Nissan Electrico

ELECTRICAL SYSTEM
SECTION
EL
When you read wiring diagrams:

I Read GI section, HOW TO READ WIRING DIAGRAMS.
When you perform trouble diagnoses, read GI section, HOW TO FOLLOW FLOW CHART IN
TROUBLE DIAGNOSES and HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL
INCIDENT.
CONTENTS
PRECAUTIONS ...............................................................2
Supplemental Restraint System (SRS) AIR
BAG (4WD models) ...................................................2
BAG (2WD models) ...................................................2
HARNESS CONNECTOR................................................3
Description ...................................................................3
STANDARDIZED RELAY ................................................4
Description ...................................................................4
POWER SUPPLY ROUTING ...........................................6
Schematic ....................................................................6
Wiring Diagram - POWER - ........................................7
Fuse ...........................................................................15
Fusible Link................................................................15
Circuit Breaker Inspection .........................................15
GROUND DISTRIBUTION.............................................16
BATTERY .......................................................................20
How to Handle Battery ..............................................20
Battery Test and Charging Chart...............................23
Service Data and Specifications (SDS).....................27
STARTING SYSTEM .....................................................28
Wiring Diagram - START -.........................................28
Trouble Diagnoses.....................................................29
Construction...............................................................30
Removal and Installation ...........................................34
Magnetic Switch Check .............................................34
Pinion/Clutch Check ..................................................34
Brush Check ..............................................................34
Yoke Check................................................................35
Armature Check.........................................................35
Assembly ...................................................................36
CHARGING SYSTEM ....................................................38
Wiring Diagram - CHARGE -.....................................38
Construction...............................................................42
Removal and Installation ...........................................43
Disassembly...............................................................44
Rotor Check...............................................................44
Brush Check ..............................................................44
Stator Check ..............................................................45
Diode Check ..............................................................46
Assembly ...................................................................47
COMBINATION SWITCH...............................................49
Combination Switch/Check........................................49
Replacement..............................................................51
HEADLAMP ...................................................................52
Wiring Diagram - H/LAMP -.......................................52
Bulb Replacement .....................................................57
Bulb Specifications ....................................................57
Aiming Adjustment .....................................................57
Low Beam..................................................................58
EXTERIOR LAMP..........................................................59
Parking, License and Tail Lamps/Wiring Diagram
- TAIL/L - ....................................................................59
Stop Lamp/Wiring Diagram - STOP/L -.....................61
Back-up Lamp/Wiring Diagram - BACK/L - ...............62
Turn Signal and Hazard Warning
Lamps/Schematic ......................................................63
Turn Signal and Hazard Warning Lamps/Wiring
Diagram - TURN - .....................................................64
Turn Signal and Hazard Warning Lamps/Trouble
Diagnoses ..................................................................67
Combination Flasher Unit Check...............................67
INTERIOR LAMP ...........................................................69
Illumination/Wiring Diagram - ILL - ............................69
Interior and Spot Lamps/Wiring Diagram INT/L - ........................................................................73
METER AND GAUGES .................................................76
Combination Meter ....................................................76
CONTENTS
Speedometer, Tachometer, Temp. and Fuel
Gauges/Schematic.....................................................80
Gauges/Wiring Diagram - METER -..........................81
Unified Control Meter System Description ................87
Meter/gauge Operation and Odo/Trip Meter
Segment Check in Diagnosis Mode ..........................87
Flexible Print Circuit (FPC)........................................88
Electrical Components Inspection .............................94
WARNING LAMPS ........................................................96
Schematic ..................................................................96
Wiring Diagram - WARN - .........................................97
Electrical Components Inspection ...........................107
WARNING BUZZER ....................................................108
Wiring Diagram - BUZZER -....................................108
WIPER AND WASHER................................................110
System Description..................................................110
Front Wiper and Washer/Wiring Diagram WIPER -...................................................................112
Trouble Diagnoses...................................................119
Wiper Installation and Adjustment ...........................120
Washer Nozzle Adjustment .....................................121
Washer Tube Layout ...............................................121
Wiper Linkage..........................................................122
HORN, CIGARETTE LIGHTER AND CLOCK ............123
Wiring Diagram - HORN - .......................................123
REAR WINDOW DEFOGGER.....................................125
Wiring Diagram - DEF -...........................................125
Filament Check........................................................126
Filament Repair .......................................................127
AUDIO ..........................................................................128
Wiring Diagram - AUDIO -.......................................128
AUDIO ANTENNA .......................................................134
Manual Antenna.......................................................134
(Contd)
Power Antenna/Wiring Diagram - P/ANT -..............135

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

COOLING FAN ............................................................................................................... LC SECTION
ECCS, IGNITION SYSTEM, QUICK-GLOW SYSTEM ................................................. EC SECTION
ANTI-LOCK BRAKE SYSTEM ...................................................................................... BR SECTION
SRS AIR BAG ............................................................................................................ RS SECTION
HEATER AND AIR CONDITIONER .............................................................................. HA SECTION
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
PRECAUTIONS
BAG (4WD models)
The Supplemental Restraint System Air Bag, used along with a seat belt, helps to reduce the risk or severity of injury to the driver in a frontal collision. The Supplemental Restraint System consists of an air bag module (located in the center of the steering wheel), a diagnosis sensor unit, warning lamp, wiring harness and
spiral cable. Information necessary to service the system safely is included in the RS section of this Service
Manual.
WARNING:
I To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed
by an authorized NISSAN dealer.
I Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system.
I Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses are covered with yellow insulation either just before the
harness connectors or for the complete harness, for easy identification.

BAG (2WD models)
The Supplemental Restraint System Air Bag, used along with a seat belt, helps to reduce the risk or severity of injury to the driver in a frontal collision. The Supplemental Restraint System consists of an air bag module (located in the center of the steering wheel), a diagnosis sensor unit, warning lamp and spiral cable. Information necessary to service the system safely is included in the RS section of this Service Manual.
WARNING:
I To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed
by an authorized NISSAN dealer.
I Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system.
I Do not use electrical test equipment on any circuit related to the SRS.
EL-2
HARNESS CONNECTOR
Description
HARNESS CONNECTOR
GI
I All harness connectors have been modified to prevent accidental looseness or disconnection.
I The connector can be disconnected by pushing or lifting the locking section.
CAUTION:
Do not pull the harness when disconnecting the connector.
MA
EM
[Example]
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
SEL769D
EL-3
IDX
STANDARDIZED RELAY
Description
NORMAL OPEN, NORMAL CLOSED AND MIXED TYPE RELAYS
Relays can mainly be divided into three types: normal open, normal closed and mixed type relays.
SEL881H
TYPE OF STANDARDIZED RELAYS

1M
.................... 1 Make
2M
.................... 2 Make
1T
.................... 1 Transfer
1M1B .................... 1 Make 1 Break
SEL882H
EL-4
STANDARDIZED RELAY
Description (Contd)
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
SEL661TA
EL-5
POWER SUPPLY ROUTING

Schematic
HEL884
EL-6

Wiring Diagram POWER
BATTERY POWER SUPPLY IGNITION SWITCH IN ANY POSITION
GI
Gasoline engine
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL885
EL-7

Wiring Diagram POWER (Contd)
Gasoline engine
HEL886
EL-8

BATTERY POWER SUPPLY IGNITION SWITCH IN ANY POSITION
Diesel engine
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL887
EL-9

Diesel engine
HEL888
EL-10

ACCESSORY POWER SUPPLY IGNITION SWITCH IN ACC OR ON
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL889
EL-11

IGNITION POWER SUPPLY IGNITION SWITCH IN ON OR START
HEL890
EL-12

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL891
EL-13

HEL892
EL-14

Fuse
a. If fuse is blown, be sure to eliminate cause of problem
before installing new fuse.
b. Use fuse of specified rating. Never use fuse of more than
specified rating.
c. Do not partially install fuse; always insert it into fuse
holder properly.
d. Remove fuse for ELEC B if vehicle is not used for a long
period of time.
GI
MA
EM
LC
SEL954JA
Fusible Link
GEL186
A melted fusible link can be detected either by visual inspection or

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

For example, when current is 30A, the circuit is broken within 8 to
20 seconds.
Circuit breakers are used in the following systems.
I Power window
I Power door lock
BR
ST
RS
BT
SBF284E
HA
IDX
EL-15
GROUND DISTRIBUTION
EARTH
M1/M54
CONNECT TO
ACCESSORY RELAY (In fuse block)
AIR BAG DIAGNOSIS SENSOR UNIT (4WD
models)
ASHTRAY ILLUMINATION
BLOWER RELAY (In fuse block)
CHECK CONNECTOR (NA engine)
CONN. NO.
M14
EL-POWER
M110
RS-SRS
M34
M14
M12
EL-ILL
EL-POWER
EC-CHOKE
CHECK CONNECTOR (Z engine)

CIGARETTE LIGHTER SOCKET
M13
M37
EC-CHOKE
EL-HORN
COMBINATION FLASHER UNIT

DOOR LOCK TIMER
FAN SWITCH ILLUMINATION (Except for
Australia)
FAN SWITCH ILLUMINATION (For Australia)
FAN SWITCH (Except for Australia)
FAN SWITCH (For Australia)
FRONT WIPER AMPLIFIER
(RHD models without KA engine and LHD models)
FRONT WIPER AND WASHER SWITCH
FRONT WIPER MOTOR
(RHD models without KA engine and LHD models)
FUEL FILTER SWITCH (LHD models with diesel
engine)
FUEL PUMP CONTROL MODULE
FUEL RETURN CONTROL SOLENOID VALVE
(LHD models with NA engine)
M15
M51
EL-TURN
EL-D/LOCK
M403
HA-HEATER
M40
M404
M39
HA-HEATER EL-ILL
EC-FIPOT HA-HEATER
HA-HEATER
M220
EL-WIPER
M28
EL-WIPER
M221
EL-WIPER
M259
EL-WARN
M22
EC-FPCM
M257
EC-F/RTN
M29
EC-GLOW
EC-PLA
M30
EC-GLOW
EC-PLA
M253
EC-GLOW
M256
M41
EC-GLOW
EL-TURN
IACV-FICD SOLENOID VALVE (KA engine)

IGNITION RELAY (In fuse block)
POWER WINDOW RELAY
M203
M14
M9
EC-FICD HA-A/C
EL-POWER
EL-WINDOW
REAR WINDOW DEFOGGER SWITCH

SEAT BELT SWITCH
M42
M109
EL-DEF
EL-WARN
SPIRAL CABLE (2WD models with air bag)

FRONT WIPER AMPLIFIER (RHD models with
KA engine)
FRONT WIPER MOTOR (RHD models with KA
engine)
COMBINATION METER (4WD WARNING
LAMP)
COMBINATION METER (ABS WARNING
LAMP)
COMBINATION METER (AIR BAG WARNING
LAMP)
COMBINATION METER (CLOCK ILLUMINATION)
COMBINATION METER (DIGITAL CLOCK)
M26
RS-SRS
F20
EL-WIPER
F21
EL-WIPER
N6
EL-WARN
N6
BR-ABS
EL-WARN
N5
RS-SRS
EL-WARN
N6
EL-ILL
GLOW CONTROL UNIT

