Cab&Chaissis Electrical

WORKSHOP MANUAL
2007MY N-SERIES
CAB AND CHASSIS ELECTRICAL (LEFT HAND DRIVE MODEL)

SECTION 8
Isuzu Motors Limited Service Marketing Department
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-0A under the heading GENERAL REPAIR INSTRUCTIONS.
All material contained in this manual is based on latest product information available at the time of publication. All rights are reserved to make changes at any time without prior notice.
Applicable Model: N-Series This manual is applicable to 2007 year model.
THIS MANUAL INCLUDES THE FOLLOWING SECTIONS:

SECTION No. 8
CONTENTS
CAB AND CHASSIS ELECTRICAL
8-1

CAB AND CHASSIS ELECTRICAL Contents
GENERAL INFORMATION..................................... 8-2 General Information............................................. 8-2 Notes for Working on Electrical Items ................. 8-2 Symbols and Abbreviations ................................. 8-8 Parts for Electrical Circuit .................................. 8-11 Reading The Circuit Diagram ............................ 8-19 MAIN DATA AND SPECIFICATIONS ................... 8-22 Bulb Specifications ............................................ 8-22 Fuse and Fusible Link Location......................... 8-24 Reference Table of Fuse and Circuit Breaker ... 8-30 Relay Location................................................... 8-33 Diode Location................................................... 8-35 Reference Table of Grounding Point ................. 8-36 Grounding Point Location .................................. 8-37 Cable Harness Routing ..................................... 8-38 SYSTEM REPAIR ................................................. 8-41 Start and Charging ............................................ 8-41 Exhaust Brake System and Engine Control ...... 8-49 Headlight, Fog Light, Rear Fog Light and Cornering Light .. 8-92 Headlight Leveling ........................................... 8-117 Clearance Light, Taillight, License Plate Light and Illumination Light ... 8-126 Turn Signal Light, Hazard Warning Light and Stoplight .... 8-139 Horn, Backup Light and Backup Buzzer.......... 8-154 Dome Light and Backup Buzzer ...................... 8-166 Power Door Lock ............................................. 8-177 Power Window................................................. 8-189 Windshield Wiper and Washer ........................ 8-204 Audio and Cigar Lighter................................... 8-223 Meter and Warning/indicator Light................... 8-231 Heater and Air Conditioning ............................ 8-280 Rear Heater ..................................................... 8-286 ABS/ASR System ............................................ 8-290 Transmission Control System (Smoother)....... 8-296 Tacho Graph.................................................... 8-315 SECTION 8
8-2 CAB AND CHASSIS ELECTRICAL
GENERAL INFORMATION
General Information
The chassis electrical system is of 24-volt specifications with a negative ground polarity. Wire sizes are appropriate to respective circuits, and classified by color. (The classification of harnesses by color is shown on the circuit diagram for ease of harness identification.) The wire size is determined by load capacity and the length of wire required. The vehicle harnesses are: body harness, floor harness, engine harness, frame front harness, frame rear harness, rear body harness, dome light harness, door harness and battery cable. The harnesses are protected either by tape or corrugated tube, depending on harness location. The circuit for each system consists of the power source, wire, fuse, relay switch, load parts and ground, all of which are shown on the circuit diagram. In this manual, each electrical device is classified by system. For major parts shown on the circuit based on the circuit diagram for each system, a summary, diagnosis of troubles, inspection and removal and installation procedures are detailed.
N8B5125E
Notes for Working on Electrical Items

Battery Cable
Disconnecting The Battery Cable 1. All switches should be in the OFF position. 2. Disconnect the battery ground cable 1. 3. Disconnect the battery positive cable 2. 4. Disconnect the battery cable 3. 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. Caution: Clean the battery terminal and apply a light coat of grease to prevent terminal corrosion.
Connector Handling Disconnecting The Connectors 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. Firmly grasp both sides (male and female) of the connector. Release the tang lock and carefully pull the two halves of the connector apart.
N8A0003E
Never pull on the wires to separate the connectors. This will result in wire breakage.
8-3
N8A0004E
N8A0006E
Connecting the Connector 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.
Never insert the circuit tester test probes into the connector open end to test the continuity. Broken or open connector terminals will result.
N8A0007E
N8A0005E
Connector Inspection Use a circuit tester to check the connector for continuity. Insert the test probes from the connector wire side.
Waterproof Connector Inspection 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 2 to the connector to be tested. Connect the test probes to the cut wires to check the connector continuity.
N8A0008E
N8A0010E
Connector Pin Removal Connector Housing Tang Lock Type 1. Insert a slender shaft into the connector housing open end. 2. Push the tang lock up (in the direction of the arrow in the illustration). Pull the wire with pin free from the wire side of the connector.
Connector Pin Insertion 3. Check that the tang lock is fully up. 4. Insert the pin from the connector wire side. Push the pin in until the tang lock closes firmly. 5. Gently pull on the wires to make sure that the connector pin is firmly set in place.
N8A0011E N8A0009E
Pin Tang Lock Type 1. Insert a slender shaft into the connector housing open end. 2. Push the tang lock flat (toward the wire side of the connector). Pull the wire with pin free from the wire side of the connector.
Parts Handling Be careful when handling electrical parts. They should not be dropped or thrown, because short circuit or other damage may result.
8-5
N8A0012E
N8A0014E
Cable Harness When installing the parts, be careful not to pinch or wedge the wiring harness. All electrical connections must be kept clean and tight.
Position the wiring harness with an enough clearance from the other parts and guard the wiring harness with a vinyl tube and clips to avoid direct contact.
N8A0015E N8A0013E
Use a grommet or guard tube to protect the wiring harness from contacting a sharp edge or surface.
The wiring harness between engine and chassis should be long enough to prevent chafing or damage due to various vibrations.
N8A0016E
N8A0017E
Splicing Wire
1. 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 block plastic conduit, simply pull out the desired wire. 2. 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 1-2/2 (40 mm) away from other splices, harness branches, or connectors. 3. 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 stands. If the wire is damaged, repeat the procedure on a new section of wire. The two stripped wire ends should be equal in length. 4. 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, center the splice clip under the stripped wires and hold it in place.
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.
N8A0018E
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.
8-7
N8A0019E
N8A0021E
5. 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.
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.
N8A0022E N8A0020E
6. 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.
8-8 CAB AND CHASSIS ELECTRICAL Symbols and Abbreviations

Symbols
Symbol Meaning of Symbol Contact wiring Symbol Meaning of Symbol
Fuse
N8A5507E
N8A5501E
Battery
Fusible link
N8A5508E
N8A5502E
Diode
Fusible link wire
N8A5509E
N8A5503E
Electronic Parts
Switch
N8A5510E
N8A5504E
Resistor
Switch
N8A5511E
N8A5505E
Speaker
Switch (Normal close type)
N8A5512E
N8A5506E
Buzzer
N8A5513E

Symbol Meaning of Symbol Symbol Meaning of Symbol
8-9
Circuit breaker
Connector
N8A5514E
N8A5521E
Bulb
Light emitting diode
N8A5515E
N8A5522E
Double filament bulb
Reed switch
N8A5516E
N8A5523E
Motor
Condenser
N8A5517E
N8A5524E
Variable register Rheostat
Horn
N8A5518E
N8A5525E
Coil (inductor), solenoid, magnetic valve
Vacuum switching valve
N8A5519E
N8A5526E
Relay
N8A5520E

Abbreviations
Abbreviation A ABS ASM AC A/C ACC C/B CSD DIS EBCM ECGI ECM ECU EFE 4X4 FL FRT H/L IC IG Meaning of Abbreviation Ampere (S) Anti-lock brake system Assembly Alternating current Air conditioner Accessories Circuit breaker Cold start device Direct ignition system Electronic brake control module Electronic control gasoline injection Electronic control module Electronic control unit Early fuel evaporation Four-wheel drive Fusible link Front Headlight Integrated circuit Ignition Abbreviation kW LH LWB M/T OD OPT QOS RH RR RWAL ST STD SW SWB V VSV W WOT W/ W/O kilowatt Left hand Long wheel base Manual transmission Over drive Option Quick on start Right hand Rear Rear wheel anti-lock brake system Start Standard Switch Short wheel base Volt Vacuum switching valve Watt (S) Wide open throttle With Without Meaning of Abbreviation
CAB AND CHASSIS ELECTRICAL 8-11 Parts for Electrical Circuit

Wiring
Wire Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's subcircuit will have a colored stripe. Striped wires use the following codes to show wire sizes and colors.
N8A5023E
Abbreviations are used to indicate wire color within a circuit diagram. Refer to the following table. Wire Color Coding Color-Coding B W R G Y L O Meaning Black White Red Green Yellow Blue Orange Color-Coding BR LG GR P LB V Meaning Brown Light green Grey Pink Light blue Violet
Distinction of Circuit by Wire Base Color Base color B W R G Starter circuit Charging circuit Lighting circuit Signal circuits Circuits Base color Y L, O, BR, LG, GR, P, LB, V Circuits Instrument circuit Other circuit
Wire Size The size of wire used in a circuit is determined by the amount of current (amperage), the length of the circuit, and the voltage drop allowed. The following wire size and load capacity, shown below, are specified by AWG (American Wire Gauge) (Nominal size means approximate cross sectional area).
N8A0025E
Wire Size Table Nominal size 0.3 0.5 0.85 1.25 2 3 5 8 15 20 Cross sectional area (mm2) 0.372 0.563 0.885 1.287 2.091 3.296 5.227 7.952 13.36 20.61 Outside diameter (mm) 1.8 2.0 2.2 2.5 2.9 3.6 4.4 5.5 7.0 8.2 Allowable current (A) 9 12 16 21 28 37.5 53 67 75 97 AWG size (cross reference) 22 20 18 16 14 12 10 8 6 4
Fuse, Fusible Link and Circuit Breaker

Fuse 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. The replacement fuse must have the same amperage specifications as the original 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.
N8A0026E
CAB AND CHASSIS ELECTRICAL 8-13

Fusible Link 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.
N8A0027E
Fusible Link Specifications Type Connector Connector Bolted Bolted Bolted Rating 30 A 40 A 50 A 60 A 80 A Case Color Pink Green Red Yellow Black Maximum Circuit Current (A) 15 20 25 30 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.
Relay 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.
N8A0029E N8A0028E

Relay Specification, Configuration and Inspection Name/ Color Rated voltage/ Coil resistance Internal circuit Name/ Color Rated voltage/ Coil resistance Internal circuit
MR5C (1T)/ Green
24 V/ Approx. 266 Minimum operating voltage: 16 V at 25C (77F)

1 2 3 5 4
N8A0431E
N8A0433E
MR82C/ Green label

N8A0434E
N8A0432E
MR5C (1T)/ Grey
24 V/ Approx. 266 Minimum operating voltage: 20 V at 25C (77F) The way Result
(connector face)
(connector face)
Check to see if there is any continuity between the relay terminals. Result
The way
Check to see if there is any continuity between the relay terminals.
Normal Inspection Abnormal
(When no voltage is applied relay terminals 2 -4) 3 -5 continuity 1 -5 No continuity Inspection (When minimum operating voltage is applied relay terminals between 2 -4) 3 -5 continuity 1 -5 No continuity (When minimum operating voltage is applied relay terminals between 2 -4) 3 -5 No continuity 1 -5 continuity Inspection
Normal
(When no voltage is applied relay terminals 4 -5) 2 -3 No continuity (When minimum operating voltage is applied relay terminals between 4 -5) 2 -3 No continuity (When minimum operating voltage is applied relay terminals between 4 -5) 2 -3 continuity
Abnormal
Normal
Normal

Name/ Color Rated voltage/ Coil resistance Internal circuit
ACM 13222 M01/ Green
N8A5571E
N8A5572E
(connector face) The way Result Check to see if there is any continuity between the relay terminals.
Normal Inspection Abnormal
(When no voltage is applied relay terminals 3 - 5) 1 - 4 continuity 1 - 2 No continuity Inspection (When minimum operating voltage is applied relay terminals between 3 - 5) 1 - 4 continuity 1 - 2 No continuity (When minimum operating voltage is applied relay terminals between 3 - 5) 1 - 4 No continuity 1 - 2 continuity
Normal

Diode Diode Specifications and Configurations
THERE SHOULD BE CONTINUITY IN EITHER A OR B WHEN A CIRCUIT TESTER IS CONNECTED WITH DIODE TERMINAL
SHAPE
MARK/ COLOR
CONSTRUCTION
CHECKING
TERMINAL NO. 2 1 CONNECTION PATTERN A B
BLACK
TERMINAL NO. CONNECTION PATTERN A B
BLACK
TERMINAL NO. A B
CONNECTION PATTERN
BLACK
TERMINAL NO.
4 3 2 1
CONNECTION PATTERN B A
BLACK
N8A0032E
Maximum Rating (Temp. = 25C) Items Peak reverse voltage Transient peak reverse voltage Average output current Working ambient temperature Storage temperature Rating 400 V 500 V 1.5 A 30C 80C 40C 100C Temp. = 40C Remarks

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. Connector is identified with a number.
N8A0035E
The applicable terminal number is shown for each connector.

N8A0033E
The symbol illustrated in the figure is used as connector, in the circuit of this section.
N8A0036E
N8A0034E
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.

The connectors used for relays have their own terminal number assignment, irrespective of the above rule.
N8A0037E
Notice: For those connectors on which specific terminal numbers or symbols are shown (such as ECM), the terminal numbers or symbols are used in the circuit diagram, irrespective of the above rule.
N8A5038E
N8A0038E
CAB AND CHASSIS ELECTRICAL 8-19 Reading The Circuit Diagram

In this manual, each system has its own parts location illustration, circuit diagram and connector configuration used in the circuit diagram.
Parts Location
The parts location shows the location of the parts 1 and the connector 2 used in each harness routing 3.
N8A0040E

Circuit Diagram
The circuit diagram shows the power supply 4, the load or loads 5 and the grounding point(s) 6.
N8A5040E

Connector List
The connector list shows each connectors' configuration 7 and the pin number 8.
No.
Connector Face
No.
Connector Face
7
B-341
8
1 2
002-009 000-009
E-5
B-232
1 2
002-009
E-16
1 2
002-014
B-51
1 2 3 4 5 6 7 8
9 1011121314
E-110
014-001
1 2 3 6 7 8
5 9
009-003
B-52
1 7
2 8
E-76
012-003
1 3
2 4
9 10 11 12
N8A0430E
Connector Symbol
Connector Symbol B D E H J Harness name Body harness Door harness Engine harness For joint between harnesses Front frame & Rear frame harness Connector Symbol L N P R Harness name Dome Light harness Floor harness (LH & RH) Battery harness Rear body harness
MAIN DATA AND SPECIFICATIONS

Bulb Specifications
Roof Marker light (NPR/NQR EC Only)
Backup light Dome light License plate light Stoplight/ Taillight Turn signal light
Side turn signal light (EC Only) Headlight Fog light Cornering light / Clearance light
N8B0001E
Turn signal light
Light Name Halogen Headlight Front combination light Fog light Rear combination light Turn signal light Cornering light / Clearance light Front Rear Stoplight / Taillight Turn signal light Backup light
Rated Power 75 W / 70 W 21 W 21 W / 5 W 70 W 21 W 21 W / 5 W 21 W 21 W 5W 12 W 10 W 5W 21 W
No. of Bulb 2 2 2 2 1 2 2 2 2 1 1 2 2
Lens Color Clear Amber Clear Clear Red Red Amber Clear Clear White White Amber
Remarks 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V
License plate For EC light Except EC Dome light Roof marker light Side turn signal light

Rated Power Light Name Glow Engine oil pressure Fuel sedimenter Brake fluid level / Parking brake Charge High beam Indicator / Warning Light (In the meter assembly) Turn signal Fuel level Rear fog Brake booster ABS Check engine P.T.O. Smoother 1st start ECONO ASR Illumination light for meter assembly Hazard warning switch Illumination Dome light switch Front fog light switch Cigar lighter Heater bezel Ashtray Except 4HK1-TC 1.4 W 1.4 W 1.4 W 1.4 W 1.4 W 1.4 W 1.4 W 1.8 W 1.4 W 1.4 W 1.4 W 1.4 W 1.4 W 3W 1.8 W 1.8 W 1.8 W 1.8 W 1.4 W 1.4 W 4HK1-TC 1.8 W 1.8 W 1.8 W 1.8 W 1.8 W 1.8 W 1.8 W 1.8 W 1.8 W 1.8 W 1.8 W 1.8 W 1.8 W LED LED LED 1.8 W No. of Bulb 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Remarks 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V
8-24 CAB AND CHASSIS ELECTRICAL Fuse and Fusible Link Location
Fuse and Circuit Breaker
Fuse puller Spare fuse Fuse( F-25 F-28 )
Fuse label
Fuse(
F-1
F-24
Relay box (Installed on the left side rear of the cab)
Fuse(
F-29
F-31
Relay box No. 2
N8A0531E
Fuse Label-for 24 Volt (4JJ1 EURO 3) 15A (1) 10 A (2) (3) 15 A (4) 10 A (5) 20 A (6) 10 A (7) 10 A (8) 10 A (9) 15 A (10) 10 A (11) HEATER, AIR CON FUEL HEATER AUDIO (B), DOOR LOCK STOP LIGHT POWER WINDOW TAIL LIGHT FRT FOG LIGHT ENG. (IG) FRONT WIPER & WASHER TURN LIGHT
10A (12) (13) (14) 15 A (15) 10 A (16) (17) (18) 10 A (19) 15 A (20) (21) 10 A (22) 10 A (23) 10 A (24)
H/LAMP LEVEL AUDIO (IG), CIGAR LIGHTER METER ENG. (BACK UP), HSA HORN, HAZARD STARTER HEAD LIGHT RH HEAD LIGHT LH

(25) 15A (26) (27) 10 A (28) ECM. ENG. COND. FAN 10 A (21) 10 A (22) 10 A (23) 10 A (24) 15 A (25) 15 A (26) (27) 10 A (28) ECM. ENG. ABS (IG) STARTER HEAD LIGHT RH HEAD LIGHT LH MARKER LAMP COND. FAN
Fuse Label-for 24 Volt (4HK1 / 4JJ1 EURO 4) 15 A (1) 10 A (2) 15 A (3) 15 A (4) 10 A (5) 20 A (6) 10 A (7) 10 A (8) 10 A (9) 15 A (10) 10 A (11) 10 A (12) 10 A (13) 10 A (14) 15 A (15) 10 A (16) 10 A (17) 10 A (18) 10 A (19) 15 A (20) HEATER, AIR CON FUEL HEATER REAR HEATER AUDIO (B), DOOR LOCK STOP LIGHT POWER WINDOW TAIL LIGHT FRT FOG LIGHT ENG. (IG) FRONT WIPER & WASHER TURN LIGHT H/LAMP LEVEL NEES (B) REAR FOG LIGHT AUDIO (IG), CIGAR LIGHTER METER NEES (IG) HSA SRS ENG. (BACK UP), HSA HORN, HAZARD
Notice: The fuse numbers (1) (28) indicated on the fuse labels are expressed as F-1 F-28 in the circuit diagrams of this manual.

Fusible Link
2 6 1 3 7 4 8 5 9
Fusible link
Fusible link
FUSE PULLER
26
25
N8A0047E
For 24 Volt (4HK1 / 4JJ1 EURO 4) 100 A / 120 A (1) 40 A (2) 60 A (3) 30 A (4) 40 A (5) 60 A (6) 60 A (7) MAIN KEY GLOW HEAD LAMP ECM. ENG. CERAMIC HEATER NEES
60 A (8) 40 A (9)
STARTER ABS
For 24 Volt (4JJ1 EURO 3) 100 A (1) 40 A (2) 60 A (3) 30 A (4) 40 A (5) MAIN KEY GLOW HEAD LAMP ECM. ENG.

(6) (7) 60 A (8) (9) STARTER
Notice: The fusible link numbers (1) (26) are expressed as FL-1 FL-26 in the circuit diagrams of this manual.

Fuse Block Circuit
For 4JJ1 (EURO 3) Engine
GENERATOR B FL-25 FL-1 MAIN 100A FL-26
INDICATION ON LABEL
HEATER & A/C RELAY
F-1 F-2
15A
HEATER, AIR CON

CHARGE WARNING RELAY METER (BOOST IND) GENERATOR HEATER RELAY 10A
FUEL HEATER
F-3 F-4 F-5 F-6
15A
AUDIO (B), DOOR LOCK

10A
INDICATION ON LABEL
F-25 TAIL RELAY 15A
STOP LIGHT
20A
POWER WINDOW
F-7 F-8 10A
F-26
TAIL LIGHT COND. FAN

COMBINATION SWITCH 10A
FRT FOG LIGHT

F-9 F-10 10A 15A
F-27
ENG. (IG) FRONT WIPER & WASHER
F-28
10A
ECM. ENG.
FL-2 KEY 40A KEY SW OFF ACC ON ST CONDENSER FAN RELAY
KEY ON RELAY
F-11 F-12 F-13 F-14 F-15 F-16 F-17
10A
TURN LIGHT
10A
H/LAMP LEVEL
15A 10A
AUDIO (IG), CIGAR LIGHTER METER
CONDENSER FAN FL-3 GLOW 60A FL-4 HEAD LAMP 30A FL-5 ECM. ENG. 40A ECM GLOW PLUG RELAY GLOW PLUG
F-18 F-19 F-20
10A
ENG. (BACK UP), HSA

15A
ECM MAIN RELAY ECM ECM HEAD LIGHT RELAY
HORN, HAZARD
F-21 F-22 F-23 F-24
10A
FL-6
STARTER
10A
HEAD LIGHT RH
10A FL-7 COMBINATION SWITCH
HEAD LIGHT LH
FL-8 STARTER 60A
STARTER RELAY STARTER STARTER CUT RELAY
FL-9
ECM ECM
NEUTRAL SWITCH
N8B0002E

For 4HK1 / 4JJ1 (EURO 4) Engine
GENERATOR B FL-25 FL-1 MAIN 100A or 120A FL-26
INDICATION ON LABEL
HEATER & A/C RELAY
F-1 F-2
15A
HEATER, AIR CON

CHARGE WARNING RELAY METER (BOOST IND) GENERATOR MARKER LIGHT RELAY HEATER RELAY 10A
FUEL HEATER
F-3 F-4 F-5 15A
REAR HEATER
15A
AUDIO (B), DOOR LOCK

10A
INDICATION ON LABEL
F-25 15A
STOP LIGHT
MARKER LIGHT
TAIL RELAY F-6 F-7 F-8 COMBINATION SWITCH F-9 F-10 20A
MARKER LAMP
F-26 15A
POWER WINDOW
10A
TAIL LIGHT COND. FAN

10A
FRT FOG LIGHT

10A 15A
F-27
ENG. (IG) FRONT WIPER & WASHER
F-28
10A
ECM. ENG.
FL-2 KEY 40A KEY SW OFF ACC ON ST CONDENSER FAN RELAY
KEY ON RELAY
F-11 F-12 F-13 F-14 F-15 F-16 F-17
10A
TURN LIGHT
10A
H/LAMP LEVEL
10A
NEES (B)
10A
REAR FOG LIGHT

15A 10A
AUDIO (IG), CIGAR LIGHTER METER
CONDENSER FAN FL-3 GLOW 60A FL-4 HEAD LAMP 30A FL-5 ECM. ENG. 40A FL-6 CERAMIC HEATER 60A CERAMIC HEATER FL-7 NEES 60A GEAR SHIFTER RELAY TCM TCM STARTER RELAY STARTER STARTER CUT RELAY FL-9 ABS 40A ABS UNIT NEUTRAL SWITCH ECM ECM ECM GLOW PLUG RELAY GLOW PLUG
10A
F-18 F-19 F-20
NEES (IG) HSA SRS
10A
ENG. (BACK UP), HSA

15A
ECM MAIN RELAY ECM ECM HEAD LIGHT RELAY
HORN, HAZARD
F-21 F-22 F-23 F-24 COMBINATION SWITCH 10A
ABS (IG)
10A
STARTER
10A
HEAD LIGHT RH
10A
HEAD LIGHT LH
FL-8 STARTER 60A
N8B0003E
8-30 CAB AND CHASSIS ELECTRICAL Reference Table of Fuse and Circuit Breaker
Fuse
4JJ1 (EURO 3) Engine Fuse No. F-1 Capacity 15 A Indication on label HEATER, AIR CON Main parts (Load) Blower motor, Blower resistor, Fan switch, A/C switch, A/C thermo relay, Pressure switch, VSV: FICD, Electronic thermostat, A/C compressor, A/C thermo relay, Condenser fan, ECM (A/C compressor SIG.) Exhaust brake solenoid valve, Clutch switch, Accel switch, VSV: Intake throttle Radio & clock, Dome light switch, Dome light, Door switch (RH & LH), Door lock switch, Door lock actuator, Door lock controller, Speedometer, Key cylinder switch Stoplight switch, Stoplight, ECM (brake on SIG.) Power window Tail relay, Illumination light(s), Clearance light(s), Tail light(s), License light(s) Fog light switch, Fog light, Lighting switch, Cornering light relay, Cornering light, Cornering light switch ECM (IG SIG.), Starter cut relay, ECM (Exhaust brake SIG.), Exhaust brake indicator, ECM (brake off SIG.), ECM (clutch on SIG.), ALDL connector Wiper & Washer switch, Wiper motor, Washer motor, Intermittent relay Flasher unit, Front turn signal light, Rear turn signal light, Turn signal light switch, Hazard warning switch Headlight leveling switch, Headlight leveling motor (actuator) Radio, Cigar lighter, Digital clock Backup light switch, Backup light, Neutral switch, Starter relay, Glow relay, Glow indicator (Meter), Coolant temperature gauge, ECT sensor, Vehicle speed sensor (Installed on the meter assembly & transmission), Meter assembly, Power window relay, Cornering light relay, Backup buzzer, Charge relay, Heater A/C relay, VSV ECM (Back up) Horn, Horn relay, Horn switch, Flasher unit, Hazard warning switch, Turn light(s) Starter relay Headlight (RH), Dimmer relay, High beam indicator light Headlight (LH), Dimmer relay
F-2 F-3 F-4 F-5 F-6 F-7 F-8 F-9 F-10 F-11 F-12 F-13 F-14 F-15
10 A 15 A 10 A 20 A 10 A 10 A 10 A 15 A 10 A 10 A 15 A
FUEL HEATER AUDIO (B), DOOR LOCK STOP LIGHT POWER WINDOW TAIL LIGHT FRT FOG LIGHT ENG. (IG) FRONT WIPER & WASHER TURN LIGHT H/LAMP LEVEL AUDIO (IG), CIGAR LIGHTER
F-16
10 A
METER
F-17 F-18 F-19 F-20 F-21 F-22 F-23 F-24 F-25
10 A 15 A 10 A 10 A 10 A
ENG. (BACK UP), HSA HORN, HAZARD STARTER HEAD LIGHT RH HEAD LIGHT LH

Fuse No. F-26 F-27 F-28 Capacity 15 A 10 A Indication on label COND. FAN ECM. ENG. ECM Condenser fan Main parts (Load)
4HK1 / 4JJ1 (EURO 4) Engine Fuse No. F-1 Capacity 15 A Indication on label HEATER, AIR CON Main parts (Load) Blower motor, Blower resistor, Fan switch, A/C switch, A/C thermo relay, Pressure switch, VSV: FICD, Electronic thermostat, A/C compressor, A/C thermo relay, Condenser fan, ECM (A/C compressor SIG.) Exhaust brake solenoid valve, Clutch switch, Accel switch, Fuel heater, VSV: Intake throttle, ABS (Exhaust brake SIG.), Ceramic heater relay Rear heater, Rear heater switch Radio & clock, Dome light switch, Dome light, Door switch (RH & LH), Door lock switch, Door lock actuator, Door lock controller, Speedometer, Key cylinder switch, Side turn signal light(s) Stoplight switch, Stoplight, ABS (Stop on SIG.), ECM (brake on SIG.) Power window Tail relay, Illumination light(s), Clearance light(s), Tail light(s), Roof marker light, License light(s), Marker light relay Fog light switch, Fog light, Lighting switch, Cornering light relay, Cornering light, Cornering light switch ECM (IG SIG.), Starter cut relay, ECM (Exhaust brake SIG.), Exhaust brake indicator, ECM (brake off SIG.), ECM (clutch on SIG.), ALDL connector Wiper & Washer switch, Wiper motor, Washer motor, Intermittent relay Flasher unit, Front turn signal light, Rear turn signal light, Turn signal light switch, Hazard warning switch, Side turn signal light Headlight leveling switch, Headlight leveling motor (actuator) Smoother Rear fog light Radio, Cigar lighter, Digital clock Backup light switch, Backup light, Neutral switch, Starter relay, Glow relay, Glow indicator (Meter), Coolant temperature gauge, ECT sensor, Vehicle speed sensor (Installed on the meter assembly & transmission), Meter assembly, Power window relay, Cornering light relay, Backup buzzer, ABS indicator, Charge relay, Heater A/C relay, VSV Smoother (IGN SIG.) ECM (Back up)
F-2 F-3 F-4
10 A 15 A 15 A
FUEL HEATER REAR HEATER AUDIO (B), DOOR LOCK STOP LIGHT POWER WINDOW TAIL LIGHT FRT FOG LIGHT ENG. (IG) FRONT WIPER & WASHER TURN LIGHT H/LAMP LEVEL NEES (B) REAR FOG LIGHT AUDIO (IG), CIGAR LIGHTER
F-5 F-6 F-7 F-8 F-9 F-10 F-11 F-12 F-13 F-14 F-15
10 A 20 A 10 A 10 A 10 A 15 A 10 A 10 A 10 A 10 A 15 A
F-16
10 A
METER
F-17 F-18 F-19
10 A 10 A 10 A
NEES (IG) HSA SRS ENG. (BACK UP) HSA

Fuse No. F-20 F-21 F-22 F-23 F-24 F-25 F-26 F-27 Capacity 15 A 10 A 10 A 10 A 10 A 15 A 15 A 15 A (4HK1) 10 A (4JJ1) Indication on label HORN, HAZARD ABS (IG) STARTER HEAD LIGHT RH HEAD LIGHT LH MARKER LAMP COND. FAN Main parts (Load) Horn, Horn relay, Horn switch, Flasher unit, Hazard warning switch, Turn light(s), Side turn signal light ABS (IGN SIG.) Starter relay Headlight (RH), Dimmer relay, High beam indicator light Headlight (LH), Dimmer relay Marker light, Marker light relay Condenser fan
F-28
ECM. ENG.
ECM
CAB AND CHASSIS ELECTRICAL 8-33 Relay Location
X-16
X-15
X-14
X-13 Relay box No.2
Relay box No.1
X-5
X-6
X-7
X-8
X-9
X-10
X-11
X-12
X-1
X-2
X-3
X-4
X-18
X-19
X-20
X-22
X-23
X-24
X-25
X-26
X-27
X-28 X-21
N8A0054E

Relay List
: Standard, : Option X-1 Charge warning NPR75 (EURO 4) NQR75 (EURO 4) 24V NKR85 (EURO 4) NPR85 (EURO 4) NKR85 (EURO 3) X-7 Power window NPR75 (EURO 4) NQR75 (EURO 4) 24V NKR85 (EURO 4) NPR85 (EURO 4) NKR85 (EURO 3) * : Except EC X-13 Buzzer cancel NPR75 (EURO 4) NQR75 (EURO 4) 24V NKR85 (EURO 4) NPR85 (EURO 4) NKR85 (EURO 3)
*1 *2
X-2 Horn X-8 Heater
X-3 Lamp X-9 Cornering lamp * * * *
X-4 Tail X-10 Thermo A/C
X-5 Fog lamp X-11 Key ON
X-6 Dimmer X-12 Heater & A/C
X-14 Smoother emergency
X-15 NEES main
X-16 Rear fog *1 *1 *1 *1
X-18 ECM main
X-19 Gear shifter *3 *3 *3 *3
*2 *2
: For EC : With HBB *3 : With Smoother X-20 Glow plug NPR75 (EURO 4) NQR75 (EURO 4) 24V NKR85 (EURO 4) NPR85 (EURO 4) NKR85 (EURO 3) *1 : For EC X-21 Starter X-22 Marker lamp *1
*1 *1
X-25 DPD exh. throttle
X-26 Starter cut
X-27 Condenser fan
*1
CAB AND CHASSIS ELECTRICAL 8-35 Diode Location
With Smoother X-32
RELAY BOX ASM (No.1) (Installed on the instrument panel)
B-18 Without Smoother B-17
B-18
RELAY BOX ASM
RELAY BOX ASM (Installed on the cab left side rear) RELAY BOX ASM (No.1)
N8B0004E
Connector No. Usage
B-17 A/C Door switch
B-18 Lighting
L-1 Dome light
L-3 Dome light (Except Taiwan)
Connector No. Usage
X-32 Smoother, Dome light
8-36 CAB AND CHASSIS ELECTRICAL Reference Table of Grounding Point

Notice: Abnormal phenomena of electrical components are considered resulted from defective grounding. In repair, be sure to inspect grounding points and to tighten all fastening parts surrounding the grounding points. Connector No. B-1 Cable harness name Location Frame-LH (FRT) Main parts (Load) Vehicle speed sensor, Turn signal indicator light, Meter, High beam indicator light, PTO lever, TCM Charge relay, Dome light switch, Back up buzzer, Meter, Brake fluid switch, Tail relay, Cornering light switch, Cornering light, Cornering light relay, Fog light switch, Fog light, Dimmer relay, Door lock switch, Door lock relay, Power window switch (RH), Power window relay, Stoplight switch, Mirror switch, Wiper motor, Washer motor intermittent relay, Radio, Cigar lighter, Heater & A/C relay, Fan switch, Horn relay, Rear heater switch, Rear heater, Radio & clock, Blower resistor, A/C switch, Blower motor, Electronic thermostat, Accel switch, Door lock controller, Headlight leveling switch, Headlight leveling motor, Emergency relay, Select switch, Emergency adjust switch, PTO-Smoother switch Marker light relay, Marker light, Water sedimenter switch, Fuel tank unit, Starter relay, Neutral switch, Pressure switch, A/C thermo relay, VSV: FICD, Exhaust brake solenoid valve, Accel switch, Clutch switch, VSV: Intake throttle, Engine stop motor, ECM, ECM main relay, Starter cut relay, Shift 1,3,5 solenoid, Shift 2,4,R solenoid, Select solenoid, License plate light, Taillight, Rear fog light, Rear turn signal light, Stoplight, Stoplight switch, Backup light
Body harness B-7
Headlight bracket-LH
J-9
Frame front harness
Frame-LH (CTR)
CAB AND CHASSIS ELECTRICAL 8-37 Grounding Point Location
N8A5054E
B-7
N8A5055E
N8A5056E
8-38 CAB AND CHASSIS ELECTRICAL Cable Harness Routing
FLOOR HARNESS (RH)
FLOOR HARNESS (LH)
N8A0060E
DOME LIGHT HARNESS
DOOR HARNESS (RH)
BODY HARNESS
DOOR HARNESS (LH)
N8A0061E
REAR BODY HARNESS
REAR FRAME HARNESS
FRONT FRAME HARNESS
N8A0062E
SYSTEM REPAIR
Start and Charging
General Description
The system consists of the starter switch, starter, AC generator, starter relay, charge relay, heater and A/C relay, inhibitor switch and neutral switch. When the starter SW is set to the ST position, the battery voltage is applied to the starter solenoid coil through the starter relay to start the starter. On the 4HK1 / 4JJ1 engine, the function that ECM controls STARTER RELAY is added.
Starting Circuit
N8A0064E
Parts Location
B-51
J-191 ECM H-105
X-1 CHARGE RELAY
FUSE BOX ASM F-4, F-5, F-6, F-16, F-22
FL-1, FL-2, FL-8 FUSIBLE LINK X-21 STARTER RELAY X-26 STARTER CUT RELAY F-28 FUSE
J-1,J-2 GENERATOR B-66
B-67
N8B0005E
0.5W/R STARTER SWITCH RELAY; CHARGE

ACC 1 H-7 ON B-67 X-1 X-1 B-67 4 3 ST B-67
RELAY; HEATER & A/C (2)
3 W/L 3W/L 2
B
FL-2 40A KEY 3W/L 3B/Y 3B/Y 0.5B/Y 3 3B/Y F-16 10A METER 0.5B/Y 4
X-1 1
0.5W/R RELAY; HEATER (3)
For 4HK1 Engine
Circuit Diagram
30B/R FL-8 60A STARTER
P-1
P-2 X-1
0.5W/L
P-3
100A or FL-1 120A F-22 10A STARTER 0.5W/L MAIN
P-4
CHARGE WARNING LIGHT B-51 (10)
0.5W/L
P-5 15 H-5
8W/B
FRAME 3W/B
8B
1
0.3R/W
J-2
0.85W/L
GENERATOR
L J-1 1
J-1
1.25W/L
2L
STARTER RELAY; STARTER

3 X-21 X-21 4 X-21 2 14 H-8
1 J-26
J-27
3B/W 0.5R/W
X-21 5
0.5LG
0.85LG
F-28 15A ECM
1.25R
RELAY; ECM MAIN (2)
X-26
X-26 1 5
0.5R
4 X-26 3
RELAY; STARTER CUT

X-26
0.5W/L
0.5B
FRAME-LH (CENTER)
J-9
2B
14
J-191 ECM
N8B0006E
0.5W/R STARTER SWITCH RELAY; CHARGE FL-2 40A KEY

ACC
RELAY; HEATER & A/C (2)
3W/L
1 H-7 ON B-67 X-1 X-1 B-67 4 3 ST B-67
For 4JJ1 Engine
3W/L 2
B
3B/Y 3B/Y 0.5B/Y 3 3B/Y
F-16 10A METER 0.5B/Y 4

X-1 1
0.5W/R RELAY; HEATER (3)
30B/R FL-8 60A STARTER F-4

X-1 5
P-1
P-2
15A 0.85R RELAY; DOOR LOCK (6) STARTER 0.5W/L F-22 10A 0.5W/L
P-3
FL-1 100A MAIN F-5 STOP LIGHT 0.5G/Y SW; STOP LAMP B-66 (1) 0.5W/L RELAY; P/WINDOW (2)
15 H-5
AUDIO(B), DOOR LOCK 10A
P-4
CHARGE WARNING LIGHT B-51 (10)
8W/B F-6 5W/B

1 J-2 B
2 H-6
P-5
20A 2B/L
FRAME 3W/B 3W/B POWER WINDOW
0.3R/W (NPR85) 0.5R/W (NKR85)
8B
L J-1 H-105 1 8
8W
0.5W/L
GENERATOR 0.5W/L
J-1
2L
STARTER
14 H-8 2
1 J-26
2W
B X-21 X-21 4
2L 3W/B 0.5R/W
RELAY; STARTER
J-27
3B/W
X-21
X-21 5
0.5LG
0.85LG
F-28 10A ECM 1.25R
RELAY; ECM MAIN (2)
X-26
0.5R
4 X-26 3
RELAY; STARTER CUT

X-26 1 5 X-26
0.5W/L
0.5B
FRAME-LH (CENTER)
J-191 ECM
J-9
2B
14
N8B0007E

Connector List
No. Connector Face No. Connector Face
B-51
020-004
J-9
000-001
B-66 (Except 4HK1)
J-26
1 2
002-031
000-002
B-67
J-27
1 3 2 4
004-001 000-009
B-67
J-191
2 4 1 3
004-002
081-001
H-105 (Except 4HK1)
1 5 9
2 6
3 7
4 8
P-1
000-022
10 11 12
012-001
H-105 (Except 4HK1)
4 8
3 7
2 6
1 5 9
P-4
000-014
12 11 10
012-002
J-1
1 2
P-2
000-014
002-003
J-2
000-001
P-3
000-014

No. Connector Face H-6 (Except 4HK1), H-7, H-8
P-5
000-002
H-6
H-7
X-1
005-006
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 H-8
4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14
X-21
1 2 4 3 5
N8A5489E
005-003
Starter Switch
The starter switch positions are LOCK, ACC, ON and START. Turning the starter key to these positions is a circuit for starting the engine, the operation of accessories, or stop the engine.
X-26
005-006
H-5
1 7 13 19 25 31
2 8 14 20 26 32
3 9 15 21 27 33
34
35
36
37
4 10 16 22 28 38
5 11 17 23 29 39
6 12 18 24 30 40
6 12 18 24 30 40
5 11 17 23 29 39
4 10 16 22 28 38
37
36
35
34
3 9 15 21 27 33
2 8 14 20 26 32
1 7 13 19 25 31
N8A0072E
N8A5488E

Inspection Check the continuity between the starter switch connector terminals. Repair or replace the switch when the result of inspection is found abnormal.
1 3
2 4
Switch side
Connector No. Starter SW key position Removed LOCK ACC Inserted ON START Terminal No. 1 ACC 2 B
B-67 3 ON 4 ST
N8B5106E
Removal Preparation: Disconnect the battery ground cable. 1. Steering Cowl Remove four screws and take off the steering cowl. 2. Starter Switch 1) Disconnect the connector. 2) Remove the screw.
N8A5070E
Installation To install, follow the removal steps in the reverse order.

