1

10 9 8

7 6

5

(WITH POWER WINDOW AND POWER DOOR LOCK) H-7 (RHD)

H-14

1

2

3 4 5 6

2

1

6 5 4 3

1 2

3

4 5 6 7 8

3 8

7

6

2

1

5

4


No.

Connector face

No.

H-15

Connector face

H-25 2 1

1

2 8 7 6 5 4 3

3 4 5 6 7 8

14 13121110 9

910 11 121314

1

2

3

4

5

6

7

8

9

H-16

10

4

3

2

1

8

7

6

5

12 11 10

11 1 2

9

H-26

1 2

3

4

3

3

2

1

10

5

4

14 13

9

2 8

7

6

7

6

20 19

H-17

2

5

6

3 7

8

4

9 10

5

4 5 6 7 8 8

1 1

11 12

12 11

13 14

15 16 17 18 19 20

18 17 16 15

H-27

1

2

3

3

2

1

1 2

4

5

6

6

5

4

4 5 6 7 8

H-18

3

3

2 1

8 7 6 5 4

H-28

1

2

3

3

2

1

H-19

1

2

3

4

5

6

3

2

1

6

5

4

H-29 1

2

3

4

5

6

7

8

9

10 1 1 12

13

14 15 16

4

3

2

1

8

7

6

5

12 1 1 10

NOT USED

9

16 15 14 13

H-20

H-30 1

2

3

4

5

6

7

8

9

10 1 1 12

13

14 15 16

4

3

2

1

8

7

6

5

12 1 1 10

1

9

16 15 14 13

H-21

1

2

2

1

1 2

H-31

1

2

1

H-23

H-32 1

2

3

4

5

6

7

8

9

10

11 1 2

4

3

2

1

8

7

6

5

12 11 10

1

1

6 5 4 3

3 4 5 6

9

H-23

2

2

H-33 1

2

5 9 13

6

3 7

4 8

10 1 1 1 2 14

15

16

4

3

2

1

8

7

6

5

12 1 1 10

2

9

1

1 2

16 15 14 13

H-24

H-34 3

1 3

2

2

1

4

4

3

2

1

1

2

3

9

8

7

6

5

4

4

5

6

7

8

9

15

14

13

12

11

10

10

11

12

13

14

15


No.

Connector face

No.

H-35

NOT USED

H-36

1

2

2

1

H-37

1

2

3

H-38

1

2

2

1

Connector face


No.

Connector face

L-1

L-2

L-3

L-4

1

L-5

1

L-6

1

L-7

1

L-8

L-9

No.

Connector face


No.

Connector face

M-1

No.

Connector face

M-11

M-2

1

1

1

1

M-12

M-3

M-13

M-4

M-14

M-5

M-15

NOT USED

1 2

M-6

M-16 1 3

2 5

4

M-7

M-17

2

1

4

3

1

M-8

2

3

4

M-18 M-24

NOT USED

M-9

M-25

1

4

5

M-10

1

2

3

2

3

6

7

8


No.

Connector face

No.

P-1

P-9

P-2

P-10

P-3

P-11

Connector face

(DIESEL) P-3

P-12

1

(GASOLINE) P-4

(DIESEL) P-4

(GASOLINE) P-5

P-6

P-7

P-8

1


No.

Connector face

No.

R-1

R-2

NOT USED

R-3

1

2

R-4

1

R-5

NOT USED

R-6

21

Connector face


No.

Connector face

No.

T-1

1 2 3 4 5 6

3

2

1

6

5

4

T-2

NOT USED

T-3

1

2

2

1

T-4

NOT USED

T-5

NOT USED

T-6

1 2 3 4 5 6

3

2

1

6

5

4

Connector face


No.

Connector face

X-1

No.

Connector face

X-11 1 2

3

4

1

2

3

4

1

2

3

4

3

4

5

X-2

X-12 1 2

3

4

5

X-3

X-13 1 2

3

NOT USED

4

5

X-4

X-14 1 2

3

4

1

2

5

X-5

X-15 1 2

3

1 4

2

5

3

4

5

X-6

X-16 1 2

3

1 4

2

5

3

4

5

X-7

X-17 1 1 2

3

2

4

5

3

X-8

4

5

X-18 1 1 2

3

2

4

5

3

X-9

4

5

X-19 1 1 2

3

2

4

5

3

X-10

4

5

X-20 1 1 2

3

2

4

5

3

4

5


No.

Connector face

X-21 1

2 3

4

5

X-22 1

2 3

4

5

X-23 1

2 3

4

5

X-24 1

2 3

4

5

X-25 1

2 3

4

5

X-26 1 2

3

4

5

X-27

NOT USED

X-28

1

2

3

4

1

2

3

4

X-29

No.

Connector face

Isuzu TF series Electrical Body and chasys

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