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

COMBINATION METER (HIGH BEAM INDICATOR)
COMBINATION METER (ODO/TRIP METER
ILLUMINATION)
CELL CODE
EL-BUZZER
EL-ILL
EL-HORN
N6
EL-HORN
N5
EL-METER
N5
EL-H/LAMP
N6
EL-ILL
EL-16
HA-A/C
EL-ILL
HA-A/C
GROUND DISTRIBUTION
EARTH
M1/M54
M33/M207
(LHD models
with KA
engine)
CONNECT TO
COMBINATION METER (TURN LH INDICATOR)
COMBINATION METER (TURN RH INDICATOR)
COMBINATION METER (UNIFIED METER
CONTROL UNIT)
COMBINATION METER (WATER TEMP.
GAUGE)
COMBINATION METER (METER ILLUMINATION)
DOOR MIRROR REMOTE CONTROL SWITCH
INTERIOR LAMP (Single cab)
SPOT LAMP
FUEL TANK GAUGE UNIT (With electric fuel
pump)
FUEL TANK GAUGE UNIT (With mechanical
fuel pump)
LICENSE PLATE LAMP LH (With step bumper)
LICENSE PLATE LAMP LH (Without step
bumper)
LICENSE PLATE LAMP RH (With step bumper)
LICENSE PLATE LAMP RH (Without step
bumper)
REAR COMBINATION LAMP LH (BACK-UP)
(A-chassis models, and except for Australia and
China)
REAR COMBINATION LAMP LH (BACK-UP)
(For Australia and China except A-chassis models)
REAR COMBINATION LAMP LH (TAIL AND
STOP) (A-chassis models, and except for
Australia and China)
REAR COMBINATION LAMP LH (TAIL AND
STOP) (For Australia and China except Achassis models)
REAR COMBINATION LAMP LH (TURN SIGNAL) (A-chassis models, and except for
REAR COMBINATION LAMP LH (TURN SIGNAL) (For Australia and China except A-chassis
models)
REAR COMBINATION LAMP RH (BACK-UP)
(A-chassis models, and except for Australia and
China)
REAR COMBINATION LAMP RH (BACK-UP)
(For Australia and China except A-chassis models)
REAR COMBINATION LAMP RH (TAIL AND
STOP) (A-chassis models, and except for
REAR COMBINATION LAMP RH (TAIL AND
STOP) (For Australia and China except Achassis models)
REAR COMBINATION LAMP RH (TURN SIGNAL) (A-chassis models, and except for
REAR COMBINATION LAMP RH (TURN SIGNAL) (For Australia and China except A-chassis
models)
LOCK KNOB SWITCH
POWER WINDOW MAIN SWITCH (Double cab)
POWER WINDOW MAIN SWITCH (Single cab)
CONDENSER
DISTRIBUTOR (POWER TRANSISTOR)
ECM (ECCS CONTROL MODULE)
CONN. NO.
CELL CODE
GI
N6
EL-TURN
N6
EL-TURN
N5
EC-VSS
N5
EL-METER
N6
EL-ILL
N3
R4
R3
C3
EL-MIRROR
EL-INT/L
EL-INT/L
EC-FPCM EC-F/PUMP
EL-WARN
C4
EL-METER
T7
EL-TAIL/L
T6
EL-TAIL/L
T3
EL-TAIL/L
T5
EL-TAIL/L
T8
EL-BACK/L
T9
EL-BACK/L
T8
EL-TAIL/L
EL-STOP/L
T9
EL-TAIL/L
EL-STOP/L
T8
EL-TURN
T9
EL-TURN
T1
EL-BACK/L
T2
EL-BACK/L
T1
EL-TAIL/L
EL-STOP/L
RS
T2
EL-TAIL/L
EL-STOP/L
BT
T1
EL-TURN
T2
EL-TURN
D8
D5
D6
M210
M214
M32
EL-D/LOCK
EL-WINDOW
EL-WINDOW
EC-IGN/SG
EC-IGN/SG
EC-MAIN
EC-GLOW
EL-METER
MA
EM
LC
EL-METER
EC
EL-WARN
FE
CL
MT
TF
PD
FA
RA
BR
EL-17
ST
HA
EL-D/LOCK
EL-D/LOCK
IDX
GROUND DISTRIBUTION
EARTH
M208
(LHD models
with KA
engine)
E6/E39
CONNECT TO
DATA LINK CONNECTOR FOR CONSULT
DISTRIBUTOR (CAMSHAFT POSITION
SENSOR)
SHIELD WIRE (CAMSHAFT POSITION
SENSOR)
SHIELD WIRE (MASS AIR FLOW SENSOR)
SHIELD WIRE (THROTTLE POSITION
SENSOR)
SHIELD WIRE (HEATED OXYGEN SENSOR)
(With ABS)
ABS ACTUATOR ASSEMBLY
BRAKE FLUID LEVEL SWITCH
COOLING FAN MOTOR
FRONT COMBINATION LAMP LH (PARKING)
(Except for Australia and China)
FRONT COMBINATION LAMP LH (PARKING)
(For Australia and China)
FRONT COMBINATION LAMP LH (TURN SIGNAL) (Except for Australia and China)
FRONT COMBINATION LAMP LH (TURN SIGNAL) (For Australia and China)
FRONT COMBINATION LAMP RH (PARKING)
(Except for Australia and China)
FRONT COMBINATION LAMP RH (PARKING)
(For Australia and China)
FRONT COMBINATION LAMP RH (TURN SIGNAL) (Except for Australia and China)
FRONT COMBINATION LAMP RH (TURN SIGNAL) (For Australia and China)
FUEL FILTER SWITCH (RHD models with diesel engine)
FUEL RETURN CONTROL SOLENOID VALVE
(RHD models with NA engine)
GLOW RELAY (RHD models with diesel engine)
HEADLAMP LH
HEADLAMP RH
IACV-FICD SOLENOID VALVE (Diesel engine)
ISC-FI POT CONTROL SOLENOID VALVE
POWER ANTENNA
SHIELD WIRE (FRONT WHEEL SENSOR LH)
SHIELD WIRE (FRONT WHEEL SENSOR RH)
SIDE TURN SIGNAL LAMP LH
SIDE TURN SIGNAL LAMP RH
THERMOSWITCH
TRIPLE-PRESSURE SWITCH
VACUUM CONTROL SOLENOID VALVE
CONN. NO.
M11
EC-MIL/DL
ALTERNATOR (Gasoline engine)
E211
NEUTRAL POSITION SWITCH

POWER STEERING OIL PRESSURE SWITCH
(RHD 2WD models with KA engine and LHD
models)
POWER STEERING OIL PRESSURE SWITCH
(RHD 4WD models with KA engine)
SHIELD WIRE (REAR WHEEL SENSOR LH)
(4WD models)
SHIELD WIRE (REAR WHEEL SENSOR RH)
(4WD models)
SHIELD WIRE (REAR WHEEL SENSOR) (2WD
models)
M214
EC-CMPS
M32
EC-MAIN
M214
EC-CMPS
M204
EC-MAFS
M302
EC-TPS
E3
EC-HO2S
M11
BR-ABS
E4
E2
E24
BR-ABS
EL-WARN
LC-COOL/F
E11
EL-TAIL/L
E12
EL-TAIL/L
E11
EL-TURN
E12
EL-TURN
E27
EL-TAIL/L
E28
EL-TAIL/L
E27
EL-TURN
E28
EL-TURN
E5
EL-WARN
E40
EC-F/RTN
E44
E13
E26
E37
E37
E46
E15
E31
E1
E45
E18
E25
E20
E220
EC-GLOW
EL-H/LAMP
EL-H/LAMP
HA-A/C
EC-FIPOT HA-A/C
EL-P/ANT
BR-ABS
BR-ABS
EL-TURN
EL-TURN
LC-COOL/F HA-A/C
LC-COOL/F HA-A/C
EC-IDLE
EC-CHOKE EC-FPCM
EL-WARN
EC-PNP/SW
E208
EC-PST/SW
E207
EC-PST/SW
C5
BR-ABS
C5
BR-ABS
C6
BR-ABS
EL-18
CELL CODE
HA-A/C
EL-BUZZER
EL-CHARGE
GROUND DISTRIBUTION
EARTH
F7/F52
(RHD models
with KA
engine)
F8
(RHD models
with KA
engine)
A1 (Diesel
engine)
R54
CONNECT TO
CONDENSER
DISTRIBUTOR (POWER TRANSISTOR)
DISTRIBUTOR (CAMSHAFT POSITION
SENSOR)
SHIELD WIRE (CAMSHAFT POSITION
SENSOR)
SHIELD WIRE (MASS AIR FLOW SENSOR)
SHIELD WIRE (THROTTLE POSITION
SENSOR)
ALTERNATOR
ENGINE COOLANT TEMPERATURE SENSOR
REAR WINDOW DEFOGGER
CONN. NO.
F10
F14
F51
M11
EC-IGN/SG
EC-IGN/SG
EC-MAIN
EC-MIL/DL
CELL CODE
F14
EC-CMPS
F51
EC-MAIN
F14
EC-CMPS
F4
EC-MAFS
F102
EC-TPS
A7
A11
R53
EC-PLA EL-CHARGE
EC-GLOW
EL-DEF
GI
MA
EM
LC
EL-WARN
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
EL-19
BATTERY
CAUTION:
If it becomes necessary to start the engine with a booster battery and jumper cables,
a. Use a 12-volt booster battery.
b. After connecting battery cables, ensure that they are
tightly clamped to battery terminals for good contact.
c. Never add distilled water through the hole used to check
specific gravity.
How to Handle Battery

METHODS OF PREVENTING OVER-DISCHARGE
MEL040F
The following precautions must be taken to prevent over-discharging a battery.

I The battery surface (particularly its top) should always be kept
clean and dry.
I The terminal connections should be clean and tight.
I At every routine maintenance, check the electrolyte level.
This also applies to batteries designated as low maintenance
and maintenance-free.
I
When the vehicle is not going to be used over a long period of

time, disconnect the negative battery terminal.
Check the charge condition of the battery.

Periodically check the specific gravity of the electrolyte. Keep
a close check on charge condition to prevent over-discharge.
MEL041F
MEL042F
CHECKING ELECTROLYTE LEVEL

WARNING:
Do not allow battery fluid to come in contact with skin, eyes,
fabrics, or painted surfaces. After touching a battery, do not
touch or rub your eyes until you have thoroughly washed your
hands. If acid contacts eyes, skin or clothing, immediately
flush with water for 15 minutes and seek medical attention.
EL-20
BATTERY
How to Handle Battery (Contd)
I
I
Remove the cell plug using a suitable tool.