Neutral Switch
Inspection Check to see if there is any continuity between the switch terminals. Replace the switch when the result of inspection is found abnormal.
N8A5071E
FUSE & RELAY BOX ASM X-1 CHARGE RELAY F-1,F-2,F-7,F-9,F-15,F-16,F-19,F-22 FUSE N-6 SW: PARKING BRAKE B-495 DPD REGENERATE B-31 SW: ENG. WARM J-50 SW: NEUTRAL
TCM (B-426,B-427,B-428) E-114
Parts Location
For 4HK1 Engine
B-39 SW: AIR CON
E-141 E-112 E-169 E-94 E-140 J-206 E-139 E-138 E-98 E-5
J-1,J-2 AC GENERATOR
STARTER SW
J-32 V/SPEED SENSOR
J-182 H-125 E-90 J-8 E-93 E-113 H-120 H-118 H-15 J-191 ECM P-5 P-1 P-2 BATTERY P-3
ABS EHCU (J-177) E-168 E-111
RELAY BOX ASM (NO.1) X-8 HEATER RELAY X-10 THERMO A/C X-12 HEATER & A/C RELAY B-17,B-18,X-32 DIODE BOX J-31
FUEL TANK J-222 J-28
E-3 E-116 H-126
J-223 J-224 J-221
H-105
Exhaust Brake System and Engine Control
DAMU (B-500)
B-7 EARTH: HEADLIGHT BRACKET-LH
P-4
H-4~H-8
RELAY BOX ASM X-18 ECM MAIN RELAY X-20 GLOW RELAY X-21 STARTER RELAY X-25 DPD EXH.THROTTLE RELAY X-26 STARTER CUT RELAY FL-1~FL-3,FL-5,FL-8 FUSIBLE LINK F-26,F-28 FUSE
B-280 SENSOR: ACCEL
B-53 METER
B-422 SENSOR: BARO
B-89 SW: CLUTCH
B-1 EARTH: FRAME-LH (FRT)
H-12
B-69 SW: EXH.BRAKE
B-51 METER
N8B0008E
B-67 IGNITION SW "A" B-52 METER
J-166 SERVICE CONNECTOR J-271 REF HARNESS CONNECTOR J-216 MAINHOLD AIR PRESSURE SENSOR J-9 EARTH: FRAME J-225 DROP RESISTOR J-26,J-27 STARTER B-84 SW: PTO B-281 IDLE UP VOLUME B-79 DATA LINK CONNECTOR B-387 RESISTOR 1 B-497 SW: DPD A, DPD B B-431 RESISTOR 2
J-6 SW: A/C PRESS.
B-51, B-52 METER STARTER SW J-1, J-2 AC GENERATOR N-6 BRAKE SWITCH B-281 IDLE UP VOLUME B-84 PTO SWITCH J-182 MASS AIR FLOW SENSOR J-50 NEUTRAL SWITCH
EXHAUST BRAKE SW
E-13, E-14, E-15, E-16 FUEL INJECTOR E-90 COOLANT E-3 GLOW PLUG TEMPERATURE E-111 ECM SENSOR E-5 H-120 MAGNETIC FRAME CLUTCH HARNESS
B-31 ENGINE WARMING SWITCH
H-105
E-94 EVRV : EGR E-116 SCV
B-39 AIR CON SWITCH
J-8 OIL PRESSURE SWITCH E-93 FUEL TEMP SENSOR J-206 FUEL SEDIMENTER
RELAY BOX ASM (No.1) B-18 DIODE X-8 HEATER RELAY X-10 A/C THERMO RELAY X-12 HEATER A/C RELAY J-31 EXH. BRAKE SOLENOID VALVE (B) J-32 VEHICLE SPEED SENSOR E-112 CKP SENSOR
FUSE & RELAY BOX ASM X-1 CHARGE RELAY F-1, F-2, F-7, F-9, F-15, F-16, F-19, F-22 FUSE
B-500 DAMU P-5 P-1 P-2
J-166 SERVICE CONNECTOR
B-280 ACCEL SENSOR
BATTERY (24V) P-4 P-3
B-7 J-271 REF HARNESS J-191 ECM J-9 B-1 H-17 B-67, B-69 B-422 BARO SENSOR H-12 J-26, J-27 STARTER B-79 DATA LINK CONNECTOR
H-5~H-8
RELAY BOX FL-1, FL-2, FL-3, FL-5, FL-8 FUSIBLE LINK F-26, F-28 FUSE X-18 ECM MAIN RELAY X-20 GLOW RELAY X-21 STARTER RELAY X-26 STARTER CUT RELAY
E-114 THROTTLE POSITION SENSOR
B-89 CLUTCH SWITCH
J-6 B-431 RESISTOR 1 A/C PRESSURE SWITCH B-387 RESISTOR 2
N8B0009E
B-51, B-52, B-53 METER STARTER SW J-1, J-2 AC GENERATOR N-6 BRAKE SWITCH B-281 IDLE UP VOLUME B-84 PTO SWITCH
EXHAUST BRAKE SW
B-495 DPD REGENERATE SWITCH
E-13, E-14, E-15, E-16 FUEL INJECTOR E-90 COOLANT E-3 GLOW PLUG TEMPERATURE E-111 ECM SENSOR E-5 H-120 MAGNETIC FRAME CLUTCH HARNESS
B-31 ENGINE WARMING SWITCH
H-105
E-94 EVRV : EGR E-116 SCV
B-39 AIR CON SWITCH J-182 MASS AIR FLOW SENSOR J-50 NEUTRAL SWITCH
E-26 PRESSURE SENSOR J-8 OIL PRESSURE SWITCH E-93 FUEL TEMP SENSOR J-206 FUEL SEDIMENTER
RELAY BOX ASM (No.1) B-17, B-18, X-32 DIODE X-8 HEATER RELAY X-10 A/C THERMO RELAY X-12 HEATER A/C RELAY J-31 EXH. BRAKE SOLENOID VALVE (B) J-32 VEHICLE SPEED SENSOR E-112 CKP SENSOR
FUSE & RELAY BOX ASM X-1 CHARGE RELAY F-1, F-2, F-7, F-9, F-15, F-16, F-19, F-22 FUSE H-118 H-15
J-177 ABS EHCU
B-500 DAMU P-5 P-1 P-2
J-166 SERVICE CONNECTOR
B-280 ACCEL SENSOR
B-426, B-427, B-428 TCM P-4 P-3
BATTERY (24V)
B-7 J-271 REF HARNESS J-191 ECM J-9 B-1 J-26, J-27 STARTER
H-4 (Except NKR) H-5 H-8
E-114 THROTTLE POSITION SENSOR
RELAY BOX FL-1, FL-2, FL-3, FL-5, FL-8 FUSIBLE LINK F-26, F-28 FUSE X-18 ECM MAIN RELAY X-20 GLOW RELAY X-21 STARTER RELAY X-25 DPD EXH.THROTTLE RELAY X-26 STARTER CUT RELAY
B-89 CLUTCH SWITCH
B-79 B-67, B-69 DATA LINK H-12 H-17 CONNECTOR (For NKR) J-6 B-431 RESISTOR 1 B-422 A/C PRESSURE BARO SENSOR SWITCH B-387 RESISTOR 2
N8B0010E

Circuit Diagram
For 4HK1 Engine (1)
5W/B (STD AC GEN.) 8W/B (80A AC GEN.)
8W/B 8W/B FL-2 40A KEY
J-2
AC GEN. J-1
J-1
1 1.25W/L
FL-1 100A/120A MAIN
3W/L
3W/L
FL-8 60A STARTER 2L
FL-5 40A ECM
FL-3 60A GLOW
1 3W/B STARTER + P-1 RELAY:STARTER P-2 C + P-3 P-4 3B/W J-27 1 2 X-21 5 X-21 J-26 B 0.5R/W 0.5R 0.5LG F-26 15A CONDENSER FAN RELAY: CONDENSER FAN 2B/L 0.5Y/B 4 RELAY:GLOW X-20 0.5Y/B 0.5LG
RELAY:STARTER CUT
0.85LG
4 X-26
3 X-26
X-21 3
X-21 4
X-26 1
X-26 5 For SMOOTHER C/U: SMOOTHER
F-28 15A ECM
3W/R
3B/L 3 X-20 X-20 2
X-20 5
P-5 1.25R
0.5LG
3B/Y 1 H-120 3B/Y
0.5LG
0.5LG
5 RELAY:ECM MAIN X-18
3 X-18
J-50 SW:NEUTRAL
RESISTOR:DROP
SOLENOID VALVE: EXH. BRAKE
1 J-31
1 J-225 0.5R/W
1 E-3 X-18 4 X-18 2 GLOW PLUG
J-225 2 0.5G/W
J-31 2 0.5LG/B 0.5W/L 0.5L/B
J-50 1
0.5L/B
2R
35 J-191 PS -MAFBAT 0.5B 0.5B
46 J-191 IS-STARR
15 J-191 OS-EXB
14 J-191 OS -STARTR
21
40
2R
5 J-191 PS-+B
10 J-191 OS-GLOWR
24 J-191 IS-IGKEY
J-191 J-191 J-191 OS OS PS-+B -MAINR -MAINR
ECM ; ENGINE
IS-PN J-191 50 0.5B/L OP -COM2 E-111 116 OP -COM1 E-111 121 OS -INJ1 E-111 119 1.25G/W OS -INJ3 E-111 117 1.25W/Y OS -INJ2 E-111 120 1.25B/L OS -INJ4 E-111 118 1.25B OP -SCVHI E-111 105 0.5W/R OP -SCVHI E-111 113 0.5W/R IA IA -SCVLO -SCVLO E-111 89 0.5G/R E-111 97 0.5G/R IS-REF J-191 33
5 H-125 For SMOOTHER 1.25R 0.5B/L 5 1.25W H-4 C/U: SMOOTHER H-126 5 0.75G
8 H-125 H-126 8 0.75B
7 H-125 H-126 7 0.75Y
6 H-125 H-126 6 0.75L
REF HARNESS 2 E-116 SCV
3 INJECTOR E-138
3 E-141
3 E-140
3 E-139
E-138 2 0.75W
E-141 2 0.75W
E-140 2 0.75R
E-139 2 0.75R E-116 1
J-9
2B
1 H-126
4 H-126 H-125 4
3 H-126 H-125 3
2 H-126 H-125 2
FRAME-LH (CTR)
H-125 1
0.5P 1 J-271
0.5Y/B
0.5B/R
N8B0011E

For 4HK1 Engine (2)
5W/B (STD AC GEN.) 8W/B (80A AC GEN.) 2 5W/B
H-6
1.25W/L F-15 15A AUDIO (IG). CIGAR LIGHTER 3B/Y 3B/Y 3B/Y F-22 10A STARTER 0.5R/W 0.5LG 14 0.3R/W 0.5LG 8 H-105 0.5LG 3B/Y
0.85W/L
15
H-5
0.5W/L
STARTER SW OFF ACC 1 H-7 3W/L 2 B-67 ON ST B-67 B-67 B-67 1 3 4 3R/Y
0.5R/Y
CIGAR LIGHTER RELAY: ON, FUSE: ABS (IG)
3B/Y
F-16 10A METER
H-8
0.5B/Y
0.5LG
F-9 10A ENG.(IG) 0.5Y/B 0.5Y/B
0.5LG
0.5LG
13 E-168 POW GND-SLD E-168 SIG-U E-168 SIG-V E-168 SIG-W E-168 5 0.5B 1 2 3 0.5L/W 0.5Br 0.5L 4 3 2 E-169 E-169 E-169 POSITION SENSOR
0.5Y/B
18
H-5
VGS ACT.
RELAY: DPD EXT.THROTTLE
2 X-25
5 X-25 2 SW : CLUTCH H-4 SW : DPD (CONNECTOR) 0.5LG 0.5G/B
1 B-89
C/U: VGS TURBO
X-25 1
X-25 3 0.5G/O
B-497
B-89 2 0.5BR/Y
POW-SIG E-168 GND-SIG E-168
8 4
0.5R 0.5B
1 5
E-169 E-169
MTR-U E-168 MTR-V E-168 MTR-W E-168
10 11 12
0.5G/R 0.5Y/R 0.5L/R
8 7 6
E-169 E-169 E-169 10 9 0.5L 0.5L/W
3 H-105 H-4 8 0.5G/O 0.5G/B H-5 23 0.5BR/Y
CAN-L E-168 14 E-168 GND CAN-H E-168
16 15
0.5L 0.5L/W
H-105 H-105
0.5R
102 E-111 OS -DPFET
28 J-191 IS-DPF
26 J-191 IS-CL For M/T
ECM ; ENGINE
0.5B PG-POWER J-191 1 1.25B 1 J-221 VSV: DPF EXH. THROTTLE J-221 2 0.5B H-105 0.5L/W 0.5Y/B 0.5Y/R 0.5LG 0.5B 0.5B 12 0.5B 0.5R 2 J-222 SENSOR: EXHAUST TEMP (DOC IN) J-191 3 1.25B J-191 4 1.25B PG-WIGN J-191 43 0.75B J-191 62 0.75B PG -CASE J-191 81 0.5B SG -SLD3 J-191 59 0.3B SG SP-5V3 IA-EXHP1 -5VRT3 J-191 80 J-191 67 J-191 79 0.5B IA-THE1 J-191 73 IA-THE2 J-191 74
3 1.25B J-224
2 J-224 SENSOR: EXHAUST PRESSURE 1 (IN&OUT)
1 J-224
1 J-223
2 J-223
1 J-222
J-9
2B
SENSOR: EXHAUST TEMP (IN)
FRAME-LH (CTR)
N8B0012E

For 4HK1 Engine (3)
RELAY: CHARGE 5W/B 2W/B RELAY: TAIL 0.5W/R 1 X-1 3 0.5B/Y 0.85BR X-1 4 0.5B/Y
0.5W/L RELAY: HEATER & A/C 5 3L F-1 15A HEATER. AIR CON
0.5W/L
X-1
X-1
SW : AIR CON 0.85B/R 0.85L BLOWER MOTOR 1 B-39 B-39 2 0.5LG
3W/B
1 0.5W/R 2
X-12 X-12 X-12 X-12
0.5B
0.5B/Y 0.5W/L
RELAY: HEATER 1 3B/R
F-2 10A FUEL HEATER
3W/B
2 3
X-8 X-8 X-8 X-8
0.5B/R
0.5B 0.5B/Y
0.5B/Y 3W/B 3W/B RELAY: TAIL, FUSE: AUDIO(B), DOOR LOCK FUSE: STOP LIGHT FUSE: POWER WINDOW FUSE: NEES(B) FUSE: HORN, HAZARD
DIAG CONNECTOR
B-79 4 0.5B B-79 5 0.5B B-79 13 0.3W/G B-79 2 0.3W/B B-79 16 0.5R B-79 12 0.5Y B-79 7 0.5LB B-79 14 0.5L B-79 6 0.5L/W RESISTOR2
F-19 10A ENG. (BACK UP) HSA
H-8 12
H-8 0.5W/R 13
RESISTOR1
B-431 1
B-431 2
CONT UNIT. ABS

DIAG J-177 ALDL J-177 L J-177 27 H J-177 26 0.5L/W H J-177 14 0.5L/W L J-177 15 0.5L
B-387 1
B-387 2
4 29
0.3W/G 0.3W/B
H-15 H-15
11 6
0.3W/G 0.3W/B
13 B-500 0.5L/W H-5 37 0.5L/W 58 J-191 0.75G 6 E-94 W V 0.5L 0.3B/W 0.3LB 0.5Y H-8 10 H-5 36 0.5L 78 J-191 103 110 8 E-94 U 0.75LG/R 7 E-94 B-428 B-426 52 J-191 IS-DIAG 0.5Y 18 9 E-111 93 E-111 99 E-111 E-111 E-111 111 0.5G/O 3 E-94 0.5P/B 2 E-94 0.75B/O 0.5B/W 0.5R
C/U: DAMU
B-500 8 B-500 2
0.5L
10 H-15 0.5L
5 H-15
14 9
H-15 H-15
0.5L 0.5L/W
8 7
H-8 H-8
0.5L 0.5L/W
Without ABS
0.5L/W 0.5L 0.5L/W 37 J-191 18 J-191
3 B-427 H
2 B-427 L
CONT UNIT. SMOOTHER

For SMOOTHER
2B
CC CC -CAN-L -CAN-H SG IF-CAM -5VRT5 E-111 98 E-111 101 SP -5V5 E-111 87 IA -PFUEL E-111 90
ECM ; ENGINE
SG-SLD5 E-111 100 IA -PFUEL E-111 82 IS IS IS -EBMPOS1 -EBMPOS2 -EBMPOS3 E-111 94
CC CC -ISOCAN-H -ISOCAN-L OM OM OM -EBM1 -EBM2 -EBM3
0.5B
0.5B/W
0.5B/W
0.5L/W
B-7
3B 1 2 E-112 3 E-112 3 E-113 1 E-113 SENSOR; Pc 2 E-113 1 E-94 5 E-94 4 E-94 SENSOR: EGR VALVE
HEADLIGHT BRACKET-LH
5B
E-112
B-1
1.25B
SENSOR; CAM ANGLE (MRE)
0.5W
0.5R
0.5R
0.5Y
MOTOR: EGR BRUSH-LESS DC FRAME-LH (FRT)
N8B0013E

For 4HK1 Engine (4)
RELAY: THERMO A/C SW : A/C PRESS. 0.85BR For M/T DIODE BOX 0.5LG 0.5B/Y 0.5W/L SW: DPD REGENERATE 0.5B/R 0.5B/R 6 2 B-495 B-495 B-495 B-495 3 5 Tail Relay 3W H-8 F-7 10A TAIL LIGHT 0.85LG/R 0.3W/R 6 HBB OIL SENSOR 3 B-17 B-17 4 0.5LG/B 1 2 X-10 X-10 X-10 X-10 4 0.5P/G ELECTRO THERMO A/C COMPRESSOR 0.5B/Y 0.5W/L 5 0.85G/W H-5 2 0.85G/W 1 J-6 J-6 2 0.85G/O 4 H-105 0.75G/O 1 E-5
For SMOOTHER 3 X-32 X-32 4
0.5B/Y 0.5W/R
1 B-18 DIODE BOX B-18 2 0.5W/B For M/T H-12 3
H-5 31 0.5B/R
0.5B/R
5 0.5B/Y SW : EXH. BRAKE For SMOOTHER 10 0.5B B-69
0.85LG/R 0.5B SW : ENG. WARM
0.5B/Y
9 H-118
H-118
0.85LG/R
0.5G/O
0.5B 5 3 B-69 2 0.5LG/R 1
B-31 B-31 B-31
B-31 B-31 B-31
2 0.5LG/R 6 4 0.5LG/L
For SMOOTHER 0.5W/B H-12 5 0.3W/B 1 SW: PARKING BRAKE 19 H-5 H-5 25 SP -5V4 E-111 95 SG IF -5VRT4 -CRANK E-111 109 E-111 107 0.5B 0.5GR/R 0.5W 0.5B 3 E-98 2 E-98 SENSOR; NE, CRANK 0.5Y 1 E-98 N-6 0.5B 0.3Y/G
For SMOOTHER 0.5Y/G H-118 11 0.5Y/G
3B
H-5 6
(EC only)
H-5 29
H-4 11
0.5Y/G
1 J-32
2 J-32 V/SPEED SENSOR
3 J-32 0.5Y/G 0.5LG/L 0.5W/R 0.5W/B 34 J-191 IS-A/C 48 J-191 IS -PBRK SG -SLD4 E-111 108
19 J-191 IF-SPD
45 J-191 IS-EXB
0.5LG/R
0.5B/Y
0.5B
51 J-191 IS-QWS
47 J-191 IS -DPFREG
ECM ; ENGINE
IS-PTO J-191 44 0.5L/O OM -IDM2 E-111 104 OM IA -IDM1 -IDMPOS E-111 112 E-111 85 IA -MAP E-111 91
0.5B
0.5W/O
38 0.75R H-5 0.5L/O
0.5W
0.5B
0.75W/G
2 E-114
6 E-114
5 E-114
4 E-114
1 B-7 3B SW : PTO B-84
0.5W
B-84 0.5B 2
E-114 1
B-1
1.25B
J-216 J-216 J-216 SENSOR; MANIHOLD AIR PRESSURE
FRAME-LH (FRT)
0.5R
0.5B
SENSOR; INTAKE THROTTLE DC MOTOR POSITION
H-105 H-105 H-105
5B
0.5W
0.5R
0.5B
0.5W/B H-5 1
0.5B
N8B0014E

For 4HK1 Engine (5)
0.5B/Y 0.5W/L 18 B-51 ENGINE COOLANT TEMPERATURE GAUGE B-52 5 12 0.5LB H-5 CHECK ENG. PARKING BRAKE DPF REGENERATE SEDIMENTER B-52 10 13 0.5LB 0.5BR/W H-5 0.5LG/W EXHBRAKE
OIL PRESS
CHARGE
TACHO
SPEED
GLOW
B-51 10
B-52 20
B-52 17
B-51 13
B-51 For SMOOTHER 5
B-51 7
B-52 15
B-51 6
B-51 4 0.5LG/B
B-53 For SMOOTHER 10 0.5LG/B
B-52 8
B-51 11
B-51 5 For M/T 0.3W/V
B-51 For SMOOTHER 4 0.3W/V
B-52 6
For M/T 0.5L/R
0.5L/R
For M/T
H-5 0.3Y/G 0.5B 24
H-5 30
H-5 40
H-5 7
H-4 19
H-8 3
H-5 39 0.5BR/B
SW: OIL LEVEL
21 0.5Y/R
2 H-105 0.5BR/B 0.5LG/B 0.5O/L 0.5L/R 0.5L/B 0.5L/P 0.5LG
1 J-28 UNIT: FUEL SENSOR J-28 2 0.5B For W/CAB For S/CAB
UNIT: FUEL SENSOR J-28 2 0.5B
SW: OIL PRESSURE
1 J-8
0.5B 0.3Y/G
6 J-191 OS-DIAGL
17
11
9 J-191 OS -DPFREG
8 J-191 OF -TACHO
J-191 J-191 J-191 OS-SVS OS OS -GLOWL -EXBL
ECM ; ENGINE
IA-THL E-111 83 0.5B 0.5G/Y FUEL SEDIMENTER FUEL HEATER 3 E-90 METER 0.5B 0.5LG/W 16 H-105 SW: FUEL SEDIMENTER J-206 1 J-206 2 SW: FUEL LINE CLOGGING IA-THW E-111 84
0.5LG/W
0.5B
1 E-90
1 E-93 B-1 1.25B
2 E-93
SENSOR; FUEL TEMP
ECT SENSOR
ECT SENSOR
FRAME-LH (FRT)
0.5B
2 E-90
0.5LB
H-105
J-9
FRAME-LH (CTR)
0.5R 1 J-28
0.5LG/W H-5
0.5BR/B
0.5O/L
0.5L/B
0.5L/P
0.3LG
FUEL
SVS
N8B0015E

For 4HK1 Engine (6)
ACCEL SENSOR SENSOR; IDLE UP VOLUME B281 2 B-281 1 B-281 3 SENSOR; ACCEL POSITION1 B-280 6 B-280 4 B-280 5 SENSOR; ACCEL POSITION2 B-280 2 B-280 1 B-280 3
0.5L/W
0.5L/R
0.5W
0.5R
0.5L/R
0.5L/Y
0.5L
0.3B
0.5B 0.3B H-5 32
SERVICE CONNECTOR
0.5BR J-166 2 J-166 3 J-166 1 H-5 33 H-8 9 H-5 16 H-5 8 0.3B H-5 9 H-5 26 H-5 20 H-5 27 0.3B
0.5P/B
0.5P/B
0.5L/Y
0.5BR
0.5L
0.5W
0.5W
0.5R
0.5R
0.5R
0.3B
0.5B 0.5B 60 J-191 SG -5VRT2
70 J-191 IA -PTOPOS
66
41
42
20 J-191 SG -SLD1
63 J-191 IA -ACCEL1
64
61
39 J-191 SG -SLD2 0.5B 0.5R 3 B-422
J-191 J-191 J-191 SG SP IA -IDLUP -5VRT1 -5V1
J-191 J-191 SP IA -ACCEL2 -5V2
ECM ; ENGINE
IA-BARO J-191 71 SG PS-12V -12VRT IA-MAF J-191 23 J-191 22 J-191 69 IA-IAT J-191 72 0.5B 0.5G 0.5Y 0.5L
0.5BR/G
0.5R/G
1 14 H-5 0.5BR/G J-182
2 J-182 SENSOR; MASS AIR FLOW
3 J-182
4 J-182
SENSOR; INTAKE AIR TEMP
MAF SENSOR
0.5B 5 J-182
2 B-422
1 B-422 SENSOR; BARO
N8B0016E

For 4JJ1 (EURO 3) Engine (1)
8W/B
8W 8W/B 2W
1 2
J-2 J-1
AC. GEN.
J-1
1 1.25W/L
FL-1 100A MAIN
3W/L 1 FL-2 40A KEY
H-7
3W/L
30B/R STARTER + P-1 P-2 + P-3 P-4 -
2L
2L
8B
FL-8 60A STARTER
FL-5 40A ECM
FL-3 60A GLOW
1 3W/B J-26 B 0.5R/W 0.5R RELAY:STARTER CUT 2 RELAY:STARTER X-21 5 X-21 4 X-26 3 X-26 0.85LG 3B/L 0.5LG F-26 15A CONDENSER FAN RELAY: CONDENSER FAN 2B/L 0.5Y/B 4 RELAY:GLOW X-20 0.5Y/B
C J-27 1 3B/W
3W/R
X-21
X-21
X-26
X-26
F-28 10A ECM
3 X-20
1.25R
X-20 2 3B/Y
X-20 0.5Y/B 0.5B/R 10 J-191 OS-GLOWR 24 J-191 IS-IGKEY PG-WIGN J-191 4 1.25B J-191 43 0.75B J-191 62 0.75B PG -CASE J-191 81 0.75B 5
0.5LG
0.5LG
P-5
0.5LG
3 X-18
1 J-31
RESISTOR:DROP
1 J-50 SW:NEUTRAL
1 J-225
1 H-120 3B/Y X-18 4 X-18 2 1 E-3 GLOW PLUG 0.5L/B 2R 40 2 J-191 PS-+B 2R 5 IS-REF J-191 33 J-191 1 1.25B PG-POWER J-191 3 1.25B 0.5P 1 J-271 REF HARNESS J-9 FRAME-LH (CTR) 2B
J-225 2 0.5G/W 0.5R/W
J-31 2 0.5LG/B 0.5W/L 0.5L/B 21 OP -SCVHI E-111 113 E-111 89
J-50 2 0.5B/L 50 J-191 IS-PN
35 J-191 PS -MAFBAT
46 J-191 IS-STARR
15 J-191 OS-EXB
14 J-191 OS -STARTR
ECM ; ENGINE
OP -COM2 0.5B 0.5B E-111 116 OP -COM1 E-111 121 OS -INJ1 E-111 119 1.25G/W OS -INJ4 E-111 117 1.25W/Y OS -INJ3 E-111 120 1.25B/L OS -INJ2 E-111 118 1.25B OP -SCVHI E-111 105 IA IA -SCVLO -SCVLO E-111 97
0.5W/R
0.5W/R
0.5G/R
CYLINDER #1 FUEL INJECTOR
0.5W/R
1.25B
1 E-13
1 E-16
1 E-15
1 E-14
2W
2R
E-13 2
E-16 2
E-15 2
E-14 SCV 2
E-116
E-116 1 J-9 2B 1.25W 1.25R 2W 2R
FRAME-LH (CTR)
0.5G/R 2
0.5G/R
N8B0017E

8W/B
RELAY: CHARGE H-6 5W/B 2W/B RELAY: TAIL 0.5W/R 1 X-1 3 0.5B/Y 0.85BR 3L F-1 15A HEATER. AIR CON F-2 10A FUEL HEATER 0.85BR 1 B-39 SW : AIR CON 0.85L BLOWER MOTOR 0.5B/Y 0.5W/L 4 3B/Y F-15 15A AUDIO (IG). CIGAR LIGHTER 0.5R/Y RELAY: HEATER 1 3B/R B-39 2 0.5LG X-1 4 0.5B/Y
0.5W/B
H-105
0.85W/L
15
H-5
0.5W/L RELAY: HEATER & A/C RELAY: ON 3B/Y 3W/B 1 X-12 X-12 X-12 X-12 4 0.5B 5
0.5W/L
X-1
X-1
STARTER SW OFF ACC 3W/L 2 B-67 ON ST B-67 B-67 B-67 1 3 3R/Y
0.5W/R 2
3B/Y
F-22 10A STARTER 0.5R/W 14 H-8 0.3R/W
3W/B
2 3
X-8 X-8 X-8 X-8
0.5B/R
5 0.5B 0.5B/Y 0.5B/Y
3B/Y CIGAR LIGHTER F-16 10A METER
F-9 10A ENG.(IG) 0.5Y/B 18 H-5 0.5Y/B 0.5Y/B 3W/B
3B/Y
3W/B
RELAY: TAIL, FUSE: AUDIO(B), DOOR LOCK FUSE: STOP LIGHT FUSE: POWER WINDOW FUSE: HORN, HAZARD
DIAG CONNECTOR
B-79 4 B-79 5 B-79 16 B-79 12 B-79 7 B-79 14 B-79 6
1 SW : CLUTCH B-89
0.5L/W
0.5LB
0.5R
0.5B
0.5B
0.5Y
0.5L
F-19 10A ENG. (BACK UP) HSA 0.5W/R
RESISTOR2
B-431 1
B-431 2
B-89 2
0.5W/R 0.5BR/Y 13 RESISTOR1 B-500
H-5 23 0.5BR/Y B-387 1 0.5L 0.5L/W 37 J-191 18 J-191 8 7 H-8 H-8 0.5L 0.5L/W B-387 2
C/U: DAMU
B-500 8 B-500 2
H-8 10 0.5Y
H-8 5 0.5LB
H-5 36 0.5L
37 0.5L/W 58 J-191 0.5W 6 E-94 W
26 J-191 IS-CL 0.85B 2B
52 J-191 IS-DIAG
38 J-191 CC -KW2000
78 J-191
ECM ; ENGINE
IA -PFUEL E-111 82 IS IS IS -EBMPOS1 -EBMPOS2 -EBMPOS3 E-111 94 E-111 93 E-111 99
CC CC -ISOCAN-H -ISOCAN-L OM OM OM -EBM1 -EBM2 -EBM3 E-111 E-111 E-111 111 103 110
SG-SLD5 E-111 100
0.5B
0.5B/O
0.5LG/B
0.5W/O
0.5Y/B
0.5LG
0.5LB
0.5B/W
0.5Y/B
0.5Y/B
8 E-94 U
0.5LG
0.5LG
0.5W
B-7
3B 1 2 E-112 3 E-112 3 E-113 1 E-113 SENSOR; Pc 2 E-113 1 E-94 5 E-94 4 E-94 SENSOR: EGR VALVE 3 E-94 2 E-94
5B
E-112
B-1
0.5O
7 E-94 V
0.5L/W H-5
0.5L
N8B0018E

RELAY: THERMO A/C SW : A/C PRESS. 0.85BR 0.5LG 10 X-33 DIODE BOX 0.5B/Y 0.5W/L Tail Relay 3W 0.5B/R X-33 3 0.5LG/B 1 2 X-10 X-10 X-10 X-10 4 0.5P/G ELECTRO THERMO A/C COMPRESSOR 0.5B/Y 0.5W/L METER (PARKING BRAKE) 5 0.85G/W H-5 2 0.85G/W 1 J-6 J-6 2 0.85G/O 7 H-105 0.75P 1 E-5
0.5B/Y
F-7 10A TAIL LIGHT
H-5 31
0.85LG/R
0.5B/R
DIODE BOX B-18 4 0.5W/B 0.5G/O
5 B-69 SW : EXH. BRAKE SW : ENG. WARM 0.5B 5 3 1 B-69 2 0.5LG/R B-31 B-31 B-31 B-31 B-31 B-31 2 6 4 0.5LG/R
0.5B/R
0.5W/V 3 B-18
0.5W/B
H-12
3 0.3W/B 1 SW: PARKING BRAKE N-6
0.5B/Y
3B
0.5B
0.5LG/L
H-5 29
H-5 0.5LG/R 0.5Y/G 1 J-32 2 J-32 V/SPEED SENSOR 3 J-32 0.5Y/G 6
0.5W/B H-5 1
19 25 0.5LG/L 0.5W/B
H-5 H-5
0.5B 0.3Y/G
19 J-191 IF-SPD
45 J-191 IS-EXB
51 J-191 IS-QWS
34 J-191 IS-A/C
48 J-191 IS -PBRK
ECM ; ENGINE
IS-PTO J-191 44 0.5L/O OM -IDM2 E-111 104 OM IA -IDM1 -IDMPOS E-111 112 E-111 85 IA -MAP E-111 91 SG -SLD4 E-111 108 SP -5V4 E-111 95 SG IF -5VRT4 -CRANK E-111 109 E-111 107 0.5B 0.5GR/R
0.5B
0.75B/G
0.5V/W
38 H-5 0.5L/O
0.5Y
0.5B
B-7
1 B-84 SW : PTO
0.75G
2 E-114
5 E-114
6 E-114
3 E-114
5B
SENSOR; INTAKE THROTTLE DC MOTOR POSITION B-84 2 E-114 1
3 E-98
2 E-98
SENSOR; NE, CRANK
B-1
0.85B
0.5B
FRAME-LH (FRT)
0.5R/L 1 E-98
0.5R
0.5B
0.5Y
0.5Y
0.5B
N8B0019E

0.5B/Y 0.5W/L 18 B-51 ENGINE COOLANT TEMPERATURE GAUGE B-52 5 12 0.5LB H-5 CHECK ENG. PARKING BRAKE SEDIMENTER B-52 10 13 0.5LB 0.5LG/W H-5 0.5LG/W EXHBRAKE
OIL PRESS
CHARGE
TACHO
SPEED
GLOW
B-51 10
B-52 20
B-52 17
B-51 13
B-51 7
B-52 15
B-51 6
B-52 8
B-51 11
B-51 5 0.3W/V
B-52 6
H-5 0.3Y/G 0.5B 24
H-5 30
H-5 40
H-5 7
H-8 3
H-5 39 0.5BR/B
SW: OIL LEVEL
21
6 H-105 0.5BR/B 0.5O/L 0.5L/R 0.5L/B 0.5L/P 0.5LG
SW: OIL PRESSURE
1 0.5BR/B J-8
UNIT: FUEL SENSOR J-28 2 0.5B
0.5B 0.3Y/G
6 J-191 OS-DIAGL 0.85B
17
11
8 J-191 OF -TACHO
16 J-191 OS -LOWOIL
ECM ; ENGINE
IA-THL E-111 83 IA-THW E-111 84 IS -LOWOIL J-191 53 0.5V/Y
0.5B 0.5G/Y
5 0.5B H-105 3 SW:LOW OIL LEVEL E-90 METER 0.5V/Y FUEL HEATER
FUEL SEDIMENTER SW: FUEL SEDIMENTER J-206 1 J-206 2 SW: FUEL LINE CLOGGING
0.5LG/W
0.5B
1 E-90
2 E-90
1 E-93 B-1
2 E-93
1 E-137
SENSOR; FUEL TEMP
ECT SENSOR
ECT SENSOR
FRAME-LH (FRT)
E-137 2 0.5B 0.5B 0.5LG/W 12
J-9
H-105
0.5LB FRAME-LH (CTR)
H-105
0.5Y/R 1 J-28
0.5LG/W H-5
0.5BR/B
0.5O/L
0.5L/B
0.5L/R
0.5L/P
0.3LG
FUEL
SVS
N8B0020E

0.5L/W
0.5L/R
0.5W
0.5R
0.5L/R
0.5L/Y
0.5L
0.3B
0.5B 0.3B H-5 32
SERVICE CONNECTOR
0.5P/B
0.5P/B
0.5L/Y
0.5BR
0.5L
0.5W
0.5W
0.5R
0.5R
0.5R
0.3B
0.5B 0.5B 60 J-191 SG -5VRT2
70 J-191 IA -PTOPOS
66
41
42
20 J-191 SG -SLD1
63 J-191 IA -ACCEL1
64
61
39 J-191 SG -SLD2 0.5B 0.5R 3 B-422
ECM ; ENGINE
0.5BR/G
0.5R/G
1 14 H-5 0.5BR/G J-182
3 J-182
4 J-182
MAF SENSOR
0.5B 5 J-182
2 B-422
N8B0021E

8W/B
8W 8W/B 2W
1 2
J-2 J-1
AC. GEN.
J-1
1 1.25W/L
FL-1 100A MAIN
3W/L FL-2 40A KEY
30B/R STARTER + P-1 P-2
2L
2L
8B
FL-8 60A STARTER 1
FL-5 40A ECM
FL-3 60A GLOW
J-26 3W/B B 0.5R/W 0.5R RELAY:STARTER CUT 2 RELAY:STARTER X-21 5 X-21 4 X-26 3 X-26 0.85LG 3B/L 0.5LG F-26 15A CONDENSER FAN RELAY: CONDENSER FAN 2B/L 0.5Y/B 4 RELAY:GLOW X-20 0.5Y/B 0.5LG
+ P-3 P-4 3B/W C J-27 1
3W/R
X-21
X-21
X-26
X-26 For SMOOTHER C/U: SMOOTHER
F-28 10A ECM
3 X-20
1.25R
0.5LG
P-5 0.5LG 0.5LG
X-20 2 3B/Y
X-20 0.5Y/B 0.5B/R 10 J-191 OS-GLOWR 24 J-191 IS-IGKEY IA IA -SCVLO -SCVLO E-111 89 E-111 97 IS-REF J-191 33 0.5G/R 0.5G/R 0.5G/R REF HARNESS 2 E-116 SCV E-116 1 0.5P 1 0.5W/R J-271 5
3 X-18
1 J-31
RESISTOR:DROP
1 J-50 SW:NEUTRAL
1 J-225
1 H-120 3B/Y X-18 4 X-18 2 1 E-3 GLOW PLUG 0.5L/B 2R 40 2 J-191 PS-+B OS -INJ3 E-111 120 1.25B/L OS -INJ2 E-111 118 1.25B 2R 5 OP -SCVHI E-111 105 OP -SCVHI E-111 113 0.5W/R CYLINDER #3 FUEL INJECTOR 1 E-15 CYLINDER #2 FUEL INJECTOR 1 E-14 E-15 2 E-14 2 1.25R 2R 0.5W/R
J-225 2 0.5G/W 0.5R/W
J-31 2 0.5LG/B 0.5W/L 0.5L/B 21 OP -COM1 E-111 121 OS -INJ1 E-111 119 1.25G/W
J-50 2
35 J-191 PS -MAFBAT
46 J-191 IS-STARR
15 J-191 OS-EXB
14 J-191 OS -STARTR
ECM ; ENGINE
IS-PN 0.5B 0.5B J-191 50 OP -COM2 E-111 116 OS -INJ4 E-111 117 1.25W/Y CYLINDER #4 FUEL INJECTOR 1 E-16 E-16 2 2W
0.5B/L
1.25B
0.5B/L
For SMOOTHER (except NKR) 2W 2R H-4 C/U: SMOOTHER
1 E-13
0.5B/L
For SMOOTHER (NKR only) H-17 C/U: SMOOTHER
E-13 2
J-9
2B 1.25W
FRAME-LH (CTR)
N8B0022E

8W/B
H-6
5W/B
0.5W/B
H-105
8 F-15 15A AUDIO (IG). CIGAR LIGHTER 3B/Y 3B/Y 3B/Y F-22 10A STARTER 3B/Y
0.85W/L
15
H-5
0.5W/L
STARTER SW OFF ACC 1 H-7 3W/L 2 B-67 ON ST B-67 B-67 B-67 1 3 4 3R/Y
0.5R/Y
CIGAR LIGHTER RELAY: ON, FUSE: ABS (IG)
3B/Y
F-16 10A METER
0.5R/W 0.5LG
14
H-8
0.3R/W 0.5B/Y 0.5LG
0.5LG
F-9 10A ENG.(IG) 0.5Y/B 0.5Y/B
2 H-105
0.5LG
0.5LG
0.5Y/B
18
H-5 1 H-17 NKR only 2 H-4
RELAY: DPD EXT.THROTTLE
2 X-25
5 X-25
1 Except NKR SW : CLUTCH B-89
X-25 1
X-25 3 0.5G/O
SW : DPD (CONNECTOR) 0.5LG 0.5G/B
B-497
B-89 2 0.5BR/Y
3 H-105 H-17 2 NKR only 0.5G/O 0.5G/B H-4 8 Except NKR 0.5BR/Y 0.5W/G 96 E-111 OP -EVRV H-5 23
0.5R
102 E-111 OS -DPFET
28 J-191 IS-DPF
26 J-191 IS-CL For M/T
TURBO CONTROL VALVE E-167 2
0.5LG 1 E-167
ECM ; ENGINE
PG-POWER J-191 1 1.25B 1 J-221 VSV: DPF EXH. THROTTLE J-221 0.5L/W 0.5Y/B 0.5Y/R 0.5LG 0.5B 0.5B 2 0.5B 0.5R 2 J-222 SENSOR: EXHAUST TEMP (DOC IN) J-191 3 1.25B J-191 4 1.25B PG-WIGN J-191 43 0.75B J-191 62 0.75B PG -CASE J-191 81 0.75B SG -SLD3 J-191 59 0.3B SG SP-5V3 IA-EXHP1 -5VRT3 J-191 80 J-191 67 J-191 79 0.5B IA-THE1 J-191 73 IA-THE2 J-191 74
3 1.25B J-224
2 J-224 SENSOR: EXHAUST PRESSURE 1 (IN&OUT)
1 J-224
1 J-223
2 J-223
1 J-222
J-9
2B
SENSOR: EXHAUST TEMP (IN)
FRAME-LH (CTR)
N8B0023E

RELAY: CHARGE 5W/B 2W/B RELAY: TAIL 0.5W/R 1 X-1 3 0.5B/Y 0.85BR X-1 4 0.5B/Y
0.5W/L RELAY: HEATER & A/C 5 3L F-1 15A HEATER. AIR CON
0.5W/L
X-1
X-1
SW : AIR CON 0.85BR 1 0.85L BLOWER MOTOR B-39 B-39 2 0.5LG
3W/B
1 0.5W/R 2
X-12 X-12 X-12 X-12
0.5B
0.5B/Y 0.5W/L
RELAY: HEATER 1 3B/R
F-2 10A FUEL HEATER
3W/B
2 3
X-8 X-8 X-8 X-8
0.5B/R
0.5B 0.5B/Y
0.5B/Y
3W/B 3W/B
F-19 10A ENG. (BACK UP) HSA
0.3W/G
0.5W/R
0.3W/B
0.5L/W
RELAY: TAIL, FUSE: AUDIO(B), DOOR LOCK FUSE: STOP LIGHT FUSE: POWER WINDOW FUSE: NEES(B) FUSE: HORN, HAZARD
DIAG CONNECTOR
B-79 4 0.5B B-79 5 0.5B B-79 13 B-79 2 B-79 16 B-79 12 0.5Y B-79 7 0.5LB B-79 14 0.5L B-79 6 RESISTOR2
0.5W/R
RESISTOR1 H-8 H-8 13
B-431 1
B-431 2
0.5W/R
CONT UNIT. ABS

DIAG J-177 ALDL J-177 L J-177 27 H J-177 26 H J-177 14 L J-177 15
4 29
0.3W/G 0.3W/B
H-15 H-15
11 6
12 0.3W/G 0.3W/B
B-387 1
B-387 2
13 0.5L B-500 0.5LB 0.5L/W H-5 37 0.5L/W 58 W
C/U: DAMU
B-500 8 B-500 2
0.5L/W
0.5L/W
0.5L
0.5L
14 9
H-15 H-15
0.5L 0.5L/W
8 7
H-8 H-8
0.5L H-8 0.3B/W 0.5L/W 0.3LB 10 H-8 5 0.5LB H-5 36
10 H-15
5 H-15
0.5Y
0.5Y
Without ABS
3 B-427 H
2 B-427 L
18 B-428
9 B-426
0.5L 0.5L/W 0.85B(NKR85)/1.25B(NPR85) 37 J-191 18 J-191
CONT UNIT. SMOOTHER

For SMOOTHER
52 J-191 IS-DIAG
38
78
2B
ECM ; ENGINE
SG-SLD5 E-111 100 IA -PFUEL E-111 82 IS IS IS -EBMPOS1 -EBMPOS2 -EBMPOS3 E-111 94 E-111 93 E-111 99
J-191 J-191 J-191 CC -KW2000 CC CC -ISOCAN-H -ISOCAN-L
OM OM OM -EBM1 -EBM2 -EBM3 E-111 E-111 E-111 111 103 110
0.5B
0.5B/O
0.5LG/B
0.5W/O
0.5Y/B
0.5LG
0.5LB
0.5B/W
0.5Y/B
0.5Y/B
8 E-94 U
7 E-94 V
0.5LG
0.5LG
0.5W
B-7
3B 1 2 E-112 3 E-112 3 E-113 1 E-113 SENSOR; Pc 2 E-113 1 E-94 5 E-94 4 E-94 SENSOR: EGR VALVE 3 E-94 2 E-94
5B
E-112
B-1
0.5W 6 E-94
0.5O
0.5L
N8B0024E

RELAY: THERMO A/C SW : A/C PRESS. 0.85BR 0.5LG/B DIODE BOX 0.5LG 0.5B/Y 0.5W/L SW: DPD REGENERATE 0.5B/R 0.5B/R 6 2 B-495 B-495 B-495 B-495 3 5 Tail Relay 3W 0.5W/V 10 X-33 X-33 3 1 2 X-10 X-10 X-10 X-10 4 0.5P/G ELECTRO THERMO A/C COMPRESSOR 0.5B/Y 0.5W/L METER (PARKING BRAKE) 0.3W/V F-7 10A TAIL LIGHT 0.85LG/R 0.5W/V 0.3W/B 3 B-18 DIODE BOX 4 3 0.3W/B 5 0.85G/W H-5 2 0.85G/W 1 J-6 J-6 2 0.85G/O 7 H-105 0.75P 1 E-5
J-269 J-269 SHORT CONNECTOR (FOR NPR85)
0.5B/Y 0.5W/R
3 B-18 DIODE BOX B-18 4 (FOR NKR85)
H-5 31
0.85LG/R
0.5B/R
0.5B/R
0.85LG/R 5 B-69 SW : EXH. BRAKE SW : ENG. WARM 0.5B 5 3 1 B-69 2 0.5LG/R B-31 B-31 B-31 B-31 B-31 B-31 2 0.5LG/R 6 4 0.5B
B-18 2 For M/T 0.5W/B 0.5W/B H-12 For SMOOTHER 0.3W/B 1 SW: PARKING BRAKE 19 25 H-5 H-5 IA -EVRV E-111 92 0.5B N-6 0.5B 0.3Y/G 0.5B 1 E-26 H-12 5 3
0.5G/O
0.5B/Y
0.5LG/L
Except NKR NKR only H-4 11 H-17 3
3B
0.5B
(EC only)
H-5 29
H-5 0.5LG/R 0.5Y/G 1 J-32 2 J-32 V/SPEED SENSOR 3 J-32 0.5Y/G 6
0.5LG/L
0.5W/R
19 J-191 IF-SPD
45 J-191 IS-EXB
51 J-191 IS-QWS
47 J-191 IS -DPFREG
34 J-191 IS-A/C
48 J-191 IS -PBRK
ECM ; ENGINE
IS-PTO J-191 44 0.5L/O OM -IDM2 E-111 104 OM IA -IDM1 -IDMPOS E-111 112 E-111 85 IA -MAP E-111 91 SG -SLD4 E-111 108 SP -5V4 E-111 95 SG IF -5VRT4 -CRANK E-111 109 E-111 107
0.5B
0.75B/G
0.5V/W
38 H-5 0.5L/O
0.5Y
0.5B
0.5GR/R
0.5W/B
0.5W/B H-5 1
0.5R/L
0.5R
0.5B
0.5Y
B-7
1 B-84 SW : PTO
0.75G
2 E-114
5 E-114
6 E-114
3 E-114
5B
SENSOR; INTAKE THROTTLE DC MOTOR POSITION B-84 2 E-114 1
3 E-98
2 E-98
1 E-98
3 E-26
SENSOR; NE, CRANK
SENSOR; PRESSURE
B-1
0.85B(NKR85) 1.25B(NPR85)
0.5B
FRAME-LH (FRT)
0.5G 2 E-26
0.5Y
0.5B
0.5Y
N8B0025E

0.5B/Y 0.5W/L 18 B-51 ENGINE COOLANT TEMPERATURE GAUGE B-52 5 12 0.5LB H-5 CHECK ENG. PARKING BRAKE DPF REGENERATE SEDIMENTER B-52 10 13 0.5R(W/CAB) 0.5LB 0.5LG/W H-5 0.5LG/W EXHBRAKE
OIL PRESS
CHARGE
TACHO
SPEED
GLOW
B-51 10
B-52 20
B-52 17
B-51 13
B-51 For SMOOTHER 5
B-51 7
B-52 15
B-51 6
B-51 4 0.5LG/B
B-53 For SMOOTHER 10 0.5LG/B
B-52 8
B-51 11
B-51 5 For M/T 0.3W/V
B-51 For SMOOTHER 4 0.3W/V
B-52 6
For M/T 0.5L/R
0.5L/R
For M/T
H-5 0.3Y/G 0.5B 24
H-5 30
H-5 40
H-5 7
H-17 4 NKR only
H-4 19 Except NKR
H-8 3
H-5 39 0.5BR/B
SW: OIL LEVEL
21 0.5Y/R(S/CAB) 1 J-28 UNIT: FUEL SENSOR J-28 2 0.5B 16 J-191 OS -LOWOIL SW: FUEL LINE CLOGGING 0.5BR/B 0.5LG/W 12 H-105 1 H-105
6 H-105
0.5LG/B
0.5O/L
0.5L/R
0.5L/B
0.5L/P
0.5LG
SW: OIL PRESSURE
0.5B 0.3Y/G
0.85B(NKR85)/1.25B(NPR85)
6 J-191 OS-DIAGL
17
11
9 J-191 OS -DPFREG
8 J-191 OF -TACHO
ECM ; ENGINE
IA-THL E-111 83 IA-THW E-111 84 IS -LOWOIL J-191 53 0.5V/Y
0.5B 0.5G/Y
5 0.5B H-105 3 SW:LOW OIL LEVEL E-90 METER 0.5V/Y FUEL HEATER
FUEL SEDIMENTER SW: FUEL SEDIMENTER J-206 1 J-206 2
0.5LG/W
0.5B
1 E-90
2 E-90
1 E-93 B-1
2 E-93
1 E-137
SENSOR; FUEL TEMP
ECT SENSOR
ECT SENSOR
FRAME-LH (FRT)
E-137 2 0.5B 0.5B
J-9
0.5LB FRAME-LH (CTR)
0.5BR/B
1 J-8
0.5LG/W H-5
0.5BR/B
0.5O/L
0.5L/B
0.5L/P
0.3LG
FUEL
SVS
N8B0026E

0.5L/W
0.5L/R
0.5W
0.5R
0.5L/R
0.5L/Y
0.5L
0.3B
0.5B 0.3B H-5 32
SERVICE CONNECTOR
0.5P/B
0.5P/B
0.5L/Y
0.5BR
0.5L
0.5W
0.5W
0.5R
0.5R
0.5R
0.3B
0.5B 0.5B 60 J-191 SG -5VRT2
70 J-191 IA -PTOPOS
66
41
42
20 J-191 SG -SLD1
63 J-191 IA -ACCEL1
64
61
39 J-191 SG -SLD2 0.5B 0.5R 3 B-422
ECM ; ENGINE
0.5BR/G
0.5R/G
1 14 H-5 0.5BR/G J-182
3 J-182
4 J-182
MAF SENSOR
0.5B 5 J-182
2 B-422
N8B0027E

Connector List
For 4HK1 Engine No. Connector Face B-53 B-1
012-009 000-001
No.
Connector Face
B-67 B-7
000-001
1 4 3
2 3 4
004-001 004-002
B-17 (For M/ T)
B-67
1 2 3 4
2 4
1 3
004-002 004-004
B-69 B-18
1 2 3 4
1 5
2 3 4 6 7 8
008-001
004-004
B-69 B-31
1 4 2 5 3 6
4 3 2 8 7 6
1 5
008-002
006-001
B-79 B-39
1 2 3
003-019
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
016-005
B-84 B-51
020-004
1 2
002-022
B-89 B-52
020-005
1 2
002-009

B-280
1 2 3 4 5 6
B-495
006-024 006-022
B-281
003-028
B-497
1
001-024
B-387
002-038
B-497
1
001-025
B-422
003-027
B-500
1 7
2 8
3 9 10
11 12 13
013-001
B-426 (For Smoot her)

024-001
E-3
000-009

017-001
E-5
001-021

022-006
E-90
1 3
003-004
B-431
002-038
E-93
002-035

E-94
1 2 3 4 5 6 7 8
E-139
008-007 003-031
E-98
003-026
E-140
003-031
121
120
119
E-111
113 112 111 110 109 108 107 106 105 104 103 102 101 100 99 98 97 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82
118 116
117 114
E-141
040-001 003-031
115
2 6
3 7
4 8
E-112
003-026
E-168
9 10 11 12 13 14 15 16
016-008
E-113
003-029
E-169
1 5
23 6 7
4 8
008-027
E-114
006-030
H-4
1 2 3 4 5 10 11 12 13 14 15
6 7 8 9 16 1718 19 20
020-002
E-116
002-036
H-4
9 8 7 6 20 19 18 17 16
5 4 3 2 1 15 14 13 12 11 10
020-003
E-138
003-031
H-12 (For M/ T)
1 2 3 7 8 9 10
4 5 6 11 12 13 14
014-002

No. Connector Face No. H-118 (For Smoot her)
014-003
Connector Face
H-12 (For M/ T)
6 5 4 14 13 12 11
3 2 1 10 9 8 7
4 8
3 7
2 6
1 5 9
12 11 10
012-002
H-12 (For Smoot her)
1 2 3 4 5 11 12 13 14 15 16
6 7 8 9 10 17 18 19 20 21 22
H-120
022-001
001-023
10 9 8 7 6 22 21 20 19 18 17
5 4 3 2 1 16 15 14 13 12 11
H-120
022-002
001-022
2 6 7
3 8
4 9
H-15
10 11 12 13 14 15 16
H-125
016-003
1 5
2 6
3 7
4 8 008-019
3 8 7
2 6
1 5
H-15
14 13 12 11 10
H-125
016-004
4 8
3 7
2 1 6 5 008-020
16
15
H-105
1 5 9
2 6
3 7
4 8
H-126
016-001
5 1
6 2
7 3
8 4 008-022
10 11 12
13 14 15 16
H-105
4 8
3 7
2 6
1 5 9
H-126
016-002
8 4
7 3
12 11 10
16 15 14 13
2 1 008-021
1 5 9
2 6
3 7
4 8
H-159
012-001 001-021
10 11 12

J-1
J-31
002-003
2
002-011
J-2
000-001
J-32
003-018
J-6
1 3
2 4
004-001
J-50
002-035
J-8
1
J-166
001-013
3
003-001
J-9
000-001
J-177
034-001
J-26
000-002
J-177
034-002
J-27
000-009
J-182
5
005-008
J-28
2
002-011
J-191
081-001

J-206
N-6
002-001
2 1
002-023
J-216
1 2 3
003-032
P-1
000-022
J-221
2
002-011
P-4
000-014
J-222
P-2
002-052 000-014
J-223
P-3
002-053 000-014
J-224
003-037
P-5
000-002
J-225
2
002-049
X-1
003-018 005-006
J-271
1
001-026
X-8
005-006

No. Connector Face H-5
X-10
1 2 3 5 4
005-001
X-12
1 2 3 5 4
1 7 13 19 25 31
2 8 14 20 26 32
3 9 15 21 27 33
34
35
36
37
4 10 16 22 28 38
5 11 17 23 29 39
6 12 18 24 30 40
6 12 18 24 30 40
5 11 17 23 29 39
4 10 16 22 28 38
37
36
35
34
3 9 15 21 27 33
2 8 14 20 26 32
1 7 13 19 25 31
005-001
X-18
2 4
3 5
N8A5488E
005-003
H-6, H-7, H-8
X-20
2 4
3 5
005-003
H-6
1
1
H-7
X-21
1 2 3 4
3
4 3 2 1 8 7 6 5 H-8 13 12 11 10 9 18 17 16 15 14
2 4
5 6 7 8 9 10 11 12 13
005-003
14 15 16 17 18
X-25
005-006
N8A5489E
X-26
005-006
X-32 (For Smoot her)
1 2 3 4
004-004

For 4JJ1 (EURO 3) Engine No. Connector Face
1
No.
Connector Face
X-21 B-1
000-001
2 4
3 5
005-003
X-26 B-7
005-006 000-001
B-18 X-1
1 2 3 4
004-004 005-006
B-31 X-8
005-006
1 4
2 5
3 6
006-001
B-39 X-10
1 2 3 5 4
1 2 3
003-019
005-001
B-51 X-12
1 2 3 5 4
020-004 005-001
B-52 X-18
1 2 4 3 5
020-004 005-003
B-67
1
X-20
1 3
2 4
004-001
2 4
3 5
005-003

B-67
2 4
1 3
B-387
004-002 002-038
B-69
1 5
2 3 4 6 7 8
008-001
B-387
002-039
B-69
4 3 2 8 7 6
1 5
008-002
B-422
003-027
B-79
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
016-005
B-431
002-038
B-84
1 2
002-022
B-431
002-039
B-89
1 2
002-009
B-500
1 7
2 8
3 9 10
11 12 13
013-001
B-280
1 2 3 4 5 6
H-12
006-024
1 2 3 7 8 9 10
4 5 6 11 12 13 14
014-002
B-281
003-028
H-12
6 5 4 14 13 12 11
3 2 1 10 9 8 7
014-003

H-105
1 5 9
2 6
3 7
4 8
E-15
012-001 002-036
10 11 12
H-105
4 8
3 7
2 6
1 5 9
E-16
012-002 002-036
12 11 10
H-120
E-90
001-022
1 3
003-004
H-120
E-93
001-023 002-035
E-3
000-009
E-94
1 2 3 4 5 6 7 8
008-007
E-5
001-021
E-98
003-026
121
120
119
E-13
002-036
E-111
113 112 111 110 109 108 107 106 105 104 103 102 101 100 99 98 97 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82
118 116
117 114
115
040-001
E-14
002-036
E-112
003-026

E-113
003-029
J-9
000-001
E-114
006-030
J-26
000-002
E-116
002-036
J-27
000-009
E-137
1 2
002-025
J-28
2
002-011
J-1
J-31
002-003
2
002-011
J-2
000-001
J-32
003-018
J-6
1 3
2 4
004-011
J-50
002-035
J-8
1
J-166
001-013
3
003-001

J-182
5
005-004
P-2
000-014
J-191
081-001
P-3
000-014
J-206
P-4
002-001 000-014
J-216
1 2 3
003-032
P-5
000-002
H-5 J-225
1 2
002-049
J-271
1
001-026
1 7 13 19 25 31
2 8 14 20 26 32
3 9 15 21 27 33
34
35
36
37
4 10 16 22 28 38
5 11 17 23 29 39
6 12 18 24 30 40
6 12 18 24 30 40
5 11 17 23 29 39
4 10 16 22 28 38
37
36
35
34
3 9 15 21 27 33
2 8 14 20 26 32
1 7 13 19 25 31
N-6
2 1
002-023
N8A5488E
P-1
000-022

H-6, H-7, H-8
H-6
H-7
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 H-8
4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14
N8A5489E

For 4JJ1 (EURO 4) Engine No. Connector Face
1
No.
Connector Face
X-21 B-1
000-001
2 4
3 5
005-003
X-25 B-7
005-006 000-001
X-26 X-1
005-006 005-006
X-8
005-006
1 2 3 4
004-004
X-10
1 2 3 5 4
B-17 (For M/ T)
1 2 3 4
004-004 005-001
B-18 X-12
1 2 3 5 4
1 2 3 4
004-004 005-001
B-31 X-18
1 2 4 3
1 4
2 5
3 6
006-001
5
005-003
B-39
1
1 2 3
X-20
2 4
3 5
003-019 005-003

B-51
020-004
B-84
1 2
002-022
B-52
020-004
B-89
1 2
002-009
B-53
012-009
B-280
1 2 3 4 5 6
006-024
B-67
1 3
2 4
004-001
B-281
003-028
B-67
2 4
1 3
B-387
004-002 002-038
B-69
1 5
2 3 4 6 7 8
008-001
B-387
002-039
B-69
4 3 2 8 7 6
1 5
008-002
B-422
003-027
B-79
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
016-005

024-001

No. B-427 (For Smoot her)
017-001
Connector Face
No.
Connector Face
H-4 (Excep t NKR)
9 8 7 6 20 19 18 17 16
5 4 3 2 1 15 14 13 12 11 10
020-003

022-006
H-4 (For NKR)
1 5 9
2 6
3 7
4 8
10 11 12
012-001
B-431
002-038
H-4 (For NKR)
4 8
3 7
2 6
1 5 9
12 11 10
012-002
B-431
002-039
H-17 (For M/ T)
1 3
2 4
004-011
B-495
006-022
H-17 (For M/ T)
004-018
B-497
1
001-025
1 5 9
2 6
3 7
4 8
10 11 12
13 14 15 16
016-001
B-500
1 7
2 8
3 9 10
11 12 13

013-001
4 8
3 7
2 6
1 5 9
12 11 10
16 15 14 13
016-002
H-4 (Excep t NKR)
1 2 3 4 5 10 11 12 13 14 15
6 7 8 9 16 1718 19 20
H-12 (For M/ T)
020-002
1 2 3 7 8 9 10
4 5 6 11 12 13 14
014-002

H-12 (For M/ T)
6 5 4 14 13 12 11
3 2 1 10 9 8 7
H-118
014-003 008-018
1 2 3 4 5 11 12 13 14 15 16
6 7 8 9 10 17 18 19 20 21 22
H-120
022-001
001-022
10 9 8 7 6 22 21 20 19 18 17
5 4 3 2 1 16 15 14 13 12 11
H-120
022-002
001-023
2 6 7
3 8
4 9
H-15
10 11 12 13 14 15 16
E-3
016-003 000-009
3 8 7
2 6
1 5
H-15
14 13 12 11 10
E-5
016-004 001-021
16
15
H-105
1 5 9
2 6
3 7
4 8
E-13
012-001 002-036
10 11 12
H-105
4 8
3 7
2 6
1 5 9
E-14
012-002 002-036
12 11 10
H-118
1 5
2 6
3 7
4 8
008-003
E-15
002-036

E-16
002-036
E-113
003-029
E-26
003-027
E-114
006-030
E-90
1 3
E-116
003-004 002-036
E-93
002-035
E-137
1 2
002-025
E-94
1 2 3 4 5 6 7 8
E-167
008-007
002-016
E-98
003-026
J-1
002-003
121
120
119
E-111
113 112 111 110 109 108 107 106 105 104 103 102 101 100 99 98 97 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82
118 116
117 114
J-2
040-001 000-001
115
E-112
003-026
J-6
1 3
2 4
004-011

J-8
1
J-166
001-013
3
003-001
J-9
000-001
J-177
034-001
J-26
000-002
J-182
5
005-004
J-27
000-009
J-191
081-001
J-28
2
002-011
J-206
002-001
J-31
2
002-011
J-216
1 2 3
003-032
J-32
J-221
003-018
2
002-011
J-50
002-035
J-222
002-056

J-223
002-041
P-5
000-002
H-5 J-224
003-037
J-225
2
002-049
1 7 13 19 25 31
2 8 14 20 26 32
3 9 15 21 27 33
34
35
36
37
4 10 16 22 28 38
5 11 17 23 29 39
6 12 18 24 30 40
6 12 18 24 30 40
5 11 17 23 29 39
4 10 16 22 28 38
37
36
35
34
3 9 15 21 27 33
2 8 14 20 26 32
1 7 13 19 25 31
N-6
2 1
002-023
N8A5488E
H-6, H-7, H-8 P-1

000-022
H-6
P-2
1 2 H-7 2 1
000-014
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 H-8
4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14
P-3
000-014
N8A5489E
Neutral Switch
P-4
000-014
Refer to START AND CHARGING in this section.
Starter Relay
Charge Relay

Starter Switch
Refer to START AND CHARGING in this section. Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Check to see if the accel pedal has been returned by the return spring to the specified position. 2. Turn the accel switch clockwise until the tip of the threaded portion of the switch contacts the pedal arm. 3. Tighten the lock nut to the specified torque. Tighten: Lock nut to 13 Nm (130 kgfcm / 115 lbfin)
Accel Switch
Inspection 1. Check the continuity between the switch connector terminals. 2. Check to see if switch push rod operates smoothly. Repair or replace the accel switch when result of inspection is found abnormal.
Clutch Switch
Inspection 1. Check the continuity between the switch connector terminals. 2. Check to see if switch push rod operates smoothly. Repair or replace the switch when result of inspection is found abnormal.
N8A5091E
Removal Preparation: Disconnect the battery ground cable. 1. Accel Switch 1) Disconnect the connector. 2) Loosen the lock nut of the switch. 3) Remove the switch by turning it.
N8A0089E
Removal and Installation Refer to Accel Switch in this section.
N8A0088E

Exhaust Brake Switch
Inspection Check the continuity between the terminals of the exhaust brake switch. Repair or replace the switch when the result of inspection is found abnormal.
N8A5095E
Removal and Installation Refer to HEADLIGHT, FOG LIGHT, REAR FOG LIGHT AND CORNERING LIGHT in this section.

Exhaust Brake Solenoid Valve
Inspection Connect the solenoid valve connector terminal No. 1 to the battery (+) terminal and terminal No. 2 to the () terminal and then check the continuity among each port.
Intake Throttle Solenoid Valve

Inspection Connect the solenoid valve connector terminal No. 1 to the battery (+) terminal and terminal No. 2 to the () terminal and then check the continuity among each port. Repair or replace the intake throttle solenoid valve when the result of inspection is found abnormal.
B
J-31
A
2 1
B
J-31
C
Port Operation When battery voltage applied When battery voltage not applied
N8B5133E
C
Port Operation When battery voltage applied When battery voltage not applied
N8B5133E
8-92 CAB AND CHASSIS ELECTRICAL Headlight, Fog Light, Rear Fog Light and Cornering Light
General Description
The circuit consists of headlight, fog light, cornering light, starter switch, combination switch (Lighting switch, dimmer / passing switch, cornering light switch, rear fog light switch), fog light switch, rear foglight, high beam indicator light and relay. When the lighting SW is turned on by setting it at headlight position, the lighting relay is actuated to turn on the headlight. The optical axis of the headlight can be turned up or down by operating the dimmer SW while headlight is on. The passing SW is independent of the lighting SW, and the optical axis of the passing light can be turned up only while the switch lever is pulled up and held in this state. Fog light turns on by switching it to ON position to activate relay only while lighting SW is on. Rear fog light turns on by switching it to ON position to activate relay only while lighting SW is at headlight position. When the headlight is on, turn the turn-signal switch left or right, and then the cornering switch built in the combination switch turns on, followed by the cornering light turning on.
Lighting Circuit
CORNERING LIGHT HEADLIGHT
Battery (+) Starter sw.(ON)
FOG LIGHT
REAR FOG LIGHT
Lighting sw.
OFF RR FOG
Headlight relay
Tail relay
Cornering light relay
Rear fog light relay Headlight
Cornering light sw.

LO HI
Fog light sw. Rear fog light
Dimmer sw. Cornering light Dimmer relay Fog light relay
Fog light
N8B5110E
Notice: Arrow marks indicate the direction of current.
Parts Location
RELAY BOX ASM (No.1) X-5 FOG LIGHT RELAY X-6 DIMMER RELAY X-9 CORNERING LIGHT RELAY STARTER SWITCH R-13 REAR FOG LIGHT (RH) B-67 B-87 FRONT FOG LIGHT SWITCH H-16
COMBINATION SWITCH (LIGHTING SWITCH, CORNERING LIGHT SWITCH, REAR FOG LIGHT SWITCH)
RELAY BOX ASM (No.2) X-16 REAR FOG LIGHT RELAY
H-14 R-12 REAR FOG LIGHT (LH) P-5 P-2 BATTERY P-4 P-3 RELAY BOX ASM FL-1,FL-2,FL-4 FUSIBLE LINK J-9 B-51 HIGH BEAM INDICATOR LIGHT (METER) REAR FOG LIGHT INDICATOR LIGHT (METER) B-3 FOG LIGHT (LH) B-5 CORNERING LIGHT (LH) P-1
FUSE BOX ASM F-7,F-8,F-14,F-16, F-23,F-24 X-3 HEADLIGHT RELAY X-4 TAIL RELAY X-33 DIODE
B-74 CORNERING LIGHT (RH)
B-7
B-73 HEADLIGHT (RH)
B-72
FOG LIGHT (RH)
H-5,H-6,H-7,H-8 B-70 B-1
B-4 HEADLIGHT (LH)
N8B0028E
FL-2 40A 3W/L
KEY SW
(FOR 4HK1)
8W/B 5W/B H-6 1 STARTER SWITCH 2W/B 3W/B OFF ACC 3 B-67 3B/Y RELAY; TAIL F-7 TAIL LIGHT 0.85LG/R 10A TAIL LIGHT X-4 5 F-16 10A METER 3W 0.85LG/R 2R FRT FOG LIGHT, CORNERING LAMP F-8 10A 1 X-4 3 X-4 X-4 2 2 B-67 ON ST 3 X-3 X-3 2 B2 H-7 3W/L 2 2W/R H-7 5W/B 2 5W/B
2L
8B
P-1 2W/R
Circuit Diagram
P-2
FL-1 100A or 120A MAIN
(FOR 4JJ1)
FL-4 30A HEAD LAMP
P-3
P-4
RELAY; HEADLIGHT
X-3 5 0.3R 1
X-3
P-5 0.3R 0.5B/Y 0.3R DIODE X-33 1 0.3L/R 8 1 F-24 HEAD LIGHT (LH) 0.3G/O 0.5R 0.5R/L 7 0.3L X-9 3 B-4 HI LO RELAY; CORNERING LAMP X-9 X-9 1 B-4 1 5 2 0.5R/B 0.5R/G 0.85R/Y 2R X-9 LH 10 4 3 2 RH 3 B-73 HI LO 10A X-33 X-33 F-23 2R 0.85LG/R 2 3 0.5R/L
FRAME
LIGHTING SWITCH
OFF
B-70
0.85LG/R
0.85LG/R
B-70
10A HEAD LIGHT (RH)
For 4HK1 / 4JJ1 Engine (Without Rear Fog Light)
B-70
Hu
B-70
6 B-87
2 B-87
B-70
COMBINATION SWITCH B-4 2 HEADLIGHT (LH) HEADLIGHT (RH) 0.3R/L 0.85R/Y 0.5R/G 0.5R/G 3 X-6 X-6 X-6 2 4 2 B-51 H X-6 5 1 X-6 L RELAY; DIMMER B-51 15 HIGH BEAM INDICATOR LIGHT (METER) 1.25B 0.85B 0.5B 3B 2B 1.25B(except NKR)/0.85B(NKR)
E2
LO
HIGH PASS
B-73 2
B-73 1 B-87 3 0.5R/Y B-87 5
CORNERING LIGHT SWITCH
FOG LIGHT SWITCH
B-70
LH
RH
0.85R/Y 0.5R/G RELAY; FOG LIGHT X-5 1 0.85R/G
2 X-5
3 X-5
B-70 11
B-70 9
X-5 5
0.5P
B-5
0.5P/B
B-74
0.85R/G
0.85R/G
(RH)
CORNERING LAMP
(LH)
B-5
B-74
0.5B
0.5B
1 B-3
1 B-72
3B
2B
0.85B
0.85B
FOG LIGHT (LH)
FOG LIGHT (RH)
FRAME-LH (FRONT)
B-1
B-3 2 0.5B
B-72 2 0.5B
N8B0029E
HEADLIGHT BRACKET (LH)
B-7
3B
5B
2B
3B
3B
2B
(FOR 4HK1)
8W/B 8 W/B
H-6 F-14 (10A) H-7 2W/B 3W/B 3 X-3 3 X-4 TAIL LIGHT 0.85LG/R 0.85LG/R FRT. COMBINATION LIGHT (LH) (4) X-4 F-7 10A 2 X-3 2 2 2W/R REAR FOG LIGHT 5W/B 2 3W/B 3W/B
5W/B
2L
8B
P-1
FL-1 100A or 120A
(FOR 4JJ1)
2W/R
P-2
MAIN
FL-4 30A
HEAD LAMP
P-3
P-4 X-3 5 X-4 X-4 1 0.85LG/R 3W 0.85LG/R FRT FOG LIGHT F-8 10A 0.5LG 5 2R 0.3R 1 X-3
RELAY; TAIL
RELAY; HEAD LIGHT
LIGHTING SW
OFF
RR FOG
P-5 1 0.85LG/R 0.85LG/R 0.85LG/R 8 HEAD LIGHT (LH) 14 0.5GR /B HEAD LIGHT (RH) 0.3G/O F-24 10A F-23 10A 0.3R 2R
B-70
FRAME
B-70
B-70 0.5R 7 LH 3 B-73 HI LO B-87 B-87 RH 6 2 10 3 B-4 HI LO 2R 4 0.3R
5 X-16
2 X-16
0.5R/L
For 4HK1 / 4JJ1 Engine (With Rear Fog Light)
COMBINATION SW FOG LIGHT SWITCH B-4 B-4 2 0.85R/Y 2 1 B-73 1 0.5R/G B-73 B-87 3 0.5R/Y B-87 5 HEADLIGHT (LH) HEADLIGHT (RH) 2 0.85R/Y 0.5R/G 0.5R/G X-5 3 X-5 0.3R/L 0.85R/Y 0.5R/G 3 X-6 X-6 RELAY; DIMMER X-6 2 4 RELAY; FOG LIGHT X-5 1 0.85R/G X-5 5 H 0.5R/G X-6 5 2 B-51 1 X-6 L 0.5R/G 0.85R/G 0.85R/G 19 0.5B 0.5B 1 B-3 B-51 15 0.5B B-3 2 0.5B 1 B-72 B-51 1.25B(Except NKR)/0.85B(NKR) HIGH BEAM INDICATOR LIGHT (METER) 1.25B 0.85B B-51 B-72 2 0.5B 15 0.5B FOG LIGHT (LH) FOG LIGHT (RH) 3B 2B 3B 3B 2B 2B 2B H-14 1.25B 7 1.25B H-16 7 1.25B 0.85B
B-70
Hu
B-70
B-70
RELAY; RR FOG LIGHT X-16 3 0.5LG/R 0.5R/G X-16 1
E2
LO
HIGH PASS
H-8 H-5 5 1 0.85R/G
LICENSE LIGHT 3 H-14 0.85R/G 3 H-16 0.85R/G METER INDICATOR (REAR FOG LIGHT)
1 R-12
0.85R/G
1 R-13
0.85R/G
FRAME-LH (FRONT)
B-1
RR FOG LIGHT (LH)
RR FOG LIGHT (RH)
0.85B
0.85B
B-7
3B
5B
R-12 2
R-13 2
FRAME-LH (CENTER)
J-9
N8B0030E

Connector List
B-1
000-001
B-5
1 3
2 4
004-012
B-7
000-001
B-5
2 1 4 3
004-013
B-3
B-74
1 2
1 3
2 4
004-012
002-001
B-3
B-74
2 1
2 1 4 3
004-013
002-002
B-72
X-33
1 2
1 2 3
003-034
002-001
B-72
X-3
2 1
002-002
005-006
B-4
X-4
005-006
003-007
B-73
X-5
005-006
003-007

X-6
005-006
B-87
1 4
2 5
3 6
006-006
X-9
005-006
H-14 (With ABS)
1 5 6
2 7
3 8
4 9
10 11 12 13 14 15 16
016-003
X-16
005-006
H-14 (With ABS)
4 9 8
3 7
2 6
1 5
14 13 12 11 10
16
15
016-004
B-51
020-004
H-14 (Without ABS)
1 5
2 6
3 7
4 8
008-003
B-67
1 3
2 4
004-001
H-14 (Without ABS)
4 8
3 7
2 6
1 5
008-004
B-67
2 4
1 3
H-16
004-002
1 5
2 6
3 7
4 8
008-003
B-70
1 2 3 7 8 9 10
4 5 6 11 12 13 14
H-16
014-002
4 8
3 7
2 6
1 5
008-004
B-70
6 5 4 14 13 12 11
3 2 1 10 9 8 7
J-9
014-003 000-001

P-1
000-022
R-13
002-002
H-5 P-4
000-014
P-2
000-014
1 7 13 19 25 31
2 8 14 20 26 32
3 9 15 21 27 33
34
35
36
37
4 10 16 22 28 38
5 11 17 23 29 39
6 12 18 24 30 40
6 12 18 24 30 40
5 11 17 23 29 39
4 10 16 22 28 38
37
36
35
34
3 9 15 21 27 33
2 8 14 20 26 32
1 7 13 19 25 31
P-3
000-014
N8A5488E
H-6, H-7, H-8 P-5

000-002
H-6
R-12
H-7
1 2 3 4
4 3 2 1 8 7 6 5 H-8 13 12 11 10 9 18 17 16 15 14
002-001
5 6 7 8 9 10 11 12 13 14 15 16 17 18
R-12
002-002
N8A5489E
R-13
002-001

Diagnosis
Quick Chart for Check Point 1. Headlight Check point Fuse F-23 (10 A) 1-1. Both Headlights inoperative 1-2. Headlight on the left (or right) side inoperative 1-3. Headlight in low-beam inoperative 1-4. Headlight in high-beam inoperative Trouble mode 1-5. Headlight on the left (or right) side in low (or high)-beam inoperative 1-6. Headlight beam does not change 1-7. Headlights remain on when the lighting switch turned off 1-8. Headlights come on with the lighting SW at the clearance light position Notice: Figure in parenthesis ( ) indicates the order of inspection. (1) (2) (2) (1) (2) (1) ((1)) (1) (1) F-24 (10 A) Fusible link FL-4 (30A) (2) Headl ight relay Lighting SW Dimmer / Passing SW Dimmer relay Headlight bulb LH RH Cable harness
DIOD E
(1)
(4)
(5) (2) (2) (3)
(3)
(1)
((1))
(2)
(3) (3)
(1)

2. Fog Light Check point Fog light bulb Fuse F-7 (10 A) F-8 (10 A) Taillight relay Fog light SW Cable harness Fog light relay (Except 4JJI (EURO 3)) (3)
LH
RH
2-1. Both fog lights inoperative (while lighting switch is on) Trouble mode 2-2. Fog light on the left (or right) side inoperative (while lighting switch is on) 2-3. Fog lights remain on
(1)
(2)
(4) (1) ((1))
(5) (2) (4)
(1)
(3)
(2)
Notice: Figure in parenthesis ( ) indicates the order of inspection. 3. Cornering Light Check point Fuse F-8 (10 A) 3-1. Both cornering lights inoperative Trouble mode 3-2. Cornering light on the left (or right) side inoperative 3-3. Cornering light remains on even when steering wheel is in the straight ahead position (2) F-16 (10 A) (1) Cornering light SW (5) (2) (1) (1) Cornering light bulb Cornering light relay (3) Cable harness (4) (3)
4. Rear Fog Light Check point Fuse F-14 (10 A) Trouble mode 4-1. Rear fog light inoperative (while headlight is ON) (2) Rear fog light SW (4) Rear fog light relay (3) Rear fog light bulb (1) Cable harness (5)

1. Headlight 1-1. Both Headlights Inoperative
8-101
N8B0085E
1-2. Headlight on The Left (or Right) Side Inoperative
IS THE FUSE F-24 (10A) OR F-23 (10A) NORMAL?
YES REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN FUSE F-24 (10A) AND 3 B-4 , FUSE F-23 (10A) AND 3 B-73
NO REPLACE THE FUSE
N8B5141E

1-3. Headlight in Low-beam Inoperative
IS THE DIMMER RELAY NORMAL?
YES REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 1 B-4 (OR 1 B-73 ) AND 4 X-6
NO REPLACE THE RELAY
N8B5142E
1-4. Headlight in High-beam Inoperative
YES DISCONNECT THE DIMMER / PASSING SW CONNECTOR IS THERE ANY CONTINUITY BETWEEN SW SIDE CONNECTORS 4 B-70 AND 10 B-70 WHEN THE SW IS AT HIGH-BEAM POSITION?
YES DISCONNECT THE HEADLIGHT RELAY IS THERE ANY CONTINUITY BETWEEN CHASSIS SIDE CONNECTORS 10 B-70 AND 1 X-3 ?
NO REPAIR OR REPLACE THE SW
YES REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 2 X-6 AND 2 B-4 ( 2 B-73 )
NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 10 B-70 AND 1 X-3
N8B0086E

1-5. Headlight on The Left (or Right) Side in Low (or High)-beam Inoperative
8-103
IS THE BULB NORMAL?
YES REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT (LOW BEAM) BETWEEN 1 B-4 (OR 1 B-73 ) AND 4 X-6 (HIGH BEAM) BETWEEN 2 B-4 (OR 2 B-73 ) AND 2 X-6
NO REPLACE THE BULB
N8B5143E
1-6. Headlight Beam Does Not Change
YES DOES THE DIMMER / PASSING SW LEVER OPERATE SMOOTHLY AND SECURELY?
YES DISCONNECT THE DIMMER / PASSING SW CONNECTOR (COMBINATION SW) CHECK IF THERE IS CONTINUITY BETWEEN 4 B-70 AND 10 B-70 DIMMER SW "LO" POSITION ......... NO CONTINUITY "HI" POSITION .......... CONTINUITY
NO REPAIR OR REPLACE THE DIMMER / PASSING SW
NO REPAIR OR REPLACE THE DIMMER / PASSING SW (COMBINATION SW)

N8B5144E

1-7. Headlight Remains On When The Lighting SW is Turned Off
IS THE HEADLIGHT RELAY NORMAL?
YES
NO REPLACE THE HEADLIGHT RELAY
DISCONNECT THE LIGHTING SW CONNECTOR IS THE CONTINUITY BETWEEN THE SWITCH CONNECTOR TERMINALS 1 B-70 AND 4 B-70 NORMAL?
YES REPAIR A SHORT CIRCUIT BETWEEN 5 X-3 AND 1 B-70
NO REPAIR OR REPLACE THE LIGHTING SW
N8B5145E
1-8. Headlight Comes On With The Lighting SW at The Clearance Light Position
DISCONNECT THE LIGHTING SW CONNECTOR WITH THE LIGHTING SW AT THE CLEARANCE LIGHT POSITION, IS THE CONTINUITY BETWEEN 1 B-70 AND 4 B-70 NORMAL? (NO CONTINUITY NORMAL)
NO REPAIR OR REPLACE THE LIGHTING SW
N8A0125E

2. Fog Light 2-1. Both Fog Lights Inoperative (while Lighting Switch is On)
8-105
IS THE FUSE F-7 (10A) OR F-8 (10A) NORMAL?
YES IS THE TAIL RELAY NORMAL?
NO REPLACE THE FUSE
YES IS THE FOG LIGHT RELAY NORMAL?
YES
REMOVE THE FOG LIGHT SW WHEN THE SWITCH IS "ON", IS THERE CONTINUITY BETWEEN THE SWITCH CONNECTOR TERMINALS 3 B-87 AND 6 B-87 ?
YES IS THE BATTERY VOLTAGE APPLIED BETWEEN THE HARNESS SIDE CONNECTOR 6 B-87 (2 X-5 , 2 B-87 ) AND THE GROUND, WHILE THE LIGHTING SW IS ON?
YES IS THE BATTERY VOLTAGE APPLIED BETWEEN THE HARNESS SIDE CONNECTOR 3 B-87 AND THE GROUND, WHILE THE LIGHTING SW IS ON?
NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 6 B-87 (OR 2 X-5 ) AND F-8 , 2 B-87 AND F-7
YES REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 1 X-5 AND 1 B-3 (OR 1 B-72 ), 5 X-5 AND B-7
NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 3 B-87 AND 3 X-5
N8B5146E

2-2. Fog Light on The Left (or Right) Side Inoperative (while Lighting Switch is On)
IS THE BULB NORMAL?
YES
NO REPLACE THE BULB
REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 2 B-3 AND B-7 (2 B-72 AND B-7 )
N8A0127E
Notice: Figures in parenthesis ( ) indicate place of inspection for the fog light on the right. 2-3. Fog Light Remains On
DO THE TAILLIGHTS GO OFF?
YES
NO
IS THE FOG LIGHT RELAY NORMAL?
REPLACE THE TAIL RELAY
YES

N8B0087E
REPAIR OR REPLACE THE FOG LIGHT SWITCH

3. Cornering Light 3-1. Both Cornering Lights Inoperative
DO THE HEADLIGHT LIGHT COME ON?
8-107
YES IS THE FUSE F-16 (10A) NORMAL?
NO TURN THE HEADLIGHT ON (REFER TO DIAGNOSIS CHART FOR HEADLIGHT)
YES IS THE FUSE F-8 (10A) CONNECTED?
NO REPLACE THE FUSE
YES IS B-7 GROUNDED SECURELY?
NO REPLACE THE FUSE
YES IS THE CORNERING LAMP RELAY NORMAL?
NO GROUND IT SECURELY
YES REMOVE THE CORNERING LAMP RELAY TURN THE STARTER SWITCH ON IS THERE A BATTERY VOLTAGE APPLIED BETWEEN THE RELAY HARNESS SIDE CONNECTOR 3 X-9 (OR 2 X-9 ) AND GROUND?
NO REPAIR OR REPLACE THE RELAY
YES TURN THE STARTER SWITCH ON REMOVE THE HEADLIGHT RELAY DISCONNECT THE COMBINATION SWITCH CONNECTOR IS THERE A BATTERY VOLTAGE APPLIED BETWEEN SWITCH HARNESS SIDE CONNECTOR 1 B-70 AND THE GROUND?
NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN FUSE F-16 (10A) AND 3 X-9 , F-8 (10A) AND 2 X-9
YES IS THERE ANY CONTINUITY BETWEEN THE SWITCH CONNECTORS 2 B-70 AND 11 B-70 (WHEN TURNING LEFT) OR 2 B-70 AND 9 B-70 (WHEN TURNING RIGHT) RESPECTIVELY?
NO REPAIR A POOR CONNECTION OR AN OPEN CIRCUIT AT THE CONNECTORS BETWEEN 5 X-9 AND 1 B-70
YES REPAIR A POOR CONNECTION OR AN OPEN CIRCUIT BETWEEN THE HARNESS SIDE CONNECTORS 1 X-9 AND 2 B-70
N8B0088E

3-2. Cornering Light on The Left (or Right) Side Inoperative
N8A5149E
Notice: Figures in parenthesis ( ) indicate place of inspection for the cornering light on the right. 3-3. Cornering Light Remains On Even When Steering Wheel is in Straight Ahead Position
DOES THE CORNERING LIGHT SWITCH OPERATE SMOOTHLY?
NO REPAIR OR REPLACE THE CORNERING LIGHT SWITCH (COMBINATION SWITCH)
N8A0131E

4. Rear Fog Light 4-1. Rear Fog Light Inoperative (while Headlight is ON)
8-109
IS THE REAR FOG LIGHT BULB NORMAL?
NO REPLACE THE BULB
YES IS J-9 GROUNDED SECURELY?
NO REPLACE THE FUSE
YES IS THE REAR FOG LIGHT RELAY NORMAL?
YES
NO REPAIR OR REPLACE THE RELAY
DISCONNECT THE REAR FOG LIGHT SWITCH CONNECTOR IS THERE ANY CONTINUITY BETWEEN THE SWITCH CONNECTORS 1 B-70 AND 14 B-70 WHEN THE SWITCH IS ON?
YES
NO REPAIR OR REPLACE THE SWITCH
RECONNECT THE RELAYS AND REAR FOG LIGHT SWITCH CONNECTOR IS THERE A BATTERY VOLTAGE APPLIED BETWEEN SWITCH HARNESS SIDE CONNECTOR 1 B-70 AND GROUND WHEN REAR FOG LIGHT SWITCH IS ON?
YES
NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 5 X-3 AND 1 B-70
CONTINUED ON THE FOLLOWING PAGE
N8B5033E
CONTINUED FROM THE PREVIOUS PAGE
SET THE REAR FOG LIGHT SWITCH TO ON POSITION IS THERE BATTERY VOLTAGE APPLIED BOTH BETWEEN REAR FOG LIGHT RELAY HARNESS SIDE CONNECTOR 2 X-16 (OR 5 X-16 ) AND GROUND?
YES DISCONNECT THE REAR FOG LIGHT CONNECTOR IS THERE A BATTERY VOLTAGE APPLIED BETWEEN REAR FOG LIGHT HARNESS SIDE CONNECTOR 1 R-12 (OR 1 R-13 ) AND GROUND WHEN REAR FOG LIGHT SWITCH IS ON?
NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN F-14 (10A) AND 2 X-16 , 14 B-70 AND 5 X-16
YES REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 2 R-12 (OR 2 R-13 ) AND J-9 (GROUND)
NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 1 R-12 (OR 1 R-13 ) AND 1 X-16
N8B5147E
Starter Switch
High Beam Indicator Light

Refer to METER AND WARNING/INDICATOR LIGHT in this section.
1 2 3
Headlight Bulb Replacement

Removal 1. Remove the battery ground cable at the battery. 2. Remove the headlight assembly. (Refer to Headlight Replacement below.) 3. Remove the headlight bulb. Remove the dust cover (3). Remove the clip (1). Remove the headlight bulb (2). Caution: Do not touch the glass portion of the bulb with your fingers.
N8A5468E
Installation 1. Install the headlight bulb. Set the headlight bulb (2). Fix the headlight bulb with clip (1). Install the dust cover (3). 2. Install the headlight assembly. (Refer to Headlight Replacement below.) 3. Connect the battery ground cable at the battery. 4. Check if the light lights.
8-111
Remove the front combination light connector. 4. Remove the front grille (4). Remove the bolt at the center of the front grille. Remove the four clips securing the front grille.
1 2 3
The grille is secured by 4 clips (2 clips at the inside of each headlight). Pull the grille toward you to remove it. 5. Remove the front corner panel. 6. Remove the headlight (1). Remove the four bolts securing the headlight (loosen the fixing bolts at the bottom of the front side panel to create working space). Remove the headlight clips. Remove the headlight connector.
N8A5468E
Caution: Do not touch the glass portion of the new bulb with your fingers.
Headlight Replacement
Removal Preparation: Disconnect the battery ground cable. 1. Remove the battery ground cable at the battery. 2. Remove the seal rubber (3). Remove the seal rubber from beneath the headlight. 3. Remove the front combination light (2). Open the cab door. Insert a screwdriver (1) into the space between the cab and the cab door. Use the screwdriver to force out the stud pin at the center of the grommet (the pin securing the front combination light).
4
N8A5472E
Installation 1. Assemble the headlight assembly (1). Connect the connector. Fix it to body panel with four bolts (5). 2. Assemble the front panel side. (Refer to DOOR in section 2.) 3. Install the front grille (4). 4. Install the front combination assembly (2). 1) Position it by aligning two pawls with the groove of H/L. 2) Fit the iron PIN in the upper portion by aligning it with the center of corresponding grommet. Notice: Push it into securely with a force of approx. 250 N (25 kgf) until click is heard.
Door side
Cab side
1
N8A5471E
Remove the fixing screw. Remove the two catches.
3) Pull the front combination light assembly lightly toward the front of vehicle to make sure that the PIN and grommet are engaged securely. 4) Tighten one bolt (6) in the lower portion of front combination light assembly. 5) Hook the seal rubber (3) on two projections under H/L.

5. Connect the battery ground cable. 6. Check the operation and lighting of each lamp.
1 2
6 3
5 4
N8A0441E
N8A5474E
Horizontal Adjustment
Insert the tip of a screwdriver into the hole beneath the headlight (the shaft of the screwdriver must be slanted up) until contact is made with the head of the adjusting screw. Turn the screw to adjust headlight focus to the left or right.
Aiming of Headlight
Preparation: Place the unloaded vehicle on a level surface and check to see if the inflation pressure of the tires is correct, the lenses are clean, and the battery is sufficiently charged. Adjust the aim with the headlight tester. When adjusting, follow the procedure of the tester manufacturers.
N8A5475E
N8A5473E
Vertical Adjustment
Insert the tip of a screwdriver into the hole beneath the headlight (the shaft of the screwdriver must be slanted up) until contact is made with the head of the adjusting screw. Turn the screw to adjust headlight focus up or down. Two vertical aim screws should be turned in the same direction at the same time to adjust aiming.

Cornering Light Bulb Replacement
Removal 1. Remove the battery ground cable at the battery. 2. Remove the front combination light. Open the cab door. Insert a screwdriver (1) into the space between the cab and the cab door. Use the screwdriver to force out the stud pin at the center of the grommet (the pin securing the front combination light). Installation 1. Install the cornering / clearance bulb.
8-113
While pressing the bulb (2), turn it clockwise to fit. Notice: Do not let the glass portion dirty with sebum etc. Turn the bulb socket (3) clockwise to fit.
Door side
Cab side 3
2 1
N8A5471E N8A0442E
Remove the fixing screw. Remove the two catches. Remove the front combination light (1) connector.
2. Installation procedure of front combination light assembly Connect the connector of the front combination light assembly. Position it by aligning two pawls with the groove of H/L. Fit the iron PIN (1) in the upper portion of the side by aligning it with the center of corresponding grommet. Notice: Push it into securely with a force of approx. 250 N (25 kgf) until click is heard.
3 1
Pull the front combination light assembly lightly toward the front of vehicle to make sure that the PIN and grommet are engaged securely. Tighten one bolt in the lower portion of front combination light assembly. 3. Hook the seal rubber on two projections under H/L. 4. Connect the battery ground cable. 5. Check lighting of each light.
N8A5477E
3. Remove the cornering light bulb. Turn the cornering / clearance bulb socket (3) to the left to remove it. Press the bulb (2) in and turn it to the left to remove it from the socket.