Add distilled water up to the MAX level.
GI
MA
EM
LC
MEL043F
SULPHATION
A battery will be completely discharged if it is left unattended
for a long time and the specific gravity will become less than
1.100. This may result in sulphation on the cell plates.
To determine if a battery has been sulphated, note its voltage and current when charging it. As shown in the figure, less
current and higher voltage are observed in the initial stage of
charging sulphated batteries.
A sulphated battery may sometimes be brought back into service by means of a long, slow charge, 12 hours or more, followed by a battery capacity test.
SEL709E
EC
FE
CL
MT
SPECIFIC GRAVITY CHECK

1. Read hydrometer and thermometer indications at eye level.
TF
PD
FA
RA
MEL042FA
BR
ST
RS
BT
HA
IDX
EL-21
BATTERY
How to Handle Battery (Contd)
2. Convert into specific gravity at 20C (68F).
Example:
I When electrolyte temperature is 35C (95F) and specific gravity of electrolyte is 1.230, converted specific gravity at 20C
(68F) is 1.240.
I When electrolyte temperature is 0C (32F) and specific gravity of electrolyte is 1.210, converted specific gravity at 20C
(68F) is 1.196.
SEL007Z
EL-22
BATTERY
Battery Test and Charging Chart
GI
Chart I
MA
VISUAL INSPECTION
I Check battery case for cracks or bends.
I Check battery terminals for damage.
I If the difference between the max. and min. electrolyte level in cells is within 10 mm (0.39 in), it is OK.
EM
OK
NG
Replace
battery.
CHECKING SPECIFIC GRAVITY

Refer to Specific Gravity Check.
LC
EC
Below 1.100
1.100 - 1.220
Above 1.220
FE
CL
SLOW CHARGE
Refer to A: Slow
Charge.
Ready for
use
OK
NG
Replace
battery.
Ready for use
QUICK CHARGE
Refer to C: Quick Charge.
I Time required: 45 min.
OK
Ready for use
CAPACITY TEST
Refer to Chart II.
ST
CAPACITY TEST
Refer to Chart II.
RA
BR
FA
H
CHECKING SPECIFIC
GRAVITY
Refer to Specific Gravity
Check.
RECHARGE
I If battery temperature rises above 60C (140F), stop
charging. Always charge battery when its temperature
is below 60C (140F).
OK
PD
Ready for use

I Mount battery again and
check loose terminals.
Also check other related
circuits.
CAPACITY TEST
Refer to Chart II.
NG
NG
CAPACITY TEST
Refer to Chart II.
TF
OK
OK
CAPACITY TEST
Refer to Chart II.
QUICK CHARGE
STANDARD CHARGE
Refer to B: Standard
Charge.
MT
H
H
NG
Replace
battery.
RS
BT
HA
NG
Ready for Replace

use
battery.
* STANDARD CHARGE is recommended if the vehicle is in storage after charging.
EL-23
IDX
BATTERY
Battery Test and Charging Chart (Contd)
I Check battery type and determine the specified current
using the following table.
Fig. 1 DISCHARGING CURRENT
(Load Tester)
Chart II
CAPACITY TEST
Test using battery checker.
Test using load tester.
Follow manufacturers instructions to check and determine

if battery is serviceable.
Read load tester voltage

when specified discharging
current (Refer to Fig. 1.) flows
through battery for 15 seconds.
OK
Ready for use
NG
Go to next
step.
Above 9.6
volts
OK
H
Ready for use
Type
Current (A)
28B19R(L)
90
34B19R(L)
99
46B24R(L)
135
55B24R(L)
135
50D23R(L)
150
55D23R(L)
180
65D26R(L)
195
80D26R(L)
195
75D31R(L)
210
95D31R(L)
240
115D31R(L)
240
95E41R(L)
300
130E41R(L)
330
Below 9.6
volts
NG
H
Go to next
step.
SEL008Z
EL-24
BATTERY
A: SLOW CHARGE
GI
Determine initial charging current from specific gravity referring to Fig. 2.
MA
Fig. 2 INITIAL CHARGING CURRENT SETTING (Slow charge)

H
Below
1.100
H
Below 12 volts or above 15

volts
12 to 15 volts
OK
4.0
(A)
5.0
(A)
7.0
(A)
8.0
(A)
9.0
(A)
10.0
(A)
130E41R(L)
95E41R(L)
115D31R(L)
95D31R(L)
75D31R(L)
80D26R(L)
65D26R(L)
55D23R(L)
50D23R(L)
55B24R(L)
46B24R(L)
34B19R(L)
CONVERTED
SPECIFIC
GRAVITY
28B19R(L)
BATTERY TYPE
I Charge battery.
I Check charging voltage 30 minutes after starting the battery charge.
EM
LC
14.0
(A)
EC
I Check battery type and determine the specified current using the table
shown above.
I After starting charging, adjustment of charging current is not necessary.
FE
Fig. 3 ADDITIONAL CHARGE (Slow charge)
CL
NG
Continue to charge for 12

hours.
Replace battery.
Below 1.150
1.200 - 1.240
Above 1.240
MT

1.150 - 1.200
Charge for 5
hours at initial charging
current setting.
Charge for 4
current setting.
Charge for 2
current setting.
TF
PD
Conduct additional charge as per Fig. 3, if necessary.

H
FA
Go to CAPACITY TEST.
H
CAUTION:
I Set charging current to value specified in Fig. 2. If charger
is not capable of producing specified current value, set its
charging current as close to that value as possible.
I Keep battery away from open flame while it is being
charged.
I When connecting charger, connect leads first, then turn on
charger. Do not turn on charger first, as this may cause a
spark.
I If battery temperature rises above 60C (140F), stop
charging. Always charge battery when its temperature is
below 60C (140F).
RA
BR
ST
RS
BT
HA
IDX
EL-25
BATTERY
B: STANDARD CHARGE
Fig. 4 INITIAL CHARGING CURRENT SETTING

(Standard charge)
Determine initial charging current from

specific gravity, referring to Fig. 4.
CONVERTED
SPECIFIC
GRAVITY

130E41R(L)
115D31R(L)
7.0 (A)
8.0
(A)
9.0 (A)
13.0
(A)
1.130 - 1.160
3.0 (A)
4.0 (A)
5.0 (A)
6.0 (A)
7.0
(A)
8.0 (A)
11.0
(A)
1.160 - 1.190
2.0 (A)
3.0 (A)
4.0 (A)
5.0 (A)
6.0
(A)
7.0 (A)
9.0
(A)
1.190 - 1.220
2.0 (A)
2.0 (A)
3.0 (A)
4.0 (A)
5.0
(A)
5.0 (A)
7.0
(A)
95E41R(L)
95D31R(L)
65D26R(L)
55D23R(L)
6.0 (A)
55B24R(L)
5.0 (A)
46B24R(L)
4.0 (A)
34B19R(L)
1.100 - 1.130
28B19R(L)
75D31R(L)
80D26R(L)
Charge battery for 8 hours.
50D23R(L)
BATTERY TYPE
I Check battery type and determine the specified current using the table shown above.
Fig. 5 ADDITIONAL CHARGE (Standard charge)
Below 1.150
1.150 - 1.200
1.200 - 1.240
Above 1.240
Conduct additional charge as per Fig. 5, if

necessary.
H
H
Charge for 3.5

hours at initial
charging current
setting.
H
Charge for 2.5

hours at initial
charging current
setting.
Charge for 1.5

hours at initial
charging current
setting.
CAUTION:
I Do not use standard charge method on a battery whose specific gravity is less than 1.100.
I Set charging current to value specified in Fig. 4. If charger is not capable of producing specified
current value, set its charging current as close to that value as possible.
I Keep battery away from open flame while it is being charged.
I When connecting charger, connect leads first, then turn on charger. Do not turn on charger first,
as this may cause a spark.
I If battery temperature rises above 60C (140F), stop charging. Always charge battery when its
temperature is below 60C (140F).
EL-26
BATTERY
CONVERTED SPECIFIC GRAVITY
Charge battery.
15 (A)
20 (A)
30 (A)
1.100 - 1.130
2.5 hours
1.130 - 1.160
2.0 hours
1.160 - 1.190
1.5 hours
1.190 - 1.220
1.0 hours
Above 1.220
0.75 hours (45 min.)
130E41R(L)
95E41R(L)
115D31R(L)
95D31R(L)
75D31R(L)
80D26R(L)
65D26R(L)
55D23R(L)
50D23R(L)
55B24R(L)
10 (A)
46B24R(L)
CURRENT [A]
Determine initial charging current setting and charging time from specific gravity, referring to Fig. 6.
34B19R(L)
BATTERY TYPE
28B19R(L)
Fig. 6 INITIAL CHARGING CURRENT SETTING AND CHARGING TIME (Quick

charge)
C: QUICK CHARGE
40
(A)
FE
CL
Australia
Type
Capacity
V-AH
Z24
Option
TF
PD
FA
RA
ST
Middle East
TD27, QD32
MT
BR
Service Data and Specifications (SDS)
Standard
EM
EC
CAUTION:
I Do not use quick charge method on a battery whose specific gravity is less than 1.100.
I Set initial charging current to value specified in Fig. 6. If charger is not capable of producing
specified current value, set its charging current as close to that value as possible.
I Keep battery away from open flame while it is being charged.
I When connecting charger, connect leads first, then turn on charger. Do not turn on charger first,
as this may cause a spark.
I Be careful of a rise in battery temperature because a large current flow is required during quickcharge operation.
If battery temperature rises above 60C (140F), stop charging. Always charge battery when its
temperature is below 60C (140F).
I Do not exceed the charging time specified in Fig. 6, because charging battery over the charging
time can cause deterioration of the battery.
KA24
MA
LC
I Check battery type and determine the specified current using the table shown
above.
Applied model
GI
TD27
Standard
Option
55D23R
75D31R
95D31R
34B19R
75D31R
95D31R
12-48
12-60
12-64
12-27
12-60
12-64
RS
BT
General areas
Applied model
NA20, Z24
Standard
Type
Capacity
V-AH
KA24
Option
Standard
HA
TD27, QD32
Standard
Option
34B19R
55D23R
75D31R
95D31R
80D26R, 80D26L
12-27
12-48
12-60
12-64
12-55
IDX
EL-27
STARTING SYSTEM
Wiring Diagram START
HEL893
EL-28
STARTING SYSTEM
Trouble Diagnoses
If any abnormality is found, immediately disconnect battery negative terminal.
Starter does not stop.
GI
Replace magnetic switch.
MA
Engine does not start.
EM
Does engine turn by cranking?
Yes
Yes
Does engine turn normally?
No
Check ignition/fuel system.
LC
No (Turns slowly.)
OK
Check battery as follows:

I Charging condition
I Terminal connections
I Terminal corrosion
Repair starter motor.
EC
FE
H NG
q
A
H
Does starter motor turn?
Yes
Yes
Does gear shaft turn?
No
Check pinion clutch.
No
CL
MT
Check reduction gear, armature

and gear shaft.
TF
Check fuse and fusible link.