Fog Light Bulb
Notice: The configuration of the fog light assembly is different in each manufacturer. Removal 1. Remove the battery ground cable at the battery. 2. Remove the screws (1). 3. Remove the cover which holds fog light assembly. (If equipped) 4. Remove the connector (3). 5. Remove the fog light assembly (2). Installation 1. Install the fog light bulb. Set the fog light bulb (2). Hook the clip (1) to secure fog light bulb. Install the back cover. (If equipped)
N8A0443E
2. Connect the two locations of connector (4). 3. Install the fog light assembly.
3 2
Hold the fog light (2) with right and left covers (1) and secure it with screws (3). (If equipped)
N8A5478E
Notice: Make sure that TOP mark on the lens comes upside. 4. Connect the battery ground cable. 5. Check lighting.
6. Bulb Remove the back cover. (If equipped) Push the clip (1) inward as arrow to remove. Remove the bulb (2).
1 2 4 2 3
N8A0444E
N8A5479E

Fog Light Switch
Inspection Check the continuity between the connector terminals while operating the switch. Replace the switch when the result of inspection is found abnormal.
8-115
or
B-87
2
Terminal SW No. position ON OFF 3 6 2 5
N8B5134E
Removal Preparation: Disconnect the battery ground cable. 1. Meter Cluster Refer to METER AND WARNING/INDICATOR LIGHT in this section. 2. Fog Light Switch Release the lock pushing the switch from the back side of the meter cluster.
N8B5138E

Combination Switch (Lighting Switch, Dimmer/Passing Switch, Cornering Light Switch and Rear Fog Light Switch)
Terminal No. SW position
10
11
12
13
14
Lighting SW
REAR FOG SW OFF High beam Passing Turning left
Cornering light SW
Neutral Turning right
N8A0143E
Removal Preparation: Disconnect the battery ground cable. 1. Horn Pad 1) Hold the horn pad and pull it upward. 2. Steering Wheel 1) Remove the steering shaft nut. 2) Remove the steering wheel by using steering wheel remover. (Refer to Section 3B4 STEERING COLUMN for steering wheel removal steps.) 3. Steering Cowl Remove the four screws.
4. Combination Switch 1) Remove the four screws. 2) Disconnect the connector.

Operation of The Circuit
8-117
1. When headlight leveling SW is turned to 1 position

STARTER SW "ON"
IG SW
FUSE Converter DC-DC HEADLIGHT LEVELING RESISTOR
N8A0144E
4 3 2 1 0
Installation To install, follow the removal steps in the reverse order, noting the following point. 1. Tighten the steering shaft nut to the specified torque. Tighten: Shaft nut to 49 Nm (5 kgfm / 36 lbfft)
HEADLIGHT LEVELING SW
HEADLIGHT LEVELING ACTUATOR - LH
HEADLIGHT LEVELING ACTUATOR - RH
N8B5119E
Headlight Leveling
General Description
The circuit consists of starter SW, headlight leveling SW and headlight leveling actuator. When the headlight leveling SW is operated with the starter SW at ON position, the actuator is operated to change the angle of the optical axis of the headlight.
2. When headlight leveling SW is turned to 0 position

STARTER SW "ON"
IG SW
FUSE Converter DC-DC HEADLIGHT LEVELING RESISTOR
HEADLIGHT LEVELING SW
HEADLIGHT LEVELING ACTUATOR - LH
HEADLIGHT LEVELING ACTUATOR - RH
N8B5120E
Parts Location
RELAY BOX ASM (No.1) X-11 KEY ON RELAY B-421 HEADLIGHT LEVELING RESISTOR B-420 DC-DC CONVERTER STARTER SW B-156 HEADLIGHT LEVELING SWITCH P-5
FUSE BOX ASM F-12
B-7 P-1 P-2 BATTERY P-3 P-4
B-152 HEADLIGHT H-7 LEVELING ACTUATOR (RH) B-155 HEADLIGHT LEVELING ACTUATOR (LH) B-67 RELAY BOX ASM FL-1,FL-2 FUSIBLE LINK
B-1
N8B0032E
(FOR 4JJ1)
2L 8W/B
ACG B
(FOR 4HK1)
2L 8W/B
8B
Circuit Diagram
FUSE BLOCK STARTER SWITCH

ACC
P-1
P-2
FL-2 40A KEY SW
3W/L
H-7 ON B-67 ST 3 1 B-67 2
3W/L 3W/L
0.5B
4 1 X-11 X-11
P-3
P-4
3B/Y
RELAY; KEY ON
X-11 2 5 X-11
2B 3B/Y
P-5
FRAME
F-12
3L 0.5L/O
1 6
10A H/LAMP LEVEL B-420 B-420
0.5B
CONVERTER; DC-DC(HLL)
B-420 B-420
3 0.5B/W 2 0.5R/W
0.5R/W 0.5B/W
H/L LEVELING SWITCH

B-156 4 3 B-156 2 10
R1
0.5O/G
B-421 R2 9
B-421
1 0.5R/W
0.5B/W
0.5B/W
0.5R/W
0.5R/W
1.25B(Except NKR)/0.85B(NKR)
B-7 B-155 B-155 B-155
HEADLIGHT FRAME-LH (FRONT) BRACKET (LH)
3B 0.5R/Y
4 B-156
0.5O/B
3 B-421 R3 B-156 8
0.5O/W
B-421 R4 1 0 B-156 6 B-156 7
RESISTOR; H/L LEVELING
0.5R/Y
0.5R/Y
0.5O/L
B-421 R5 R6
5B
3 1 2
B-1
0.5O
B-152
B-152
B-152
B-421
B-421
14 0.5B/W
ACTUATOR; HLL (RH) (AS SIDE HEAD LAMP)
ACTUATOR; HLL (LH) (DR SIDE HEAD LAMP)
N8B0033E
8-119

Connector List
B-1
000-001
P-1
000-022
B-7
000-001
P-2
000-014
B-67
P-3
1 3 2 4
004-001 000-014
B-67
2 4
1 3
P-4
000-014
004-002
B-152
1 2 3
003-016
P-5
000-002
B-155
1 2 3
003-016
B-420
1 4
2 5
3 6
006-019
B-156
1 2 5 6 7 8
3 4 9 10
B-421
1 2 3 7 8 9 10
4 5 6 11 12 13 14
010-002
014-002
X-11
1 2 3 5 4
005-001

H-7
8-121
H-6
H-7
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 H-8
4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14
N8A5489E
Diagnosis
Quick Chart for Check Points Check point Fuse F-12 (10 A) 1. Both actuators inoperative Trouble mode 2. Actuator on the left (right) side inoperative 3. When leveling SW is turned to a certain position, actuator inoperative (1) (2) (1) DC-DC converter (2) Headlight leveling resistor (3) Headlight leveling switch (4) (1) (3) Headlight leveling actuator Cable harness (5) (2) (4)
Notice: Figure in parenthesis ( ) indicates the order of inspection.

1. Both Actuators Inoperative
IS THE FUSE F-12 (10A) NORMAL?
NO REPLACE THE FUSE
YES
TURN THE STARTER SW TO ON POSITION IS THE BATTERY VOLTAGE APPLIED BETWEEN THE FUSE TERMINAL AND THE GROUND?
YES IS THE DC-DC CONVERTER NORMAL?
NO REPAIR AN OPEN CIRCUIT BETWEEN STARTER SW AND FUSE F-12 (10A)
YES IS THE HEADLIGHT LEVELING RESISTOR NORMAL?
NO REPLACE THE DC-DC CONVERTER
YES IS THERE CONTINUITY BETWEEN HEADLIGHT LEVELING RESISTOR AND THE HEADLIGHT LEVELING SWITCH?
NO REPLACE THE HEADLIGHT LEVELING RESISTOR
YES IS THE CONTINUITY IN THE HEADLIGHT LEVELING SW NORMAL?
NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN THE CIRCUITS
YES IS THERE CONTINUITY BETWEEN 4 B-156 AND 2 B-152 (OR 2 B-155 )?
YES REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 3 B-420 AND 1 B-152 (OR 1 B-155 ), 2 B-420 AND 2 B-152 (OR 2 B-155 )
NO
REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN THE CIRCUITS
N8B0089E

2. Actuator on the Left (Right) Side Inoperative
8-123
IS THE ACTUATOR ON THE LEFT (RIGHT) SIDE NORMAL?
YES IS THERE CONTINUITY BETWEEN 4 B-156 AND 2 B-152 (OR 2 B-155 )?
NO REPLACE THE ACTUATOR
YES REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 3 B-420 AND 1 B-152 (OR 1 B-155 ), 2 B-420 AND 2 B-152 (OR 2 B-155 )
NO
N8B0091E

3. When Headlight Leveling SW is Turned to A Certain Position, Actuator Inoperative
IS THE HEADLIGHT LEVELING RESISTOR NORMAL?
YES IS THERE CONTINUITY BETWEEN HEADLIGHT LEVELING RESISTOR AND THE HEADLIGHT LEVELING SWITCH?
NO REPLACE THE HEADLIGHT LEVELING RESISTOR
YES IS THE CONTINUITY IN THE HEADLIGHT LEVELING SW NORMAL?
NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN THE CIRCUITS
YES IS THE ACTUATOR ON THE RIGHT (LEFT) SIDE NORMAL?
YES REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT (REFER TO THE FOLLOWING PAGE)
NO REPLACE THE ACTUATOR
N8B0092E
Inspect and repair the circuit that is corresponding to the headlight leveling switch position where the actuator becomes inoperative. Actuator - LH Headlight leveling SW position 0 1 2 3 4 Circuit Between 6 B-156 and 2 B-155 Between 7 B-156 and 2 B-155 Between 8 B-156 and 2 B-155 Between 9 B-156 and 2 B-155 Between 10 B-156 and 2 B-155
Actuator - RH Headlight leveling SW position 0 1 2 3 4 Circuit Between 6 B-156 and 2 B-152 Between 7 B-156 and 2 B-152 Between 8 B-156 and 2 B-152 Between 9 B-156 and 2 B-152 Between 10 B-156 and 2 B-152
Starter Switch
Refer to START AND CHARGING in this manual.
Headlight Leveling Switch

Inspection Check the continuity between the switch connector terminals.

Repair or replace the switch when the result of inspection is found abnormal.
8-125
B-156
4 3 10 9 8 7
2 1 6 5
Switch side
If the power supply is not 12 V, the SIGNAL output varies in proportion to its voltage. 2. Connect the connector of actuator and vehicle harness connector. Make sure that the reflector of headlight moves to the position indicated by HEAD LAMP LEVELING SW.
Terminal No. SW position 0 4 6 7 8 9 10
B-152 B-155
2
1 2 3
Actuator side
N8B5121E
Removal Preparation: Disconnect the battery ground cable. 1. Switch Bezel 2. Headlight Leveling Switch Disconnect the connector. SIGNAL
N8A0154E
2 + Input signal voltage ratio for SIGNAL when the voltage difference between positive and negative is specified as 100%
Position 0 Position 1 Position 2 Position 3 Position 4
10.0% (1.2 V) 23.4% (2.8 V) 36.7% (4.4 V) 50.0% (6.0 V) 63.4% (7.6 V)
0V 0V 0V 0V 0V
12 V 12 V 12 V 12 V 12 V
N8A5175E
HEAD LAMP POSITION
Headlight Leveling Actuator

Inspection This actuator has a mechanism that the angle of head light leveling varies according to input voltage of SIGNAL. 1. Make sure that the voltage specified in table is output to vehicle harness connector which will be connected to actuator.
Caution: 1. For vehicles with 12 V and 24 V, this leveling input voltage is 12 V. 2. Input to SIGNAL must be less than 65% of the input voltage to positive terminal.
8-126 CAB AND CHASSIS ELECTRICAL Clearance Light, Taillight, License Plate Light and Illumination Light
General Description
The circuit consists of the lighting switch, clearance light, taillight, license plate light and the illumination light for each of switch, meter and ashtray. All these lights come on when the lighting switch is turned on with the switch to either clearance or headlight position.
Lighting Circuit
N8A0156E
Parts Location
L-34 ROOF MARKER LIGHT (RH) (FOR EC / TURKEY N2 CATEGORY ONLY) LIGHTING SW B-87 FOG LIGHT SW B-46 ASHTRAY B-17 DIODE B-18 DIODE B-33 HEATER BEZEL SW
L-33 ROOF MARKER LIGHT (LH) (FOR EC / TURKEY N2 CATEGORY ONLY)
FUSE & RELAY BOX ASM F-7 FUSE X-4 TAIL RELAY
B-501 DIODE H-14
B-28
B-7
B-1 B-335 B-52 METER B-51 METER B-31 ENGINE WARM UP SW F-25 X-22 H-10 B-5
H-5, H-6
B-86 DOME LIGHT SW
N8B0034E
8-127

Circuit Diagram
(Except EC) CORNERING LIGHT SWITCH (9) (COMBINATION SWITCH) 0.85LG/R CLEARANCE LIGHT (RH) B-74 3
B-74
0.85B
B-5
0.85LG/R
H-14
H-16
7 H-16
1.25B 2B 3B 2B 1.25B 0.85B (NKR only) 2B 5B B-7 J-9 FRAME-LH (FRONT) B-1 3B 2B HEADLIGHT BRACKET (LH) FRAME-LH (CENTER) 2B 1.25B
LICENSE PLATE LIGHT H-14 H-16 1 R-3 Except NKR85 (CHILE/TAIWAN) H-5 R-2 0.85LG/R 0.5LG/R 0.5LG/R 0.5LG/R 0.5B 1 5 5 5
7 H-14
H-5
R-1 6
1 R-1
0.85LG/R
0.5G/R
0.5G/R
TAILLIGHT-LH (REAR COMBINATION LIGHT) 0.5LG/R 1.25B
R-6 6
1 R-6
TAILLIGHT-RH (REAR COMBINATION LIGHT) 0.5LG/R 1.25B
B-5
0.85LG/R
(Except EC) CORNERING LIGHT SWITCH (11) (COMBINATION SWITCH)
CLEARANCE LIGHT (LH) 3 B-5
B-74
0.85B
1.25B
MARKER LIGHT
0.5LG/R
RELAY: MARKER LIGHT MARKER LIGHT
X-22
J-24
X-22
3W/B
2LG/W
X-22
X-22
0.5B
ASH TRAY ILLUMINATION B-46 B-46 0.5LG/R 1 0.3B 2
HEATER BEZEL B-33 B-33 0.5LG/R 1 0.3B 2
RADIO 10 B-28 B-28 0.5LG/R 0.5B 9
(NKR85 only)
ILLUMINATION LIGHT (METER) 17 B-51 B-51 0.5LG/R 0.5B 15
TAILLIGHT
0.85LG/R
10A
CIGAR LIGHTER B-43 B-43 0.5LG/R 1 0.3B 2
RELAY; TAIL X-4

3W/B 3W/B
H-6
X-4
X-4
8W/B
5W/B
2W/B
X-4
3W
F-7
B-495
B-495
(EC only) NKR85 (CHILE) only 3 DIODE RELAY; DIMMER (5) B-501 2
DPD REGENERATE SWITCH 0.85LG/R 2 5
Except NKR (CHILE) 0.5B
B-501
J-25
1.25LG/B
0.85B
ENG. WARM SWITCH B-31 B-31 0.5LG/R 2
EC only 0.5B
DIODE B-17 B-17 0.3R 3 2
FOG LIGHT & ROOM LIGHT SWITCH B-87 B-87 0.85LG/R 2 0.5B 5
RELAY; HEADLIGHT (5)
0.3L/R 0.3R (EC only)
8W/B
0.3G/O
10 0.3R/L
0.3R
TACHO GRAPH (METER) 0.5LG/R 4 6 B-70 B-335 B-335
EC only 0.5B
B-70
B-70
FL-1 100A or 120A
B-70
B-70
HAZARD SWITCH PASS Hu B-30 B-30 0.5LG/R 8 H T 0.3B 7 E
MAIN
LIGHTING SWITCH
HIGH PASS
(NKR85 only)
1.25B
0.5LG/R
OFF
LO
1 L-33
L-33 2
2L
H-10
0.5R/G
0.5B
COMBINATION SWITCH FRAME
1 L-34
P-1
P-2
P-3
P-4
P-5
NPR / NQR (EC)
L-34 2
0.5R/G
0.5B
ROOF MARKER LIGHT (RH)
H-10
0.5B
ROOF MARKER LIGHT (LH)
3B
N8B0035E
1.25B (NPR85/NKR85)
F-25
15A

Connector List
8-129
B-1
000-001
B-33
1 2
002-022
B-5
1 3
2 4
004-012
B-33
2 1
002-023
B-5
2 1 4 3
004-013
B-43
1 2
002-009
B-7
000-001
B-43
1 2
002-010
B-17
B-46
1 2 3 4 1 2
004-004 002-022
B-28
1 7
2 8
3 9 10
B-46
11 12 13
2 1
002-023
013-001
B-30
B-51
1 5 2 6 3 7 4 8
008-005
020-004
B-31
B-70
1 4 2 5 3 6
1 2 3 7 8 9 10
4 5 6 11 12 13 14
006-001
014-002

B-70
6 5 4 14 13 12 11
3 2 1 10 9 8 7
H-10
014-003
3 4 5 6
006-029
B-74
1 3
2 4
004-012
H-14 (With ABS)
1 5 6
2 7
3 8
4 9
10 11 12 13 14 15 16
016-003
B-74
2 1 4 3
004-013
H-14 (With ABS)
4 9 8
3 7
2 6
1 5
14 13 12 11 10
16
15
016-004
B-87
1 2 4 5
3 6
006-028
H-14 (Without ABS)
1 5
2 6
3 7
4 8
008-003
B-335
1 2 3 4
5 6 7 8 008-014
H-14 (Without ABS)
4 8
3 7
2 6
1 5
000-011 008-004
B-495
006-022
H-16
1 5
2 6
3 7
4 8
008-003
B-501
1 2 3 4
H-16
004-004
4 8
3 7
2 6
1 5
000-011 008-004
H-10
6 5 4 3
J-9
006-003 000-001

8-131
J-24
000-010
P-1
000-022
J-24
000-011
P-4
000-014
J-25
000-010
P-2
000-014
J-25
000-011
P-3
000-014
L-33
2 1
002-054
P-5
000-002
L-33
1 2
002-055
R-1
1 4
2 5
3 6
006-004
L-34
2 1
002-054
R-1
3 6
2 5
1 4
006-005
L-34
1 2
002-055
R-2
000-011

R-2
000-010
R-3
000-011
1 7 13 19 25 31
2 8 14 20 26 32
3 9 15 21 27 33
34
35
36
37
4 10 16 22 28 38
5 11 17 23 29 39
6 12 18 24 30 40
6 12 18 24 30 40
5 11 17 23 29 39
4 10 16 22 28 38
37
36
35
34
3 9 15 21 27 33
2 8 14 20 26 32
1 7 13 19 25 31
R-3
000-010
N8A5488E
H-6
R-6
1 4
2 5
3 6
006-004
H-6
H-7
R-6
3 6
2 5
1 4
006-005
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 H-8
4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14
X-4
005-006
N8A5489E
X-22
005-006

Diagnosis
Quick Chart for Check Point Check point Fuse F-7 (10 A) 1. Both clearance lights inoperative 2. Clearance light on the left (or right) side inoperative Trouble mode 3. Both taillights inoperative 4. Taillight on the left (or right) side inoperative 5. License plate light inoperative 6. Marker light inoperative (2) (1) (3) (1) (1) (3) (2) F-25 (15 A) Ligh ting SW Taillight bulb Tail light relay Clearance light bulb (1) (1) License plate light bulb Marker light relay Cable harness (2) (2) (4) (2) (2) (4)
8-133
Marker light bulb
(1)
Notice: Figure in parenthesis ( ) indicates the order of inspection. 1. Both Clearance Lights Inoperative
ARE BOTH TAILLIGHTS OPERATIVE?
YES IS THE CLEARANCE LIGHT BULB NORMAL?
NO TURN TAILLIGHTS ON (REFER TO TAILLIGHT DIAGNOSIS IN THIS SECTION) NO REPLACE THE BULB
YES IS B-7 SECURELY GROUNDED?
YES TURN THE LIGHTING SWITCH TO OR POSITION IS THERE BATTERY VOLTAGE APPLIED TO CLEARANCE LIGHT CONNECTOR 4 B-5 (OR 4 B-74 ) AND GROUND?
YES
NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN FUSE F-7 (10A) AND 4 B-5 (OR 4 B-74 )
N8B5148E
REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN CLEARANCE LIGHT CONNECTOR TERMINALS 1 B-5 (OR 1 B-74 ) AND B-7

Notice: Figure in parenthesis ( ) indicates place of inspection for clearance light on the right side. 2. Clearance Light on the Left (or Right) Side Inoperative
N8B5149E
Notice: Figure in parenthesis ( ) indicates place of inspection for clearance light on the right side.

3. Both Taillights Inoperative
8-135
YES IS J-9 SECURELY GROUNDED?
NO REPLACE THE FUSE
YES IS THE TAIL RELAY NORMAL?
YES IS THE LIGHTING SWITCH NORMAL?
YES
NO REPAIR OR REPLACE THE LIGHTING SWITCH
IS THE BATTERY VOLTAGE APPLIED BETWEEN LIGHTING SWITCH HARNESS SIDE CONNECTOR 8 B-70 AND THE GROUND?
YES TURN THE LIGHTING SWITCH TO OR POSITION IS THERE BATTERY VOLTAGE APPLIED TO 4 H-16 AND GROUND?
NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN THE HARNESS SIDE CONNECTOR 5 X-4 AND 8 B-70
YES
NO
REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN LIGHTING SWITCH HARNESS SIDE CONNECTORS 7 H-16 AND J-9
REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN TAILLIGHT RELAY CONNECTORS 1 X-4 AND 4 H-16
N8B0082E

4. Taillight on the Left (or Right) Side Inoperative
IS TAILLIGHT BULB ON THE LEFT (OR RIGHT) SIDE NORMAL?
YES REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN CONNECTOR TERMINAL 4 H-16 AND TAILLIGHT CONNECTOR 1 R-1 ( 1 R-6 )
NO REPLACE THE BULB
N8A0163E
Notice: Figure in parenthesis ( ) indicates place of inspection for taillight on the right side. 5. License Plate Light Inoperative
ARE BOTH TAILLIGHTS OPERATIVE?
YES IS THE LICENSE PLATE LIGHT BULB NORMAL?
NO TURN THE TAILLIGHTS ON (REFER TO TAILLIGHT DIAGNOSIS IN THIS SECTION)
YES IS THERE BATTERY VOLTAGE APPLIED BETWEEN 1 R-3 AND THE GROUND WHEN TURNING THE LIGHTING SWITCH ON?
NO REPLACE THE BULB
YES REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 1 R-2 AND 7 H-16
NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT IN THE CIRCUIT
N8B5107E

6. Marker Light Inoperative
8-137
N8B5151E
Lighting Switch
Refer to HEADLIGHT, FOG LIGHT, REAR FOG LIGHT AND CORNERING LIGHT in this section.
Clearance Light Bulb

Removal 1. Remove the battery ground cable at the battery. 2. Remove the front combination light. Open the cab door. Insert a screwdriver (1) into the space between the cab and the cab door. Use the screwdriver to force out the stud pin at the center of the grommet (the pin securing the front combination light).
Door side Cab side
1
N8A5471E
Remove the fixing screw.

Remove the two catches. Remove the front combination light (1) connector. Position it by aligning two pawls with the groove of H/L. Fit the iron PIN (1) in the upper portion of the side by aligning it with the center of corresponding grommet. Notice: Push it into securely with a force of approx. 250 N (25 kgf) until click is heard. Pull the front combination light assembly lightly toward the front of vehicle to make sure that the PIN and grommet are engaged securely.
3 1
Tighten one bolt in the lower portion of front combination light assembly. 3. Hook the seal rubber on two projections under H/L. 4. Connect the battery ground cable. 5. Check lighting of each light.
Taillight Bulb
2
N8A5477E
3. Remove the clearance light bulb. Turn the bulb socket (3) to the left to remove it. Press the bulb (2) in and turn it to the left to remove it from the socket. Installation Installation procedure of cornering/clearance light bulb 1. Install the cornering/clearance light bulb. While pressing the bulb (2), turn it clockwise to fit. Notice: Do not let the glass portion dirty with sebum etc. Turn the bulb socket (3) clockwise to fit.
Removal 1. Lens 2. Bulb
1
N8A0167E

3
2
N8A0442E
2. Installation procedure of front combination light assembly Connect the connector of the combination light assembly.

License Plate Light Bulb
Removal 1. Cover 2. Lens 3. Bulb
8-139
Installation Follow the removal procedure in the reverse order.
Turn Signal Light, Hazard Warning Light and Stoplight

General Description
The circuit consists of the starter switch, turn signal light (front and rear), turn signal light switch, hazard warning light, flasher unit, stoplight and stoplight switch. When turning on the respective switches with the starter switch on, the turn signal light will operate. When the turn signal light is flashing, the indicator light in the meter also starts flashing. When the hazard warning switch is turned on, the current flows to the flasher unit through the hazard warning switch to cause the hazard warning light to flash, independent of the position of the starter switch. At the same time, the indicator lights in the meter also start flashing. The stoplight switch will turn on and the light comes on once the brake pedal is depressed, independent of the position of the starter switch.
N8A0168E
Roof Marker Light

Removal Preparation : Disconnect the battery ground cable. 1. Lens 2. Bulb
1 2
N8B5128E
Legend 1. Lens 2. Bulb 3. Base with Gasket
RELAY BOX ASM (No.1) X-11 ON RELAY B-30 HAZARD WARNING SW TURN SIGNAL / CORNERING LIGHT SW STARTER SW
Parts Location
FUSE & RELAY BOX ASM F-4, F-5, F-7, F-11, F-20 FUSE
B-16 FLASHER UNIT
J-104 R-6 STOPLIGHT (RH) SIDE TURN SIGNAL LIGHT (RH) R-1 STOPLIGHT (LH) (FOR EC N2 CATEGORY S/CAB ONLY) H-16
H-22
H-14 P-5 P-1 P-2 BATTERY P-3 P-4 J-9 RELAY BOX ASM
D-20 SIDE TURN SIGNAL LIGHT (RH) (FOR EC N2 CATEGORY W/CAB ONLY)
J-103 SIDE TURN SIGNAL LIGHT (LH) (FOR EC N2 CATEGORY S/CAB ONLY)
B-7
B-74 FRONT COMBINATION LIGHT (RH) B-1 B-67 H-20
FL-1, FL-2 FUSIBLE LINK B-51 TURN SIGNAL INDICATOR LIGHT (LH) (METER) B-52 TURN SIGNAL INDICATOR LIGHT (RH) (METER)
H5 - H7 B-66 STOPLIGHT SW
D-21 SIDE TURN SIGNAL LIGHT (LH) (FOR EC N2 CATEGORY W/CAB ONLY) B-5 FRONT COMBINATION LIGHT (LH)
N8B0036E

Circuit Diagram
11
8-141
B-66
B-66
H-14
H-16
2 R-6
H-5
H-5
0.85R F-4 15A
0.85R
0.85R
28
STOPLIGHT (LH)
AUDIO (B), DOOR LOCK SIDE TURN SIGNAL LIGHT (RH) (S/CAB)
J-104 J-104 1
(S/CAB EC ONLY)
0.5B
0.5LG/W 0.5G/W (NKR85(INDP))
0.5B
3W/B
F-20 15A HORN, HAZARD
RELAY: ON
X-11
J-103
J-103 1
0.5G/B
0.5B (Except NKR85(INDP))
3W/B
X-11
3B/Y
2
3B/Y
X-11
X-11
F-11 10A 0.5Y/R TURN LIGHT
HAZARD SWITCH
(NPR/NQR W/CAB EC ONLY)
3L
5
SIDE TURN SIGNAL LIGHT (LH) (S/CAB)
3W/L
0.5G
B-67
STARTER SWITCH
ACC
ON
B-30
ST
SIDE TURN SIGNAL LIGHT (RH) (DOOR)

4 H-20 D-20 D-20 H-20
0.5G/W
0.5B
10
0.5B
OFF
RH
B-16
B-30
0.5G/W 0.5G/B
B-67
TB
FLASHER UNIT
B-16
B-30
B-30
0.5BR
5
LH
0.5G/W
5W/B
B-30
IG
0.5LG/B
1
FU
B-30
H-6
0.85LG/R 0.5LG/R (THAI only) 0.5LG/R
B-30
B-30
0.3B
7
TURN SIGNAL INDICATOR LIGHT (RH) (METER)

B-52 B-52
3W/L
0.5G/W
0.5B
0.5BR
B-16
B-74
B-74
TURN SIGNAL LIGHT (FRONT COMBINATION LIGHT-RH) 0.85B 0.5G/W

2
3W/L
F-7 10A TAIL LIGHT
5W/B
0.85LG/R
3W
RELAY; TAIL (1)

17 H-5 H-14 8
(NPR75/NQR75)
B-70 13
H-16
3 R-6
H-7
12 B-70
LH
10 H-5
H-14
H-16
B-70 5
3 R-1
3W/L
FL-2 40A
TURN SIGNAL LIGHT SWITCH (COMBINATION SWITCH) 0.5G/B
B-5
KEY
B-5
0.85B 1.25B 1.25B (NPR/NQR) 0.85B (NKR85) 2B (NPR75/NQR75) 1.25B 1.25B FRAME-LH (CENTER)
J-9 7 H-14
8W/B
TURN SIGNAL LIGHT (FRONT COMBINATION LIGHT-LH)
FL-1 100A or 120A
MAIN
0.5G/B
TURN SIGNAL INDICATOR LIGHT (LH) (METER)
B-51
B-51
0.5G/B
15
0.5B
H-16
TURN SIGNAL LIGHT (REAR COMBINATION LIGHT-LH)
0.3B
R-1 6
0.5G/B
0.5G/B
R-6 6
0.5G/W
TURN SIGNAL LIGHT (REAR COMBINATION LIGHT-RH) 0.5G/W 1.25B
RH
20
1.25B
R-1 6
R-1
POWER SOURCE (SERVICE)
0.5G
R-6 6
3W/B
F-5 10A STOP LIGHT
STOPLIGHT SWITCH 0.5G/Y 0.5G
(Except NKR) 0.5G 0.5G 0.5G 0.5G

2 2
STOPLIGHT (RH) 1.25B
1.25B
(NPR/NQR W/CAB EC ONLY)
2L
SIDE TURN SIGNAL LIGHT (LH) (DOOR)

4 H-22 D-21 D-21 H-22
2B
5B
B-1
FRAME
P-1
P-2
P-3
P-4
P-5
FRAME-LH (FRONT)
B-7
3B
N8B0037E
2B
0.5G/B
0.5B 2B
0.5B
3B
2B
2B
1.25B

Connector List
B-1
000-001
B-66
1 2
002-031
B-5
1 3
2 4
004-012
B-67
1 3
2 4
004-001
B-5
2 1 4 3
004-013
B-67
2 4
1 3
004-002
B-7
000-001
B-70
6 5 4 14 13 12 11
3 2 1 10 9 8 7
014-003
B-16
1 4
2 5
3 6
006-010
B-70
1 2 3 7 8 9 10
4 5 6 11 12 13 14
014-002
B-30
B-74
1 5 2 6 3 7 4 8
1 3
2 4
004-012
008-005
B-51
020-004
B-74
2 1 4 3
004-013
B-52
020-005
D-20
1 2 3
003-036

8-143
D-21
1 2 3
003-036
H-20
1 2
3 4
5 6 7 8 9 10
010-003
H-14 (With ABS)
1 5 6
2 7
3 8
4 9
10 11 12 13 14 15 16
H-22
016-003
4 3
2 1
10 9 8 7 6 5
010-004
H-14 (With ABS)
4 9 8
3 7
2 6
1 5
14 13 12 11 10
H-22
016-004
1 2
3 4
5 6 7 8 9 10
16 15
010-003
H-14 (Without ABS)
1 5
2 6
3 7
4 8
008-003
J-9
000-001
H-14 (Without ABS)
4 8
3 7
2 6
1 5
008-004
J-103
000-010
H-16
1 5
2 6
3 7
4 8
008-003
J-103
000-011
H-16
4 8
3 7
2 6
1 5
008-004
J-104
000-010
H-20
4 3
2 1
10 9 8 7 6 5
J-104
010-004 000-011

P-1
000-022
R-6
3 6
2 5
1 4
006-005
P-4
000-014
X-11
1 2 3 5 4
005-001
H-5 P-2
000-014
P-3
000-014
1 7 13 19 25 31
2 8 14 20 26 32
3 9 15 21 27 33
34
35
36
37
4 10 16 22 28 38
5 11 17 23 29 39
6 12 18 24 30 40
6 12 18 24 30 40
5 11 17 23 29 39
4 10 16 22 28 38
37
36
35
34
3 9 15 21 27 33
2 8 14 20 26 32
1 7 13 19 25 31
P-5
000-002
N8A5488E
H-6, H-7 R-1

1 4 2 5 3 6
006-004
H-6
R-1
3 6
2 5
1 4
006-005
H-7
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 H-8
4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14
R-6
1 4
2 5
3 6
006-004
N8A5489E

Diagnosis
Quick Chart for Check Point 1. Turn Signal Light, Hazard Warning Light Check point Fuse F-20 (15 A) 1-1. Turn signal lights inoperative Trouble mode 1-2. Turn signal lights flash too quickly 1-3. Hazard warning lights inoperative (1) (2) F-11 (10 A) (1) Turn signal light SW (4) Hazard warning light SW (2) Flasher unit (3) (1) Turn signal light bulb
8-145
Cable harness (5) (1)
Notice: Figure in parenthesis ( ) indicates the order of inspection. 2. Stoplight Check point Fuse F-5 (10 A) Trouble mode 2-1. Both stoplights inoperative 2-2. Stoplight on the left (or right) side inoperative (1) Stoplight SW (2) (1) Stoplight bulb Cable harness (3) (2)

1. Turn Signal Light, Hazard Warning Light 1-1. Turn Signal Lights Inoperative
N8A0169E
8-147
CONTINUED FROM THE PREVIOUS PAGE IS THERE ANY CONTINUITY BETWEEN THE HARNESS SIDE CONNECTORS 3 B-16 AND B-7 ?
CONTINUED FROM THE PREVIOUS PAGE GROUND IT SECURELY
YES
NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN THE CIRCUIT
DISCONNECT THE COMBINATION SWITCH CONNECTOR IS THERE ANY CONTINUITY BETWEEN THE SWITCH CONNECTORS 5 B-70 AND 12 B-70 (WHEN TURNING LEFT), 13 B-70 AND 12 B-70 (WHEN TURNING RIGHT) RESPECTIVELY?
YES REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN THE HARNESS SIDE CONNECTORS 5 B-16 AND 12 B-70
N8B5108E
1-2. Turn Signal Lights Flash Too Quickly
DOES ANY TURN SIGNAL LIGHT REMAIN UNLIGHTED?
YES
DISCONNECT AND REINSTALL THE BULB, OR REPLACE IT, OR REPAIR AN OPEN CIRCUIT IN THE CIRCUIT OF THE INOPERATIVE BULB, OR CHECK THE GROUND
N8A0171E

1-3. Hazard Warning Lights Inoperative
IS FUSE F-20 (15A) NORMAL?
F-20 (15A) AND
N8B5041E
2. Stoplight 2-1. Both Stoplights Inoperative
YES IS J-9 GROUNDED SECURELY?
NO REPLACE THE FUSE
YES IS BATTERY VOLTAGE APPLIED TO 1 B-66 OF THE STOPLIGHT SW?
YES IS STOPLIGHT SWITCH NORMAL?
NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN THE FUSE F-5 (10A) AND 1 B-66
YES DOES THE PUSH ROD OF THE STOPLIGHT SW OPERATE SMOOTHLY?
NO REPLACE THE STOPLIGHT SW
YES REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 2 B-66 AND J-9
NO REPLACE THE STOPLIGHT SW
N8A0173E

2-2. Stoplight on The Left (or Right) Side Inoperative
8-149
IS THERE CONTINUITY BETWEEN THE STOPLIGHT CONNECTORS 2 R-1 AND 2 H-16 ( 2 R-6 AND 2 H-16 )?
REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN THE STOPLIGHT CONNECTORS 6 R-1 AND 7 H-16 ( 6 R-6 AND 7 H-16 )
N8B5109E
Notice: Figure in parenthesis ( ) indicates the place of inspection for the right side stoplight.
Starter Switch
Front Turn Signal Light Bulb

Removal 1. Remove the battery ground cable at the battery. 2. Remove the front combination light. Open the cab door. Insert a screwdriver (1) into the space between the cab and the cab door. Use the screwdriver to force out the stud pin at the center of the grommet (the pin securing the front combination light).
Remove the front combination light (1) connector. 3. Remove the front turn signal light bulb. Turn the bulb socket (2) to the left to remove it. Press the bulb (3) in and turn it to the left to remove it from the socket.
2 1
Door side
Cab side
N8A5484E
Installation 1. Install the front turn signal light bulb.

1
N8A5471E
While pressing the bulb (2), turn it clockwise to fit. Notice: Do not let the glass portion dirty with sebum etc. Turn the bulb socket (3) clockwise to fit.
Remove the fixing screw. Remove the two catches.
1 2
N8A0445E
N8A0176E
2. Installation procedure of front combination light assembly Connect the connector of the front combination light assembly. Position it by aligning two pawls with the groove of H/L. Fit the iron PIN (1) in the upper portion of the side by aligning it with the center of corresponding grommet. Notice: Push it into securely with a force of approx. 250 N (25 kgf) until click is heard. Pull the front combination light assembly lightly toward the front of vehicle to make sure that the PIN and grommet are engaged securely. Tighten one bolt in the lower portion of front combination light assembly. 3. Hook the seal rubber on two projections under H/L. 4. Connect the battery ground cable. 5. Check lighting of each light.
Side Turn Signal Light Bulb

Removal Preparation: Disconnect the battery ground cable. 1. Lens 2. Bulb
Rear Turn Signal Light Bulb

2 1
N8B5129E

Turn Signal Light Switch (Combination Switch)
Inspection Check the continuity between the terminals of the turn signal light switch. Repair or replace the switch when the result of inspection is found abnormal.
8-151
Terminal No. SW position Turning left Turn signal light SW Neutral Turning right
11
12
13
N8A0177E
Removal and Installation

Refer to HEADLIGHT, FOG LIGHT, REAR FOG LIGHT AND CORNERING LIGHT in this section.
Flasher Unit
Inspection When a 55W bulb is connected to the unit side terminals L and E while connecting the battery (+) terminal to terminal B, and the battery () terminal to terminal E, does the bulb light on and off? Replace the unit when the result of inspection is found abnormal.
N8B5002E
Stoplight Bulb
Removal and Installation Refer to CLEARANCE LIGHT, TAILLIGHT, LICENSE PLATE LIGHT AND ILLUMINATION LIGHT for TAILLIGHT BULB removal and installation steps in this section.