H
NG
PD
A
q
NG
OK
H
Check starting system wiring.
NG
FA
H
E I Charge battery.
I Repair connections and corrosion of battery terminals.
Repair.
Does starter turn under no load by

connecting wires as follows?
RA
BR
OK
Does magnetic switch operation

sound occur?
H
Replace.
OK
Check battery as follows:

I Charging condition
I Terminal connections
I Terminal corrosion
No
ST
Yes
Check condition of pinion and ring

gear mesh.
OK
Yes
RS
E
BT
NG
No
I Adjust pinion movement.

I Check pinion moving mechanism.
I Check ring gear.
SEL009Z
EL-29
HA
E
Repair starter motor.
IDX
STARTING SYSTEM
Construction
MEL673EA
SEL600JA
EL-30
STARTING SYSTEM
Construction (Contd)
GI
MA
EM
LC
EC
FE
CL
MT
TF
MEL437H
PD
FA
RA
BR
ST
RS
BT
HA
IDX
MEL158FA
EL-31
STARTING SYSTEM
MEL438H
MEL439H
EL-32
STARTING SYSTEM
GI
MA
EM
LC
EC
FE
CL
MT
TF
MEL440H
PD
FA
RA
BR
ST
RS
BT
HA
IDX
MEL423HA
EL-33
STARTING SYSTEM
Removal and Installation
MEL271H
Magnetic Switch Check

I
I
1.
I
Before starting to check, disconnect battery ground cable.

Disconnect M terminal of starter motor.
Continuity test (between S terminal and switch body).
No continuity ... Replace.
SEL036H
2. Continuity test (between S terminal and M terminal).

I No continuity ... Replace.
SEL038H
Pinion/Clutch Check
SEL630BA
1. Inspect pinion teeth.

I Replace pinion if teeth are worn or damaged. (Also check condition of ring gear teeth.)
2. Inspect reduction gear teeth (If equipped).
I Replace reduction gear if teeth are worn or damaged. (Also
check condition of armature shaft gear teeth.)
3. Check to see if pinion locks in one direction and rotates
smoothly in the opposite direction.
I If it locks or rotates in both directions, or unusual resistance is
evident. ... Replace.
Brush Check
BRUSH
Check wear of brush.
Wear limit length:
Refer to SDS, EL-37.
I Excessive wear ... Replace.
SEL014Z
EL-34
STARTING SYSTEM
Brush Check (Contd)
BRUSH SPRING PRESSURE
Check brush spring pressure with brush spring detached from
brush.
Spring pressure (with new brush):
I Not within the specified values ... Replace.
GI
MA
EM
LC
SEL015Z
BRUSH HOLDER
1. Perform insulation test between brush holder (positive side)
and its base (negative side).
I Continuity exists. ... Replace.
2. Check brush to see if it moves smoothly.
I If brush holder is bent, replace it; if sliding surface is dirty, clean.
EC
FE
CL
MT
SEL568B
Yoke Check
Magnet is secured to yoke by bonding agent. Check magnet to see
that it is secured to yoke and for any cracks. Replace malfunctioning parts as an assembly.
CAUTION:
Do not clamp yoke in a vice or strike it with a hammer.
TF
PD
FA
RA
SEL305H
Armature Check
1.
I
2.
I
Continuity test (between two segments side by side).

No continuity ... Replace.
Insulation test (between each commutator bar and shaft).
Continuity exists. ... Replace.
BR
ST
RS
BT
SEL019Z
3. Check commutator surface.

I Rough ... Sand lightly with No. 500 - 600 emery paper.
HA
IDX
SEL020Z
EL-35
STARTING SYSTEM
Armature Check (Contd)
4. Check diameter of commutator.
Commutator minimum diameter:
I Less than specified value ... Replace.
SEL021Z
5. Check depth of insulating mold from commutator surface.

I Less than 0.2 mm (0.008 in) ... Undercut to 0.5 to 0.8 mm
(0.020 to 0.031 in)
SEL022Z
Assembly
Apply high-temperature grease to lubricate the bearing, gears and
frictional surface when assembling the starter.
Carefully observe the following instructions.
PINION PROTRUSION LENGTH ADJUSTMENT

Clearance
With pinion driven out by magnetic switch, push pinion back to
remove slack and measure clearance between the front edge
of the pinion and the pinion stopper.
Clearance :
SEL026Z
EL-36
STARTING SYSTEM
Assembly (Contd)
Movement
Compare movement in height of pinion when it is pushed out
with magnetic switch energized and when it is pulled out by hand
until it touches stopper.
Movement :
GI
MA
EM
LC
SEL497D
Not in the specified value ... Adjust by adjusting plate.
EC
FE
CL
MT
SEL633BA

TF
STARTER
M3T70381 M3T29482D S114-348A S114-295B M0T60081A M2T52882
Type
MITSUBISHI
HITACHI
MITSUBISHI
Non-reduction
KA24
S14-205
HITACHI
4WD
NA20, Z24
Standard
System voltage
S13-327
PD
Reduction
2WD
Applied model
S114-459
KA24
Z24
Option
2WD
4WD
TD27
QD32
Standard
FA
RA
12
No-load
Terminal voltage
11.5
11.0
11.5
Current
Less than 60
Less than
90
Less than 100
Revolution
rpm
More than 6,500
Minimum diameter of commutator

mm (in)
31.4 (1.236)
Minimum length of brushmm (in)
11.5 (0.453)
Brush spring tension
N (kg, lb)
Clearance between pinion

front edge and pinion stopper
mm (in)
0.5 - 2.0
(0.020 - 0.079)
6,000
39.0 (1.535)
12.0
(0.472)
11.0
(0.433)
17.7 - 21.6 13.7 - 17.7

(1.8 - 2.2, (1.4 - 1.8,
4.0 - 4.9)
3.1 - 4.0)
13.7 - 25.5
(1.4 - 2.6, 3.1 - 5.7)
Clearance between bearing

metal and armature shaftmm (in)
Movement in height of pinion assembly

mm (in)
7,000
More than
2,500
3,000
3,900
28.8
(1.134)
31.4
(1.236)
29.0
(1.142)
7.0 (0.276)
11.5
(0.453)
11.0
(0.433)
11.8 - 23.5
(1.2 - 2.4,
2.6 - 5.3)
16.7 - 21.6 15.7 - 19.6

(1.7 - 2.2, (1.6 - 2.0,
3.7 - 4.9)
3.5 - 4.4)
Less than 0.2 (0.008)
0.3 - 2.5
(0.012 0.098)
1.3 - 2.0
(0.051 0.079)
0.5 - 2.0
(0.020 - 0.079)
*: Not include the current of the magnet switch circuit
EL-37
BR
11.0
Less than
160
Less than
160*
More than
4,000
More than
4,100
35.5 (1.398)
ST
RS
9.0 (0.354)
11.0
(0.433)
BT
28.4 - 34.3
(2.9 - 3.5,
6.4 - 7.7)
HA
0.3 - 1.5
(0.012 - 0.059)
0.3 - 2.0
(0.012 0.079)
IDX
CHARGING SYSTEM
Wiring Diagram CHARGE
GASOLINE ENGINE
HEL894
EL-38
CHARGING SYSTEM
Wiring Diagram CHARGE (Contd)
DIESEL ENGINE
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL895
EL-39
CHARGING SYSTEM
Trouble Diagnoses
Before conducting an alternator test, make sure that the battery is fully charged. A 30-volt voltmeter and suitable test probes are necessary for the test. The alternator can be checked easily by referring to the Inspection Table.
I Before starting, inspect the fusible link.
I Use fully charged battery.
GASOLINE ENGINE MODELS
Ignition switch
ON
Warning lamp
OFF
Disconnect connector (S, L) and

ground L harness side.
Check the following:

I Warning
lamp bulb
I Fuse for
warning lamp
Warning lamp
OFF
Warning lamp
ON
Damaged IC
regulator.
Replace.
Warning lamp
ON
Engine start.
Engine speed:
1,500 rpm
Warning lamp
ON
Warning lamp
OFF
OK

I Drive belt
I Fuse for S terminal
I Connector (S, L terminal) connection
Engine idling
Warning lamp
OFF
OK
More than
15.5V
Damaged IC
regulator.
Replace.
No generation
Field circuit is
open.
Warning lamp
ON
Engine speed:
1,500 rpm
(Measure B
terminal voltage)
Warning lamp: CHARGE warning lamp in combination meter
Note:
I If the inspection result is OK even though the charging system is malfunctioning, check the B terminal connection. (Check the tightening torque.)
I When field circuit is open, check condition of rotor coil, rotor slip ring and brush. If necessary,
replace faulty parts with new ones.
Malfunction indicator
The IC regulator warning function activates to illuminate CHARGE warning lamp, if any of the following
symptoms occur while alternator is operating:
I Field circuit is open.
I Excessive voltage is produced.
EL-40
CHARGING SYSTEM
Trouble Diagnoses (Contd)
DIESEL ENGINE MODELS
Ignition switch
ON
Warning lamp
OFF
Disconnect connector (S, L) and

ground L harness side.
Warning lamp
OFF
Warning lamp
ON

I Warning
lamp bulb
I Fuse for
warning lamp
GI
Damaged IC
regulator.
Replace.
EM
LC
Warning lamp
ON
Engine idling
Warning lamp
OFF
MA
Warning lamp
ON

I Drive belt
I Field circuit
Engine speed: 1,500 rpm

(Measure B terminal voltage)
More than
15.5V
13 - 15V

I Fuse for S
terminal
I Open circuit
for S terminal
I IC regulator
OK
EC
FE
CL
MT
TF
Warning lamp: CHARGE warning lamp in combination meter
Note:
I If the inspection result is OK even though the charging system is malfunctioning, check the B terminal connection (check the tightening torque).
I When field circuit is open, check condition of rotor coil, rotor slip ring and brush. If necessary,
replace faulty parts with new ones.
PD
FA
RA
BR
ST
RS
BT
HA
IDX
EL-41
CHARGING SYSTEM
Construction
MEL441H
MEL383I
EL-42
CHARGING SYSTEM
GI
MA
EM
LC
EC
FE
CL
MT
TF
MEL443H
PD
FA
RA
Removal and Installation

CAUTION:
I Start service operation after removing the negative terminal from the battery.
I Also remove the undercover, if equipped, before servicing.
BR
ST
RS
BT
HA
IDX
MEL444H
EL-43
CHARGING SYSTEM
Removal and Installation (Contd)
CAUTION:
I Start service operation after removing the negative terminal from the battery.
I Also remove the undercover, if equipped, before servicing.
MEL445H
Disassembly
REAR COVER
CAUTION:
Rear cover may be hard to remove because a ring is used to
lock outer race of rear bearing. To facilitate removal of rear
cover, heat just bearing box section with a 200W soldering
iron.
Do not use a heat gun, as it can damage diode assembly.
SEL032Z
REAR BEARING
CAUTION:
I Do not reuse rear bearing after removal. Replace with a
new one.
I Do not lubricate rear bearing outer race.
Rotor Check
1. Resistance test
Resistance: Refer to SDS, EL-48.
I Not within the specified values ... Replace rotor.
2. Insulator test
I Continuity exists. ... Replace rotor.
3. Check slip ring for wear.
Slip ring minimum outer diameter:
I Not within the specified values ... Replace rotor.
SEL033Z
Brush Check
1.
I
2.
I
Check smooth movement of brush.