Stoplight Switch
Inspection 1. Check to see if the stoplight switch is installed correctly to the specified position. Adjust the position when the result of the inspection is found abnormal. 2. Check to see if there is any continuity between the terminals of the stoplight switch. Replace the switch when the result of inspection is found abnormal. Installation To install, follow the removal steps in the reverse order, noting the following points. 1) Check to see if the brake pedal has been returned by the return spring to the specified position. 2) Turn the stoplight switch clockwise until the tip of the threaded portion of the switch contacts the pedal arm. 3) Turn the switch counterclockwise until the space between the tip of the threaded portion and the pedal arm is 0.5 to 1.0 mm (0.02 0.04 in.).
B-66
1 2
Switch side
Terminal No. SW position Depress brake pedal (Push rod out) Release brake pedal (Push rod in)
N8A0179E
Removal Preparation: Disconnect the battery ground cable. 1. Stoplight Switch 1) Disconnect the connector. 2) Loosen the lock nut of the switch. 3) Remove the switch by turning it.
N8A0181E
Hazard Warning Switch

Inspection Check the continuity between the terminals of the hazard warning switch. Repair or replace the switch when the result of inspection is found abnormal.
B-30
Terminal No. SW position
ON OFF
N8A0180E N8A0182E

Removal Preparation: Disconnect the battery ground cable. 1. Meter Cluster Refer to the METER AND WARNING/INDICATOR LIGHT in this section. 2. Hazard Warning Switch Release the lock pushing the switch from the back side of the meter cluster.
8-153
N8A0436E
Installation To install, follow the removal steps in the reverse order noting the following point. 1. Push the switch with your fingers until locks securely.
8-154 CAB AND CHASSIS ELECTRICAL Horn, Backup Light and Backup Buzzer
General Description
The circuit consists of the starter switch, horn, horn switch, backup light (Rear combination light), backup light switch, backup buzzer and the relay. When the horn switch is turned on independent of the position of the starter switch, the relay is activated to sound the horn. When the backup light switch turns on with the starter switch on, the backup light will operate. Backup Light and Backup Buzzer Circuit
N8A5216E
Parts Location
X-2 HORN RELAY STARTER SW R-6 REAR COMBINATION LIGHT (RH) (BACKUP BUZZER)
FUSE & RELAY BOX ASM F-16, F-20 FUSE J-49 BACKUP LIGHT SW
RELAY BOX ASM (No.1)
H-16
H-119
H-14
P-5 P-1 P-2 BATTERY P-3 P-4 RELAY BOX ASM (No.1) FL-1, FL-2 FUSIBLE LINK R-6 REAR COMBINATION LIGHT (LH)
H-5
H-7
J-4 HORN (RH)
B-70 J-5 HORN (LH) B-67 B-51 METER "A"
J-9 EARTH: FRAME
N8B0038E
8-155
STARTER SWITCH FL-2 40A KEY 3W/L

1 H-7 ON B-67 3 B ACC
F-16 10A 3B/Y 0.5B/Y METER B-51 (18) 3B/Y 0.5B/Y METER
3W/L 2 B-67
ST
Circuit Diagram
FL-1 100A or 120A 0.5B/Y 5W/B

H-6 H-5 22 2
2L 5W/B 3W/B 3W/B
(NPR75/NQR75 only)
8B
MAIN
8W/B
P-1
P-2
0.5B/Y F-20 15A 0.5B/Y

H-119
0.5B/Y
11 H-119
HORN, HAZARD 0.5B/Y

10
(4HK1 with Smoother)
0.5B/Y
0.5G
P-3 1 J-49
(4JJ1(EURO-4) with Smoother)
P-4
BACKUP LIGHT SWITCH
X-2
0.5G
2 X-2 5
P-5
J-49 2
FRAME
X-2 1 3 X-2
RELAY; HORN 0.3G/R
0.5R/L
9
0.5R/L 0.5R/L
H-119 H-119

12
3 H-5
HORN (LH)
HORN SWITCH (COMBINATION SWITCH)
1.25B
1.25B
(Except NPR75/NQR75)
J-9
HORN (RH)
J-4 J-5
0.5G/W 0.5G/W
3 B-70
0.5R/L
0.5R/L
6 H-14
H-16
0.5R/L
6
0.5G/W HORN CONTACT

1 1
5 R-6
BACKUP LIGHT (REAR COMBINATION LIGHT-RH)
R-6 6
0.5R/L 0.5R/L
5 R-1
BACKUP LIGHT (REAR COMBINATION LIGHT-LH)

R-1 6
N8B0039E
FRAME-LH (CENTER)
2B
1.25B
1.25B
H-14
1.25B
H-16

Connector List
8-157
X-2
005-006
J-49
2 1
002-026
B-51
020-004
H-14 (Without ABS)
1 5
2 6
3 7
4 8
008-003
B-67
1 3
2 4
004-001
H-14 (Without ABS)
4 8
3 7
2 6
1 5
008-004
B-67
2 4
1 3
H-14 (With ABS)

004-002
1 5 6
2 7
3 8
4 9
10 11 12 13 14 15 16
016-003
B-70
1 2 3 7 8 9 10
4 5 6 11 12 13 14
H-14 (With ABS)

014-002
4 9 8
3 7
2 6
1 5
14 13 12 11 10
16
15
016-004
B-70
6 5 4 14 13 12 11
3 2 1 10 9 8 7
H-16
1 5
2 6
3 7
4 8
008-003
014-003
J-9
000-001
H-16
4 8
3 7
2 6
1 5
008-004
J-49
1 2
002-025
H-119 (With Smoot her)
1 5 9
2 6
3 7
4 8
10 11 12
13 14 15 16
016-001

No. H-119 (With Smoot her) Connector Face No. Connector Face
4 8
3 7
2 6
1 5 9
12 11 10
R-1
016-002
1 4
2 5
3 6
16 15 14 13
006-004
J-4
R-1
001-018
3 6
2 5
1 4
006-005
J-5
R-6
001-018
1 4
2 5
3 6
006-004
P-1
000-022
R-6
3 6
2 5
1 4
006-005
H-5 P-4
000-014
P-2
000-014
1 7 13 19 25 31
2 8 14 20 26 32
3 9 15 21 27 33
34
35
36
37
4 10 16 22 28 38
5 11 17 23 29 39
6 12 18 24 30 40
6 12 18 24 30 40
5 11 17 23 29 39
4 10 16 22 28 38
37
36
35
34
3 9 15 21 27 33
2 8 14 20 26 32
1 7 13 19 25 31
P-3
000-014
N8A5488E
P-5
000-002

H-6, H-7
8-159
H-6
H-7
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 H-8
4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14
N8A5489E
Diagnosis
Quick Chart for Check Point 1. Horn Check point Fuse F-20 (15 A) Trouble mode 1-1. Horn does not sound 1-2. Horn does not shut off (1) Horn (6) Horn SW (4) (2) Horn relay (2) (1) Horn contact (3) Cable harness (5) (3)
Notice: Figure in parenthesis ( ) indicates the order of inspection. 2. Backup Light Check point Fuse F-16 (10 A) 2-1. Both backup lights inoperative Trouble mode 2-2. Backup light on the left (or right) side inoperative 2-3. Backup light remains on Notice: Figure in parenthesis ( ) indicates the order of inspection. (1) (1) Backup light SW (Inhibitor SW) (3) (1) Backup light bulb Backup buzzer Cable harness (2) (2)

1. Horn 1-1. Horn Does Not Sound
YES IS THE HORN RELAY NORMAL?
NO REPLACE THE FUSE
YES IS THE HORN NORMALLY GROUNDED?
NO REPLACE THE HORN RELAY
YES IS THE HORN CONNECTOR 1 J-4 OR 1 J-5 SECURELY CONNECTED?
NO CLEAN UP THE FITTING SURFACE AND THE GROUND FIRMLY
YES
NO CONNECT THE CONNECTOR SECURELY
DISCONNECT THE HORN SWITCH CONNECTOR IS THERE BATTERY VOLTAGE APPLIED BETWEEN 3 B-70 AND THE GROUND?
YES
NO
IS THERE ANY CONTINUITY BETWEEN THE HORN RELAY HARNESS SIDE CONNECTORS 3 H-5 AND 1 J-4 (OR 1 J-5 )?
REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT OR REPAIR A POOR CONNECTION AT THE HORN CONNECTOR
YES
DOES THE HORN SOUND WHEN CONNECTING THE BATTERY (+) TERMINAL TO THE HORN CONNECTOR 1 J-4 (1 J-5 ), AND (-) TERMINAL TO THE HORN BRACKET?
NO REPLACE THE HORN
N8B0040E

1-2. Horn Does Not Shut Off
8-161
IS THE HORN RELAY NORMAL?
YES REMOVE THE HORN SW IS THE MOVABLE PORTION OF THE HORN SW ALWAYS OUT OF CONTACT WITH THE GROUND BRACKET?
NO REPLACE THE HORN RELAY
YES REPAIR A SHORT CIRCUIT BETWEEN HORN RELAY HARNESS SIDE CONNECTORS 3 X-2 AND 3 B-70
NO REPAIR OR REPLACE THE HORN SW

N8B0041E
2. Backup Light 2-1. Backup Lights Inoperative
YES IS J-9 SECURELY GROUNDED?
NO REPLACE THE FUSE
YES TURN THE STARTER SW ON IS THE BATTERY VOLTAGE APPLIED BETWEEN THE BACKUP LIGHT SWITCH HARNESS SIDE CONNECTOR 1 J-49 AND THE GROUND?
YES
NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN FUSE F-16 (10A) AND 1 J-49
ENTER THE TRANSMISSION SHIFT LEVER TO REVERSE POSITION WHEN REMOVE THE CONNECTOR OF THE BACKUP LIGHT SWITCH, IS THERE ANY CONTINUITY BETWEEN THE SW SIDE CONNECTORS 1 J-49 AND 2 J-49 ?
YES
NO REPAIR OR REPLACE THE BACKUP LIGHT SWITCH OR INHIBITOR SW
REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN THE BACKUP LIGHT SWITCH HARNESS SIDE CONNECTORS 2 J-49 AND 6 H-14 (OR 6 H-16 )
N8B5046E

2-2. Backup Light on the Left (or Right) Side Inoperative
IS THERE BATTERY VOLTAGE APPLIED BETWEEN THE BACKUP LIGHT HARNESS SIDE CONNECTOR 5 R-1 (5 R-6 ) AND 6 H-16 ?
REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN BACKUP LIGHT HARNESS SIDE CONNECTORS 6 R-1 (6 R-6 ) AND J-9
N8B5047E
2-3. Backup Light Remains On
REPAIR OR REPLACE THE BACKUP LIGHT SW OR INHIBITOR SW
N8A0191E
Starter Switch
Horn
Inspection Check to see if horn sounds when a battery voltage is between horn terminal and the fixing bracket. Repair or replace the horn when the result of inspection is found abnormal.
N8A0192E

Removal Preparation: Disconnect the battery ground cable. 1. Bumper Refer to BUMPER in section 2. 2. Horn Disconnect the connector (3).
8-163
Removal Preparation: Disconnect the battery ground cable. 1. Horn Pad 1) Hold the horn pad and pull it upward. 2. Steering Wheel 1) Remove the steering shaft nut. 2) Remove the steering wheel by using steering wheel remover. (Refer to Section 3B4 STEERING COLUMN for steering wheel removal steps.) 3. Horn Switch
1 2 3
N8A5485E
Horn Switch
Inspection With the contact point of the horn switch pressed to the switch bracket, check the continuity between the connector terminal and the bracket of the switch. Check the contact condition between horn contact of the combination switch and contact plate of steering wheel. Repair or replace the switch when the result of inspection is found abnormal.
N8A0476E
Installation To install, follow the removal steps in the reverse order, noting the following point. 1. Tighten the steering shaft nut to the specified torque. Tighten: Shaft nut to 49 Nm (5 kgfm / 36 lbfft)
N8A0194E

Backup Light Bulb
N8A0196E
N8A0195E
Backup Light Switch

Inspection 1. With the switch installed to the transmission, check the continuity between the terminals of the switch connectors. When the continuity is found between the terminals only with the switch shifted to the reverse position, the switch is normal. 2. When the result of the above inspection is found abnormal, remove the switch from the transmission and conduct a test on the switch alone. If the continuity appears between the connector terminals when the ball of the switch is pushed, the switch is normal. (When the ball is released, the continuity disappears.) 3. If there is no continuity with the switch installed to the transmission, even though the switch is found to be normal, then adjust the stroke of the switch by changing the thickness of the switch gasket.
Removal Preparation: Disconnect the battery ground cable. 1. Backup Light Switch 1) Disconnect the connectors. 2) Remove the switch by turning it counterclockwise. Installation 1. Backup Light Switch Apply liquid gasket to the screw portion of the switch to prevent oil leak.
Backup Buzzer
Inspection Apply battery voltage to the backup buzzer connector to check the buzzer sound. Repair or replace the buzzer when the result of inspection is found abnormal.
N8A0197E

Removal Preparation: Disconnect the battery ground cable. 1. Rear Combination Light Cover 2. Backup Buzzer 1) Remove the rear combination light connector fixing screw. 2) Remove buzzer fixing screw. 3) Disconnect the connector.
8-165
N8A0198E
8-166 CAB AND CHASSIS ELECTRICAL Dome Light and Backup Buzzer
General Description
The circuit consists of the starter switch, dome light, dome light switch, door switch, backup light switch and the backup buzzer. The dome light lights up when the left or right side door is opened with the switch set at the door mode. It can be lit by operating ON or OFF of the dome light switch. The dome light can be lit by respective switch independent of the position of the starter switch. By operating the dome light switch fitted on the instrument panel, the dome light can be lit independent of the switch position of dome light.
Lighting Circuit
BATTERY (+)
OFF
DOOR DOME LIGHT ON
DOME LIGHT (FOR CREW CAB)
DOME LIGHT SW : Lighting circuit by door sw : Lighting circuit by dome light sw
DOOR SW (FRT PASSENGER SIDE)
DOOR SW (DRIVER SIDE)
NOTE: Arrow marks "
" indicate the direction of current
N8A0199E
RELAY BOX ASM (No.1) L-3 DIODE (W/CAB) L-1 DIODE L-4 DOME LIGHT
Parts Location
L-2 DOME LIGHT
W/CAB
N-7 DOOR SW (RH)
J-49 H-119
N-2 DOOR SW (LH)
X-38 DIODE
FUSE & RELAY BOX ASM F-4, F-16 FUSE
H-16 H-14
P-5 P-1 P-2 BATTERY P-3 P-4 RELAY BOX ASM FL-1, FL-2 FUSIBLE LINK
H-3
STARTER SW
B-7
H-5
H-8
B-51 H-10 B-67 H-12 B-83 BACKUP BUZZER B-87 DOME LIGHT SW
N8B0042E
8-167
FL-2
OFF 11 H-119 ACC
STARTER SWITCH
40A KEY 0.5B/Y 0.5B/Y

H-7 2 3 ST ON B-67
3W/L
B-67 B
3W/L 3B/Y (4JJ1(EURO-4) with Smoother)

10 H-119
Except Europe
Circuit Diagram
3B/Y
F-16 10A METER 0.5B/Y 0.5B/Y
2L
H-6 3 H-10 H-5 22
0.5B/Y
8B 0.5B/Y 0.5B/Y
FL-1 100A or 120A MAIN 3W/B 3W/B F-4 15A AUDIO(B), DOOR LOCK 0.85R 0.5R
8W/B
(NPR75/NQR75) 5W/B
P-1
P-2
0.5B/Y
0.5R METER B-51 (18)
1 J-49
0.5B/Y
1 L-2
P-3
(NPR/NQR only)
P-4
BACKUP SWITCH
OFF ON L-2 B-83 3 2 L-2 6
DOOR
0.5B/Y
DOME LIGHT
P-5
J-49 2
FRAME
(Smoother for NPR75/NQR75) 0.5R/L
(Smoother) 0.5R/L
BACK BUZZER
B-83 B-83 5 2 H-119 12 H-119 9
0.5GR/B
0.5R/L
H-10
0.5GR
2 1 H-10
0.5R/L
0.5B
0.5GR/B
1 X-38
0.5R/L
H-8
0.5R/L
(M/T)
(Smoother)
0.5R/L
DIODE
X-38 2
0.5GR 0.5GR/R
0.5GR/B
H-14
0.5R/L
H-3 2 B-87 B-87 4
0.5GR/R
0.5GR/R
RELAY; TAIL (1)

3
3W
F-7 10A TAIL LIGHT 0.85LG/R 0.85LG/R 0.85LG/R
6 H-16 H-12 6 H-12
0.5R/L
1.25GR/B
1
1.25GR/R
1 B-87 5 B-87 1 N-7 N-2
DOME LIGHT SWITCH 0.5B 0.5B
BACKUP LIGHT
DOOR SWITCH (LH)
DOOR SWITCH (RH)
DOOR SWITCH (RH)

N-2
1.25GR/R
1
N8B0043E
3B
B-7
3B
FL-2
OFF ACC 11 H-119
STARTER SWITCH (4HK1 with Smoother)
40A KEY 3W/L 0.5B/Y 0.5B/Y

2 3 ST B-67 ON B-67 B
3W/L 3B/Y 3B/Y
For Europe
H-7

10 H-119
FL-1
F-16 10A METER F-4 15A AUDIO(B), DOOR LOCK 0.5B/Y 0.5B/Y 0.85R (Except NKR)
6 H-10 H-5 22 3 H-10
0.5B/Y
2L 3W/B 0.5B/Y 0.5B/Y 3W/B 0.5R
8B
100A or 120A MAIN
(NPR75/NQR75) 8W/B 8W/B 5W/B
P-1
H-6
P-2
(W/CAB only) 0.5B/Y 0.5R

H-20 1 L-2 2
0.5R
1 J-49
0.5B/Y
P-3
METER B-51 (18) 0.5B/Y
P-4
BACKUP SWITCH
OFF 6 B-83 ON L-2 3 B-83 2 2 L-2
DOOR
DOME LIGHT
P-5
J-49
FRAME
B-83 5
(Smoother for NPR75/NQR75) 0.5R/L
(Smoother) 0.5R/L
1 L-1 3 2 X-32
0.5GR
L-4
0.5R 0.5Y 0.5GR/B (Except NKR)

1 4 H-10 1 L-1 H-10
BACK BUZZER
H-119
H-119
0.5R/L
H-8
0.5R/L 0.5B
12
0.5R/L
2
0.5R/L
DIODE 0.5GR/B
1 X-38
0.5R/L
6 H-14 X-38
(W/CAB for NPR75 /NPR85/NQR75)
0.5GR
DIODE
L-3 H-20 2
L-4
0.5Y 1
1
L-3
0.5GR 0.5GR/B
0.5GR
X-32
(NPR/NQR with Smoother) DIODE
(NKR with Smoother) DIODE 0.5GR/R
N8B0044E
8-169
DOME LIGHT (Except NKR)

5 H-10 H-10 2
0.5GR/B
0.5GR/R
0.5GR/R
0.5GR/B
H-16
0.5R/L
6
0.5GR
(W/CAB with M/T)
0.5R/L
RELAY; TAIL (1)

2 B-87 B-87 4
3W
F-7 10A TAIL LIGHT 0.85LG/R 0.85LG/R 0.85LG/R

4 H-12
3 H-3
6 H-12
3 H-3
1.25GR/R
0.5GR/B
1.25GR/B (S/CAB) 0.5GR/B (W/CAB)
1.25GR/R
B-87 5
B-87 1
1 N-2
1 N-7
1 N-2
DOME LIGHT SWITCH 0.5B 0.5B
BACKUP LIGHT
DOOR SWITCH (LH)

N-7
DOOR SWITCH (LH)
DOOR SWITCH (RH)
DOOR SWITCH (RH)
B-7
3B
3B

Connector List
B-7
000-001
H-3
3 6
2 5
1 4
006-015
B-51
020-004
H-10 (Excep t 4HK1)
1 2 3
003-009
B-67
1 3
2 4
004-001
H-10 (Excep t 4HK1)
3 2 1
003-010
B-67
2 4
1 3
H-10 (4HK1)
004-002
3 4 5 6
006-029
B-83
1 4
2 5
3 6
006-010
H-10 (4HK1)
6 5 4 3
006-003
B-87
1 2 4 5
3 6
006-028
H-12 (For M/T)
1 2 3 7 8 9 10
4 5 6 11 12 13 14
014-002
X-38
1 2
002-050
H-12 (For M/T)
6 5 4 14 13 12 11
3 2 1 10 9 8 7
014-003
H-3
1 4
2 5
3 6

006-014
1 2 3 4 5 11 12 13 14 15 16
6 7 8 9 10 17 18 19 20 21 22
022-001

No. H-12 (For Smoot her) Connector Face No. Connector Face
8-171
10 9 8 7 6 22 21 20 19 18 17
5 4 3 2 1 16 15 14 13 12 11
H-20
022-002
1 2
002-010
H-14 (Without ABS)
1 5
2 6
3 7
4 8
008-003
1 5 9
2 6
3 7
4 8
10 11 12
13 14 15 16
016-001
H-14 (Without ABS)
4 8
3 7
2 6
1 5
008-004
4 8
3 7
2 6
1 5 9
12 11 10
16 15 14 13
016-002
H-14 (With ABS)
1 5 6
2 7
3 8
4 9
10 11 12 13 14 15 16
J-49
016-003 002-035
H-14 (With ABS)
4 9 8
3 7
2 6
1 5
14 13 12 11 10
L-1
016-004
2
002-027
16
15
H-16
1 5
2 6
3 7
4 8
008-003
L-2
1 2 3
003-009
H-16
4 8
3 7
2 6
1 5
008-004
L-2
3 2 1
003-010
H-20
1 2
002-009
L-3
2
002-027

L-4
1 2
002-022
P-5
000-002
H-5 L-4
2 1
002-023
N-2
1
001-009
1 7 13 19 25 31
2 8 14 20 26 32
3 9 15 21 27 33
34
35
36
37
4 10 16 22 28 38
5 11 17 23 29 39
6 12 18 24 30 40
6 12 18 24 30 40
5 11 17 23 29 39
4 10 16 22 28 38
37
36
35
34
3 9 15 21 27 33
2 8 14 20 26 32
1 7 13 19 25 31
N-7
1
001-009
N8A5488E
H-6, H-7, H-8 P-1

000-022
H-6
P-4
000-014
H-7
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 H-8
4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14
P-2
000-014
N8A5489E
Starter Switch
Refer to START AND CHARGING in this section. P-3
000-014
Backup Light Switch

Refer to HORN, BACKUP LIGHT AND BACKUP BUZZER in this section.

Dome Light Bulb
Removal Preparation: Disconnect the battery ground cable. 1. Lens Hold the lens and pull it downward.
8-173
Dome Light Switch

Inspection Check the continuity between the dome light switch connector terminals. Repair or replace the switch when the result of inspection is found abnormal.
1 2 4 5
Terminal SW No. position
3 6
B-87
ON OFF
N8A5243E
N8B0093E
2. Bulb Installation To install, follow the removal steps in the reverse order.
Dome Light Bulb (for Crew Cab)

Removal Preparation: Disconnect the battery ground cable. 1. Lens Hold the lens and pull it down. 2. Bulb
Removal Preparation: Disconnect the battery ground cable. 1. Meter cluster Refer to the METER AND WARNING/INDICATOR LIGHT in this section. 2. Dome Light Switch Release the lock pushing the switch from the back side of the meter cluster.
N8A0203E
Connector No. Te rm ina lN SW o. operation
N-2
N-7
Body
Push Release
N8A5160E
N8A0206E
Installation To install, follow the removal steps in the reverse order noting the following point. 1. Push the switch with your fingers until locks securely.
Door Switch
Inspection Check to see if there is any continuity between the terminals and the body while operating the door switch. Repair or replace the switch, when the result of inspection is found abnormal.
Removal Preparation: Disconnect the battery ground cable. 1. Door Switch 1) Remove the screw. 2) Disconnect the connector of the switch.
N8A0207E

Backup Buzzer
Warning function Warning to reverse driving Operative conditions When the transmission shift lever is engaged to the reverse position.
8-175
N8A5249E
Inspection of the Buzzer Circuit Disconnect the backup buzzer connector, measure the continuity and voltage between the harness side connector terminals.
N8B5153E

Starter Switch
Inspection Check to see if there is any continuity between the connector terminals of the key cylinder switch. Repair or replace the switch when the result of inspection is found abnormal.
ST
AC
ON
B-67
1 3
2 4
Switch side Terminal No. Starter key position Key removed LOCK Key inserted ACC ON START
N8B0045E
CAB AND CHASSIS ELECTRICAL Power Door Lock

General Description
8-177
The circuit consists of the door lock switch, actuator for the front passenger door, rear doors and the door lock controller. The door lock controller is always provided with battery voltage. The key or the inside lock knob on the drivers door can activate the lock mechanism of all the doors. When the drivers door lock switch is turned on, current flows for about one second to the door lock actuator of each door connected in parallel with the controller to activate the actuator to lock and unlock the doors.
Operation of Door Lock Controller
When locking the door.
When locking the door.
Battery(+)
Battery(+)
Relay;Door lock
Relay;Door lock
To actuator (Actuator operates to lock side)
To actuator (Actuator operates to unlock position)
Door lock sw. (Lock position)
Door lock sw. (Unlock position)
N8A0211E
Parts Location
D-10 REAR DOOR LOCK ACTUATOR (W/CAB) (RH) <REAR DOOR (W/CAB) (RH)>
F-4 H-18 (W/CAB) <REAR DOOR (W/CAB) (LH)> H-19 (W/CAB)
D-9 REAR DOOR LOCK ACTUATOR (W/CAB) (LH)
H-2(S/CAB), H-20(W/CAB)
B-7
H-18 (W/CAB)
N8B0046E

Circuit Diagram
Except 4JJ1 / 4HK1 80A ACG 8W/B
8-179
5W/B F-4 15A AUDIO(B), DOOR LOCK

H-6
8W/B 4JJ1 / 4HK1 80A ACG
5W/B
3W/B
0.85R
0.5R
DOME LIGHT
2L
8B
0.85R
P-1 P-2
RELAY; DOOR LOCK

P-3 P-4
6 B-12
B-12
0.85BR/R
5
0.5BR/R
B-12 P-5
0.85BR/Y 0.5BR/Y
4
0.5BR/R
FRAME 0.85BR/R
1 2 3
0.85BR/Y
B-12
B-12
B-12
0.3R/G
0.3G/B
FOR M/T
5 H-12 7 H-12
FOR M/T
13 H-12 19 H-12 1 H-3 4 H-3
0.5BR/W
(FOR W/CAB EC) (FOR W/CAB EC) (FOR W/CAB EC)
0.5BR/Y
0.5BR/R
0.5BR/R
2 H-22
5 H-22
2 H-11
4 H-11
FOR SMOOTHER
0.5BR/Y
(FOR S/CAB)
FOR SMOOTHER
5 H-20
4 H-2
3 H-20
3 H-2
2 H-18
1 H-18
2 H-19
0.85BR/R
0.85BR/R
0.85BR/Y
0.85BR/R
UNLOCK
LOCK 0.85B
2 D-4
3 D-4
2 D-8
0.85BR/Y
0.3R/G
0.3G/B
1 D-8
1 D-9
2 D-9
1 D-10
0.85BR/Y
2 D-10
(FOR S/CAB)
(FOR S/CAB)
0.5BR/Y
1 H-19
0.5BR/Y
UNLOCK
UNLOCK
DOOR LOCK SWITCH-LH D-4

1
2B
(FOR W/CAB EC)
0.3B
(FOR S/CAB) 3
3 H-22
H-11
DOOR LOCK ACTUATOR-RH
DOOR LOCK ACTUATOR-LH (W/CAB)
DOOR LOCK ACTUATOR-RH (W/CAB)
HEADLIGHT BRACKET (LH) FRAME-LH (FRONT)
B-7
3B 5B
3B
2B
2B
B-1
N8B0047E
UNLOCK
LOCK
LOCK
LOCK

Connector List
B-1
000-001
D-9
002-002
B-7
000-001
D-10
002-001
B-12
1 4
2 5
3 6
006-010
D-10
002-002
D-4
3
003-003
H-18 (W/ CAB)
002-001
D-4
H-18 (W/ CAB)

003-011
002-002
D-8
H-19 (W/ CAB)

002-001
002-001
D-8
H-19 (W/ CAB)

002-002
002-002
D-9
H-2 (S/ CAB)

002-001
1 2
4 5 6 7 8
008-009

8-181
H-2 (S/ CAB)
2 1
8 7 6 5 4
H-20 (W/ CAB)

008-010
4 3
2 1
10 9 8 7 6 5
010-004
H-11 (S/ CAB)
1 2
4 5 6 7 8
H-22 (W/ CAB)

008-009
1 2
3 4
5 6 7 8 9 10
010-003
H-11 (S/ CAB)
2 1
8 7 6 5 4
H-22 (W/ CAB)

008-010
4 3
2 1
10 9 8 7 6 5
010-004
H-3
1 4
2 5
3 6
P-1
006-014 000-022
H-3
3 6
2 5
1 4
P-4
006-015 000-014
H-12
1 2 3 7 8 9 10
4 5 6 11 12 13 14
P-2
014-002 000-014
H-12
6 5 4 14 13 12 11
3 2 1 10 9 8 7
P-3
014-003 000-014
H-20 (W/ CAB)
1 2
3 4
P-5
010-003 000-002
5 6 7 8 9 10

H-6
H-6
H-7
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 H-8
4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14
N8A5489E
Diagnosis
Quick Chart for Check Point Check point Fuse F-4 (15 A) 1. All the doors do not lock and unlock 2. All the doors do not get locked (or unlocked) 3. Driver side door does not get locked (or unlocked) 4. Front passenger side door does not get locked (or unlocked) 5. Rear door-RH side does not get locked (or unlocked) 6. Rear door-LH side does not get locked (or unlocked) Notice: Figure in parenthesis ( ) indicates the order of inspection. (1) Door lock controller (3) (2) Door lock SW (Driver side) (2) (1) (1) (1) (1) (1) Door lock actuator Front (Passenger side) Rear (RH) Rear (LH) Cable harness (4) (3) (2) (2) (2) (2)
Trouble mode

All the Doors Do Not Lock and Unlock
8-183
N8A5256E
All the Doors Do Not Get Locked (or Unlocked)
N8A5257E

Driver Side Door Does Not Get Locked (or Unlocked)
REPLACE THE DOOR LOCK SWITCH
N8A0216E
FRT Passenger Side Door Does Not Get Locked (or Unlocked) RR Door-RH Side Does Not Get Locked (or Unlocked) RR Door-LH Side Does Not Get Locked (or Unlocked)
REPLACE THE DOOR LOCK ACTUATOR
N8A0217E

Inspection of the Door Lock Circuit Check the voltage and the continuity between the controller harness side connector terminals.
8-185
B-12
1 4
2 5
3 6
Harness side
Terminal No. 1 2 3 4 5 6
Wire color R/G G/B B BR/Y BR/R R
Connected to Door lock SW (Unlock) Door lock SW (Lock) Ground Actuator (Unlock) Actuator (Lock) Fuse F-4 (15A)
Item to be checked
Connecting terminal 1-Ground 2-Ground
Checking conditions Driver seat side door Driver seat side door Unlock Lock Unlock Lock
Standard Continuity No continuity No continuity Continuity Continuity Continuity (There is some resistance) Continuity (There is some resistance) Battery voltage
Continuity (Resistance)
3-Ground 4-5 5-4
Voltage
6-Ground
N8B5118E

Door Lock Controller The door lock controller sends out to each door lock actuator the lock/unlock signals received from door lock switch of driver seat side. door lock controller, apply battery voltage to each of the terminals to conduct the operation test. When the door lock will not operate, check the door lock actuator for any trouble.
B-12 Harness side
1 4
2 5
3 6
Connecting terminal 4 (BR/Y) 5 (BR/R)
Operation Unlock Lock
N8B5116E
N8A0221E
Inspection Remove the connector of the door lock controller, and check the continuity and the voltage between the controller side connector terminals. (Connect the (+) terminal of the battery to 6 B-12 and the () terminal to 3 B-12 .) 3 B-12 5 B-12 .................Continuity 3 B-12 4 B-12 .................Continuity (Then, ground 2 B-12 .) 5 B-12 ..................Voltage for approx. 1 second (Disconnect the ground of 2 B-12 , and ground 1 B-12 .) 4 B-12 ..................Voltage for approx. 1 second Replace the controller when the result of inspection is found abnormal.
Door Lock Switch (Driver Seat Side)

The door lock switch on the drivers door is connected with the door lock cylinder and the inside lock knob with a rod. The switch sends lock/unlock signals to the door lock controller.
B-12
N8A0223E
3 6
2 5
1 4
Controller side
Inspection Check to see if there is any continuity between the connector terminals of the door lock switch. Replace the switch when the result of inspection is found abnormal.
N8A0220E
Door Lock Operation Test After confirming that there is continuity between the harness side connector terminals 4 B-12 and 5 B-12 of the
8-187
D-4
Switch side
1 2 3
Operation
Terminal No.
Lock Unlock
N8A0224E
Removal and Installation Refer to Section 2 FRAME AND CAB for DOOR LOCK ASSEMBLY.
Door Lock Actuator

Receiving forward or reverse current from the door lock controller, the door lock actuator locks or unlocks the door with the rod connected to the door lock mechanism.
N8A0225E
Inspection of the Door Lock Actuator Apply the battery voltage to the connector terminals of the door lock actuator to check the operation. 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 door lock controller for any failure.
D-8 Door lock ASM
D-9
D-10
Actuator side
Actuator side
Door Actuator Connector No. Terminal No. Operation Lock Unlock
FRT Passenger
RR-LH D-9
RR-RH D-10
D-8 1 2 1
N8A0226E
Removal and Installation Refer to Section 2 FRAME AND CAB for DOOR LOCK ASSEMBLY.
CAB AND CHASSIS ELECTRICAL Power Window

General Description
8-189
The circuit consists of the starter switch, power window switch for each of the windows and power window motor. When the starter switch is turned on, the battery voltage is applied to each of the power window switches through the circuit breaker and the power window relay on the circuit. By operating the switches of each window to select UP or DOWN, the revolving direction of the power window motor changes to open or close the window. The drivers power window switch has a built-in one-touch operating circuit which allows to automatically open the window by operating the switch to the AUTO position. When the drivers power lock switch at the driver side is depressed, the power source to the passengers power window switches will be shut off and passengers side power window motor will not operate if the switch is operated.
Operation of Passenger Side Window
NOTE: Arrow marks "
" indicate the direction of current
N8A0227E
Parts Location
F-6, F-16
X-7
B-7
FL-1, FL-2 FUSIBLE LINK
N8B0048E
FL-1
Except 4JJ1 / 4HK1 80A ACG RELAY; POWER WINDOW

2 X-7 X-7 H-2 H-20 1 1 1
2L 3W/B 1.25L/B 2L/B

OFF 3 X-7 5 X-7
8B 2L/B 2L/B FOR W/CAB EC FOR S/CAB POWER WINDOW SWITCH (DRIVER)
6 D-3 B
100A or 120A MAIN FOR S/CAB 2L/B 1.25L/B 1.25L/B F-6 20A POWER WINDOW 2B/L 1.25L/B
8W/B 5W/B
Circuit Diagram
8W/B
H-6
5W/B
P-1 ACC ON B-67 3 H-22 1 1 H-11
4JJ1 / 4HK1 80A ACG 0.5B/Y F-16 10A METER 3B/Y 2L/B 2L/B 0.5B/Y
STARTER SWITCH
P-2
3W/L
ST
H-7
3W/L
B-67
FL-2 40A
KEY SW 2L/B
8 D-3 E
P-3
P-4
0.3B
WINDOW LOCK SWITCH

FL SW UP D-3 5 4 D-3
WINDOW SWITCH (PASSENGER)
METER B-51 (18)
P-5
2B
FRAME
DOWN
1.25G/Y
1.25R/Y
1.25L/B
AUTO CIRCUIT
FOR S/CAB
WINDOW SWITCH (DRIVER)
3 3 H-22 H-11
9 H-22
8 H-11
5 H-11
6 H-22
FOR W/CAB EC
FOR S/CAB 2B 2B
1.25R/Y
1.25G/Y
1.25G/Y
1.25R/Y
FOR W/CAB EC
FOR W/CAB EC
UP D-3 1
DOWN D-3 2
9 H-20
8 H-2
5 H-2
6 H-20
1.25G/Y
D-7
1.25R/Y
2
4 D-7
1 D-7
1.25L
POWER WINDOW SWITCH (PASSENGER)
1.25L/W
UP D-7 3
DOWN D-7 5
1.25L/Y
1.25BR/Y
B-7
3B
3B
1 D-2
2 D-2
1 D-6
2 D-6
5B
FRAME-LH (FRONT)
B-1
UP
DOWN
UP
DOWN
N8B0049E
8-191
POWER WINDOW MOTOR (DRIVER)
POWER WINDOW MOTOR (PASSENGER)

Connector List
X-7
005-006
D-6
002-029
B-1
000-001
D-3
1 4
2 5 6 7
3 8
008-011
B-7
000-001
D-7
005-005
B-67
1 3
2 4
004-001
H-2 (S/ CAB)
1 2
4 5 6 7 8
008-009
B-67
2 4
1 3
H-2 (S/ CAB)

004-002
2 1
8 7 6 5 4
008-010
D-2
H-11 (S/ CAB)

002-028
1 2
4 5 6 7 8
008-009
D-2
H-11 (S/ CAB)

002-029
2 1
8 7 6 5 4
008-010
D-6
H-20 (W/ CAB)

002-028
1 2
3 4
5 6 7 8 9 10
010-003

No. Connector Face H-6, H-7
8-193
H-20 (W/ CAB)
4 3
2 1
10 9 8 7 6 5
010-004
H-6
H-7
H-22 (W/ CAB)
1 2
3 4
1 2 3 4 5 6 7 8 9 10 11 12 13 H-8
4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14
5 6 7 8 9 10
010-003
14 15 16 17 18
H-22 (W/ CAB)
4 3
2 1
10 9 8 7 6 5
N8A5489E
010-004
P-1
000-022
P-4
000-014 000-004
P-2
000-014 000-004
P-3
000-014 000-004
P-5
000-002 000-004

Diagnosis
Quick Chart for Check Point Check point Fuse F-16 (10A) All windows do not operate Lock SW does not function Driver side window Window does not operate One-touch operation does not operate Window operates in only one direction Front passenger side window Trouble mode Window does not operate Window does not operate when operating the driver side SW Window does not operate when operating the passenger side SW Window operates in only one direction when operating the driver side SW Window operates in only one direction when operating the passenger side SW Notice: Figure in parenthesis ( ) indicates the order of inspection. (1) (2) (1) (1) (3) (4) (2) (1) (1) (1) (2) (3) (1) Fuse F-6 (20A) (2) Power window relay (3) Power window SW Driver side (4) (1) Passenger side Power window motor Driver side Passenger side Cable harness (5)
(1)
(2)
(2)
(1)
(2)

All Windows Do Not Operate
8-195
NO REPLACE THE FUSE
YES IS THE POWER WINDOW RELAY NORMAL?
NO REPLACE THE FUSE
YES IS B-7 SECURELY GROUNDED?
YES DISCONNECT THE POWER WINDOW SW CONNECTOR ON THE DRIVER SEAT SIDE TURN THE STARTER SWITCH ON IS THE BATTERY VOLTAGE APPLIED BETWEEN THE HARNESS SIDE CONNECTOR 6 D-3 AND THE GROUND?
YES IS THE POWER WINDOW SW ON THE DRIVER SIDE NORMAL?
NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 6 D-3 AND 1 X-7
YES IS THE BATTERY VOLTAGE APPLIED BETWEEN B-7 AND THE GROUND?
NO REPLACE THE SWITCH
NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 8 D-3 AND B-7
N8B5117E

Lock SW Does Not Function
REPAIR OR REPLACE THE POWER WINDOW SW ON THE DRIVER SEAT SIDE
N8A0231E
Window on the Driver Side Does Not Operate
IS THE POWER WINDOW SWITCH ON THE DRIVER SEAT SIDE NORMAL?
YES DISCONNECT THE CONNECTOR OF THE POWER WINDOW MOTOR ON THE DRIVER SEAT SIDE WHEN CONNECTING THE MOTOR CONNECTOR 1 D-2 TO THE BATTERY (+) TERMINAL AND 2 D-2 TO THE (-) TERMINAL, DOES THE MOTOR ROTATE IN THE "UP" DIRECTION OF THE WINDOW (OR WHEN CONNECTING 2 D-2 TO THE (+) TERMINAL AND 1 D-2 TO THE (-) TERMINAL, DOES THE MOTOR ROTATE IN THE "DOWN" DIRECTION OF THE WINDOW)?
NO REPLACE THE POWER WINDOW SWITCH ON THE DRIVER SEAT SIDE
YES
NO REPAIR OR REPLACE THE POWER WINDOW MOTOR
REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN HARNESS SIDE CONNECTOR TERMINALS 1 D-3 AND POWER WINDOW MOTOR 1 D-2 OR 2 D-3 AND 2 D-2
N8A0232E

Window on the Front Passenger Side Does Not Operate
IS THE FRONT PASSENGER SIDE POWER WINDOW SW NORMAL?
8-197
YES IS THE DRIVERS POWER WINDOW SW NORMAL?
YES REMOVE THE CONNECTOR OF THE FRONT PASSENGER SIDE POWER WINDOW MOTOR WHEN CONNECTING THE MOTOR CONNECTOR 1 D-6 TO THE BATTERY (+) TERMINAL AND 2 D-6 TO THE (-) TERMINAL, DOES THE MOTOR ROTATE IN THE "UP" DIRECTION OF THE WINDOW? (OR WHEN CONNECTING 2 D-6 TO THE (+) TERMINAL AND 1 D-6 TO THE (-) TERMINAL, DOES THE MOTOR ROTATE IN THE "DOWN" DIRECTION OF THE WINDOW?)
YES WITH THE SWITCH AT THE NEUTRAL POSITION, IS THERE ANY CONTINUITY BETWEEN THE HARNESS SIDE CONNECTORS 1 D-6 AND 2 D-6 ?
NO REPAIR OR REPLACE THE POWER WINDOW MOTOR
YES
NO
REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 5 D-3 AND 2 D-7 (OR 4 D-3 AND 4 D-7 )
REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN THE PASSENGER SIDE POWER WINDOW SW AND THE MOTOR CONNECTOR
N8A0233E

Starter Switch
Power Window Switch-Driver Side

Circuit Inspection Disconnect the switch connectors to check the voltage and the continuity between the harness side connector terminals.
D-3
Harness side
Wire color L/W L G/Y R/Y L/B B
Connected to Driver seat side motor Passenger side power window SW Power window relay Ground
Item to be checked Continuity (resistance) Voltage Continuity (resistance)
Connecting terminal 1-2 4-5 5-4 6-Ground 8-Ground
Checking conditions
Standard
Continuity
Starter SW "ON" -
Battery voltage Continuity
N8A0234E

Inspection Check the continuity between the connector terminals of the switch. Repair or replace the switch when the result of inspection is found abnormal.
8-199
D-3
Switch side
Window SW Terminal position No. UP OFF DOWN UP LOCK OFF 6
Driver side 1 2 8
Passenger side 6 5 4 8
DOWN
N8A0235E

Removal Preparation: Disconnect the battery ground cable. 1. Switch 1) Insert the screw driver to the cut off portion to remove the switch. 2) Disconnect the connector.
N8A0236E
Power Window Switch-Passenger Side

Circuit Inspection Disconnect the switch connectors to check the voltage and the continuity between the harness side connector terminals.
N8A5280E

8-201
D-7
Switch side
SW position UP OFF
Terminal No.
DOWN
N8A0238E
Removal Preparation: Disconnect the battery ground cable. 1. Switch 1) Insert the screw driver to the cut off portion to remove the switch. 2) Disconnect the connector.
N8A0239E

Driver Seat Side Power Window Motor
Inspection Before checking to see if the motor functions correctly, be sure to check the circuit through the connector D-3 of the drivers power window switch. If the motor does not operate smoothly, either the motor or the circuit between the switch and the motor is defective. 1. Circuit inspection of the driver side window switch Disconnect the switch connector and apply battery voltage to the harness side connector terminals to check its function. Removal Preparation: Disconnect the battery ground cable. 1. Window Regulator Assembly Refer to Section 2 for Window Regulator and Glass. 2. Power Window Motor Remove three screws.
D-3 Harness side
Connecting terminal 1 (L/W) 2 (L)
Operation DOWN UP
N8A0242E

N8A0240E
2. Inspection of the driver seat side motor Remove the motor connector and apply battery voltage to the motor side connector terminals to check its function. Replace the motor when the result of inspection is found abnormal.
D-2
Direction of operation
Terminal No.
DOWN UP
N8A0241E

Front Passenger Seat Side Power Window Motor
Inspection Before checking to see if the motor functions correctly, be sure to check the circuit through the front passengers switch connector D-7 and the drivers power window switch connector D-3 . If the motor does not operate smoothly, either the motor or the circuit between the switch and the motor is defective. 1. Circuit inspection of the front passenger seat side window Disconnect the switch connector and apply battery voltage to the harness side connector terminals to check its function.
8-203
3. Inspection of the front passenger window motor Disconnect the motor connector and apply battery voltage to the motor side connector terminals to check its function. Repair or replace the motor when the result of inspection is found abnormal.
M D-6
Direction of operation
D-7
Terminal No.
DOWN UP
Harness side
N8A0245E
Connecting terminal 3 (L/Y) 5 (BR/Y)
Direction of operation DOWN UP
N8A0243E
Removal Preparation: Disconnect the battery ground cable. 1. Window Regulator Assembly Refer to Section 2 for Window Regulator and Glass. 2. Power Window Motor Remove three screws.
2. Circuit inspection of the driver seat side switch Disconnect the switch connector and apply battery voltage to the harness side connector terminals to check its function.
D-3
Harness side
Connecting terminal 4 (G/Y) 5 (R/Y) + +
Direction of operation DOWN UP

N8A0246E

N8A0244E
8-204 CAB AND CHASSIS ELECTRICAL Windshield Wiper and Washer

General Description
The circuit consists of the starter switch, windshield wiper & washer switch, wiper motor, washer motor and the intermittent relay. When the wiper & washer switch is turned on with starter switch on, the battery voltage is applied to the wiper motor to activate the wiper. The washer motor squirts glass cleaning fluid while the washer switch is being pushed. The intermittent relay is used to control motion of the wiper.
Operation of Windshield Wiper Motor

(When wiper LO or INT position)
N8A0250E

Parts Location
8-205
RELAY BOX ASM (No.1)
X-11 KEY ON RELAY
B-7
N8B0084E

Circuit Diagram
3W/L FL-1 100A or 120A MAIN 2L 8B FL-2 40A KEY SW 3W/L FUSE BLOCK STARTER SWITCH
ACC 1 H-7 2
P-2
ST
3B/Y
2
X-11
P-1
3W/L
B-67
ON
B-67
1
X-11
P-3 P-4
X-11 X-11
RELAY KEY ON
0.5B
P-5
3L FRAME F-10 15A FRONT WIPER & WASHER 0.5L
0.5L
0.5L
2B
1 B-69
WIPER, WASHER SWITCH (COMBINATION SWITCH)
0.5L
OFF P 8 B-69 3 PS B-9 3 6
(WITHOUT RELAY; INTERMITTENT)
SHORT CIRCUIT CONNECTOR
B-9
B-9 B
B-69 8
B-69 7
B-69 4
B-69 6
0.5L/R 0.5BR/W
2 B-11 LO B-11 B-11 B P
RELAY; INTERMITTENT
B-9
0.5L/O
0.5BR/R
3 B-11 HI
0.85L/R
4 PM B-9 W B-9 E B-9 2 7 4
B-9
0.5BR/Y
0.85L/R
WIPER MOTOR
B-11 1
0.5L/B
1 B-8
0.5L/B
B-8
0.5B
0.5B
B-7
3B
2B
0.3B
WASHER MOTOR
N8B0050E

Connector List
8-207
B-7
000-001
B-69
4 3 2 8 7 6
1 5
008-002
B-8
1 2
002-009
P-1
000-022
B-9
P-4
1 5 2 6 3 7 4 8
008-012
000-014
B-11
P-2
1 4 2 5 3 6
006-001
000-014
B-11
3 6
2 5
1 4
P-3
000-014
006-016
B-67
P-5
1 3 2 4
004-001 000-002
B-67
2 4
1 3
X-11
1 2 3 5 4
004-002
005-001
B-69
1 5
2 3 4 6 7 8
008-001

H-7
H-6
H-7
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 H-8
4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14
N8A5489E
Diagnosis
Quick Chart for Check Point 1. Windshield Wiper and Washer Check point Fuse F-10 (15A) 1. Windshield wiper does not operate at any switch position 2. Windshield wiper does not operate at INT position 3. Windshield wiper does not operate at LO position Trouble mode 4. Windshield wiper does not operate at HI position 5. Auto-stop function of the windshield wiper motor does not operate 6. Rotation of the windshield wiper motor does not stop 7. Windshield washer motor does not operate Notice: Figure in parenthesis ( ) indicates the order of inspection. (1) Wiper& washer SW (3) (1) (1) (1) (1) (1) (1) (4) (3) (3) (2) (2) (2) (3) (2) Intermittent relay Wiper motor (4) Washer motor Cable harness (2) (2) (2) (3) (3)

1. Windshield Wiper and Washer 1-1. Windshield Wiper Does Not Operate at Any Switch Position
8-209
YES
NO REPLACE THE FUSE
DISCONNECT THE CONNECTOR OF THE WINDSHIELD WIPER & WASHER SWITCH TURN THE STARTER SWITCH ON IS THE BATTERY VOLTAGE APPLIED BETWEEN THE SWITCH HARNESS SIDE CONNECTOR 1 B-69 AND THE GROUND?
YES IS CONTINUITY IN THE WINDSHIELD WIPER & WASHER SWITCH NORMAL?
NO
REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN THE FUSE F-10 (15A) AND 1 B-69
YES DISCONNECT THE CONNECTOR OF THE WINDSHIELD WIPER MOTOR WITH THE MOTOR CONNECTOR 2 B-11 CONNECTED TO THE BATTERY (+) TERMINAL, AND THE CONNECTOR 1 B-11 TO THE (-) TERMINAL, DOES THE MOTOR ROTATE AT A LOW SPEED? AND WITH THE CONNECTOR 3 B-11 CONNECTED TO THE (+) TERMINAL, DOES THE MOTOR ROTATE AT A HIGH SPEED?
YES REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 1 B-11 AND B-7
NO REPAIR OR REPLACE THE WINDSHIELD WIPER MOTOR
N8B5154E

1-2. Windshield Wiper Does Not Operate at INT Position
IS CONTINUITY IN THE WINDSHIELD WIPER & WASHER SWITCH NORMAL?
YES
NO REPAIR OR REPLACE WINDSHIELD WIPER & WASHER SWITCH
DISCONNECT THE CONNECTOR OF THE INTERMITTENT RELAY IS THERE CONTINUITY BETWEEN THE RELAY AND THE WINDSHIELD WIPER & WASHER SWITCH HARNESS SIDE CONNECTOR 6 B-9 AND 8 B-69 , OR 3 B-9 AND 3 B-69 RESPECTIVELY?
YES REPLACE THE INTERMITTENT RELAY
NO REPAIR A POOR CONNECTION OR AN OPEN CIRCUIT BETWEEN THE CIRCUITS
N8A0255E
1-3. Windshield Wiper Does Not Operate at LO Position
YES DISCONNECT THE WINDSHIELD WIPER MOTOR CONNECTOR CONNECT THE BATTERY (+) TERMINAL TO THE WINDSHIELD WIPER MOTOR CONNECTOR 2 B-11 AND THE (-) TERMINAL TO 1 B-11 DOES THE MOTOR ROTATE AT A LOW SPEED?
NO REPAIR OR REPLACE THE WINDSHIELD WIPER & WASHER SWITCH
YES
REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN THE CONNECTORS 7 B-69 AND 2 B-11
N8A0256E

1-4. Windshield Wiper Does Not Operate at HI Position
8-211
YES DISCONNECT THE WINDSHIELD WIPER MOTOR CONNECTOR CONNECT THE BATTERY (+) TERMINAL TO THE WINDSHIELD WIPER MOTOR CONNECTOR 3 B-11 AND THE (-) TERMINAL TO 1 B-11 DOES THE MOTOR ROTATE AT A HIGH SPEED?
YES REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 4 B-69 AND 3 B-11
N8A0257E

1-5. Auto-stop Function of The Windshield Wiper Motor Does Not Operate
YES
DISCONNECT THE CONNECTOR OF THE WINDSHIELD WIPER MOTOR CONNECT THE MOTOR CONNECTOR 2 B-11 TO THE BATTERY (+) TERMINAL, AND 1 B-11 TO THE BATTERY (-) TERMINAL, AND THEN CHANGE THE CONNECTION OF THE BATTERY (+) TERMINAL TO THE CONNECTOR 4 B-11 WHILE ROTATING THE MOTOR AT A LOW SPEED WHEN CONNECTING THE CONNECTOR TERMINALS 2 B-11 AND 5 B-11 IN THIS CONDITION, DOES THE MOTOR STOP AT AUTO-STOP POSITION?
YES TURN THE STARTER SWITCH ON IS THERE BATTERY VOLTAGE APPLIED BETWEEN THE WINDSHIELD WIPER MOTOR HARNESS SIDE CONNECTOR TERMINAL 4 B-11 AND GROUND?
YES DISCONNECT THE CONNECTOR OF THE WINDSHIELD INTERMITTENT RELAY IS THERE CONTINUITY BETWEEN THE RELAY HARNESS SIDE CONNECTOR 7 B-9 AND THE WINDSHIELD WIPER MOTOR HARNESS SIDE CONNECTOR 5 B-11 ?
NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN THE FUSE F-10 (15A) AND 4 B-11
YES REPLACE THE WINDSHIELD INTERMITTENT RELAY
NO
N8A0258E

1-6. Rotation of The Windshield Wiper Motor Does Not Stop
8-213
YES
THE MOMENT THE WINDSHIELD WIPER COMES TO AUTO-STOP POSITION, TURN THE STARTER SWITCH OFF (ALTERNATIVELY, CONNECT THE BATTERY (+) TERMINAL TO THE WINDSHIELD WIPER MOTOR CONNECTOR 2 B-11 AND THE (-) TERMINAL TO 1 B-11 , AND THEN MOVE THE WINDSHIELD WIPER MOTOR TO AUTO-STOP POSITION AND STOP IT)
YES
CONFIRM CONTINUITY BETWEEN THE WINDSHIELD WIPER MOTOR SIDE CONNECTOR TERMINALS 4 B-11 AND 5 B-11 , AND REPAIR OR REPLACE THE MOTOR
N8A0259E

1-7. Windshield Washer Motor Does Not Operate
YES TURN THE STARTER SWITCH ON IS THE BATTERY VOLTAGE APPLIED BETWEEN THE WINDSHIELD WIPER & WASHER SWITCH HARNESS SIDE CONNECTOR TERMINAL 1 B-69 AND THE GROUND?
YES
NO
DISCONNECT THE CONNECTOR OF THE WINDSHIELD WASHER MOTOR TURN THE STARTER SWITCH ON WITH THE WASHER BUTTON OF THE WINDSHIELD WIPER & WASHER SWITCH DEPRESSED, IS THE BATTERY VOLTAGE APPLIED BETWEEN THE WASHER MOTOR HARNESS SIDE CONNECTOR TERMINAL 1 B-8 AND THE GROUND?
REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN FUSE F-10 (15A) AND 1 B-69
NO
REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 1 B-8 AND 6 B-69
YES CONNECT THE MOTOR SIDE CONNECTOR 1 B-8 OF THE WINDSHIELD WASHER MOTOR TO THE BATTERY (+) TERMINAL, AND THE CONNECTOR 2 B-8 TO THE (-) TERMINAL DOES THE MOTOR ROTATE?
YES REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 2 B-8 AND B-7
NO REPAIR OR REPLACE THE WINDSHIELD WASHER MOTOR
N8A0260E

Starter Switch
8-215
Windshield Wiper & Washer Switch

With the starter switch on, the windshield wiper and washer switch controls the start and stop operation as well as the change of operating speeds. Both the windshield washer motor and the wiper motor jointly operate while the washer button is pushed.
N8A0261E
B-69
1 5
2 3 4 6 7 8
Switch side
Washer SW
Wiper SW OFF INT
OFF
LO HI
ON
MIST,OFF INT,LO,HI
N8A0262E
Removal and Inspection Refer to HEADLIGHT, FOG LIGHT, REAR FOG LIGHTY AND CORNERING LIGHT in this section.