Not smooth ... Check brush holder and clean.
Check brush for wear.
Replace brush if it is worn down to the limit line.
SEL631DA
EL-44
CHARGING SYSTEM
Stator Check
1. Continuity test
I No continuity ... Replace stator.
GI
MA
EM
LC
SEL108E
2. Ground test
I Continuity exists. ... Replace stator.
EC
FE
CL
MT
SEL109E
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
EL-45
CHARGING SYSTEM
Diode Check
MAIN DIODES
I
I
Use an ohmmeter to check condition of diodes as indicated in chart below.

If any of the test results is not satisfactory, replace diode assembly.
Ohmmeter probes
Positive !
Negative @
Positive diode plate
Diode terminals
Diode terminals
Positive diode plate
Negative diode plate
Diode terminals
Diode terminals
Negative diode plate
Diodes check (Positive side)
Diodes check (Negative side)
Judgement
Diode conducts in only one
direction.
Diode conducts in only one
direction.
SEL039Z
EL-46
CHARGING SYSTEM
Assembly
RING FITTING IN REAR BEARING
I
Fix ring into groove in rear bearing so that it is as close to the

adjacent area as possible.
CAUTION:
Do not reuse rear bearing after removal.
GI
MA
EM
LC
SEL044Z
REAR COVER INSTALLATION

1. Fit brush assembly, diode assembly, regulator assembly and
stator.
2. Push brushes up with fingers and install them to rotor.
Take care not to damage slip ring sliding surface.
EC
FE
CL
MT
SEL048Z
TF
PD
FA
RA
SEL049Z
BR
ST
RS
BT
HA
IDX
EL-47
CHARGING SYSTEM
ALTERNATOR
A5TA0676A
A7T03171A
A5T05472A
LR160-727C
LR160-728C
Type
MITSUBISHI
HITACHI
Z24
Applied model
NA20
Nominal rating
V-A
KA24
12-70
Standard
Option*
12-35
12-70
Ground polarity
TD27, QD32
12-60
Negative
Minimum revolution under noload

(When 13.5V is applied)
rpm
Hot output current
A/rpm
Regulated output voltage
Less than 1,300

More than
19/1,300
More than
50/2,500
(When 14V is
applied)
More than
27.5/2,500
(When 14V is
applied)
Less than 1,000

More than
14/1,300
More than
44/2,500
(When 14V is
applied)
14.1 - 14.7
Minimum length of brush
5.0 (0.20)
6.0 (0.236)
4.6 - 5.8 (470 - 590, 16.58 - 20.81)
1.0 - 3.43 (102 - 350, 3.60 - 12.34)
22.1 (0.870)
26.0 (1.024)
mm (in)
Brush spring pressure
N (g, oz)
Slip ring minimum outer diameter
mm (in)
Rotor (Field coil) resistance
More than 17/1,300

More than 48/2,500
More than 57/5,000
(When 13.5V is applied)
2.5 - 2.9
2.6 - 3.1
*: Models with power steering and air conditioner
EL-48
2.5 - 2.9
2.58
COMBINATION SWITCH
Combination Switch/Check
LHD MODELS
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL896
EL-49
COMBINATION SWITCH
Combination Switch/Check (Contd)
RHD MODELS
HEL897
EL-50
COMBINATION SWITCH
Replacement
For removal and installation of spiral cable, refer to RS section
[Installation Air Bag Module and Spiral Cable, SUPPLEMENTAL RESTRAINT SYSTEM (SRS)].
I Each switch can be replaced without removing combination
switch base.
GI
MA
EM
LC
MEL304D
To remove combination switch base, remove base attaching

screw.
EC
FE
CL
MT
MEL326G
Before installing the steering wheel, align the steering wheel

guide pins with the screws which secure the combination switch
as shown in the left figure.
TF
PD
FA
RA
SEL151V
BR
ST
RS
BT
HA
IDX
EL-51
HEADLAMP
Wiring Diagram H/LAMP
LHD MODELS
HEL898
EL-52
HEADLAMP
Wiring Diagram H/LAMP (Contd)
LHD MODELS
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL899
EL-53
HEADLAMP
RHD MODELS
HEL900
EL-54
HEADLAMP
RHD MODELS
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL901
EL-55
HEADLAMP
Trouble Diagnoses
Symptom
LH headlamps do not operate.
Possible cause
1. Bulb
2. Grounds
3. 15A fuse
E6
and
E39
1. Bulb
2. Grounds
3. 15A fuse
E6
1. Check bulb.
2. Check grounds E6 and E39 .
3. Check 15A fuse (No. 32 , located in fusible link and
fuse box). Verify battery positive voltage is present

8 of lighting switch.
at terminal q
4. Check lighting switch.
4. Lighting switch
RH headlamps do not operate.
Repair order
and
E39
1. Check bulb.
3. Check 15A fuse (No. 31 , located in fusible link and
fuse box). Verify battery positive voltage is present

5 of lighting switch.
at terminal q
4. Lighting switch
LH high beams do not operate, but 1. Bulbs
LH low beam operates.
2. Open in LH high beams circuit
3. Lighting switch
LH low beam does not operate, but 1. Bulb
LH high beam operates.
2. Open in LH low beam circuit
3. Lighting switch
RH high beams do not operate, but 1. Bulbs
RH low beam operates.
2. Open in RH high beams circuit
3. Lighting switch
RH low beam does not operate, but 1. Bulb
RH high beam operates.
2. Open in RH low beam circuit
3. Lighting switch
High beam indicator does not work. 1. Bulb
2. Grounds M1 and M54
3. Open in high beam circuit
EL-56
1. Check bulbs.
2. Check R/L wire between lighting switch and LH headlamps for an open circuit.
1. Check bulb.
2. Check R/G wire between lighting switch and LH headlamp for an open circuit.
1. Check bulbs.
2. Check R/Y wire between lighting switch and RH headlamps for an open circuit.
1. Check bulb.
2. Check R/B wire between lighting switch and RH headlamp for an open circuit.
1. Check bulb in combination meter.
2. Check grounds M1 and M54 .
3. Check R/L wire between lighting switch and combination meter for an open circuit.
HEADLAMP
Bulb Replacement
The headlamp is a semi-sealed beam type which uses a replaceable halogen bulb. The bulb can be replaced from the engine compartment side without removing the headlamp body.
I Grasp only the plastic base when handling the bulb. Never
touch the glass envelope.
1. Disconnect the battery cable.
2. Disconnect the harness connector from the back side of the
bulb.
3. Pull off the rubber cap.
4. Push and raise retaining pin to loosen it.
5. Remove the headlamp bulb carefully. Do not shake or rotate
the bulb when removing it.
6. Install in the reverse order of removal.
CAUTION:
Do not leave headlamp reflector without bulb for a long period
of time. Dust, moisture, smoke, etc. entering headlamp body
may affect the performance of the headlamp. Remove headlamp bulb from the headlamp reflector just before a replacement bulb is installed.
GI
MA
EM
LC
EC
FE
CL
MT
GEL187
Bulb Specifications
TF
Item
Wattage (W)
Semi-sealed beam
High/Low
60/55
Aiming Adjustment
When performing headlamp aiming adjustment, use an aiming
machine, aiming wall screen or headlamp tester. Aimers should be
in good repair, calibrated and operated in accordance with respective operation manuals.
If any aimer is not available, aiming adjustment can be done as
follows:
For details, refer to the regulations in your own country.
a. Keep all tires inflated to correct pressures.
b. Place vehicle and tester on one and same flat surface.
c. See that there is no-load in vehicle (coolant, engine oil
filled up to correct level and full fuel tank) other than the
driver (or equivalent weight placed in drivers position).
PD
FA
RA
BR
ST
RS
BT
HA
IDX
EL-57
HEADLAMP
Low Beam
1. Turn headlamp low beam on.
2. Use adjusting screws to perform aiming adjustment.
I First tighten the adjusting screw all the way and then make
adjustment by loosening the screw.
GEL188
Adjust headlamps so that main axis of light is parallel to

center line of body and is aligned with point P shown in
illustration.
I Figure to the left shows headlamp aiming pattern for driving on right side of road; for driving on left side of road,
aiming pattern is reversed.
I Dotted lines in illustration show center of headlamp.
H:
Horizontal center line of headlamps
WL: Distance between each headlamp center
L:
5,000 mm (196.85 in)
C:
65 mm (2.56 in)
SEL254I
EL-58
EXTERIOR LAMP
Parking, License and Tail Lamps/Wiring
Diagram TAIL/L
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL902
EL-59
EXTERIOR LAMP
Parking, License and Tail Lamps/Wiring
Diagram TAIL/L (Contd)
HEL903
EL-60
EXTERIOR LAMP
Stop Lamp/Wiring Diagram STOP/L
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL904
EL-61
EXTERIOR LAMP
Back-up Lamp/Wiring Diagram BACK/L
HEL905
EL-62
EXTERIOR LAMP
Turn Signal and Hazard Warning Lamps/
Schematic
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL906
EL-63
EXTERIOR LAMP
Diagram TURN
HEL907
EL-64
EXTERIOR LAMP
Diagram TURN (Contd)
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL908
EL-65
EXTERIOR LAMP
Diagram TURN (Contd)
HEL909
EL-66
EXTERIOR LAMP
Turn Signal and Hazard Warning Lamps/
Trouble Diagnoses
Symptom
Turn signal and hazard warning
lamps do not operate.
Turn signal lamps do not operate

but hazard warning lamps operate.
Possible cause
GI
Repair order
1. Check hazard switch.

1. Hazard switch
2. Refer to combination flasher unit check.
2. Combination flasher unit
3. Open in combination flasher unit 3. Check wiring to combination flasher unit for open circuit.
circuit
1. Check 7.5A fuse (No. 3 , located in fuse block).
Turn ignition switch ON and verify battery positive
voltage is present at terminal q
2 of hazard switch.
2. Hazard switch
3. Turn signal switch
3. Check turn signal switch.
4. Open in turn signal switch circuit 4. Check G wire between combination flasher unit and
turn signal switch for open circuit.
MA
EM
1. 7.5A fuse
Hazard warning lamps do not oper- 1. 10A fuse

ate but turn signal lamps operate.
2. Hazard switch
3. Open in hazard switch circuit
Front or side turn signal lamp LH
or RH does not operate.
1. Bulb
2. Grounds
E6
and
Rear turn signal lamp LH or RH

does not operate.
1. Bulb
2. Grounds
M1
and
LH and RH turn indicators do not

operate.
LH or RH turn indicator does not
operate.
1. Check 10A fuse (No. 5 , located in fuse block).

Verify battery positive voltage is present at terminal
q
3 of hazard switch.
3. Check G wire between combination flasher unit and
hazard switch for open circuit.
LC
EC
FE
CL
MT
E39
1. Check bulb.
2. Check grounds
E6
and
E39
M54
1. Check bulb.
2. Check grounds
M1
and
M54
1. Ground
1. Check grounds
M1
and
M54
1. Bulb
1. Check bulb in combination meter.
TF
PD
FA
Combination Flasher Unit Check

I
I
Before checking, ensure that bulbs meet specifications.

Connect a battery and test lamp to the combination flasher unit,
as shown. Combination flasher unit is properly functioning if it
blinks when power is supplied to the circuit.
RA
BR
ST
RS
SEL122E
BT
HA
IDX
EL-67
EXTERIOR LAMP
Bulb Specifications
Item
Wattage (W)
Headlamp (Semi-sealed beam)

High/Low
60/55
Front combination lamp

Front turn signal lamp
21
Parking lamp
Side turn signal lamp
Rear combination lamp

Turn signal lamp
21
Stop/Tail lamp
21/5
Back-up lamp
21
License plate lamp

Step bumper
10
Standard bumper
EL-68
INTERIOR LAMP
Illumination/Wiring Diagram ILL
LHD MODELS
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL910
EL-69
INTERIOR LAMP
Illumination/Wiring Diagram ILL (Contd)
LHD MODELS
HEL911
EL-70
INTERIOR LAMP
RHD MODELS
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL912
EL-71
INTERIOR LAMP
RHD MODELS
HEL913
EL-72
INTERIOR LAMP
Interior and Spot Lamps/Wiring Diagram
INT/L
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL914
EL-73
INTERIOR LAMP
Interior and Spot Lamps/Wiring Diagram
INT/L (Contd)
HEL915
EL-74
INTERIOR LAMP
Bulb Specifications
Item
Interior lamp
Spot lamp
Wattage (W)
10
8
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
EL-75
METER AND GAUGES

Combination Meter
EXCEPT FOR THE MIDDLE EAST (With tachometer)
HEL990
EL-76
METER AND GAUGES

Combination Meter (Contd)
EXCEPT FOR THE MIDDLE EAST (Without tachometer)
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL991
EL-77
METER AND GAUGES

FOR THE MIDDLE EAST (With tachometer)
HEL992
EL-78
METER AND GAUGES

FOR THE MIDDLE EAST (Without tachometer)
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL993
EL-79
METER AND GAUGES

Gauges/Schematic
HEL994
EL-80
METER AND GAUGES

Gauges/Wiring Diagram METER
GI
LHD MODELS
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL995
EL-81
METER AND GAUGES

Gauges/Wiring Diagram METER (Contd)
LHD MODELS
HEL996
EL-82
METER AND GAUGES

LHD MODELS
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL920
EL-83
METER AND GAUGES

RHD MODELS
HEL997
EL-84
METER AND GAUGES

RHD MODELS
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL998
EL-85
METER AND GAUGES

RHD MODELS
HEL923
EL-86
METER AND GAUGES

Unified Control Meter System Description
UNIFIED CONTROL METER
GI
Speedometer, odo/trip meter, tachometer, fuel gauge and water

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

Segment Check in Diagnosis Mode
EC
DIAGNOSIS FUNCTION
I
I
Odo/trip meter segment can be checked in diagnosis mode.

Meters/gauges can be checked in diagnosis mode.
FE
CL
MT
HOW TO ALTERNATE DIAGNOSIS MODE
SEL110V
1. Turn ignition switch to ON and change odo/trip meter to TRIP

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

should be as shown left during pushing odo/trip meter switch if
it is no malfunctioning.
NOTE: It takes about 1 minute for indication of fuel gauge to
become stable.
HA
IDX
SEL163V
EL-87
METER AND GAUGES

Segment Check in Diagnosis Mode (Contd)
SEL164V
Flexible Print Circuit (FPC)

Tachometer, fuel gauge and water temperature gauge are connected with unified meter control unit (speedometer) by Flexible
Print Circuit (FPC) connector. When replace or remove and install
unified control unit (speedometer), disconnect and connect FPC
connector according to the following steps.
DISCONNECT
1. Open connector cover.
2. Release connector lock by holding both ends of it and pulling it
up.
3. Disconnect FPC by pulling it up.
SEL109V
CONNECT
1. Insert FPC into connector and lock connector pushing FPC
downward.
2. Check secure connection of FPC.
3. Check continuity of check land terminals for secure connection
of FPC.
Resistance: 0
4. Close connector cover.
SEL162V
EL-88
METER AND GAUGES

Trouble Diagnoses
PRELIMINARY CHECK
GI
CHECK-IN
MA
H
Can Diagnosis mode

be activated? Refer to
Meter/Gauge Operation and Odo/Trip Meter
Segment Check in
Diagnosis Mode,
EL-87.
No
Do meter warning
lamps operate?
Yes
No
Check the screws

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

be activated?
G
No
Yes
EM
LC
EC
Yes
H
FE
Check power supply

and ground circuit.
Refer to POWER SUPPLY AND GROUND
CIRCUIT CHECK,
EL-91.
CL
MT
Check meter/gauge
operation in Diagnosis
mode.
TF
PD
H
Malfunction is indicated
in Diagnosis mode.
No malfunction is indicated in Diagnosis

mode.

I FPC connector connection
Refer to Flexible
Print Circuit (FPC),
EL-88.
I Screws securing the
malfunctioning meter/
gauge
(The screws are
located behind the
combination meter.
For details refer to
EL-94.)
SYMPTOM CHART 2
Refer to EL-90.
Replace speedometer
(unified meter control
unit).
FA
RA
BR
ST
NG
RS
BT
HA
OK
H
SYMPTOM CHART 1
Refer to EL-90.
Reconnect FPC connector and check continuity between

check land terminals and/or repair malfunctioning part.
Refer to FLEXIBLE PRINT CIRCUIT (FPC), EL-88.
EL-89
IDX
METER AND GAUGES

Before starting trouble diagnoses below, perform PRELIMINARY CHECK, EL-89.
SYMPTOM CHART 1 (MALFUNCTION IS INDICATED IN DIAGNOSIS MODE)

Symptom
Speedometer and/or odo/trip
meter indicate(s) malfunction
in Diagnosis mode.
Possible causes
Repair order
I Speedometer (Unified meter control unit)
I Replace speedometer (unified meter control unit).
I Meter/Gauge
I Speedometer (Unified meter control unit)
1. Check resistance of meter/gauge indicating malfunction. If

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

malfunction in Diagnosis
mode.
One of tachometer/fuel gauge/
water temp. gauge indicates
malfunction in Diagnosis
mode.
SYMPTOM CHART 2 (NO MALFUNCTION IS INDICATED IN DIAGNOSIS MODE)

Symptom
Speedometer and odo/trip
meter are malfunctioning.
Possible causes
Repair order
1. Sensor
- Speedometer, Odo/Trip meter
2. FPC connector
3. Speedometer (Unified meter control unit)
Multiple meter/gauge are malfunctioning. (except

speedometer, odo/trip meter)
1. FPC connector
One of tachometer/fuel gauge/

water temp. gauge is malfunctioning.
1. Sensor/Engine revolution signal

- Tachometer
- Fuel gauge
- Water temp. gauge
2. FPC connector
EL-90
1. Check vehicle speed sensor.

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

POWER SUPPLY AND GROUND CIRCUIT CHECK
Power supply circuit check
GI
Terminals
SEL165V
Ignition switch position

@
OFF
ACC
ON
q
38
Ground
Battery
voltage
Battery
voltage
Battery
voltage
q
29
Ground
0V
0V
Battery
voltage
If NG, check the following.

I 7.5A fuse [No. 6 , located in fuse block (J/B)]
I 10A fuse [No. 1 , located in fuse block (J/B)]
I Harness for open or short between fuse and combination meter
MA
EM
LC
EC
FE
CL
MT
Ground circuit check

Terminals
Continuity
q
26 - Ground
Yes
TF
PD
FA
RA
SEL166V
BR
ST
RS
BT
HA
IDX
EL-91
METER AND GAUGES

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

OK.
Replace vehicle speed

sensor.
NG
H
NG
CHECK VEHICLE SPEED SENSOR.

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

speedometer and vehicle speed sensor.
SEL118V
INSPECTION/ENGINE REVOLUTION SIGNAL (Models

with tachometer)
Terminals
Engine
Injection
Check item
DC voltage
Carburetor
AC voltage
q
9
Diesel
SEL168V
Explanation
q
26
Higher rpm = Higher voltage

Lower rpm = Lower voltage
Voltage should change with
rpm.
If NG, check the following.

Engine
Check item
Injection
I Harness for open or short and connection
Carburetor

I Resistor etc.
Diesel

I Engine revolution sensor etc.
EL-92
METER AND GAUGES

INSPECTION/FUEL TANK GAUGE
CHECK GROUND CIRCUIT FOR FUEL
TANK GAUGE UNIT.
Check harness continuity between fuel
tank gauge unit terminal q
3 and ground.
Continuity should exist.
NG
GI
Repair harness or connecE
tor.
MA
EM
OK
H
SEL169V
CHECK GAUGE UNITS.

Refer to FUEL TANK GAUGE UNIT
CHECK (EL-94).
NG
Repair or replace.
Refer to FE section.
LC
EC
OK
FE
H
CHECK HARNESS.
1. Disconnect combination meter connector N4 and fuel tank gauge unit connector.
2. Check harness continuity between combination meter terminal q
7 and fuel
tank gauge unit terminal q
1 .
3. Check continuity between combination
meter terminal q
7 and ground.
Continuity should not exist.
NG
Repair harness or connector.
CL
MT
TF
PD
OK
FA
Fuel tank gauge is OK.
RA
SEL170V
INSPECTION/THERMAL TRANSMITTER
CHECK THERMAL TRANSMITTER.
Refer to THERMAL TRANSMITTER
CHECK (EL-95).
NG
BR
Repair or replace.
ST
OK
RS
H
CHECK HARNESS.
1. Disconnect combination meter connector N4 and thermal transmitter connector.
2. Check harness for open or short
between combination meter terminal q
6
and thermal transmitter terminal q
1 .
3. Check continuity between combination
meter terminal q
6 and ground.
Continuity should not exist.
OK
H
Thermal transmitter is OK.