Windshield Wiper Motor
2. Windshield Wiper Motor 1) Disconnect the connector. 2) Remove four screws. 3) Remove the ball joint between crank arm and wiper link.
N8A0263E
Inspection 1. Operation in low speed With the motor connector terminal 2 B-11 connected to the battery (+) terminal and the connector 1 B-11 to the () terminal, check to see if the motor rotates in low speed. 2. Operation in high speed With the motor connector terminal 3 B-11 connected to the battery (+) terminal and the connector 1 B-11 to the () terminal, check to see if the motor rotates in high speed. 3. Stop operation Operate the windshield wiper at the low speed in item No. 1 and stop them at the position in the way. When the connectors 2 B-11 and 5 B-11 are connected, while connecting the motor connector terminal 4 B-11 to the battery (+) terminal, check to see if the motor rotates at low speed and stops at the auto-stop position. Repair or replace the motor when the results of the above inspections are found abnormal. Removal Preparation: Disconnect the battery ground cable. 1. Glove Box Refer to INSTRUMENT PANEL of section 2.
N8A0264E
Installation To install, follow the removal steps in the reverse order, noting the following points. Windshield Wiper Motor When the crank arm is removed from the windshield wiper motor, tighten the motor shaft nut with the specified torque. Tighten: Shaft nut to 17 Nm (170 kgfcm/147 lbfin) Temporarily fit the motor by using one of the four wiper motor fixing screws. Put the crank arm ball joint in the wiper link hole and fix them together while pulling the wiper link.

Windshield Washer Motor
Inspection With the battery (+) terminal connected to the washer motor connector terminal 1 B-8 and the () terminal to the connector 2 B-8 , check to see if the cleaning fluid pushes out. Replace the tank/motor when the result of inspection is found abnormal.
8-217
B-8
N8A0265E
Removal Preparation: Disconnect the battery ground cable. 1. Instrument Panel Under Cover Refer to INSTRUMENT PANEL of section 2. 2. Washer Tank 1) Disconnect the washer motor connector. 2) Disconnect the washer hose. 3) Remove three fixing screws. 3. Clip Band 4. Windshield Washer Motor Hold the motor and pull it out from the washer tank.
2 1
N8A0266E

Intermittent Relay
Circuit Diagram
N8A0267E

Removal Preparation: Disconnect the battery ground cable. 1. Glove Box Open the lid and remove the four screws. 2. Intermittent Relay 1) Press A position with your finger and pry up B position with the tip of a screwdriver. 2) When the relay moves up by about 2/3 of its size, tilt and take off the relay to avoid interference with the instrument panel. 3) Disconnect the connector.
8-219
Windshield Wiper Arm & Blade

Removal 1. Cover 2. Wiper Arm Nut 3. Wiper Arm & Blade
A Instrumental panel 2 S
N8A0269E
B 1
Instrument panel reinforcement
Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Before installing the wiper arm & blade to the shaft, confirm that the motor stops at the auto-stop position. 2. Set the wiper arm & blade so that the tips of both blades are positioned as shown in the illustration. 3. Tighten the wiper arm nut to the specified torque. Tighten: Wiper arm nut to 17 Nm (170 kgfcm/147 lbfin)
2 View S
N8A0268E
Approx. 45mm(STD Cab) Approx. 70mm(Wide Cab)
N8A0270E

Windshield Wiper Linkage
Location of Rod and Pivot
Pivot (Wiper: LH)
Pivot (Wiper: RH)
Rod
Rod
Wiper motor
N8A0271E
Removal Preparation: Disconnect the battery ground cable. 1. Wiper Arm & Blade Remove the cover, nut and wiper arm & blade.
2. Pivot Nut Remove the rubber seal, nut and retaining rubber.
Cover
Nut 1 Rubber seal Retaining rubber
N8A0273E
N8A0272E

3. Instrument Panel Assembly Refer to INSTRUMENT PANEL of section 2.
8-221
5. Instrument Panel Reinforcement Refer to INSTRUMENT PANEL of section 2.
N8A0274E
N8A0276E
4. Wiper Motor 1) Remove the four screws. 2) Disconnect the ball joint between the crank arm and the wiper link.
6. Wiper Link Assembly Remove two retaining nuts from right hand side of pivot.
Pivot (Wiper: LH)
N8A0277E N8A0275E

Remove two retaining nuts from left hand side of pivot. Notice: When the wiper blade has been removed, wrap the tip of the wiper arm with cloth, to avoid damaging the glass.
Pivot (Wiper: RH)
N8A0278E
Installation To install, follow the removal steps in the reverse order, noting the following points. Temporarily fit the wiper motor by using one of the four wiper motor fixing screws. Put the crank arm ball joint in the wiper link hole and fix them together while pulling the wiper link. Fit the motor with four screws. Tighten the pivot nut with the specified torque. Tighten: Pivot nut to 8 Nm (80 kgfcm/70 lbfin) Tighten the wiper arm nut with the specified torque. Tighten: Wiper arm nut to 17 Nm (170 kgfcm/147 lbfin)
N8A0477E
2. Wiper Blade Rubber 1) Pull the end of rubber and remove the projection from the click of the blade stay. 2) Pull the rubber out in the same direction.
Wiper Blade Rubber

Removal 1. Wiper Blade Push the wiper blade lock while pulling the wiper blade in the arrow direction.
N8A0280E

Installation 1. Wiper Blade Rubber Install the click of the blade stay in the groove of the new rubber and slide it in. Complete installation by pushing the click.
8-223
2
N8A0486E
Audio and Cigar Lighter

General Description
N8A0281E
Finally, check that the click of the stay has caught in the hole of the rubber.
The circuit consists of the starter switch, radio, cigar lighter and the relay. The audio circuit is designed for the current to flow through the receiver circuit when the radio switch is turned on with the starter switch in ACC or ON. Current runs through the memory circuit of the audio regardless of the position of the starter switch. When the cigar lighter is pushed in with the starter switch at either ACC or ON position, a circuit is formed in the cigar lighter case to heat the lighter coil. The cigar lighter is spring back to its original position after the lighter coil is heated.
N8A0282E
2. Wiper Blade Push the lock of wiper blade (1) into the retentive portion on the tip of wiper arm (2).
Parts Location
X-4 TAIL RELAY
H-2(S/CAB), H-20(W/CAB) H-11(S/CAB), H-22(W/CAB)
D-5 SPEAKER (RH)
F-4, F-7, F-15
N8B0051E
D-1 SPEAKER (LH)

Circuit Diagram
8-225
STARTER SWITCH FL-2 40A KEY SW 3W/L FL-1 100A or 120A 2L

P-1 P-2 1 H-7 2 B-67 B OFF ACC B-67 1
3W/L
ON ST
8B
MAIN 4JJ1 /4HK1 80A ACG Except 4JJ1 /4HK1 80A ACG 8W/B
8W/B
P-3
2 H-6
5W/B
P-4
3W/B
5W/B
3W/B F-4 15A AUDIO (B), DOOR LOCK
3R/Y F-15 15A AUDIO (IG) CIGAR LIGHTER 0.5R 0.5R/Y 0.5R/Y
P-5
2W/B
FRAME
3 X-4
3W/B
2 X-4 X-4
RELAY; TAIL
X-4 5
3W 0.85LG/R
F-7 10A TAIL LIGHT
0.85LG/R 0.85LG/R
0.5LG/R
0.85LG/R
0.5LG/R
10 B-28 11 B-28 4 B-28 1 1 B-44
0.3G/O
CIGAR LIGHTER
B-43
RADIO & CLOCK

B-28 9 B-28 12 B-28 5 B-28 13 B-28 6
0.5G
0.5GR
0.5B
0.5O
B-43 2
0.5R/Y
B-45 1
0.3B
LIGHTING SWITCH(8) (COMBINAITION SWITCH)
CLEARANCE LIGHT (LH)
0.5B
8 H-22
7 H-11
6 H-11
7 H-22
8 H-20
7 H-2
6 H-2
7 H-20
0.5GR
0.5G
1 D-1 D-1
1 D-5 D-5
0.5O
0.5B
For W/CAB EC
For S/CAB
For For W/CAB W/CAB EC EC
For S/CAB
For W/CAB EC
2
2B
SPEAKER (LH)
SPEAKER (RH)
B-7
3B
2B
2B
N8B0052E

Connector List
X-4
005-006
D-5
1 2
002-010
B-7
000-001
B-44
1
001-011
B-28
1 7
2 8
3 9 10
B-45
1
001-009
11 12 13
013-001
B-43
1 2
002-009
B-67
1 3
2 4
004-001
B-43
1 2
002-010
B-67
2 4
1 3
004-002
D-1
1 2
002-009
H-2 (S/ CAB)
1 2
4 5 6 7 8
008-009
D-1
1 2
002-010
H-2 (S/ CAB)
2 1
8 7 6 5 4
008-010
D-5
1 2
002-009
H-11 (S/ CAB)
1 2
4 5 6 7 8
008-009

8-227
H-11 (S/ CAB)
2 1
8 7 6 5 4
P-3
008-010 000-014
H-20 (W/ CAB)
1 2
3 4
P-5
010-003 000-002
5 6 7 8 9 10
H-6, H-7 H-20 (W/ CAB)

4 3 2 1
10 9 8 7 6 5
010-004
H-6
H-22 (W/ CAB)
1 2
3 4 1 2 H-7 2 1
5 6 7 8 9 10
1 2 3 4
4 3 2 1 8 7 6 5 H-8 13 12 11 10 9 18 17 16 15 14
010-003
5 6 7 8 9 10 11 12 13 14 15 16 17 18
H-22 (W/ CAB)
4 3
2 1
10 9 8 7 6 5
010-004
N8A5489E
P-1
000-022
P-4
000-014
P-2
000-014

Diagnosis
Cigar Lighter Does Not Heat Sufficiently
NO REPLACE THE FUSE
YES
REMOVE THE CIGAR LIGHTER SET THE STARTER SWITCH TO EITHER "ACC" OR "ON" POSITION IS THE BATTERY VOLTAGE APPLIED BETWEEN THE BIMETAL AT THE CENTER OF THE CASE AND OUTER OF THE CASE?
YES SET THE STARTER SWITCH TO EITHER "ACC" OR "ON" IS THE BATTERY VOLTAGE APPLIED BETWEEN B-7 AND GROUND?
NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN FUSE F-15 (15A) AND 1 B-44
YES REPLACE THE CIGAR LIGHTER ASSEMBLY
NO
REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 1 B-45 AND B-7
N8A0285E
The Cigar Lighter Does Not Spring Out After Being Heated
IS THE FORM OF CIGAR LIGHTER NORMAL?
YES REPLACE THE CIGAR LIGHTER ASSEMBLY (INCLUDE OUTER CASE)
NO REPLACE THE CIGAR LIGHTER
N8A0286E

Starter Switch
8-229
Radio
Removal Preparation: Disconnect the battery ground cable. 1. Center Cluster 1) Pull it to remove. Pry off three clips by the tip of screwdriver. 2) Remove the cigar lighter power source and its illumination connector. Notice: To remove the center cluster, do not force to pry off three clips at upper portion of the center cluster.
1
N8A0393E
Legend 1. Radio Installation To install, follow the removal steps in the reverse order.
Antenna
Inspection The metal A is connected to the pole D at the top of the antenna through the core of the feeder. The metal B is fitted in the feeder shielding the core, and grounded at the screw C to avoid the core hampered by noise. Defective grounding would cause noise.
N8A0392E
Legend 1. Center Cluster 2. Radio 1) Remove the two radio fixing screws. 2) Disconnect the connector and feeder plug.
N8A0289E

In checking, measure the following three points with the circuit tester in the range of resistance x 1 (). Between A and B No continuity (No reading at the indicator) Normal Continuity (A bite in the feeder. The core grounded) Lower reception Between B and C Continuity (Indicator reading: 0) Normal No continuity (Shielded core disconnected or defective grounding at the screw Hampered by noise) Between A and D Continuity or no continuity There are some antenna feeders and relay feeders with a condenser built in their connections. Measuring resistance between the two points does not result in correct judgment. Connect temporarily another normal antenna to the radio and check to see if its reception is audible. Most antenna now available are slide type. Rust at the screw C and the cab panel where grounded would lead no continuity, followed by lower reception. Keep this portion clean to avoid rust. Removal Preparation: Disconnect the battery ground cable. 1. Antenna 1) Disconnect the joint connector. 2) Remove the upper and lower side antenna bracket. 3) Pull out the antenna feeder. Notice: For easier fitting, tie the lead wire to the end of the antenna feeder in advance.
5 4 7 6
N8A0394E
Legend 1. 2. 3. 4. 5. 6. 7. Antenna Antenna Bracket Feeder Joint Connection Feeder Clip Radio
Speaker
Inspection 1. With the circuit tester set to the range of 1 (), connect the circuit tester probes (red and black) to the (+) and () terminals of the speaker. 2. When the speaker is normal, a low buzzing sound is heard. 3. When the speaker is defective, no sound is heard. However, the distortion or chattering of the sound cannot be identified. When the speaker is installed to the vehicle, disconnect the connectors before checking. When no sound is heard, the following are considered as the cause. The speaker wiring is disconnected at the speaker terminals. The speaker body is defective.

There is an open circuit somewhere in the speaker harness on the vehicle side. The speaker harness on the vehicle side is grounded or caught up. Removal Preparation: Disconnect the battery ground cable. 1. Door Pad Refer to FRONT DOOR TRIM PAD of section 2. 2. Speaker Panel Disconnect the speaker connector. 3. Speaker 4. Waterproof Sheet
8-231
Cigar Lighter
Removal Preparation: Disconnect the battery ground cable. 1. Center Cluster Refer to RADIO in this section. 2. Cigar Lighter Assembly Remove the nut, then remove cigar lighter assembly, bezel and outer case.
2 4 1
N8A0395E
Legend
N8A5341E
Legend 1. 2. 3. 4. Trim Panel Speaker Panel Speaker Waterproof Sheet
1. 2. 3. 4. 5.
Bezel Cigar Lighter Assembly Center Cluster Outer Case Nut
Meter and Warning/indicator Light

General Description
The circuit consists of the starter switch, meter assembly, vacuum tank switch, oil pressure switch, fuel sedimenter switch, brake fluid switch, parking brake switch, vehicle speed sensor, fuel tank unit, thermo unit and engine speed sensor. The meter assembly contains the speedometer, tachometer, fuel meter, thermometer and the warning/indicator light. The meter warning/indicator lights and their bulb sockets are a unit, they are installed from the back of the speedometer assembly.
TCM (B-425,B-427) N-6 SW: PARKING BRAKE N-19 SW: SELECT J-1,J-2 AC GENERATOR J-206 SW: FUEL SEDIMENTER J-32 V/SPEED SENSOR FUEL TANK E-111
Parts Location
For 4HK1 Engine
RELAY BOX ASM (NO.1) X-8 HEATER RELAY X-12 HEATER & A/C RELAY B-18, X-32 DIODE BOX STARTER SW J-8 E-90 H-118 H-14
H-16 H-105
FUSE & RELAY BOX ASM X-1 CHARGE RELAY F-1,F-2,F-4,F-7,F-16 FUSE J-28
B-502 DIODE
ABS EHCU (J-177)
H-15 P-5 P-1 P-2 BATTERY P-4 P-3

RELAY BOX ASM FL-1,FL-2 FUSIBLE LINK
RELAY BOX ASM (NO.2) X-13 BUZZER CANCEL RELAY
H-4 H-8
J-191 ECM
B-53 METER H-12
J-128 SW: HBB LEVEL J-9 EARTH: FRAME J-26,J-27 STARTER
B-57 METER
B-51 METER B-52 METER
B-85 SW: BRAKE OIL LEVEL B-71 SW: VACUUM TANK
B-67 IGNITION SW "A"
N8B0053E
B-236 SW: PRESSURE
B-425,B-427 TCM (EURO-4) N-6 SW: PARKING BRAKE N-19 SW: SELECT (EURO-4) J-1,J-2 AC GENERATOR J-206 SW: FUEL SEDIMENTER J-32 V/SPEED SENSOR H-105 FUEL TANK J-28
For 4JJ1 Engine
E-90 COOLANT TEMPERATURE SENSOR FRAME HARNESS
RELAY BOX ASM (NO.1) X-8 HEATER RELAY X-12 HEATER & A/C RELAY B-18, X-32(EURO-4) DIODE BOX STARTER SW
FUSE & RELAY BOX ASM X-1 CHARGE RELAY F-1,F-2,F-4,F-7,F-16 FUSE
J-8 SW: OIL PRESSURE H-14

H-16 J-177 ABS EHCU (EURO-4)
H-15 (EURO-4) P-5 P-1 P-2 BATTERY P-4 P-3

RELAY BOX ASM FL-1,FL-2 FUSIBLE LINK
H-5 H-8
H-4 (EURO-4 NKR)
J-191 ECM
B-53 METER (EURO-4) B-51 METER H-12

J-9 EARTH: FRAME J-26,J-27 STARTER
B-57 METER
H-17 (EURO-4 NKR)
B-85 SW: BRAKE OIL LEVEL B-52 METER
B-67 IGNITION SW "A" B-71 SW: VACUUM TANK
N8B0054E
8-233

Circuit Diagram
For 4HK1 Engine
RELAY: CHARGE
1
STARTER
J-26 B 1 H-7
FL-2 40A KEY

3W/L 2 J-1 AC GEN. J-1 J-2 1 1 1.25W/L 0.85W/L 15 H-5 8W/B

0.5W/L
0.5W/R 1
X-1 X-1
0.5B/Y
2L
0.5W/L 5
X-1
X-1
0.5B/Y
Relay: Thermo A/C F-1 15A HEATER, AIR CON SW: Thermo F-2 10A FUEL HEATER
8W/B
0.5W/L
RELAY: HEATER & A/C

X-12 X-12 X-12 X-12 4 0.5B 5 3L
5W/B (STD AC GEN.) 8W/B (80A AC GEN.) 3W/L C J-27 1 2 H-6 5W/B
3W/B
1 0.5W/R 2
3W/B
RELAY: STARTER
2 B-67 0.5W/L
RELAY: HEATER
3W/B 3W/B 2 X-8 X-8 1 3B/R
STARTER SW
3W/B
F-4 15A AUDIO(B), DOOR LOCK

0.85R 0.5R
X-8
X-8
5 0.5B
ST
ON
30B/R
ACC
OFF
10 B-67 3 + DPF REGENERATE B-51
16 B-52
18 B-51
CHARGE
BRAKE
P-2 + P-3 P-4 -
EXH BRAKE
FUEL
3B/Y
0.5B/Y
F-16 10A METER
POWER SUPPLY CIRCUIT
I/F & METER IC
LAMP DRIVER
FUEL
SVS
TACHO
SPEED
ENGINE COOLANT TEMPERATURE GAUGE
B-51 5
B-51 4
B-51 5 0.5L/R
B-51 13
B-51 7
B-51 4
B-53 10
B-52 15
B-51 6 0.5L/P
B-51 15 0.5B
B-52 6 0.5LG/W
B-52 8 0.3LG
B-52 17 0.3Y/G
B-52 20 0.5B
B-52 5 0.5LB
Smoother
Smoother
0.5B/Y
FRAME
0.3W/V 0.5B/Y 0.3W/L 0.5W/B
13 21 0.5B H-5 0.3W/V 0.5B/Y 0.3Y/G H-5 0.5LG/W 12 H-5 0.5LB 1 H-5 16 H-105 0.5LG/W 1
0.5Y/R (S/CAB) 0.5R (W/CAB)
2 LEVEL SW: B & C OIL B-85
24 H-5
30 H-5
19 H-4
40 H-5
7 H-5
31 H-5
3 H-8 0.5LG
25 H-5 0.5Y/G
19 H-5 0.5B
1.25B
1 J-28 UNIT: FUEL SENSOR J-28 2
2B
SW: FUEL SEDIMENTER
B-85 9 0.5O/L 0.5L/P H-118 10 H-118 11 H-118
Smoother
0.5LG/B
0.5L/R
0.5L/B
3 E-90
0.5LB
0.5B
0.5W/B
H-105
3B
1 0.5B J-32 5B B-1 J-9 3B 6 J-191 OSDIAGL B-7 17 J-191 OS-SVS 9 J-191 OSDPFREG 11 J-191 OSGLOWL 7 J-191 OSEXBL
2 J-32
3 J-32 8 J-191 OFTACHO 0.5Y/G
METER ECT SENSOR48
V/SPEED SENSOR
19 J-191 IF-SPD
J-191 ISPBRK
ECM: ENGINE
FRAME-LH (FRT)
FRAME-LH (CTR)
N8B0055E
0.5BR/W 2 J-206 J-206 1
P-5
10
M/T
M/T
M/T
0.5LG/B
0.5LG/B
0.3W/V
0.3W/V
0.5O/L
0.5L/R
0.5L/B
SEDIMENTER B-52
CHECK ENG.
P-1
3B/Y
GLOW
W/CAB only
17 0.5LG/R 0.85LG/R 0.85LG/R 3W 0.5B/Y ILL B-51 0.3W/L 0.5W/B 0.3W/V
2B
1.25B
RELAY: TAIL
J-9 ILL ILL ILL ILL
FRAME-LH (CTR)
0.5B 2 J-128 6 4
34 0.5W/R 0.3W/R 1 H-8 J-128 B-18
0.5BR
J-128
F-7 10A TAIL LIGHT
3B 2B 0.3B 1 3 4 0.3BR 0.3BR B-57 BUZZER X-13 X-13 3
H-5
35
0.5W/B
J-128
H-5
SW: HBB LEVEL M/T EC only

REAR FOG B-51 0.5R/G 0.5R/G 19 2 3
SW: PARKING BRAKE DIODE

0.5W/B B-18 H-12
0.3W/B
SW: PRESSURE
N-6
RELAY: RR FOG
8 8 0.5G/W H-14 0.5G/W 0.5G/W H-16 17 H-5
Smoother
3 0.3W/B 1 TURN (LH) 1 H-5 H-14 B-51 0.5G/B 0.5G/B 0.5G/B 10
5 H-12 3 B-18 TURN (RH) B-52 0.5G/B 0.5G/W 0.5G/W 1 5 3 2 X-13 X-13 B-51 HIGH BEAM 0.5R/G
TURN SIGNAL LAMP (R-1)

0.5G/B H-16
TURN SIGNAL LAMP (R-6)
0.3BR
HEAD LAMP (RH/LH)
B-236
B-236
B-7 B-502
HEADLIGHT BRACKET-LH RELAY; BUZZER CANCEL

B-502 BOOST 9 B-51 2 39 11 OIL PRESS 0.5BR/B B-51 H-5 0.3BR 0.3BR 0.3W/V 0.3W/B 0.3W/R
0.3BR/Y 0.3BR/Y
B-502
5B
DIODE
B-1
FRAME-LH (FRT)
10 6 3 4 5 1 20 ASR 0.3W/L B-51 12
SW: VACUUM TANK
B-71
SW: OIL PRESSURE

2 1 0.5BR/B 0.5BR/B H-105 J-8
1.25B
SHORT CONNECTOR (With HBB)

30 18 4 0.3W/L H-8 0.3W/L H-15
ASR IND
J-177 6 17 3 0.3W/V B-51 INVERTER CIRCUIT 0.3W/V H-8 0.3W/V H-15
With ABS
C/U: ABS
0.5B ABS 21 3 0.5Y/R H-12 0.5Y/R N-19 8 0.3G/O B-53 7 0.3Y/G B-53 2 1 6 0.5Y/R X-32 0.5Y/R 0.5Y X-32 B-53 1 0.3P B-53 METER IC
J-177
SHORT CONNECTOR (Without HBB)
METER IND
15
Smoother
SELECTOR LEVER
0.5B
0.5B
H-12
N-19
0.3B 2B
11
Without ABS
FRAME-LH (CTR)
SMOOTHER
J-9
B-425
12
ECONO
B-425
TCM
1st START
B-427
14
SHIFT IND
B-425
N8B0056E
8-235

RELAY: CHARGE
1 J-2 2W 2 J-1 AC GEN. J-1 1 0.5W/L H-105 8 0.5W/L 15 H-5 0.5W/L 0.5W/L 5 X-1 X-1 3 0.5B/Y 0.5W/R 1 X-1 X-1 4 0.5B/Y
Relay: Thermo A/C F-1 15A HEATER, AIR CON SW: ENG. WARM, DPD REGENERATE F-2 10A FUEL HEATER
8W
FL-2 40A KEY

8W/B 3W/L
FL-1 100A MAIN

0.5W/L
RELAY: HEATER & A/C

X-12 X-12 X-12 X-12 4 0.5B 5 3L
8B
3W/B
1 0.5W/R 2
1 H-7 2L
2 H-6 5W/B
3W/L
30B/R
2L
RELAY: HEATER
3W/B 2 X-8 X-8 1 3B/R
1 J-26 B
STARTER
+ P-1 P-2 + P-3 P-4 -
3W/B
2 B-67
3W/B
X-8
X-8
5 0.5B 0.85R
C J-27 1
STARTER SW
OFF
10 B-51
18 B-51
RELAY: STARTER
ON B-67 3
ACC
ST
SEDIMENTER
P-5
3B/Y
F-16 10A METER
BUZZER
FRAME
B-51 5
B-57 3
B-52 10 0.5LG/W
11 0.5BR/B
0.5B/Y
0.5W/V
OIL PRESS B-51
CHARGE
3B/Y
BRAKE
0.5W/V 0.5B/Y 0.5LG/W
H-5
0.5Y/R
LEVEL SW: B & C OIL
0.5W/V 2 B-85 H-5 13 0.3BR 0.5LG/W H-5 39 0.5BR/B 6 H-105 0.5BR/B 2B B-85 1 0.5B
21
12 H-105 0.5LG/W 1 B-71
3B
SW: FUEL SEDIMENTER
J-206
SW: OIL PRESSURE
SW: VACUUM TANK
1 J-8
0.5B
J-9
3B B-7
J-206 1
FRAME-LH (CTR)
N8B0057E

TURN SIGNAL LAMP (R-1) TURN SIGNAL LAMP (R-6)
8-237
RELAY: TAIL
0.5G/W
3W
H-16 8 0.5G/W
F-7 10A TAIL LIGHT

0.85LG/R
H-14 8 0.5G/W
0.5G/B H-14 1 0.5G/B
0.5G/B H-16 1
17 0.85LG/R H-5 0.5G/W
10 H-5 0.5G/B
0.85R
0.5LG/R
0.5G/W
0.5G/B
16 B-52
17 B-51
3 B-52
1 B-51
CHECK ENG.
EXH BRAKE
FUEL
FUEL
SVS
TACHO
SPEED
GLOW
ILL
ILL
ILL
ILL
B-51 13 0.5L/R
B-51 7 0.5L/B
B-52 15 0.5O/L
B-51 6 0.5L/P
B-51 15 0.5B
B-52 6 0.5LG/W
B-52 8 0.3LG
B-52 17 0.3Y/G
B-52 20 0.5B
B-52 5 0.5LB
0.5W/V 0.5B/Y 0.5LG/W 0.5B
3 B-18
DIODE
B-18 0.3Y/G 4 0.5B 0.5W/B
0.5W/B H-5 24 H-5 30 H-5 40 H-5 7 H-5 31 H-8 3 0.5LG H-5 25 0.5Y/G H-5 19 0.5B H-5 12 0.5LB H-5 1
0.5B/Y
0.85B
1 0.5W/B H-105 0.5LB H-12 3 0.3W/B
0.5O/L
0.5L/R
0.5L/B
0.5L/P
1 J-32
2 J-32
3 J-32 0.5Y/G
3 E-90
V/SPEED SENSOR
METER SW: PARKING BRAKE ECT SENSOR
6 B-1 J-191 OSDIAGL
17 J-191 OS-SVS
11 J-191 OSGLOWL
7 J-191 OSEXBL
8 J-191 OFTACHO
19 J-191 IF-SPD
48 J-191 ISPBRK
FRAME-LH (FRT)
ECM: ENGINE
0.5W/B
1 N-6
ILL
POWER SUPPLY CIRCUIT
I/F & METER IC
LAMP DRIVER
HIGH BEAM
TURN (RH)
TURN (LH)
0.5R/G 2 B-51
0.5R
N8B0058E
HEAD LAMP (RH/LH)

RELAY: CHARGE
1 J-2 2W 2 J-1 AC GEN. J-1 1 0.5W/L H-105 8 0.5W/L 15 H-5 0.5W/L 0.5W/L 5 0.5W/R 1 X-1 X-1 3 0.5B/Y 4 0.5B/Y
X-1
X-1
Relay: Thermo A/C F-1 15A HEATER, AIR CON SW: ENG. WARM, DPD REGENERATE F-2 10A FUEL HEATER
FL-2 40A KEY

3W/L 8W/B 8B 1 H-7 3W/L 2 B-67 B
FL-1 100A MAIN STARTER SW

OFF ACC ON ST B-67 3 3B/Y 3B/Y 3W/B 0.5W/L
8W
RELAY: HEATER & A/C

X-12 X-12 X-12 X-12 4 0.5B 5 3L
2 H-6 3W/B 5W/B
1 0.5W/R 2
2L
RELAY: HEATER
3W/B 2 X-8 X-8 1 3B/R
30B/R
2L
STARTER
+ P-1
J-26 B
F-16 10A METER

0.5B/Y
3W/B
P-2 + P-3 P-4 C J-27 1 10 B-51
X-8
X-8
5 0.5B
0.85R
0.5R
16 B-52
18 B-51
DPF REGENERATE
EXH BRAKE
FUEL
P-5
FRAME POWER SUPPLY CIRCUIT LAMP DRIVER
I/F & METER IC
FUEL
SVS
TACHO
SPEED
B-51
B-51 4
B-51 5
B-51 13
B-51 7
B-51 4
B-53 10
B-52 15
B-51 6 0.5L/P
B-51 15 0.5B
B-52 6 0.5LG/W
B-52 8 0.3LG
B-52 17 0.3Y/G
B-52 20 0.5B
B-52 5 0.5LB
M/T
10 0.5BR/W (NPR) 0.5LG/W (NKR) 0.5W/B 13 H-5 1 H-5 12 H-105 0.5LG/W 2 J-206 J-206 1 J-191 ISPBRK
Smoother
Smoother
M/T
M/T
0.5LG/B
0.5LG/B
0.3W/V (NPR) 0.5W/V (NKR)
0.5O/L
0.5L/R
0.5L/R
0.5L/B
0.3Y/G
0.5B/Y
0.5Y/R (S/CAB) 0.5R (W/CAB)
2 LEVEL SW: B & C OIL B-85
24 H-5
30 H-5
4 H-17
19 H-4
40 H-5
7 H-5
31 H-5
3 H-8
25 H-5 0.5Y/G
19 H-5
12 H-5
2B
0.5LG
NKR
1.25B (NPR) 0.85B (NKR)
NPR
0.5LB
0.5B
B-85 1 0.5B 0.5LG/B 0.5O/L 0.5L/R 0.5L/B 0.5L/P
1 0.5W/B H-105 0.5LB
1 J-32
2 J-32
3 J-32 0.5Y/G
3 E-90
0.5B
V/SPEED SENSOR
5B 3B 6 J-191 OSDIAGL 17 J-191 OS-SVS 9 J-191 OSDPFREG 11 J-191 OSGLOWL 7 J-191 OSEXBL 8 J-191 OFTACHO
METER ECT SENSOR48
19 J-191 IF-SPD
B-1
J-9
B-7
ECM: ENGINE
FRAME-LH (FRT)
FRAME-LH (CTR)
N8B0059E
SW: FUEL SEDIMENTER
3B
0.5B/Y
0.5LG/W
H-5
0.5B
21
SEDIMENTER B-52
CHECK ENG.
CHARGE
RELAY: STARTER
BRAKE
GLOW

TURN SIGNAL LAMP (R-1) TURN SIGNAL LAMP (R-6) C/U: ABS ASR IND METER IND
8-239
SW: OIL PRESSURE
RELAY: TAIL
0.5G/W
0.5G/B
J-8 1 0.5BR/B
J-177 30 0.3W/L
J-177 6 0.3W/V H-15 3 0.3W/V
3W
H-16 8 0.5G/W
H-16 1 0.5G/B
EC only
RELAY: RR FOG
F-7 10A TAIL LIGHT

0.85LG/R
H-105
H-14 8 0.5G/W
H-14 1 0.5G/B
H-15 4 0.3W/L
HEAD LAMP (RH/LH)
6 0.5BR/B
Without ABS (RIGID)

0.3B 2B
Without ABS (INDP)

0.3B 1.25B 2B
17 H-5
10 H-5 0.5G/B
0.85LG/R
39 H-5
18 H-8
17 H-8 J-9 0.3W/V
0.5R/G
0.5G/W
0.5BR/B
J-9
0.5LG/R
0.5G/W
0.5G/B
0.5R/G
0.5R/G
0.3W/L
FRAME-LH (CTR)
FRAME-LH (CTR)
17 B-51
19 B-51
3 B-52
1 B-51
2 B-51
11 B-51
20 B-51
12 B-51
INVERTER CIRCUIT
SMOOTHER
SHIFT IND ECONO 1st START
BUZZER
HIGH BEAM
REAR FOG
TURN (RH)
TURN (LH)
OIL PRESS
ILL
ILL
ILL
ILL
ILL
With ABS
B-57 3 0.3BR B-53 8 B-53 7 B-53 6 0.5Y B-53 1
NPR
0.3BR 0.3BR 1
1 X-32
NKR
0.5W/B
2 (NPR) 4 (NKR)
DIODE
B-18 B-18 3
0.3W/V 4 0.3W/B 3 10 6
SHORT CONNECTOR
DIODE
NKR
X-32 2 0.5Y/R
0.5Y/R 21 H-12 0.5Y/R
0.5W/B
SW: VACUUM TANK
1 B-71
0.3G/O
0.3Y/G
0.5Y/R
Smoother
3 N-19
M/T
H-12 3
H-12 5
SELECTOR LEVER
N-19 9 0.5B 11 B-425 12 B-425 1 B-427 14 B-425
0.3W/B
1 N-6
TCM
SW: PARKING BRAKE
15 1.25B (NPR) 0.85B (NKR) H-12 0.5B
B-1
Smoother
FRAME-LH (FRT)
0.5B
0.3P
METER IC
ASR
ABS
N8B0060E

Connector List
For 4HK1 Engine No. Connector Face B-71
1
No.
Connector Face
B-1
001-013 000-001
B-85 B-7
000-001
1 2
002-009
B-236 B-18
1 2 1 2 3 4
002-022 004-004
B-51
020-004

031-001
B-52
020-005

017-001

012-009
B-57
3 2 1
003-035
B-502 B-67
1 3 2 4
004-001
1 2 3
003-033
E-90 B-67
2 4 1 3
1 3
003-004 004-002

No. Connector Face No. H-14 (Without ABS)
020-002
8-241
Connector Face
H-4
1 2 3 4 5 10 11 12 13 14 15
6 7 8 9 16 1718 19 20
1 5
2 6
3 7
4 8
008-003
H-4
9 8 7 6 20 19 18 17 16
5 4 3 2 1 15 14 13 12 11 10
H-14 (Without ABS)

020-003
4 8
3 7
2 6
1 5
008-004
H-12 (For M/T)
2 6 7
3 8
4 9
1 2 3 7 8 9 10
4 5 6 11 12 13 14
H-15
014-002
10 11 12 13 14 15 16
016-003
H-12 (For M/T)
3 8 7
2 6
1 5
6 5 4 14 13 12 11
3 2 1 10 9 8 7
H-15
014-003
14 13 12 11 10
16
15
016-004
1 2 3 4 5 11 12 13 14 15 16
6 7 8 9 10 17 18 19 20 21 22
H-16
022-001
1 5
2 6
3 7
4 8
008-003
10 9 8 7 6 22 21 20 19 18 17
5 4 3 2 1 16 15 14 13 12 11
H-16
022-002
4 8
3 7
2 6
1 5
008-004
H-14 (With ABS)
1 5 6
2 7
3 8
4 9
10 11 12 13 14 15 16
H-105
016-003
1 5 9
2 6
3 7
4 8
10 11 12
13 14 15 16
016-001
H-14 (With ABS)
4 9 8
3 7
2 6
1 5
14 13 12 11 10
H-105
016-004
4 8
3 7
2 6
1 5 9
12 11 10
16 15
16 15 14 13
016-002

No. H-118 (For Smoot her) Connector Face No. Connector Face
1 5 9
2 6
3 7
4 8
J-28
012-001
10 11 12
2
002-011
4 8
3 7
2 6
1 5 9
J-32
012-002
12 11 10
003-018
J-1
J-128
002-003 004-018
J-2
000-001
J-177 (With ABS)

034-001
J-8
1
J-191
001-013 081-001
J-9
000-001
J-206
002-001
J-26
000-002
N-6
2 1
002-023
J-27
000-009
N-19 (For Smoot her)
1 2
3 4
5 6 7 8 9 10
010-003

8-243
P-1
000-022
X-13
005-006
P-4
000-014
1 2 3 4
004-004
H-5 P-2
000-014
P-3
000-014
1 7 13 19 25 31
2 8 14 20 26 32
3 9 15 21 27 33
34
35
36
37
4 10 16 22 28 38
5 11 17 23 29 39
6 12 18 24 30 40
6 12 18 24 30 40
5 11 17 23 29 39
4 10 16 22 28 38
37
36
35
34
3 9 15 21 27 33
2 8 14 20 26 32
1 7 13 19 25 31
P-5
000-002
N8A5488E
H-6, H-7, H-8 X-1

005-006
H-6
X-8
005-006
H-7
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
1 2 3 5 4
4 3 2 1 8 7 6 5 H-8 13 12 11 10 9 18 17 16 15 14
X-12
005-001
N8A5489E

For 4JJ1 Engine No. Connector Face B-71
1
No.
Connector Face
B-1
001-013 000-001
B-85 B-7
000-001
1 2
002-009
B-18
1 2 3 4
B-425 (For EURO 4 with Smoot her) B-427 (For EURO 4 with Smoot her)
031-001
004-004
B-51
020-004
017-001
B-57 B-52
3 21 1
003-035 001-013
020-005
B-53 (For EURO 4 with Smoot her)
E-90
1 3
003-004 012-009
B-67
1 3
2 4
004-001
H-4 (For NPR85 )
1 2 3 4 5 10 11 12 13 14 15
6 7 8 9 16 1718 19 20
020-002
B-67
2 4
1 3
H-4 (For NPR85 )