SEL171V
EL-93
NG
BT
HA
IDX
METER AND GAUGES

Electrical Components Inspection
METER/GAUGE RESISTANCE CHECK
1. Disconnect FPC connector. Refer to EL-88.
2. Check resistance between installation screws of meter/gauge.
Screws
Tachometer
Fuel/Temp. gauge
Resistance
A-C
A-C
Approx. 70 - Approx. 140
B-D
B-C
Approx. 90 - Approx. 170
SEL172V
SEL173V
FUEL TANK GAUGE UNIT CHECK (With electric fuel

pump)
I For removal, refer to FE section.
Check the resistance between terminals q
1 and q
4 .
Ohmmeter
(+)
()
q
1
q
4
Float position
mm (in)
60 (13-1/4
Imp gal) tank
80 (17-5/8
Imp gal) tank
Resistance
value
()
Full
253 (9.96)
247 (9.72)
Approx. 4 - 6
*2
1/2
130 (5.12)
130 (5.12)
27 - 35
*3
Empty
27 (1.06)
26 (1.02)
78 - 85
*1
*1 and *3: When float rod is in contact with stopper.
GEL189
EL-94
METER AND GAUGES

Electrical Components Inspection (Contd)
FUEL TANK GAUGE UNIT CHECK (With mechanical fuel
pump)
I For removal, refer to FE section.
Check the resistance between terminals q
1 and q
2 .
Ohmmeter
(+)
Float position
()
*1
q
1
q
2
Full
mm (in)
60 (13-1/4
Imp gal) tank
80 (17-5/8
Imp gal) tank
Resistance
value
()
50 (1.97)
247 (9.72)
Approx. 4 - 6
*2
1/2
174 (6.85)
130 (5.12)
27 - 35
*3
Empty
277 (10.91)
26 (1.02)
78 - 85
GI
MA
EM
LC
EC
FE
CL
MT
GEL190
THERMAL TRANSMITTER CHECK

Check the resistance between the terminals of thermal transmitter
and body ground.
Water temperature
Resistance
60C (140F)
Approx. 167 - 211
100C (212F)
Approx. 47 - 53
TF
PD
FA
RA
MEL424F
VEHICLE SPEED SENSOR SIGNAL CHECK

1. Remove vehicle speed sensor from transmission.
2. Turn vehicle speed sensor pinion quickly and measure voltage
a and q
b .
between terminals q
BR
ST
RS
BT
SEL378PA
HA
IDX
EL-95
WARNING LAMPS
Schematic
HEL924
EL-96
WARNING LAMPS
Wiring Diagram WARN
LHD MODELS
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL988
EL-97
WARNING LAMPS
Wiring Diagram WARN (Contd)
LHD MODELS
HEL999
EL-98
WARNING LAMPS
LHD MODELS
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL927
EL-99
WARNING LAMPS
LHD MODELS
HEL928
EL-100
WARNING LAMPS
LHD MODELS
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL929
EL-101
WARNING LAMPS
RHD MODELS
HEL930
EL-102
WARNING LAMPS
RHD MODELS
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL931
EL-103
WARNING LAMPS
RHD MODELS
HEL932
EL-104
WARNING LAMPS
RHD MODELS
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL964
EL-105
WARNING LAMPS
RHD MODELS
HEL965
EL-106
WARNING LAMPS
FUEL WARNING LAMP SENSOR CHECK
I
GI
It will take a short time for the bulb to light.
MA
EM
LC
EC
FE
CL
MT
GEL191
OIL PRESSURE SWITCH CHECK
TF
Oil pressure
kPa (bar, kg/cm2, psi)
Continuity
Engine start
More than 10 - 20
(0.10 - 0.20, 0.1 - 0.2, 1 - 3)
NO
PD
Engine stop
Less than 10 - 20
(0.10 - 0.20, 0.1 - 0.2, 1 - 3)
YES
FA
Check the continuity between the terminals of oil pressure switch

and body ground.
MEL425F
DIODE CHECK
I
I
Check continuity using an ohmmeter.

Diode is functioning properly if test results are as shown in the
figure at left.
NOTE: Specification may vary depending on the type of tester.
Before performing this inspection, be sure to refer to
the instruction manual for the tester to be used.
RA
BR
ST
RS
BT
SEL901F
Diodes for warning lamps are built into the combination meter
printed circuit.
HA
IDX
GEL192
EL-107
WARNING BUZZER
Wiring Diagram BUZZER
HEL933
EL-108
WARNING BUZZER
WARNING BUZZER CHECK
GI
MA
EM
LC
GEL208
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
EL-109
WIPER AND WASHER

System Description
WIPER OPERATION
The wiper switch is controlled by a lever built into the combination switch.
There are two or three wiper switch positions:
I LO speed
I HI speed
I INT (Intermittent wiper models only)
With the ignition switch in the ACC or ON position, power is supplied
I through 20A fuse (No. 16 , located in the fuse block)
I to wiper motor terminal q
4 .
Low and high speed wiper operation
Ground is supplied to wiper switch terminal q
17 through body grounds M1 and M54 .
When the wiper switch is placed in the LO position, ground is supplied
I through terminal q
14 of the wiper switch
2 .
With power and ground supplied, the wiper motor operates at low speed.
When the wiper switch is placed in the HI position, ground is supplied
3 .
With power and ground supplied, the wiper motor operates at high speed.
Auto stop operation
With wiper switch turned OFF, wiper motor will continue to operate until wiper arms reach windshield base.
When wiper arms are not located at base of windshield with wiper switch OFF, ground is provided
I from terminal q
2 , in order to continue wiper motor operation at low speed.
Ground is also supplied
I to wiper amplifier terminal q
2 (Intermittent wiper models only)
7 of the wiper amplifier (Intermittent wiper models only)
5
6 of the wiper motor, and
I through body grounds M1 and M54 .
4 and q
5 are connected instead of terWhen wiper arms reach base of windshield, wiper motor terminals q
minals q
5 and q
6 . Wiper motor will then stop wiper arms at the PARK position.
Intermittent operation
The wiper motor operates the wiper arms one time at low speed at an interval of approximately 7 seconds.
This feature is controlled by the wiper amplifier.
When the wiper switch is placed in the INT position, ground is supplied
1
I from wiper switch terminal q
15
2
I through the wiper switch terminal q
14
I to wiper switch terminal q
13
I through wiper amplifier terminal q
2
3
With power and ground supplied, the wiper motor operates at low speed intermittently.
EL-110
WIPER AND WASHER

System Description (Contd)
WASHER OPERATION
With the ignition switch in the ACC or ON position, power is supplied
1 .
I to washer motor terminal q
With intermittent wiper

When the lever is pulled to the WASH position, ground is supplied
2 , and
6
I from terminal q
17 of the wiper switch, and
With power and ground supplied, the washer motor operates.
When the lever is pulled to the WASH position for one second or more, the wiper motor operates at low speed
for approximately 3 times after the lever is released. This feature is controlled by the wiper amplifier in the
same manner as the intermittent operation.
GI
MA
EM
LC
EC
Without intermittent wiper

When the lever is pulled to the WASH position, ground is supplied
2
I from terminal q
17 of the wiper switch, and
With power and ground supplied, the washer motor operates.
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
EL-111
WIPER AND WASHER

Front Wiper and Washer/Wiring Diagram
WIPER
LHD MODELS WITH INTERMITTENT WIPER
HEL934
EL-112
WIPER AND WASHER

WIPER (Contd)
LHD MODELS WITH INTERMITTENT WIPER
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL935
EL-113
WIPER AND WASHER

WIPER (Contd)
LHD MODELS WITHOUT INTERMITTENT WIPER
HEL936
EL-114
WIPER AND WASHER

WIPER (Contd)
RHD MODELS WITH INTERMITTENT WIPER
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL937
EL-115
WIPER AND WASHER

WIPER (Contd)
RHD MODELS WITH INTERMITTENT WIPER
HEL938
EL-116
WIPER AND WASHER

WIPER (Contd)
RHD MODELS WITHOUT INTERMITTENT WIPER
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL939
EL-117
WIPER AND WASHER

WIPER (Contd)
RHD MODELS WITHOUT INTERMITTENT WIPER
HEL940
EL-118
WIPER AND WASHER

Trouble Diagnoses
DIAGNOSTIC PROCEDURE 1
GI
SYMPTOM: Intermittent wiper does not operate.

Check whether wiper operates with the
wiper switch at Lo position.
NG
OK
SEL140VB
H
1) Turn front wiper switch to OFF.

2) Disconnect wiper amp. connector.
3) Check voltage between wiper amp. terminal q
2 and ground.
Battery voltage should exist.
NG
OK
H
SEL141VB
CHECK INTERMITTENT SWITCH INPUT

SIGNAL.
Check harness continuity between wiper
amp. terminal q
1 and ground.
Condition of
wiper switch
Continuity
OFF
No
INT
Yes
NG
Check the following.

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

I Wiper switch
short between wiper
amp. terminal q
2 and
wiper switch terminal q
13
EC
SEL142VB

I Wiper switch
short between wiper
amp. terminal q
1 and
15
I Ground circuit for front
17
OK
H
Replace wiper amp.
FE
MT
TF
PD
NG

I 20A fuse (No. 16 ,
located in fuse block)
short between wiper
amp. and fuse
FA
RA
BR
OK
CHECK WIPER AMP. GROUND CIRCUIT.

Check harness continuity between wiper
amp. terminal q
3 and body ground.
LC
CL
OK
CHECK WIPER AMP. POWER SUPPLY

CIRCUIT.
Check voltage between wiper amp. terminal q
5 and ground while ignition switch is
ACC.
Battery voltage should exist.
EM
NG
ST
RS
BT
SEL143VB
HA
IDX
EL-119
WIPER AND WASHER

SYMPTOM: Wiper and washer activate individually but not in
combination.
SEL145VB
CHECK WASHER SWITCH INPUT SIGNAL.

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

short between wiper amp.
terminal q
6 and wiper
switch terminal q
18 .
Continuity
OFF
No
ON
Yes
OK
H
Go to DIAGNOSTIC PROCEDURE 1.
NG
Replace wiper amp.
Wiper Installation and Adjustment
SEL543TA
1. Prior to wiper arm installation, turn on wiper switch to operate

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

illustrated. This will reduce possibility of wiper arm looseness.
SEL024J
EL-120
WIPER AND WASHER

Washer Nozzle Adjustment
I
Adjust washer nozzle with suitable tool as shown in the figure

at left.
Adjustable range: 10
GI
MA
EM
LC
GEL013-A
Unit: mm (in)
*1
470 (18.50)
*5
60 (2.36)
*2
215 (8.46)
*6
225 (8.86)
*3
380 (14.96)
*7
255 (10.04)
*4
180 (7.09)
*8
460 (18.11)
*: The diameters of these circles are less than 60 mm (2.36 in).
EC
FE
CL
MT
SEL544TA
TF
PD
FA
RA
SEL845T
Washer Tube Layout
BR
ST
RS
BT
GEL193
HA
IDX
EL-121
WIPER AND WASHER

Wiper Linkage
GEL194
REMOVAL
1.
2.
3.
Be
Remove 4 bolts that secure wiper motor.