004-002
9 8 7 6 20 19 18 17 16
5 4 3 2 1 15 14 13 12 11 10
020-003

No. Connector Face No. H-15 (For EURO 4 with ABS) H-15 (For EURO 4 with ABS) Connector Face
8-245
H-12 (For M/ T)
1 5 6
2 7
3 8
4 9
1 2 3 7 8 9 10
4 5 6 11 12 13 14
10 11 12 13 14 15 16
014-002
016-003
H-12 (For M/ T)
4 9 8
3 7
2 6
1 5
6 5 4 14 13 12 11
3 2 1 10 9 8 7
14 13 12 11 10
16
15
014-003
016-004
H-12 (For EURO 4 with Smoot her) H-12 (For EURO 4 with Smoot her)
1 2 3 4 5 11 12 13 14 15 16
6 7 8 9 10 17 18 19 20 21 22
H-16
022-001
1 5
2 6
3 7
4 8
008-003
10 9 8 7 6 22 21 20 19 18 17
5 4 3 2 1 16 15 14 13 12 11
H-16
022-002
4 8
3 7
2 6
1 5
008-004
H-14 (With ABS)
1 5 6
2 7
3 8
4 9
10 11 12 13 14 15 16
016-003
H-17 (For NKR85 , Smoot her) H-17 (For NKR85 , Smoot her) H-17 (For NKR85 , M/T)
4 8
3 7
2 6
1 5 9
12 11 10
16 15 14 13
016-002
H-14 (With ABS)
4 9 8
3 7
2 6
1 5
1 5 9
2 6
3 7
4 8
14 13 12 11 10
10 11 12
16
15
13 14 15 16
016-004
016-001
H-14 (Without ABS)
1 5
2 6
3 7
4 8
008-003
004-018
H-14 (Without ABS)
4 8
3 7
2 6
1 5
008-004
H-17 (For NKR85 , M/T)
1 3
2 4
004-011

H-105
1 5 9
2 6
3 7
4 8
J-28
012-001
10 11 12
2
002-011
H-105
4 8
3 7
2 6
1 5 9
J-32
012-002
12 11 10
003-018
J-1
J-177 (With ABS)

002-003 034-001
J-2
000-001
J-191
081-001
J-8
1
J-206
001-013
002-001
J-9
000-001
N-6
2 1
002-023
J-26
000-002
N-19 (For EURO 4 with Smoot her)
1 2
3 4
5 6 7 8 9 10
010-003
J-27
000-009
P-1
000-022

8-247
P-4
000-014
P-2
000-014
1 7 13 19 25 31
2 8 14 20 26 32
3 9 15 21 27 33
34
35
36
37
4 10 16 22 28 38
5 11 17 23 29 39
6 12 18 24 30 40
6 12 18 24 30 40
5 11 17 23 29 39
4 10 16 22 28 38
37
36
35
34
3 9 15 21 27 33
2 8 14 20 26 32
1 7 13 19 25 31
P-3
000-014
N8A5488E
H-6, H-7, H-8
P-5
000-002
H-6
H-7
X-1
005-006
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 H-8
4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14
X-8
005-006
N8A5489E
X-12
1 2 3 5 4
005-001
X-32 (For EURO 4 with Smoot her)
1 2 3 4
004-004

Diagnosis
Quick Chart for Check Point 1. Speedometer Check point Speedometer 1-1. Speedometer and odometer do not function 1-2. Speedometer does not function (odometer is normal) Trouble mode 1-3. Odometer does not function (Speedometer is normal) 1-4. Speedometer needle fluctuates (May be wide fluctuation) 1-5. Speedometer needle jumps erratically Notice: Figure in parenthesis ( ) indicates the order of inspection. 2. Tachometer Check point Tachometer 2-1. Tachometer does not function Trouble mode 2-2. Tachometer needle fluctuates (May be wide fluctuation) 2-3. Tachometer needle jumps erratically Notice: Figure in parenthesis ( ) indicates the order of inspection. 3. Coolant Temperature Gauge Check point Meter ASM 3-1. Coolant temperature gauge needle does not move Trouble mode 3-2. Coolant temperature gauge reading is too low (or high) 3-3. Needle overshoots (or goes up to the H range) (3) (4) (3) Thermo meter (4) (5) (4) ECT sensor (2) (3) (1) (1) Thermostat Cable harness (1) (2) (2) (3) (3) (3) ECM (1) (1) (1) Cable harness (2) (2) (2) (3) (1) (1) (3) (3) (1) (1) (2) (2) Vehicle speed sensor (1) Cable harness (2)

4. Fuel Gauge Check point Meter ASM 4-1. Fuel gauge needle does not move Trouble mode 4-2. Even when the tank is filled up with fuel, the needle does not reach F 4-3. When the tank is not full of fuel, the needle overshoots (or goes to F) Notice: Figure in parenthesis ( ) indicates the order of inspection. 5. Warning/indicator Light Check point Light Parking bulb brake SW 5-1. When the parking brake lever is pulled, the indicator light does not light up 5-2. Even when the parking brake lever is released, the indicator light does not go off 5-3. While the engine operating, the oil pressure warning light does not go off 5-4. Even when the tank is full with fuel, the fuel warning light lights up Trouble mode 5-5. Even when the tank is empty, the low fuel warning light does not light up 5-6. Even when the float in the water sedimenter goes up above the drain warning level, the indicator light does not light up 5-7. Even when the brake fluid is lower than specified level, the level warning light does not light up 5-8. Even when the vacuum tank is empty vacuum warning buzzer does not sound Notice: Figure in parenthesis ( ) indicates the order of inspection. (1) (1) (2) (1) (1) (2) (1) (2) (2) Brake fluid SW Oil pressure SW Fuel tank unit (3) (3) (3) Fuel gauge (4) (4) (4) Fuel tank unit (2) (2) (2)
8-249
Cable harness (1) (1) (1)
SediVacuum Cable menter SW harness SW (3) (2) (1) (2) (3) (3)
(2)
(1) (1)
(3) (2)

1. Speedometer 1-1. Speedometer and Odometer Do Not Function
DOES THE VEHICLE SPEED SENSOR OUTPUT IN NORMALLY?
YES ARE THE CIRCUITS BETWEEN THE VEHICLE SPEED SENSOR AND THE METER, AND THE FUSE F-16 (10A) AND THE GROUND NORMAL?
NO REPLACE THE VEHICLE SPEED SENSOR
YES
REPLACE THE SPEEDOMETER

N8B5155E
1-2. Speedometer Does Not Function (Odometer Is Normal)
REPLACE THE SPEEDOMETER ASSEMBLY
N8A0300E

1-3. Odometer Does Not Function (Speedometer Is Normal)
8-251
REPLACE THE SPEEDOMETER ASSEMBLY
N8A0300E
1-4. Speedometer Needle Fluctuates (May Be Wide Fluctuation)
N8A5366E
1-5. Speedometer Needle Jumps Erratically
N8A5366E

Inspection of waveform by oscilloscope 1. Connect a resistance of 1.3 to 5k ohm (1.4W or more) between the harness side connectors 18 B-51 and 17 B-52 of the meter.
B-51 B-52
2. 3. 4.
Install a speedometer tester. Turn on the starter SW. Check the waveform at the time when the vehicle speed is at 60 Km (37 mph).
Normal waveform Approximate battery voltage
0V 23.6 m sec. 2V or less

N8B0061E
2. Tachometer 2-1. Tachometer Does Not Function 2-2. Tachometer Needle Fluctuates (May Be Wide Fluctuation) 2-3. Tachometer Needle Jumps Erratically
IS THE PULSE INPUT NORMAL?
YES
NO REPAIR A POOR CONNECTION AT THE CONNECTORS IN THE CIRCUIT OR A FAILURE IN THE CABLE HARNESS, OR REPLACE ECM
REPLACE THE TACHOMETER
N8B5161E

3. Coolant Temperature Gauge 3-1. Coolant Temperature Gauge Needle Does Not Move
8-253
IS THE CONNECTOR OF THE ECT SENSOR CONNECTED SECURELY?
YES
DISCONNECT THE CONNECTOR OF THE ECT SENSOR CONNECT A 3.4W BULB BETWEEN THE HARNESS SIDE CONNECTOR 3 E-90 AND THE GROUND OF THE ECT SENSOR WHEN THE STARTER SW IS TURNED ON, DOES THE TEMPERATURE GAUGE NEEDLE MOVE ABOUT 10 SECONDS AFTER THAT?
YES IS THE ECT SENSOR NORMAL?
NO IS THE CIRCUIT BETWEEN THE TEMPERATURE GAUGE AND THE ECT SENSOR NORMAL?
YES
NO REPLACE THE ECT SENSOR
YES
NO
REPAIR A POOR CONNECTION AT THE CONNECTOR
IS THERE A BROKEN WIRE IN THE PRINTED CIRCUIT OF THE METER ASSEMBLY?
REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT IN THE CIRCUIT
YES
NO REPLACE THE PRINTED CIRCUIT BOARD
CHECK THE COOLANT TEMPERATURE GAUGE AND REPLACE IT WITH A CORRECT ONE IF NECESSARY
N8B5066E

3-2. Coolant Temperature Gauge Reading Is Too Low (or High)
DOES THE THERMOSTAT OPERATE NORMALLY?
YES
NO REPLACE THE THERMOSTAT
TURN THE STARTER SWITCH ON WHEN INSERTING AND PULLING OUT THE THERMOSTAT CONNECTOR 3 E-90 SEVERAL TIMES, DOES THE INDICATION OF THE COOLANT TEMPERATURE GAUGE VARY?
YES IS THE ECT SENSOR NORMAL?
NO REPAIR A POOR CONNECTION AT THE CONNECTOR OF THE ECT SENSOR
YES IS THERE AN OPEN CIRCUIT IN THE METER ASSEMBLY PRINTED CIRCUIT BOARD?
YES
CHECK THE COOLANT TEMPERATURE GAUGE AND REPLACE IT IF FOUND DEFECTIVE
N8B5067E

3-3. Needle Overshoots (or Goes Up to the H Range)
8-255
DISCONNECT THE CONNECTOR OF THE ECT SENSOR WHEN THE STARTER SW IS TURNED ON, DOES THE POINTER REACH TO THE "H" RANGE?
YES
IS THERE A SHORT CIRCUIT BETWEEN THE ECT SENSOR AND THE COOLANT TEMPERATURE GAUGE?
YES IS THE PRINTED CIRCUIT OF THE METER ASSEMBLY GROUNDED SECURELY?
NO REPAIR A SHORT CIRCUIT
YES
NO REPAIR OR REPLACE THE PRINTED CIRCUIT BOARD
CHECK THE COOLANT TEMPERATURE GAUGE AND REPLACE IT IF FOUND ABNORMAL
N8B5156E

4. Fuel Gauge 4-1. Fuel Gauge Needle Does Not Move
IS THE CONNECTOR OF THE FUEL TANK UNIT J-28 CONNECTED SECURELY?
YES
DISCONNECT THE CONNECTOR OF THE FUEL TANK UNIT CONNECT A 3.4W BULB BETWEEN THE HARNESS SIDE CONNECTOR 1 J-28 AND THE GROUND OF THE FUEL TANK UNIT WHEN THE STARTER SW IS TURNED ON, DOES THE FUEL GAUGE NEEDLE FLUCTUATE AFTER ABOUT 90 SECONDS?
YES IS THERE CONTINUITY BETWEEN THE FUEL TANK UNIT CONNECTOR TERMINALS 1 J-28 AND 2 J-28 ?
NO IS THE CIRCUIT BETWEEN THE FUEL GAUGE AND THE FUEL TANK UNIT NORMAL?
YES
NO REPLACE THE FUEL TANK UNIT
YES IS THERE A BROKEN WIRE IN THE PRINTED CIRCUIT OF THE METER ASSEMBLY?
NO
REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT IN THE CIRCUIT
REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN THE FUEL TANK UNIT AND THE METER
YES
NO
CHECK THE FUEL METER, AND REPLACE IT IF NECESSARY
REPLACE THE PRINTED CIRCUIT BOARD
N8B5068E

4-2. Even when The Tank Is Filled Up with Fuel, The Needle Does Not Reach F
WHEN INSERTING AND PULLING OUT THE CONNECTOR J-28 OF THE FUEL TANK UNIT SEVERAL TIMES, DOES THE POINTER OF THE FUEL GAUGE STAY AT THE SAME POSITION?
8-257
YES
NO REPAIR A POOR CONNECTION AT THE CONNECTOR OF THE FUEL TANK UNIT
DISCONNECT THE CONNECTOR OF THE FUEL TANK UNIT CONNECT THE FUEL TANK UNIT HARNESS SIDE CONNECTOR 1 J-28 AND 2 J-28 WITH A LEAD WIRE WHEN THE STARTER SW IS TURNED ON, DOES THE NEEDLE OVERSHOOT TO "F" AFTER ABOUT 5 MINUTES?
YES IS THERE A BROKEN CIRCUIT IN THE PRINTED CIRCUIT OF THE METER ASSEMBLY?
NO REMOVE THE FUEL TANK UNIT DOES THE FLOAT ARM OPERATE SMOOTHLY?
YES
YES IS THE RESISTANCE VALUE OF THE FUEL TANK UNIT NORMAL?
CHECK THE FUEL GAUGE AND REPLACE IT IF FOUND ABNORMAL

N8B5069E

4-3. When The Tank Is Not Full of Fuel, The Needle Overshoots (or Goes Up to F)
DISCONNECT THE CONNECTOR OF THE FUEL TANK UNIT WHEN THE STARTER SW IS TURNED ON, DOES THE NEEDLE STILL POINT TO "F"?
YES IS THE CIRCUIT BETWEEN THE FUEL TANK UNIT AND THE FUEL METER NORMAL?
NO REMOVE THE FUEL TANK UNIT DOES THE FLOAT ARM OPERATE SMOOTHLY?
YES IS THE PRINTED CIRCUIT OF THE METER ASSEMBLY GROUNDED SECURELY?
NO
YES ARE THE RESISTANCE VALUES OF THE FUEL TANK UNIT AT "E" AND "F" POINTS NORMAL?
REPAIR A SHORT CIRCUIT IN THE CIRCUIT
YES
NO
NO
REPAIR OR REPLACE THE PRINTED CIRCUIT BOARD
REPLACE THE FUEL TANK UNIT
CHECK THE FUEL GAUGE, AND REPLACE IT IF NECESSARY
N8A0313E

5. Warning/indicator Light 5-1. When The Parking Brake Lever Is Pulled, The Indicator Light Does Not Light Up
8-259
IS THERE CONTINUITY IN THE CIRCUIT BETWEEN THE PARKING BRAKE SWITCH CONNECTOR 1 N-6 AND 5 B-51 (METER)?
N8B5070E
5-2. Even When The Parking Brake Lever Is Released, The Indicator Light Does Not Go Off
REPAIR A SHORT CIRCUIT BETWEEN THE PARKING BRAKE SWITCH CONNECTOR 1 N-6 AND 5 B-51
N8B5071E

5-3. While The Engine Is Operating, The Oil Pressure Warning Light Does Not Go Off
IS THE ENGINE OIL PRESSURE NORMAL?
YES WITH THE OIL PRESSURE SWITCH CONNECTOR J-8 DISCONNECTED, DOES THE WARNING LIGHT GO OFF?
NO REFER TO THE "ENGINE" SECTION
YES WHILE THE ENGINE IS OPERATING, IS THERE CONTINUITY BETWEEN THE OIL PRESSURE SWITCH CONNECTOR J-8 AND THE BODY GROUND?
NO REPAIR A SHORT CIRCUIT BETWEEN 1 J-8 AND 11 B-51 (METER)
NO REPLACE THE OIL PRESSURE SWITCH
N8B5072E
5-4. Even When The Fuel Tank Is Full with Fuel, The Fuel Warning Light Lights Up
WHEN THE FUEL TANK UNIT CONNECTOR J-28 IS DISCONNECTED, DOES THE WARNING LIGHT GO OFF?
YES IS THE FUEL TANK UNIT NORMAL?
NO REPAIR A SHORT CIRCUIT BETWEEN THE FUEL TANK UNIT HARNESS SIDE CONNECTORS 1 J-28 AND 6 B-52 (METER)

N8B5073E

5-5. Even When The Fuel Tank Is Empty, The Low Fuel Warning Light Does Not Light Up
8-261
DOES THE WARNING LIGHT HAVE A BURNED OUT BULB, OR IS THE SOCKET POORLY CONNECTED?
YES IS THE FUEL TANK UNIT NORMAL?
NO REPLACE THE BULB, OR REPAIR A POOR CONNECTION AT THE SOCKET
YES
REPAIR A POOR CONNECTION AT THE CONNECTOR OR AN OPEN CIRCUIT BETWEEN THE HARNESS SIDE CONNECTORS 1 J-28 AND 6 B-52 (METER) OR 2 J-28 AND J-9
N8B5074E

5-6. Even When The Float in The Water Sedimenter Goes Up above The Drain Warning Level, The Indicator Light Does Not Light Up
DOES THE INDICATOR LIGHT HAVE A BURNED-OUT BULB OR IS THE SOCKET POORLY CONNECTED?
YES IS THE WATER SEDIMENTER SWITCH NORMAL?
NO REPLACE THE BULB, OR REPAIR A POOR CONNECTION AT THE SOCKET
YES
NO REPLACE THE WATER SEDIMENTER SWITCH
REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT IN THE CIRCUIT BETWEEN THE WATER SEDIMENTER SWITCH HARNESS SIDE CONNECTOR 2 J-206 AND 10 B-52 (METER) OR 1 J-206 AND J-9
N8B5075E
8-263
5-7. Even When The Brake Fluid Is Lower than Specified Level, The Level Warning Light Does Not Light Up
REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN THE BRAKE FLUID SWITCH HARNESS SIDE CONNECTOR 2 B-85 AND 5 B-51
N8B5076E
5-8. Vacuum Warning Buzzer Does Not Sound
REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 3 B-57 AND 1 B-71
N8B5077E
Starter Switch
Turn Signal Light Switch

Refer to TURN SIGNAL LIGHT, HAZARD WARNING LIGHT AND STOPLIGHT in this section.
Exhaust Brake Switch

Refer to EXHAUST BRAKE in this section.

Meter Assembly
Layout for Gauges, Warning, Indicator and Illumination Lights
Speedometer
Warning lens
Tachometer
Warning lens Smoother
Without Smoother
1ST START
Fuel gauge
Coolant temperature gauge
N8B0141E

Bulb Location for Warning Lens
8-265
*2 : Without Smoother *3 : For EURO4 *
1 : Smoother
1ST START
N8B0062E

Table for Meter Connector Terminal Connections
B-52
20
20
B-57
B-53
B-51
N8B5115E

B-53 (With Smoother) Terminal No. 1 2 3 4 5 6 7 8 9 10 11 12 B-51 Terminal No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Illumination + Ignition Rear Fog ASR Ground Brake Booster Charge Oil Pressure ABS (*1) / Check Engine (*2) Turn LH Beam Brake (*1) / DPD (*2, *3) Check Engine (*1) / Brake (*2) Exhaust Brake SVS B-57 Terminal No. 1 2 3 Ground Battery Connected to Connected to DPD (*3) 1st Start ECONO Smoother TCM Connected to B-52 Terminal No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Ground Glow Battery Vehicle Speed Sensor Sedimenter Front Fog TACHO Thermal Fuel Turn RH Connected to
8-267
*1: With Smoother *2: Without Smoother *3: EURO 4

Removal Preparation: Disconnect the battery ground cable. 1. Meter Cluster
N8A0327E
Speedometer
N8A0325E
2. Meter Assembly Remove the five screws.
The speedometer is made up of the cross coil type ammeter (movement) that displays indications, the stepper motor that drives and adds up the odometer and trip meter, and the driving circuit (printed circuit board) that makes exchanges between the pulse signals and the current.
N8B5157E N8B5158E
Disconnect the meter connectors. Installation To install, follow the removal steps in the reverse order.
8-269
Replace the speedometer when the result of inspection is found abnormal.

4 Pulse output B
SENSOR
GND
N8B5159E
On-vehicle Service Check the meter display accuracy and the operation of the odometer with the speedometer tester. Notice: Inappropriate tire inflation may affect the accuracy of the odometer. (To conduct this test, refer to the tester manufacturer's instruction manual.) Since the meter display permissible levels above are specifications solely for the meter, they are to be used as reference values when conducting on-vehicle service. For General Export Tester display speed 40 km/h 60 80 100 120 140 For Europe Tester display speed 20 km/h 40 60 80 Meter display permissible level 20 22.5 km/h 40 42.5 60 63.2 79.7 83.4 Meter display permissible level 37 41 km/h 58 62 77.5 82.5 97.5 103 117 122.5 137.5 143
IGN
N8A0332E
Terminal symbol IGN GND SEN GND 4P GND
Resistance value 5820 k 7020 k
Removal Preparation: Disconnect the battery ground cable. 1. Remove the meter assembly/speedometer (1). Notice: Speedometer cannot be removed as a single unit since it is integrated into the meter assembly. Refer to Meter Assembly in this section. 2. Remove the meter plate (2) and meter glass (3). Remove the two installing screws on the meter surface. Remove the meter plate by pushing the catches with your finger.
Individual Inspection Remove the speedometer from the meter assembly and measure the resistance and the current consumption between each terminals.

Tester display speed 750 2000 3000 4000 Meter display permissible level 700 800 1900 2150 2950 3200 3950 4200
Individual Inspection Remove the tachometer from the meter assembly and measure the resistance value and the current consumption between each terminals. Replace the tachometer when the result of inspection is found abnormal.
N8A0485E
Tachometer
The tachometer is made up of the cross coil type ammeter (movement) that displays indications, and the drive circuit (printed board) that makes exchange between the pulse signals and the current.
N8A0336E
1. Resistance value Use the analog type circuit tester. (Range: 1K) Terminal symbol IGN GND
N8B5160E
Tester terminal Red (+) IGN PIN GND 335 k Black () GND Black ( ) IGN PIN Red (+) GND GND
305 k 500 1000 k
PIN GND
On-vehicle Service Inspection 1. Set up the tune-up tester to the engine. 2. Start the engine and compare the readings displayed by the tachometer and the tester. When the difference between these two readings differs largely from the specified value, replace it with a correct one. Notice: Since the meter display permissible levels above are specifications solely for the meter, they are to be used as reference values when conducting on-vehicle inspection.
2. Current value Use the analog type circuit tester. Since the current consumption fluctuates as the power voltage varies, check to be sure that the voltage applied is 241 V. Voltage 24Volt Connecting terminal IGN GND Current consumption 241 V (when 241 V applied) Remarks No signal input

Removal Preparation: Disconnect the battery ground cable. 1. Remove the meter assembly/tachometer (1). Notice: Tachometer cannot be removed as a single unit since it is integrated into the meter assembly. Refer to Meter Assembly in this section. 2. Remove the meter plate (2) and meter glass (3). Remove the two installing screws on the meter surface. Remove the meter plate by pushing the catches with your finger.
8-271
N8A0485E
Coolant Temperature Gauge

Circuit Diagram
Engine coolant temperature gauge IGN UNIT
ECT sensor +
GND
N8B5162E
Inspection Remove the coolant temperature gauge from the meter assembly, and measure the resistance value between each terminal. Replace the coolant temperature gauge when the result of inspection is found abnormal.

Notice: Coolant temperature gauge and fuel gauge cannot be removed as a single unit since they are integrated into the meter assembly. Refer to Meter Assembly in this section. 2. Remove the meter plate (2) and meter glass (3). Remove the two installing screws on the meter surface. Remove the meter plate by pushing the catches with your finger.
N8A0339E
Terminal symbol IG U UE IG E
Resistance value 169 10% 333 10% 242 10%
Removal Preparation: Disconnect the battery ground cable. 1. Remove the meter assembly (1).
N8A0485E
Fuel Gauge
Circuit Diagram
N8A0341E

Inspection Remove the fuel gauge from the meter assembly, and measure the resistance value between each terminal. Replace the meter when the result of inspection is found abnormal.
8-273
1 4 3
N8A5404E
N8A0342E
Legend 1. Meter Assembly 2. Meter Glass 3. Meter Plate 4. Warning Lens Installation To install, follow the removal steps in the reverse order.
Terminal symbol IG U UE IG E
Resistance value 108.1 10% 103 10% 211.1 10%
Warning Light Bulb, Indicator Light Bulb and Illumination Light Bulb
Removal Preparation: Disconnect the battery ground cable. 1. Meter Assembly Refer to METER ASSEMBLY in this section. 2. Socket and Bulb Hold the bulb socket by hand and rotate it counterclockwise to remove them from the meter body. 3. Bulb Pull out the bulb from the socket.
Removal and Installation Refer to the COOLANT TEMPERATURE GAUGE in this section.
Warning Lens
Removal Preparation: Disconnect the battery ground cable. 1. Meter Assembly Refer to METER ASSEMBLY in this section. 2. Meter Glass Remove it by pushing the catches with your finger. 3. Meter Plate Remove it by pushing the catches with your finger. 4. Warning Lens

The voltage, with one rotation of shaft, fluctuates four times in the following range: 10 to 14V 24 or less. Replace the sensor when the result of inspection is found abnormal.
N8A0344E
Vehicle Speed Sensor

The vehicle speed sensor is installed on the rear portion of the transmission or transfer case. The number of pulses generated is four pulses per one rotation of the pinion shaft.
N8A0346E
Removal Preparation: Disconnect the battery ground cable. 1. Vehicle Speed Sensor Disconnect the connector.
N8A0345E
Connector Parking brake drum 1
Inspection 1. Connect a resistance of 390 5%, 2W between connector terminal 1 J-32 and battery (+) terminal and connect the connector terminal 2 J-32 to the battery () terminal. Caution: Be extremely careful not to connect the battery (+) terminal to the connector 3 J-32 . This may damage the vehicle speed sensor. 2. Rotate the shaft of the vehicle speed sensor slowly and measure the voltage between 3 J-32 and 2 J-32 with a digital tester.
N8A0347E

Installation 1. Tighten the vehicle speed sensor to the specified torque. Tighten: Vehicle speed sensor to 25 Nm (2.5 kgfm/18 lbfft) Caution: Tightening must be made at the hexagonal part of the sensor. To tighten the connector itself would cause damage.
8-275
Oil Pressure Switch

Inspection Check the continuity between the switch terminal and the body ground with the starter switch is OFF position. Replace the switch when the result of inspection is found abnormal.
ECT Sensor
Inspection The ECT sensor is thermistor type and must be inspected under the conditions as shown below. 1. Put the deviation of the galvanometer to 0 by using the variable resistor, switch the ECT sensor off and then measure the resistance of the resistor through the bridge. Confirm that the resistance is continuously variable in any other points than those shown below. 2. Dip the ECT sensor into 80 90C (176 194F) water and confirm that there is no bubble continuously coming out of inside of the sensor. Replace the sensor when the result of inspection is found abnormal.
N8A5410E
Circuit Inspection
1. Start the engine. 2. When disconnecting the oil pressure switch connector then connecting the harness side connector to the ground, check to see if the oil pressure warning light lights up. When the light will not light up, check the circuit between the meter and the oil pressure switch, and repair an open circuit if necessary.
N8A0348E
Temperature Check condition 50C (112F) +33.6 33.6 226.0 115C (239F) +1.71 2.21 26.4 +2.68 3.68 24.3
7 V 55 Gauge 7 V 25 Gauge
Resistance value ( )
N8A5411E

Fuel Tank Unit
The tank unit varies the internal resistance according to the float position (fluid level) to operate the fuel meter needle. Also available is the build-in switch type to warn the driver of low fuel level (about 5 liters left in the tank) by illuminating the fuel warning light.
N8A5412E

Inspection
91.5 mm (Fuel tank capacity: 75L) 91.5 mm (Fuel tank capacity: 100L)
8-277
N8B0063E
J-28
(Level Switch type of warn low fuel level) 1. Check the resistance between the connector terminals 1 J-28 F-1 and 2 J-28 F-1 while shifting the float from E to F point. 2. Check if the low fuel warning switch turns on and off at the specified positions. If found defective, replace the fuel tank unit.
N8B0064E
Float position F 1/2 E
Resistance value () 2.5 33.0 98.3

Vacuum Switch
Inspection When the pressure value is below 25030 mm Hg (33.34.0 kPa), check to see if there is continuity between the terminal and the ground. If no continuity, replace the switch with a normal one.
N8A0358E
Legend 1. Meter Assembly 2. Vacuum Warning Buzzer

N8A0357E
Removal Preparation: Disconnect the battery ground cable. 1. Vacuum Switch 1) Disconnect the connector. 2) Remove the vacuum switch. Installation Apply liquid gasket to the screw portion of the switch to prevent vacuum leak.
Water Sedimenter Switch

Inspection 1. When the float in the water sedimenter is above the drain warning level, confirm if there is continuity between the switch connector terminals. 2. Turn the starter switch on, disconnect the water sedimenter connector and connect the harness side connector terminals. Then confirm that the sedimenter warning light turns on. If found defective, replace the switch or repair a poor connection or an open circuit between the connector terminals.
Vacuum Warning Buzzer

Inspection Apply battery voltage to the buzzer connector terminals to check the buzzer sound. Replace the buzzer when the result of inspection is found abnormal. Removal Preparation: Disconnect the battery ground cable. 1. Meter Assembly Refer to METER ASSEMBLY in this section. 2. Vacuum Warning Buzzer 1) Disconnect the connector. 2) Remove the buzzer fixing screw.
Sedimenter Switch
Sedimenter Switch
N6B6083E

Brake Fluid Switch
Inspection 1. Confirm there is continuity between the switch connector terminals when the brake fluid in the tank is between 60 75 cc level. 2. Turn the switch on, disconnect the brake fluid switch connector and connect the harness side connector terminals. Then confirm that brake warning light turns on. If found defective, replace the tank, or repair a poor connection or an open circuit between the connector terminals.
8-279
N8A0361E
Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Bleed the air from brake and clutch fluid pipe line. 2. Check to see if the brake fluid level in the tank within specified level. 3. Check to see if brake warning light comes on when starter switch is turned on and then warning light goes off after the engine running.
Parking Brake Indicator Light

N8A0360E
Removal Preparation: Disconnect the battery ground cable. 1. Instrument Panel Assembly Refer to INSTRUMENT PANEL of section 2. 2. Brake Fluid Tank (Brake Fluid Switch) 1) Disconnect the switch connector. 2) Remove four fixing nuts. 3) Drain brake fluid in the tank. 4) Disconnect the tubes. Caution: Be very careful not to allow the brake fluid to come in contact with painted surfaces or resin parts surfaces.
The parking brake indicator light is connected in series with the parking brake switch installed to the parking brake lever bracket. The light comes on when the parking brake lever is pulled, and goes out when the parking brake lever is fully released. Notice: The parking brake indicator light illuminates to warn the driver that the parking brake is on. This light does not indicate the condition of the operability of the parking brake. Circuit Inspection 1. Disconnect the parking brake switch connector. 2. Connect the harness side connector terminal to the ground. 3. Check to see if the indicator light comes on with the starter switch ON. Check the bulb or the harness when the result of inspection is found abnormal.
N8A0362E
N8A0364E
Parking Brake Switch

Inspection 1. Disconnect the parking brake switch connector. 2. Check to see if there is any continuity between the switch terminal and the body ground with the circuit tester connected between them. When parking brake applied When parking brake released Continuity No continuity
Heater and Air Conditioning

General Description The air conditioning consists of compressor, evaporator, condenser, A/C switch, fan switch, etc. When the engine is rotating, the A/C starts to work with both the A/C and fan switches ON, followed by the engagement of the magnetic clutch. It stops to work when either the fan switch or the A/C switch turns OFF. In addition to the switches, the A/C has the function of temporary stop of its operation by the sensing system in the A/C cycle, such as: sensing abnormal rise of the refrigerant pressure by means of the pressure switch. sensing temperature of the blowing-off air by means of the thermo switch preventing the evaporator from freezing. sensing the coolant temperature by the thermo switch (available for limited models only).
Repair the parking brake switch or replace it when the result of inspection is found abnormal.
N8A0363E
Removal Preparation: Disconnect the battery ground cable. 1. Parking Brake Switch 1) Disconnect the connector. 2) Remove the fixing screw.
B-18 DIODE (4JJ1 NKR) B-17,X-32 DIODE <4JJ1>
Parts Location
X-10
X-12 HEATER X-12 & A/C RELAY
E-5 MAGNETIC CLUTCH
H-105
FUSE BOX ASM F-1
J-191 ECM
H-105 < 4HK1>
J-6 PRESSURE SW1 (4HK1) J-257 PRESSURE SW & CONDENSER FAN SW (4JJ1)
J-51 CONDENSER FAN1 (4HK1)
F-26 FUSE FL-1 FUSIBLE LINK X-27 CONDENSER FAN RELAY
H-105
N8B0065E
8-281
F-1 15A HEATER, AIR CON 0.85BR 0.85BR

1 X-10 X-10 J-6 J-6 X-10 4 4 3 2 X-10 5 H-5 2 J-6 J-6 J-191 1 2
For 4HK1 Engine
Circuit Diagram
30B/R ECM
2L 0.85G/W 0.85G/O 0.5G/O 34
FL-1 100A or 120A 8B MAIN 8W/B 0.85G/W
PRESSURE SWITCH 1
P-1
P-2
0.5LG/B RELAY; A/C THERMO
8W/B (80A ACG) 5W/B (STD ACG)
0.85L
P-3
3L
0.85G/O
(M/T)
P-4 B-17 X-32
2 4 4
0.5G/Y
H-6
0.85BR DIODE
(SMOOTHER) DIODE
5W/B
1 B-14 3 3 B-17 X-32
RELAY; CONDENSER FAN 0.5B

5 X-27 X-27 X-27 1 J-51 1 3 4 H-105
0.5P/G
RELAY; HEATER & A/C

X-12 4 2 1 2 B-39 B-15 B-15 B-39 3 1 B-14 5
3W/B
P-5
FRAME 0.5LG CONDENSER FAN 1 0.5LG

X-12
X-12
0.85B 2 J-51
0.85L 2 X-27
BLOWER MOTOR
X-12
0.5W/R ELECTRONIC THERMOSTAT A/C SWITCH

2 3 B-39 B-15
0.85L/Y
0.75G/O
RELAY; CHARGE (1) 0.85L/B RELAY; GLOW (3) 0.5G/Y 0.5G/Y
2B/L
F-26 15A COND. FAN

1 E-5
0.5B 0.5G/Y
B-13 1 3
0.85L/B
B-42 2 4 6 B-42 3
B-42
MAGNETIC CLUTCH (COMPRESSOR)
B-13
0.5L/O
2 5 B-42 2
B-13
0.5L/Y
3 4 B-42 1 OFF
2B
B-13
0.5L/W
BLOWER RESISTOR
HEADLIGHT BRACKET (LH) 0.85B 2B

B-42
B-7
3B 2B
1
5B
FRAME-LH (FRONT)
B-1
FAN SWITCH
FRAME-LH (CENTER)
J-9
N8B0066E
F-1 15A HEATER, AIR CON 0.85BR 0.85BR

1 X-10 X-10 J-257 J-257 X-10 4 4 5 2 X-10 5 H-5 2 J-257 J-257 J-191 1 2
30B/R
2L 0.85G/W ECM 0.85G/O 0.5G/O 34
FL-1 100A 8B MAIN 8W/B 0.85G/W
PRESSURE SWITCH
P-1
P-2
0.5LG/B
H-6
RELAY; A/C THERMO
0.85L
5W/B
P-3
3L
4 B-17 X-32 B-18 4 2
0.85G/O
0.5G/Y
P-4
(NKR) DIODE
(NPR with M/T) DIODE
0.85BR
B-17 3 3 1 X-32 B-18
1 B-14
RELAY; CONDENSER FAN 0.5B

5 X-27 J-257 6 X-27 X-27 3 7 1 H-105
(NPR with SMOOTHER) DIODE
3W/B 0.5P/G
RELAY; HEATER & A/C

X-12 4 2 1 2 B-39 B-15 B-15 B-39 3 1 B-14 5
P-5
FRAME 0.5LG CONDENSER FAN 0.5LG

X-12
X-12
0.85B 3 J-257
0.85L 2 X-27
BLOWER MOTOR
X-12
0.5W/R ELECTRONIC THERMOSTAT A/C SWITCH

2 3 B-39 B-15
0.75P 0.85L/Y
RELAY; CHARGE (1) 0.85L/B RELAY; GLOW (3) 0.5G/Y 0.5G/Y
2B/L
F-26 15A COND. FAN

1 E-5
0.5B 0.5G/Y
B-13 1 3
0.85L/B
B-42 2 4 6 B-42 3
B-42
MAGNETIC CLUTCH (COMPRESSOR)
B-13
0.5L/O
2 5 B-42 2
B-13
0.5L/Y
3 4 B-42 1 OFF
2B
B-13
0.5L/W
BLOWER RESISTOR
HEADLIGHT BRACKET (LH) 0.85B 2B

B-42
B-7
3B 2B
1
5B
FRAME-LH (FRONT)
B-1
FAN SWITCH
FRAME-LH (CENTER)
J-9
N8B0067E
8-283

Connector List
B-1
000-001
X-10
1 2 3 5 4
005-001
B-7
000-001
X-12
1 2 3 5 4
005-001
J-9
000-001
X-27
005-006
B-13
1 3
2 4
004-010
X-32
1 2 3 4
004-004
B-14
1 2
002-009
B-39
1 2 3
003-019
B-15
1 2 3
003-009
B-42
1 4
2 5
3 6
006-001
J-51 (4HK1)
E-5
1 2
1
002-001
001-013
B-17
E-5
1 2 3 4
004-004
001-014

8-285
J-6 (4HK1)
1 3
2 4
004-011
H-105
1 5 9
2 6
3 7
4 8
10 11 12
012-001
J-257 (4JJ1)
1 4
2 5
3 6
006-031
H-105
4 8
3 7
2 6
1 5 9
12 11 10
012-002
J-191
081-001
B-18 (For 4JJ1 NKR)
1 2 3 4
004-004
H-5 P-1
000-022
P-4
000-014
1 7 13 19 25 31
2 8 14 20 26 32
3 9 15 21 27 33
34
35
36
37
4 10 16 22 28 38
5 11 17 23 29 39
6 12 18 24 30 40
6 12 18 24 30 40
5 11 17 23 29 39
4 10 16 22 28 38
37
36
35
34
3 9 15 21 27 33
2 8 14 20 26 32
1 7 13 19 25 31
P-2
000-014
N8A5488E
P-3
000-014
P-5
000-002

H-6
H-6
H-7
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 H-8
4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14
N8A5489E
Rear Heater
General Description
The circuit consists of rear heater, rear heater switch and the heater relay.
Parts Location
RELAY BOX ASM (No.1) REAR HEATER UNIT (W/CAB)
X-8 HEATER RELAY
F-3
N8B0068E
8-287

Circuit Diagram
For 4HK1 / 4JJ1 (EURO 4) Engine
FL-1 100A/120A MAIN
Except 4JJ1/4HK1 80A ACG 8W/B 5W/B

2 H-6
RELAY; HEATER 5W/B 3W/B 0.5W/R

2 X-8 X-8 1
3B/R
F-3 15A REAR HEATER
8B
8W/B 4JJ1/4HK1 80A ACG
RELAY; CHARGE(5)
X-8
X-8
2L
0.5B/R
6 H-3
P-1 P-2
30B/R
P-3
0.5B
P-4
0.5B/R
1 H-25
P-5
FRAME
0.85B/R
3
REAR HEATER
N-8
N-8 2
N-8 1
0.85L/W
H-25 2
0.85L/R
H-25 3 2
0.85L/W
2B
H-3
0.85L/R
H-3 5 1
0.5L/W
0.5L/R
4 B-59 HI B-59
B-59 LO
OFF
B-7
3B 5B
FRAME-LH(FRONT)
B-1
3B
0.5B
REAR HEATER SW
N8B0069E

Connector List
8-289
X-8
005-006
N-8
003-022
B-1
000-001
N-8
003-023
B-7
000-001
P-2
000-014
B-59
P-1
1 3 2 4
004-015
000-022
H-3
1 4
2 5
3 6
P-4
000-014
006-014
H-3
3 6
2 5
1 4
P-3
000-014
006-015
H-25
1 2 3
003-020
P-5
000-002
H-25
1 3 2
003-021

H-6
H-6
H-7
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 H-8
4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14
N8A5439E N8A5489E
ABS/ASR System
General Description
ABS (Anti-lock Brake System) and ASR (Anti-Slip Regulator) are the system to prevent the wheels from locking and wheel spin, and to assure stability and steering ability of the vehicle. When a malfunction occurs in the system, fail-safe deactivate the ABS and ASR, and the warning lamp comes on. Also, the self-diagnosis function is equipped to improve serviceability.
Rear Heater Switch

N8A5438E
Rear Heater Motor

Inspection Disconnect the rear heater connector. Connect the battery positive terminal to the NO.3 terminal of the rear heater motor side connector and negative to the NO.2. Check to see if rear heater motor operates low-speed correctly. Connect the battery positive terminal to the NO.3 terminal of the rear heater motor side connector and negative to the NO.1. Check to see if rear heater motor operates high-speed correctly. Replace the rear heater motor when the result of inspection is found abnormal.
Parts Location
B-125 ASR OFF SW STARTER SW B-387 RESISTOR 1 J-149 R/LH SENSOR(4HK1) J-148 R/RH SENSOR(4HK1) J-78 RR SENSOR(4JJ1)
FL-1, FL-2, FL-9 FUSIBLE LINK
FUSE BOX ASM F-5, F-7, F-16, F-21
P-5
H-5~H-8
H-14, H-15
J-177 ABS EHCU P1~P4 BATTERY
J-74 F/RH SENSOR J-191 ECM J-9 EARTH ; FRAME
B-66 STOPLIGHT SW (BRAKE SW)
B-1 EARTH ; FRAME (FR) B-7 EARTH ; HEADLIGHT B/T
B-79 DATA LINK CONNECTOR J-75 F/LH SENSOR B-51 ABS WARNING LIGHT (METER) ASR WARNING LIGHT (METER)
B-67 IGNITION SW "A"
N8B0083E
8-291

Circuit Diagram
For 4HK1 Engine
FL-2 40A KEY SW TAIL RELAY X-4 3 3B/Y
OFF 3W/L 8W/B H-7 1 3W/L 2 B-67 B ACC ON ST STARTER SWITCH F-16 0.5B/Y 10A METER 0.5B/Y B-67
2L
3W
F-7 3B/Y F-21 10A TAIL LIGHT 18 8 B-125
8B
FL-1 100A/120A MAIN FL-9 40A ABS
ACG(B) H-6 2 5W/B
P-2
3W/B
P-1
5W/B
F-5 10A STOP LIGHT
P-3 P-4
0.5G/Y
0.5LG/R
5 B-125 B-125 6 3 5 3B B-7
15 H-8
B-51 ASR STOP LIGHT SWITCH ABS
0.5B/Y
B-66
P-5 FRAME
3R
METER
ASR SWITCH B-125
B-66 2
B-51
B-51
0.3W/L
0.3W/V
20
12
0.5G
1 H-15
0.5B/Y
3R
3R
11 H-5
18 H-8
17 H-8
0.5G
0.5B/Y
H-14
H-14
H-14
0.5L
15
16
0.3W/L
0.3W/V
0.5L
16 H-8
4 H-15 STOP LIGHT
3 H-15
2 H-15
0.3W/V
0.3W/L
0.5G
24 J-177 MTR +B
2 J-177 VLV +B VLV MTR GND GND J-177 J-177 1 3B 3B 23 DIAG ALDL J-177 J-177 0.3W/G 0.3W/B 4 29
16 J-177 BRK SW
30 J-177 ASR W/L
6 J-177 ABS W/L FL FL GND SIG J-177 J-177 33 32
3 J-177 IG FR FR GND SIG J-177 J-177 11 10
EHCU
CAN CAN CAN CAN L H L H J-177 J-177 J-177 J-177 15 14 27 26
J-177 ASR SW
RL RL RR RR GND SIG SIG GND J-177 J-177 J-177 J-177 34 22 21 12
16
15 0.3W/G
11 0.3W/B
6 0.5L/W 0.5L/W 0.5R/B 0.5W 0.5R 0.5V 0.5Y 0.5P 0.5L 0.5L 0.5L 0.5L
H-15 H-15 3B 3B
H-15 H-15
12 0.5L 0.5L/W 0.3W/G 0.3W/B H-8
13 H-8
14 H-15
9 H-15
10 H-15
5 H-15
12 H-15
7 H-15
13 H-15
8 H-15
0.5L/W
0.5L
0.5R/B
0.5V
13 B-79
2 B-79 H-8 0.5L 8 H-8 0.5L/W 7
DATA LINK CONNECTOR B-79 B-79 B-79 12 0.5Y 0.5B 5 0.5B 4
1 H-8 10 0.5Y 3B 37 J-191 CAN L 18 J-191 CAN H ECM 52 J-191 ISDIAG 1.25B
2 1 1 2 J-149 J-149 J-148 J-148 2 1 J-75 J-75 FRONT WHEEL -LEFT 2 1 J-74 J-74 FRONT WHEEL -RIGHT W W B B
B-387 B-387
REAR WHEEL -LEFT RESISTOR 1
REAR WHEEL -RIGHT
SPEED SENSOR
J-9 FRAME-LH (CENTER)
B-1 FRAME-LH (FRONT)
0.5P
0.5L
0.5L
3R
3R
2B
0.5B
0.85LG/R
10A ABS(IG)
N8B0070E

For 4JJ1 Engine
FL-2 40A KEY SW
8-293
OFF 3W/L H-7 1 3W/L 2 B-67 B ACC ON ST 8W/B 2 5W/B STARTER SWITCH F-16 0.5B/Y 10A METER 0.5B/Y B-67 3 3B/Y
TAIL RELAY X-4
2L
3W
F-7 3B/Y F-21 10A TAIL LIGHT 18 8 B-125
8B
FL-1 100A MAIN FL-9 40A ABS
P-2
3W/B
P-1
F-5 10A STOP LIGHT
P-3 P-4
0.5G/Y
0.5LG/R
5 B-125 B-125 6 3 5 3B B-7
15 H-8
B-51 ASR STOP LIGHT SWITCH ABS
0.5B/Y
B-66
P-5 FRAME
3R
METER
ASR SWITCH B-125
B-66 2
B-51
B-51
0.3W/L
0.3W/V
20
12
0.5G
1 H-15
0.5B/Y
3R
3R
11 H-5
18 H-8
17 H-8
0.5G
0.5B/Y
H-14
H-14
H-14
0.5L
15
16
0.3W/L
0.3W/V
0.5L
16 H-8
4 H-15 STOP LIGHT
3 H-15
2 H-15
0.3W/V
0.3W/L
0.5G
24 J-177 MTR +B
2 J-177 VLV +B VLV MTR GND GND J-177 J-177 1 3B 3B 23 DIAG ALDL J-177 J-177 0.3W/G 0.3W/B 4 29
16 J-177 BRK SW
30 J-177 ASR W/L
6 J-177 ABS W/L FL FL GND SIG J-177 J-177 33 32
3 J-177 IG FR FR GND SIG J-177 J-177 11 10
EHCU
CAN CAN CAN CAN L H L H J-177 J-177 J-177 J-177 15 14 27 26
J-177 ASR SW
RL RL RR RR GND SIG SIG GND J-177 J-177 J-177 J-177 34 22 21 12
16
15 0.3W/G
11 0.3W/B
6 0.5L/W 0.5L/W 0.5R/B 0.5W 0.5R 0.5V 0.5Y 0.5P 0.5L 0.5L 0.5L 0.5L
H-15 H-15 3B 3B
H-15 H-15
12 0.5L 0.5L/W 0.3W/G 0.3W/B H-8
13 H-8
14 H-15
9 H-15
10 H-15
5 H-15
12 H-15
7 H-15
13 H-15
8 H-15
0.5L/W
0.5L
0.5R/B
0.5V
13 B-79
2 B-79 H-8 0.5L 8 H-8 0.5L/W 7
DATA LINK CONNECTOR B-79 B-79 B-79 12 0.5Y 0.5B 5 0.5B 4
1 H-8 1.25B(Except NKR)/ 0.85B(NKR) 10 0.5Y 3B 37 J-191 CAN L 18 J-191 CAN H ECM 52 J-191 ISDIAG
1 2 4 3 J-78 J-78 J-78 J-78 2 1 J-75 J-75 FRONT WHEEL -LEFT 2 1 J-74 J-74 FRONT WHEEL -RIGHT W W B B
B-387 B-387
REAR WHEEL -LEFT RESISTOR 1
REAR WHEEL -RIGHT
SPEED SENSOR
J-9 FRAME-LH (CENTER)
B-1 FRAME-LH (FRONT)
0.5P
0.5L
0.5L
3R
3R
2B
0.5B
0.85LG/R
H-6
10A ABS(IG)
N8B0071E

Connector List
B-1
000-001
B-387
002-038
B-7
000-001
B-387
002-039
3 8 7
2 6
1 5
B-51
020-004
H-14
14 13 12 11 10
16
15
016-004
2 6 7
3 8
4 9
B-66
1 2
H-14
10 11 12 13 14 15 16
002-031
016-003
2 6 7
3 8
4 9
B-67
2 4
1 3
H-15
10 11 12 13 14 15 16
004-002
016-003
3 8 7
2 6
1 5
B-67
1 3
2 4
004-001
H-15
14 13 12 11 10
16
15
016-004
B-79
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
016-005
J-9
000-001
B-125
1 5
2 3 4 6 7 8
008-001
J-74
1
002-012

8-295
J-74
2
002-011
J-149 (4HK1 )
2
002-011
J-75
1
002-012
J-177
034-001
J-75
2
002-011
J-177
034-002
J-78 (4JJ1)
1 3
2 4
004-011
J-191
081-001
J-78 (4JJ1)
004-018
P-1
000-022
J-148 (4HK1 )
1
002-012
P-2
000-014
J-148 (4HK1 )
2
002-011
P-3
000-014
J-149 (4HK1 )
1
002-012
P-4
000-014

No. Connector Face
Transmission Control System (Smoother)

General Description
Smoother is the name of a new-generation drive train that provides benefits in terms of both life cycle costs (low initial cost and maintenance cost, lower fuel consumption, etc.) and easy driving. Smoother is a system that adds an automatic transmission to the existing Smoother, for even better fuel consumption and easier driving. This is accomplished by installing a solenoid system shift control box on the Smoother, which combines a manual transmission with fluid coupling, so all shifting is performed automatically in accordance with signals from the transmission control module (TCM). When starting moving the vehicle, depressing the brake pedal and operating the change lever as on an automatic vehicle causes a change lever position signal to be detected by the TCM. This actuates the shift control box solenoid and shifts the gear into the starting position or the reverse position, and then engages the shift change clutch (wet multi-disc clutch). (After the shift clutch engages, creep force is generated the same as on an AT vehicle.) Releasing the foot from the brake pedal and pressing the accelerator pedal starts the vehicle moving forward. If there is an up-shift or down-shift while running, the control unit determines the vehicle status based on vehicle speed, accelerator opening angle, and other factors, and shifts to the optimal gear automatically. If the driver moves the change lever in the + or - direction, a gear change is indicated, so sequential manual shifting is also possible. (Even during sequential manual shifting, the transmission shifts to the starting position when the vehicle is stopped.)
P-5
000-002
X-4
005-006
H-5
1 7 13 19 25 31
2 8 14 20 26 32
3 9 15 21 27 33
34
35
36
37
4 10 16 22 28 38
5 11 17 23 29 39
6 12 18 24 30 40
6 12 18 24 30 40
5 11 17 23 29 39
4 10 16 22 28 38
37
36
35
34
3 9 15 21 27 33
2 8 14 20 26 32
1 7 13 19 25 31
N8A5488E
H-6, H-7, H-8
H-6
H-7
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 H-8
4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14
N8A5489E

Parts Location
For 4HK1 / 4JJ1 (EURO 4) Engine (Except NKR Model)
N-7 DOOR SW (RH) X-32 DIODE RELAY BOX ASM (No. 1) RELAY BOX ASM (No. 2) X-14 SMOOTHER EMERGENCY RELAY X-15 SMOOTHER MAIN RELAY FUSE BOX ASM F-5,F-13, F-16, F-17, F-22
8-297
N-19 SELECT SW N-17 EMERGENCY SW N-18 EMERGENCY SHIFT SW B-417 PTO SWITCH B-425, B-426, B-427, B-428 TCM J-26, J-27 STARTER N-2 DOOR SW (LH) H-118 H-119 ECM (J-191)
STARTER SW
H-3
P-5 P-1 P-2 BATTERY P-4 P-3
B-431 RESISTOR 2 H-4, H-5, H-6, H-7, H-8 B-66 STOPLIGHT SW B-51, B-53 METER B-67 STARTER SW B-1 J-9 H-17 B-7 H-12
RELAY BOX ASM F-28 FUSE SBF1, SBF2, SBF5, SBF7, SBF8 FUSIBLE LINK X-18 ECM MAIN RELAY X-19 GEAR SHIFTER RELAY X-21 STARTER RELAY X-26 STARTER CUT RELAY
B-106 ADJUST SW B-105 RESET SW B-79 DATA LINK CONNECTOR J-232 TURBINE SPEED SENSOR J-234 SELECT SOLENOID
B-387 RESISTOR 1 J-237 SOLENOID & ATF TEMPERATURE SENSOR
J-50 NEUTRAL SW J-223 SELECT STROKE SENSOR
H-118 J-142 SHIFT STROKE SENSOR J-139 INPUT SPEED SENSOR J-236 SHIFT SOLENOID 2, 4, R J-235 SHIFT SOLENOID 1, 3, 5 H-119
N8B0072E

For 4JJ1 (EURO 4) Engine (NKR Model)
N-7 DOOR SW (RH) N-19 SELECT SW X-32 DIODE RELAY BOX ASM (No. 1) RELAY BOX ASM (No. 2) X-14 SMOOTHER EMERGENCY RELAY X-15 SMOOTHER MAIN RELAY FUSE BOX ASM F-5,F-13, F-16, F-17, F-22 N-17 EMERGENCY SW N-18 EMERGENCY SHIFT SW B-417 PTO SWITCH B-425, B-426, B-427, B-428 TCM J-26, J-27 STARTER STARTER SW ECM (J-191) N-2 DOOR SW (LH)
H-118 H-119
H-3
P-5 P-1 P-2 BATTERY P-4 P-3
B-431 RESISTOR 2 H-5, H-6, H-7, H-8 H-4 B-66 STOPLIGHT SW B-51, B-53 METER B-67 STARTER SW H-17 B-1 J-9 B-7 H-12 B-105 RESET SW B-79 DATA LINK CONNECTOR
RELAY BOX ASM F-28 FUSE SBF1, SBF2, SBF5, SBF7, SBF8 FUSIBLE LINK X-18 ECM MAIN RELAY X-19 GEAR SHIFTER RELAY X-21 STARTER RELAY X-26 STARTER CUT RELAY
B-106 ADJUST SW J-232 TURBINE SPEED SENSOR J-234 SELECT SOLENOID
B-387 RESISTOR 1 J-237 SOLENOID & ATF TEMPERATURE SENSOR
J-50 NEUTRAL SW J-223 SELECT STROKE SENSOR
H-118 J-142 SHIFT STROKE SENSOR J-139 INPUT SPEED SENSOR J-236 SHIFT SOLENOID 2, 4, R J-235 SHIFT SOLENOID 1, 3, 5 H-119
N8B0073E

Circuit Diagram
For 4HK1 Engine
8-299
FL-2 40A KEY
OFF 3W/L 1 H-7 2 3W/L B-67 ACC ON ST IGNITION SWITCH 4 8W/B 5W/B 2 H-6 5W/B 0.5B/Y 3W/B 0.5B/Y F-5 10A STOP LIGHT 1.25G/W F-13 10A NEES (B) 14 H-12 0.5B/Y 0.5Y/R 2 N-17 DIODE B-1 X-32 X-32 1 0.5B/Y 18 B-51 IPC 6 B-53 B-53 1 0.3P 8 0.3G/O B-53 7 0.3Y/G 12 B-425 B-428 18 0.3B/W 12 B-79 B-79 4 0.5B 5 0.5B B-79 B-79 14 B-425 11 B-425 F-16 10A METER 3 B-67 B-67 3B/Y 3B/Y 3B/Y 3B/Y 3W/B
2L
P-1 P-2
FL-8 60A STARTER 0.5R/W 14 H-8 0.5R/W
F-22 10A STARTER 3W/R
FL-5 40A ECM
0.5L/B 4 X-18 RELAY:MAIN
X-18
3W/B
1 SW: BRAKE PEDAL B-66
0.5G/Y
1 SW: EMERGENCY 5 X-15 0.3L/R 4 H-12 0.3L/R
P-3 2 P-4 RELAY:STARTER X-21 4 X-21
X-18 5 2
X-18
B-66 2 RELAY: SMOOTHER MAIN
0.5G/W
OIL PUMP ASM
1.25G/W
N-17
1.25R
2 X-15
ECM X-21 3 5 X-21
J-237 2 0.5Y/R F-28 10A ECM
J-237 4 0.5L/W
J-237 1 0.5R/Y
J-237 3 0.5Y/B
P-5 1 STARTER
0.85LG
J-26 B C 1 J-27 0.5LG 3B/W
2 7 15 6 H-118 H-119 H-118 H-118 0.5L/W 0.5Y/R 0.5R/Y
X-15 1 5
X-15
0.5Y/B
0.5G
1.25W/O
0.5W/V
0.5R
3 H-4 0.5Y/R
4 H-4 0.5L/W
1 H-17 0.5R/Y
3 H-17 0.5Y/B
0.3L/R
0.5LG
2 J-50 SW: NEUTRAL
0.5R 0.5R
6 B-427 J-50 1 0.5B/L
12 B-427
29 B-425
30 B-425
3 B-428
STOP LIGHT
3 B-426
15 B-425
4 B-428
TCM
5 H-4 0.5B/L B-428 10 B-425 16 B-428 12 B-426 4 B-426 8 B-426 12 B-426 17 B-428 19 B-427 2 0.5L/W B-427 3 0.5L B-426 9 0.3LB
5 H-17
0.3L/R
0.5R
0.5B
ECM 0.5W/L
0.5GR/R
RESISTOR 1
1.25B
RELAY: SMOOTHER EMERGENCY
1.25B
12 H-4
0.5W/L
2 0.5B 0.5B B-387 1 B-387 7 H-8 0.5L/W 0.5L 0.5L 8 H-8
4 RELAY: STARTER CUT X-26
3 X-26
1 X-14
3 X-14
X-26 1 0.5B 5
X-26 0.5W/L
X-14 5 0.3B 2
X-14 0.3B
ROOM LAMP 0.5GR/R 0.5GR/R
0.5L/W 37 TAIL LIGHT RESISTOR 2 0.5LG/R ECM 2 B-431 1 B-431 0.5L/W 0.5LB 0.5Y 0.5L 0.3L/W H-5 36 H-5
6 ECM H-12 1.2GR/R
3 H-3 0.5GR/B
SW: DOOR (ASSISTANT)
1 SW: DOOR (DRIVER) N-2
1 N-7 SW:PTO
1 B-417
B-417
2B
2B
DATA LINK CONNECTOR
6 B-79
14 B-79
B-417 3 2B
B-417 2
HEADLIGHT BRACKET
B-7
3B
2B
0.5B
5B
FRAME-LH(FRT) FRAME-LH(CTR)
B-1 J-9
1.25B 2B
2B
N8B0074E
0.5Y B-53
FL-7 60A NEES 3B/Y 3R F-17 10A NEES (IG) 3 0.5B/O RELAY: GEAR SHIFT CONTROL BOX X-19 2R 4 X-19 0.5B/O 0.5B/O X-19 2 GEAR SHIFT POSITION SENSOR GEAR SELECT POSITION SENSOR TURBINE SPEED SENSOR INPUT SHAFT SPEED SENSOR 3P 5
X-19
SW: HALF-CLUTCH ADJUSTMENT
B-105 SW: RESET
B-106 SLOW FAST
J-142 1 0.5R
J-142 2 0.5W
J-142 3 0.5B
J-223 1 0.5Y/B
J-223 2 0.5Y/W
J-223 3 0.5Y/R
J-232 1 0.5O/L
J-232 2 0.5W/L
J-139 1 0.5BR
J-139 2 0.5Y
18 1 H-160 H-4 3P
B-105 6
B-106 B-106 2 1
3 2 7 H-119 H-119 H-119
6 10 14 H-119 H-119 H-119 0.5Y/W
5 H-119 0.5O/L
9 H-119 0.5W/L
8 H-118 0.5BR
3 H-118
0.5Y/R
0.5Y/B
0.5W
0.5R
0.3GR/R
0.3GR/B
0.3GR/L
0.5B/O
0.5B/O
6 H-4
7 H-4
17 H-4
0.5B
13 H-4
14 H-4 0.5Y/W
15 H-4
20 H-4 0.5O/L
9 H-4 0.5W/L
10 H-4 0.5BR
1 H-4
0.5Y/R
0.5Y/B
0.5W
0.5Y
0.5Y
1 B-426
2 B-426
17 B-428
18 B-426
19 B-426
20 B-426
10 B-426
11 B-426
13 B-426
10 B-427
4 B-427
11 B-427
5 B-427
4 B-425
5 B-425
5 B-426
6 B-426
1 B-428
8 B-428
18 B-425
B-428 B-428
TCM
B-428 20 0.5R B-428 6 0.5W B-428 14 0.5G B-427 B-428 B-427 B-427 B-427 B-427 13 0.5R/B 21 0.5W/B 14 0.5O 15 0.5L/B 7 0.5P/B 8 0.5G/B B-427 1 0.5Y/R B-428 13 0.5L B-425 21 1.25B/R B-425 31 1.25B/R B-425 8 1.25B/L B-425 9 1.25B/L B-428 16 1.25W/B B-428 22 1.25W/B B-425 6 1.25B B-425 7 1.25B B-425 1 1.25B B-425 2 1.25B B-428 7 1.25B B-428 15 1.25B 9 H-17 1.25B H-17 1.25B
3 H-12
1.25W/B
1.25B/R
1.25B/L
13 H-12 0.5W
9 H-12 0.5G
8 H-12 0.5R/B
20 2 12 1 11 H-12 H-12 H-12 H-12 H-12 0.5W/B 0.5G/B 0.5P/B 0.5L/B 0.5O
21 H-12 0.5Y/R
10 H-12
1.25B
0.5R
0.5L
4 H-17 1.25B/R
6 H-17 1.25B/L
2 H-17 1.25W/B
7 H-17 1.25B
1.25B
1 N-18
2 N-18 N 1
3 N-18
2 N-19
6 N-19
7 N-19
10 N-19
8 N-19
4 N-19 SW:1ST GEAR START
3 N-19 4 SW:ECHO MODE N-20
5 N-19 6 N-20
R N-18 SW: EMERGENCY 5 SHIFT
5 H-118 2G
1 H-119 2L
13 H-119 2W/B
N-20 1
N-20 3 1-3-5 SHIFT SOLENOID
2 J235 2-4-R SHIFT SOLENOID
2 J236 SELECT SOLENOID
2 J234
A N-19 9
SELECT LEVER
J-235 1 2B
J-236 1 2B
J-234 1 2B
4 H-118 1.25B
4 H-119 1.25B
16 H-119 1.25B
0.5B
0.5B 2B
15 H-12
0.5B
N8B0075E
1.25B
0.5V/W
0.5R
0.5B
1.25P
1.25P
1.25P
1.25P
1.25P
1.25P
0.5V/W

For 4JJ1 (EURO 4) Engine (Except NKR Model) (1)
8-301
FL-2 40A KEY
OFF 3W/L 1 H-7 3W/L 2 B-67 ACC ON ST IGNITION SWITCH 4 8W/B F-16 10A METER H-6 5W/B 0.5B/Y F-5 10A STOP LIGHT 1.25G/W F-13 10A NEES (B) 14 H-12 0.5B/Y 0.5Y/R 2 N-17 DIODE B-1 X-32 X-32 1 0.5B/Y 18 B-51 IPC 6 B-53 B-53 1 0.3P 8 0.3G/O B-53 7 0.3Y/G 12 B-425 B-428 18 0.3B/W 12 B-79 B-79 4 0.5B 5 0.5B B-79 B-79 14 B-425 11 B-425 0.5B/Y 3W/B 3 B-67 B-67 3B/Y 3B/Y 2 3W/B 3B/Y
2L
P-1 P-2
FL-5 40A ECM
FL-1 100A MAIN
X-18
3W/B
0.5G/Y
X-18 5 2
X-18
0.5G/W
OIL PUMP ASM
1.25G/W
N-17
1.25R
2 X-15
ECM X-21 3 5 X-21
J-237 2 0.5Y/R F-28 10A ECM
J-237 4 0.5L/W
J-237 1 0.5R/Y
J-237 3 0.5Y/B
P-5 1 STARTER
0.85LG
J-26 3B/W B C 1 J-27 0.5LG
6 H-118 0.5Y/R
14 H-119 0.5L/W
3 H-118 0.5R/Y
7 H-118 0.5Y/B
X-15 1 5
X-15
0.5G
1.25W/O
0.5W/V
0.5R
3 H-4 0.5Y/R
4 H-4 0.5L/W
1 H-17 0.5R/Y
3 H-17 0.5Y/B
0.3L/R
0.5LG
2 J-50 SW: NEUTRAL
0.5R 0.5R
6 B-427 J-50 1 0.5B/L
12 B-427
29 B-425
30 B-425
3 B-428
STOP LIGHT
3 B-426
15 B-425
4 B-428
TCM
5 H-17
0.3L/R
0.5R
0.5B
ECM 0.5W/L
0.5GR/R
RESISTOR 1
1.25B
1.25B
12 H-4
0.5W/L
2 0.5B 0.5B B-387 1 B-387 7 H-8 0.5L/W 0.5L 0.5L 8 H-8
3 X-26
1 X-14
3 X-14
X-26 1 0.5B 5
X-26 0.5W/L
X-14 5 0.3B 2
X-14 0.3B
6 ECM H-12 1.2GR/R
3 H-3 0.5GR/B
1 N-7 SW:PTO
1 B-417
B-417
2B
2B
DATA LINK CONNECTOR
6 B-79
14 B-79
B-417 3 2B
B-417 2
HEADLIGHT BRACKET
B-7
3B
2B
0.5B
5B
B-1 J-9
1.25B 2B
2B
N8B0076E
0.5Y B-53

For 4JJ1 (EURO 4) Engine (Except NKR Model) (2)
X-19
B-105 SW: RESET
B-106 SLOW FAST
J-142 1 0.5R
J-142 2 0.5W
J-142 3 0.5B
J-223 1 0.5Y/B
J-223 2 0.5Y/W
J-223 3 0.5Y/R
J-232 1 0.5O/L
J-232 2 0.5W/L
J-139 1 0.5BR
J-139 2 0.5Y
18 1 H-160 H-4 3P
B-105 6
B-106 B-106 2 1
2 H-119
3 H-119
6 H-119
7 H-119 0.5Y/B
11 H-119 0.5Y/W
15 H-119 0.5Y/R
8 H-119 0.5O/L
12 H-119 0.5W/L
5 H-118 0.5BR
2 H-118
0.5W
0.5R
0.3GR/R
0.3GR/B
0.3GR/L
0.5B/O
0.5B/O
6 H-4
7 H-4
17 H-4
0.5B
13 H-4
14 H-4 0.5Y/W
15 H-4
20 H-4 0.5O/L
9 H-4 0.5W/L
10 H-4 0.5BR
1 H-4
0.5Y/R
0.5Y/B
0.5W
0.5Y
0.5Y
1 B-426
2 B-426
17 B-428
18 B-426
19 B-426
20 B-426
10 B-426
11 B-426
13 B-426
10 B-427
4 B-427
11 B-427
5 B-427
4 B-425
5 B-425
5 B-426
6 B-426
1 B-428
8 B-428
18 B-425
B-428 B-428
TCM
B-428 20 0.5R B-428 6 0.5W B-428 14 0.5G B-427 B-428 B-427 B-427 B-427 B-427 13 0.5R/B 21 0.5W/B 14 0.5O 15 0.5L/B 7 0.5P/B 8 0.5G/B B-427 1 0.5Y/R B-428 13 0.5L B-425 21 1.25B/R B-425 31 1.25B/R B-425 8 1.25B/L B-425 9 1.25B/L B-428 16 1.25W/B B-428 22 1.25W/B B-425 6 1.25B B-425 7 1.25B B-425 1 1.25B B-425 2 1.25B B-428 7 1.25B B-428 15 1.25B 9 H-17 1.25B H-17 1.25B
3 H-12
1.25B/R
1.25W/B
1.25B/L
13 H-12 0.5W
9 H-12 0.5G
8 H-12 0.5R/B
20 2 12 1 11 H-12 H-12 H-12 H-12 H-12 0.5W/B 0.5G/B 0.5P/B 0.5L/B 0.5O
21 H-12 0.5Y/R
10 H-12
1.25B
0.5R
0.5L
4 H-17 1.25B/R
6 H-17 1.25B/L
2 H-17 1.25W/B
7 H-17 1.25B
1.25B
1 N-18
2 N-18 N 1
3 N-18
2 N-19
6 N-19
7 N-19
10 N-19
8 N-19
5 N-19 6 N-20
R N-18 SW: EMERGENCY SHIFT
8 H-118 2G
4 H-119
16 H-119 2W/B
N-20 1
2L
2 J234
A N-19 9
SELECT LEVER
J-235 1 2B
J-236 1 2B
J-234 1 2B
1 H-118 1.25B
1 H-119 1.25B
13 H-119 1.25B
0.5B
0.5B 2B
15 H-12
0.5B
N8B0077E
1.25B
0.5V/W
0.5R
0.5B
1.25P
1.25P
1.25P
1.25P
1.25P
1.25P
0.5V/W

For 4JJ1 (EURO 4) Engine (NKR Model) (1)
8-303
FL-2 40A KEY
OFF 3W/L 1 H-7 2 3W/L B-67 ACC ON ST IGNITION SWITCH 4 8W/B F-16 10A METER H-6 5W/B 0.5B/Y F-5 10A STOP LIGHT 1.25G/W F-13 10A NEES (B) 14 H-12 0.5B/Y 0.5Y/R 2 N-17 DIODE B-1 X-32 X-32 1 0.5B/Y 18 B-51 IPC 6 B-53 B-53 1 0.3P 8 0.3G/O B-53 7 0.3Y/G 12 B-425 B-428 18 0.3B/W 12 B-79 B-79 4 0.5B 5 0.5B B-79 B-79 14 B-425 11 B-425 0.5B/Y 3W/B 3 B-67 B-67 3B/Y 3B/Y 2 3W/B 3B/Y
2L
P-1 P-2
FL-5 40A ECM
FL-1 100A MAIN
X-18
3W/B
0.5G/Y
X-18 5 2
X-18
0.5G/W
OIL PUMP ASM
1.25G/W
N-17
1.25R
2 X-15
ECM X-21 3 5 X-21
J-237 2 0.5Y/R F-28 10A ECM
J-237 4 0.5L/W
J-237 1 0.5R/Y
J-237 3 0.5Y/B
P-5 1 STARTER
0.85LG
J-26 3B/W B C 1 J-27 0.5LG
6 H-118 0.5Y/R
14 H-119 0.5L/W
3 H-118 0.5R/Y
7 H-118 0.5Y/B
X-15 1 5
X-15
0.5G
1.25W/O
0.5W/V
0.5R
7 H-17 0.5Y/R
8 H-17 0.5L/W
9 H-17 0.5R/Y
11 H-17 0.5Y/B
0.3L/R
0.5LG
2 J-50 SW: NEUTRAL
0.5R 0.5R
6 B-427 J-50 1 0.5B/L
12 B-427
29 B-425
30 B-425
3 B-428
STOP LIGHT
3 B-426
15 B-425
4 B-428
TCM
11 H-4
0.3L/R
0.5R
0.5B
ECM 0.5W/L 5
RESISTOR 1
1.25B
1.25B
H-17
0.5GR/R
0.5W/L
2 0.5B 0.5B B-387 1 B-387 7 H-8 0.5L/W 0.5L 0.5L 8 H-8
3 X-26
1 X-14
3 X-14
X-26 1 0.5B 5
X-26 0.5W/L
X-14 5 0.3B 2
X-14 0.3B
6 ECM H-12 1.2GR/R
3 H-3 0.5GR/B
1 N-7 SW:PTO
1 B-417
B-417
2B
2B
DATA LINK CONNECTOR
6 B-79
14 B-79
B-417 3 2B
B-417 2
HEADLIGHT BRACKET
B-7
3B
2B
0.5B
5B
B-1 J-9
0.85B 2B
2B
N8B0078E
0.5Y B-53

For 4JJ1 (EURO 4) Engine (NKR Model) (2)
X-19
B-105 SW: RESET
B-106 SLOW FAST
J-142 1 0.5R
J-142 2 0.5W
J-142 3 0.5B
J-223 1 0.5Y/B
J-223 2 0.5Y/W
J-223 3 0.5Y/R
J-232 1 0.5O/L
J-232 2 0.5W/L
J-139 1 0.5BR
J-139 2
12 1 H-160 H-4 3P
B-105 6
B-106 B-106 2 1
2 H-119
3 H-119
6 H-119
7 H-119 0.5Y/B
11 H-119 0.5Y/W
15 H-119 0.5Y/R
8 H-119 0.5O/L
12 H-119 0.5W/L
5 H-118 0.5BR
2 H-118
0.5W
0.5R
0.3GR/R
0.3GR/B
0.3GR/L
0.5B/O
0.5B/O
5 H-4
6 H-4
7 H-4
0.5B
1 H-4
2 H-4 0.5Y/W
3 H-4
8 H-4 0.5O/L
4 H-4 0.5W/L
10 H-4 0.5BR
9 H-4
0.5Y/R
0.5Y/B
0.5W
0.5Y
0.5Y
0.5Y
1 B-426
2 B-426
17 B-428
18 B-426
19 B-426
20 B-426
10 B-426
11 B-426
13 B-426
10 B-427
4 B-427
11 B-427
5 B-427
4 B-425
5 B-425
5 B-426
6 B-426
1 B-428
8 B-428
18 B-425
B-428 B-428
TCM
B-428 20 0.5R B-428 6 0.5W B-428 14 0.5G B-427 B-428 B-427 B-427 B-427 B-427 13 0.5R/B 21 0.5W/B 14 0.5O 15 0.5L/B 7 0.5P/B 8 0.5G/B B-427 1 0.5Y/R B-428 13 0.5L B-425 21 1.25B/R B-425 31 1.25B/R B-425 8 1.25B/L B-425 9 1.25B/L B-428 16 1.25W/B B-428 22 1.25W/B B-425 6 1.25B B-425 7 1.25B B-425 1 1.25B B-425 2 1.25B B-428 7 1.25B B-428 15 1.25B 16 H-17 1.25B
3 H-12
1.25B/R
1.25W/B
1.25B/L
13 H-12 0.5W
9 H-12 0.5G
8 H-12 0.5R/B
20 2 12 1 11 H-12 H-12 H-12 H-12 H-12 0.5W/B 0.5G/B 0.5P/B 0.5L/B 0.5O
21 H-12 0.5Y/R
10 H-12
1.25B
0.5R
0.5L
1 N-18
2 N-18 N 1
3 N-18
2 N-19
6 N-19
7 N-19
10 N-19
8 N-19
5 N-19 6 N-20
13 H-17 1.25B/R
12 H-17 1.25B/L
10 H-17 1.25W/B
14 H-17 1.25B
1.25B
15 H-17 1.25B
R N-18 SW: EMERGENCY 5 SHIFT
8 H-118 2G
4 H-119
16 H-119 2W/B
N-20 1
2L
2 J234
A N-19 9
SELECT LEVER
J-235 1 2B
J-236 1 2B
J-234 1 2B
1 H-118 1.25B
1 H-119 1.25B
13 H-119 1.25B
0.5B
0.5B 2B
15 H-12
0.5B
N8B0079E
1.25B
0.5V/W
0.5R
0.5B
1.25P
1.25P
1.25P
1.25P
1.25P
1.25P
0.5V/W

Connector list
For 4HK1 / 4JJ1 (EURO 4) Engine (Except NKR Model) No.
l
8-305
Connector Face
No.
Connector Face
B-1
000-001
B-105
006-021
B-7
000-001
B-106
1 2 3
003-014
B-51
020-004
B-387
002-038
B-53
012-009
B-387
002-039
B-66
B-417
1 2
1 3
2 4
004-001
002-031
B-67
2 4
1 3
B-425
031-001
004-002
B-67
1 3
2 4
004-001
B-426
024-001
B-79
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
016-005
B-427
017-001

B-428
022-006
H-160
001-023
B-431
002-038
H-12
10 9 8 7 6 22 21 20 19 18 17
5 4 3 2 1 16 15 14 13 12 11
022-002
B-431
002-039
H-12
1 2 3 4 5 11 12 13 14 15 16
6 7 8 9 10 17 18 19 20 21 22
022-001
H-3
1 4
2 5
3 6
H-17
006-014
1 2 3 4 5 6 7 8 9
009-004
H-3
3 6
2 5
1 4
H-17
006-015
3 2 1 6 5 4 9 8 7
009-005
H-4
9 8 7 6 20 19 18 17 16
5 4 3 2 1 15 14 13 12 11 10
H-118 (4HK1 )
020-003
1 5 9
2 6
3 7
4 8
10 11 12
012-001
H-4
1 2 3 4 5 10 11 12 13 14 15
6 7 8 9 16 1718 19 20
H-118 (4HK1 )
020-002
4 8
3 7
2 6
1 5 9
12 11 10
012-002
H-160
H-118 (4JJ1)
001-022
1 5
2 6
3 7
4 8
008-003

8-307
H-118 (4JJ1)
008-018
J-142
003-005
H-119
1 5 9
2 6
3 7
4 8
J-223
016-001
10 11 12
13 14 15 16
003-005
3 7
2 6
1 5 9
H-119
12 11 10
J-232
016-002 002-040
16 15 14 13
J-9
000-001
J-234
002-003
J-26
000-002
J-235
002-003
J-27
000-009
J-236
002-042
J-50
002-035
J-237
004-020
J-139
002-040
P-1
000-022

P-2
000-014
X-21
2 4
3 5
005-003
P-3
000-014
X-26
005-006
P-4
000-014
X-32
1 2 3 4
004-004
P-5
000-002
N-2
001-020
X-14
005-006
N-7
001-020
X -15
005-006
N-17
1 5
2 6
3 7
4 8
008-005
X-18
005-006
N-18
1 2 3 4 5 6
006-007
X-19
2 4
3 5
N-19
005-003
1 2
3 4
5 6 7 8 9 10
010-003

H-5
8-309
1 7 13 19 25 31
2 8 14 20 26 32
3 9 15 21 27 33
34
35
36
37
4 10 16 22 28 38
5 11 17 23 29 39
6 12 18 24 30 40
6 12 18 24 30 40
5 11 17 23 29 39
4 10 16 22 28 38
37
36
35
34
3 9 15 21 27 33
2 8 14 20 26 32
1 7 13 19 25 31
N8A5488E
H-6, H-7, H-8
H-6
H-7
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 H-8
4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14
N8A5489E

For 4JJ1 (EURO 4) Engine (NKR Model) No.
l
Connector Face
No.
Connector Face
B-1
000-001
B-105
006-021
B-7
000-001
B-106
1 2 3
003-014
B-51
020-004
B-387
002-038
B-53
012-009
B-387
002-039
B-66
B-417
1 2
1 3
2 4
004-001
002-031
B-67
2 4
1 3
B-425
031-001
004-002
B-67
1 3
2 4
004-001
B-426
024-001
B-79
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
016-005
B-427
017-001

8-311
B-428
022-006
H-12
1 2 3 4 5 11 12 13 14 15 16
6 7 8 9 10 17 18 19 20 21 22
022-001
B-431
002-038
H-17
1 5 9
2 6
3 7
4 8
10 11 12
13 14 15 16
016-001
3 7
2 6
1 5 9
B-431
002-039
H-17
12 11 10
16 15 14 13
016-002
H-3
1 4
2 5
3 6
H-118
006-014
1 5
2 6
3 7
4 8
008-003
H-3
3 6
2 5
1 4
H-118
006-015 008-018
3 7
2 6
1 5 9
H-4
H-119
012-002
1 5 9
2 6
3 7
4 8
12 11 10
10 11 12
13 14 15 16
016-001
H-4
1 5 9
2 6
3 7
4 8
3 7
2 6
1 5 9
H-119
012-001
10 11 12
12 11 10
16 15 14 13
016-002
H-12
10 9 8 7 6 22 21 20 19 18 17
5 4 3 2 1 16 15 14 13 12 11
H-160
022-002
001-022

H-160
J-232
001-023 002-040
J-9
000-001
J-234
002-003
J-26
000-002
J-235
002-003
J-27
000-009
J-236
002-042
J-50
002-035
J-237
004-020
J-139
002-040
P-1
000-022
J-142
P-2
003-005 000-014
J-223
P-3
003-005 000-014

8-313
P-4
000-014
X-32
1 2 3 4
004-004
P-5
000-002
N-2
001-020
X-14
005-006
N-7
001-020
X -15
005-006
N-17
1 5
2 6
3 7
4 8
008-005
X-18
005-006
N-18
1 2 3 4 5 6
006-007
X-19
2 4
3 5
N-19
005-003
1 2
3 4
5 6 7 8 9 10
010-003
X-21
2 4
3 5
N-20
005-003 006-022
X-26
005-006

H-5
1 7 13 19 25 31
2 8 14 20 26 32
3 9 15 21 27 33
34
35
36
37
4 10 16 22 28 38
5 11 17 23 29 39
6 12 18 24 30 40
6 12 18 24 30 40
5 11 17 23 29 39
4 10 16 22 28 38
37
36
35
34
3 9 15 21 27 33
2 8 14 20 26 32
1 7 13 19 25 31
N8A5488E
H-6, H-7, H-8
H-6
H-7
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 H-8
4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14
N8A5489E
Tacho Graph
Parts Location
J-32 V/SPEED SENSOR
FUSE & RELAY BOX ASM X-4 TAIL RELAY F-4,F-7,F-16 FUSE J-191 ECM
H-118
B-338 TACHO GRAPH
H-5,H-6,H-7
P-1 P-2
BATTERY P-4 P-5 P-3
B-337 PULS CONVERTER
B-1 B-67 STARTER SW
B-51, B-52 METER
RELAY BOX ASM FL-1, FL-2 FUSIBLE LINK
N8B0080E
8-315

Circuit Diagram
For 4HK1 / 4JJ1 (EURO 4) Engine (For Europe)
FOR 4HK1 FL-1 2L 100A /120A MAIN 8W/B 5W/B
2 H-6
30B/R
8B
8W/B FOR 4JJ1
5W/B
3W/B
2W/B
P-1 P-2
3W/L
3 1 X-4
3W/B
2 X-4
FL-2 40A KEY SW
F-4 15A RELAY; TAIL AUDIO(B) DOOR LOCK
H-7 P-3 P-4
3W/L
2 B-67
X-4 5
X-4 1
P-5
OFF STARTER SWITCH ST ON ACC
B-67
F-7 10A TAIL LIGHT F-16 10A METER 0.85LG/R
METER
18
3B/Y
0.5LG/R 0.5LG/R
7 6
IGN
20
B-51
0.5B/Y 0.5B/Y 0.5R 0.5R

5
17
B-52
SPEED
B-52
0.5B
0.3Y/G DIGITAL 0.3Y/G 0.5B/Y
4 3 5 B-338 B-338 B-338
0.5B 1.25B (NPR/NQR) / 0.85B (NKR)

H-5 19
H-5 25
H-5 31
TACHO GRAPH "A" / "B"
ECM
19
0.5B
0.5B/Y
B-335 B-335 B-335
0.5Y/G
IFSPD
J-191
0.5Y/G
0.5B/Y
IG
ILL
(4HK1 SMOOTHER ONLY)
10 H-118
11 H-118
9 H-118
SIG OUT GND GND

B-334 B-335 B-335
0.5W/R
0.5Y/G
0.5B/Y
0.85R +B
2
TAIL LIGHT SWITCH
FOG LAMP SWITCH
3W
0.5B 0.5B 0.85B
0.5B
0.3W/R
J-32
G V/SPEED SENSOR SIG V
0.5B/Y
J-32
B-338 B-338 B-338 1 2 6
J-32
FOR NKR
0.3B
B-337 B-337 B-337 B-337
B-337 B-337 B-337 B-337
FOR NPR/NQR
SIG OUT
IG
SIG GND IN
0.85B (NKR) / 1.25 (NPR/NQR)

B-1
CONVERTER ; PULS
FRAME-LH
0.5B
0.3W/B
1
0.5B
N8B5102E

Connector list
No.
l
8-317
Connector Face
No.
Connector Face
B-1
000-001
B-338
6 5 4 3
006-003
B-51
020-004
B-338
3 4 5 6
006-002
B-52
020-005
X-4
005-006
B-67
2 4
1 3
H-118
1 5
2 6
3 7
4 8
008-003
004-002
B-67
1 3
2 4
004-001
H-118
008-018
B-334
1 2
3 4
004-014
J-32
003-018
B-335
1 2 3 4
5 6 7 8 008-014
J-191
081-001
B-337
P-1
8765 1234
008-013 000-022

No. Connector Face H-6, H-7
P-2
000-014
H-6
H-7
P-3
000-014
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 H-8
4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14
P-4
N8A5489E
000-014
P-5
000-002
H-5
1 7 13 19 25 31
2 8 14 20 26 32
3 9 15 21 27 33
34
35
36
37
4 10 16 22 28 38
5 11 17 23 29 39
6 12 18 24 30 40
6 12 18 24 30 40
5 11 17 23 29 39
4 10 16 22 28 38
37
36
35
34
3 9 15 21 27 33
2 8 14 20 26 32
1 7 13 19 25 31
N8A5488E
LGCEL-WE-0761LH
You are requested to order this manual using the manual number that is shown above.
This manual is applicable for vehicles in all countries except the USA, Canada and Mexico.
All rights reserved. This manual may not be reproduced in whole or in part, without the permission in writing of ISUZU MOTORS LIMITED. Issued by
ISUZU MOTORS LIMITED

SERVICE MARKETING DEPARTMENT Tokyo, Japan First edition August, 2006
No.LGCEL-WE-0761LH

Cab&amp;Chaissis Electrical

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Cab&amp;Chaissis Electrical

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WORKSHOP MANUAL

CAB AND CHASSIS ELECTRICAL (LEFT HAND DRIVE MODEL)

Isuzu Motors Limited Service Marketing Department

Applicable Model: N-Series This manual is applicable to 2007 year model.

THIS MANUAL INCLUDES THE FOLLOWING SECTIONS:

CAB AND CHASSIS ELECTRICAL

CAB AND CHASSIS ELECTRICAL

8-2 CAB AND CHASSIS ELECTRICAL

Notes for Working on Electrical Items

CAB AND CHASSIS ELECTRICAL

8-4 CAB AND CHASSIS ELECTRICAL

CAB AND CHASSIS ELECTRICAL

8-6 CAB AND CHASSIS ELECTRICAL

CAB AND CHASSIS ELECTRICAL

8-8 CAB AND CHASSIS ELECTRICAL Symbols and Abbreviations

Fusible link wire

Switch (Normal close type)

CAB AND CHASSIS ELECTRICAL

Light emitting diode

Double filament bulb

Variable register Rheostat

Coil (inductor), solenoid, magnetic valve

Vacuum switching valve

8-10 CAB AND CHASSIS ELECTRICAL

CAB AND CHASSIS ELECTRICAL 8-11 Parts for Electrical Circuit

8-12 CAB AND CHASSIS ELECTRICAL

Fuse, Fusible Link and Circuit Breaker

CAB AND CHASSIS ELECTRICAL 8-13

8-14 CAB AND CHASSIS ELECTRICAL

MR5C (1T)/ Green

24 V/ Approx. 266 Minimum operating voltage: 16 V at 25C (77F)

MR82C/ Green label

24 V/ Approx. 100 Minimum operating voltage: 16 V at 20C (68F)

MR5C (1T)/ Grey

Check to see if there is any continuity between the relay terminals.

Normal Inspection Abnormal

CAB AND CHASSIS ELECTRICAL 8-15

ACM 13222 M01/ Green

24 V/ Approx. 320 Minimum operating voltage: 18 V at 25C (77F)

Normal Inspection Abnormal

8-16 CAB AND CHASSIS ELECTRICAL

TERMINAL NO. 2 1 CONNECTION PATTERN A B

TERMINAL NO. CONNECTION PATTERN A B

CAB AND CHASSIS ELECTRICAL 8-17

The applicable terminal number is shown for each connector.

8-18 CAB AND CHASSIS ELECTRICAL

CAB AND CHASSIS ELECTRICAL 8-19 Reading The Circuit Diagram

8-20 CAB AND CHASSIS ELECTRICAL

CAB AND CHASSIS ELECTRICAL 8-21

8-22 CAB AND CHASSIS ELECTRICAL

MAIN DATA AND SPECIFICATIONS

Turn signal light

CAB AND CHASSIS ELECTRICAL 8-23

Fuse puller Spare fuse Fuse( F-25 F-28 )

Relay box (Installed on the left side rear of the cab)

Relay box No. 2

CAB AND CHASSIS ELECTRICAL 8-25

8-26 CAB AND CHASSIS ELECTRICAL

CAB AND CHASSIS ELECTRICAL 8-27

8-28 CAB AND CHASSIS ELECTRICAL

HEATER & A/C RELAY

HEATER, AIR CON

AUDIO (B), DOOR LOCK

Cab&Chaissis Electrical

Cab&Chaissis Electrical

X-16 Rear fog 1 1 1 1

X-19 Gear shifter 3 3 3 3