Detach wiper motor from wiper linkage at ball joint.
Remove wiper linkage.
careful not to break ball joint rubber boot.
INSTALLATION
I Grease ball joint portion before installation.
1. Installation is the reverse order of removal.
EL-122
HORN, CIGARETTE LIGHTER AND CLOCK

Wiring Diagram HORN
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL941
EL-123
HORN, CIGARETTE LIGHTER AND CLOCK

Wiring Diagram HORN (Contd)
HEL942
EL-124

Wiring Diagram DEF
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL943
EL-125

REAR WINDOW DEFOGGER SWITCH
Check continuity between terminals when rear window defogger
switch is pushed and released.
Terminals
q
1 -q
2
GEL195
Condition
Continuity
Rear window defogger

switch is pushed
Yes
Rear window defogger

switch is released
No
Filament Check
1. Attach probe circuit tester (in volt range) to middle portion of
each filament.
SEL263
When measuring voltage, wrap tin foil around the top of

the negative probe. Then press the foil against the wire
with your finger.
SEL122R
2. If a filament is burned out, circuit tester registers 0 or 12 volts.
SEL265
EL-126

Filament Check (Contd)
3. To locate burned out point, move probe to left and right along
filament. Test needle will swing abruptly when probe passes the
point.
GI
MA
EM
LC
SEL266
Filament Repair
REPAIR EQUIPMENT
1.
2.
3.
4.
5.
6.
Conductive silver composition (Dupont No. 4817 or equivalent)

Ruler 30 cm (11.8 in) long
Drawing pen
Heat gun
Alcohol
Cloth
EC
FE
CL
MT
REPAIRING PROCEDURE
1. Wipe broken heat wire and its surrounding area clean with a
cloth dampened in alcohol.
2. Apply a small amount of conductive silver composition to tip of
drawing pen.
Shake silver composition container before use.
3. Place ruler on glass along broken line. Deposit conductive silver composition on break with drawing pen. Slightly overlap
existing heat wire on both sides [preferably 5 mm (0.20 in)] of
the break.
BE540
4. After repair has been completed, check repaired wire for continuity. This check should be conducted 10 minutes after silver
composition is deposited.
Do not touch repaired area while test is being conducted.
TF
PD
FA
RA
BR
ST
RS
BT
SEL012D
5. Apply a constant stream of hot air directly to the repaired area

for approximately 20 minutes with a heat gun. A minimum distance of 3 cm (1.2 in) should be kept between repaired area
and hot air outlet. If a heat gun is not available, let the repaired
area dry for 24 hours.
HA
IDX
SEL013D
EL-127
AUDIO
Wiring Diagram AUDIO
LHD MODELS RADIO WITH 1-SPEAKER
HEL944
EL-128
AUDIO
Wiring Diagram AUDIO (Contd)
LHD MODELS RADIO WITH 2 OR 4-SPEAKERS (Without CD deck)
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL945
EL-129
AUDIO
LHD MODELS RADIO WITH 4-SPEAKERS (With CD deck)
HEL946
EL-130
AUDIO
LHD MODELS RADIO WITH 4-SPEAKERS (With CD deck)
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL947
EL-131
AUDIO
RHD MODELS
HEL948
EL-132
AUDIO
Trouble Diagnoses
Symptom
Radio inoperative (no digital
display and no sound from
speakers).
Possible causes
Repair order
18 , located in fuse block). Turn ignition switch ON and verify battery positive voltage is
present at terminal q
10 of radio.
2. Check radio case ground.
3. Remove radio for repair.
1. 10A fuse
1. Check 10A fuse (No.
2. Poor radio case ground

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

Radio presets are lost when

ignition switch is turned OFF.
2. Radio
1. Check 7.5A fuse (No. 6 , located in fuse block) and verify

battery positive voltage is present at terminal q
6 of radio.
Individual speaker is noisy or

inoperative.
1.
2.
3.
4.
1.
2.
3.
4.
Radio stations are weak or

noisy.
1. Antenna
2. Poor radio ground
3. Radio
1. Check antenna.
2. Check radio ground.
1. Poor radio ground

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

2. Check ground bonding straps.
3. Replace ignition condenser or rear window defogger noise
suppressor condenser.
4. Check alternator.
5. Check ignition coil and secondary wiring.
1.
2.
3.
4.
1.
2.
3.
4.
Radio generates static noise

with engine running.
Radio generates static noise

with accessories on (switch
pops and motor noise).
1. 7.5A fuse
Speaker
Radio output
Speaker circuit
Radio
Poor radio ground

Antenna
Accessory ground
Faulty accessory
Check speaker.
Check radio output voltages.
Check wires for open or short between radio and speaker.
Remove radio for repair.
Check radio ground.

Check antenna.
Check accessory ground.
Replace accessory.
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
SPEAKER INSPECTION
1.
2.
I
3.
I
GI
Disconnect speaker harness connector.

Measure the resistance between speaker terminals q
1 and q
2 .
The resistance should be 2 - 4.
Using jumper wires, momentarily connect a 9V battery between speaker terminals q
1 and q
2 .
A momentary hum or pop should be heard.
RA
BR
ANTENNA INSPECTION
ST
Using a jumper wire, clip an auxiliary ground between antenna and body.
I If reception improves, check antenna ground (at body surface).
I If reception does not improve, check main feeder cable for short circuit or open circuit.
RS
RADIO INSPECTION
BT
All
I
I
I
HA
voltage inspections are made with:

Ignition switch ON or ACC
Radio ON
Radio connected (If removed for inspection, supply a ground to the case using a jumper wire.)
IDX
EL-133
AUDIO ANTENNA
Manual Antenna
LOCATION OF ANTENNA
GEL196
ANTENNA ASSEMBLY REPLACEMENT

1. Remove antenna cover in cowl top.
2. Remove wiper arm and cowl top.
GEL207
3. Loosen nut at antenna bracket.

4. Disconnect antenna feeder cable jack shown in the above illustration.
5. Remove fender protector.
6. Remove the grommet and pull the feeder cable out from fender
inner.
7. Remove antenna assembly and replace with a new one.
GEL197
EL-134
AUDIO ANTENNA
Power Antenna/Wiring Diagram P/ANT
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL949
EL-135
AUDIO ANTENNA
Power Antenna
TROUBLE DIAGNOSES
Symptom
Power antenna does not operate.
Possible causes
Repair order
1. Check 7.5A fuse (No. 6 , located in fuse block). Verify that
battery positive voltage is present at terminal q
1 of power
antenna.
2. Turn ignition switch and radio ON. Verify that battery positive
voltage is present at terminal q
3 of power antenna.
1. 7.5A fuse
2. Radio signal
3. Grounds
E6
and E39
LOCATION OF ANTENNA
SEL339V
ANTENNA ROD REPLACEMENT

Removal
1. Remove antenna nut and antenna base.
SEL240V
2. Withdraw antenna rod while raising it by operating antenna

motor.
SEL341V
EL-136
AUDIO ANTENNA
Power Antenna (Contd)
Installation
1. Lower antenna rod by operating antenna motor.
2. Insert gear section of antenna rope into place with it facing
toward antenna motor.
3. As soon as antenna rope is wound on antenna motor, stop
antenna motor. Insert antenna rod lower end into antenna
motor pipe.
4. Retract antenna rod completely by operating antenna motor.
5. Install antenna nut and base.
GI
MA
EM
LC
EC
FE
CL
MT
SEL342V
ANTENNA ASSEMBLY REPLACEMENT

1. Remove antenna nut and antenna base.
2. Loosen bolts at antenna bracket and disconnect power antenna
connector.
3. Disconnect antenna feeder cable jack shown in LOCATION
OF ANTENNA.
4. Remove fender protector.
5. Remove the grommet and pull the feeder cable out from fender
inner.
6. Remove antenna assembly and replace with a new one.
SEL240V
TF
PD
FA
RA
BR
ST
RS
BT
SEL340V
HA
IDX
EL-137
POWER DOOR MIRROR

Wiring Diagram MIRROR
HEL950
EL-138
POWER DOOR MIRROR

Wiring Diagram MIRROR (Contd)
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL951
EL-139
POWER WINDOW
System Description
Power is supplied at all times
I from 30A fusible link (Letter b , located in the fusible link and fuse box)
I to circuit breaker terminal q
1
I through circuit breaker terminal q
2
I to power window relay terminal q
3 .
With ignition switch in ON or START position, power is supplied
2 .
I to power window relay terminal q
Ground is supplied to power window relay terminal q
1
The power window relay is energized and power is supplied
I through power window relay terminal q
5
I to power window main switch terminal q
1 ,
5 .
I to power window sub-switch terminal q
MANUAL OPERATION
Driver side door
Ground is supplied
3
WINDOW UP
When the driver side switch in the power window main switch is pressed in the up position, power is supplied
2
I to driver side power window regulator terminal q
I through power window main switch terminal q
9 .
Ground is supplied
1
8 .
Then, the motor raises the window until the switch is released.
WINDOW DOWN
When the driver side switch in the power window main switch is pressed in the down position, power is supplied
1
8 .
Ground is supplied
2
9 .
Then, the motor lowers the window until the switch is released.
Front passenger side door

Ground is supplied
3
NOTE:
Numbers in parentheses are terminal numbers, when power window switch is pressed in the up and down
positions respectively.
MAIN SWITCH OPERATION
Power is supplied
I through power window main switch (q
5 ,q
6 )
4 ,q
3 ).
I to front power window sub-switch (q
The subsequent operation is the same as the sub-switch operation.
EL-140
POWER WINDOW
System Description (Contd)
SUB-SWITCH OPERATION
Power is supplied
I through front power window sub-switch (q
2 ,q
1 )
I to front passenger side power window regulator (q
2 ,q
1 ).
Ground is supplied
I to front passenger side power window regulator (q
1 ,q
2 )
I through front power window sub-switch (q
1 ,q
2 )
I to front power window sub-switch (q
3 ,q
4 )
6 ,q
5 ).
I through power window main switch (q
Then, the motor raises or lowers the window until the switch is released.
Rear door
Rear door windows will raise and lower in the same manner as front passenger side door window.
AUTO OPERATION
The power window AUTO feature enables the driver to open or close the drivers window without holding the
window switch in the respective position.
When the AUTO switch in the main switch is pressed and released, the drivers window will travel to the fully
open or closed position.
GI
MA
EM
LC
EC
FE
POWER WINDOW LOCK
CL
The power window lock is designed to lock operation of all windows except for drivers door window.
When the lock switch is pressed to lock position, ground of the sub-switches in the power window main switch
is disconnected. This prevents the power window motors from operating.
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
EL-141
POWER WINDOW
Schematic
HEL952
EL-142
POWER WINDOW
Wiring Diagram WINDOW
LHD MODELS
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL953
EL-143
POWER WINDOW
Wiring Diagram WINDOW (Contd)
LHD MODELS
HEL954
EL-144
POWER WINDOW
LHD MODELS
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL955
EL-145
POWER WINDOW
LHD MODELS
HEL956
EL-146
POWER WINDOW
RHD MODELS
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL957
EL-147
POWER WINDOW
RHD MODELS
HEL958
EL-148
POWER WINDOW
RHD MODELS
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL959
EL-149
POWER WINDOW
RHD MODELS
HEL960
EL-150
POWER WINDOW
Trouble Diagnoses
Symptom
Possible cause
Repair order
None of the power windows can be 1. 10A fuse, 30A fusible link and 1. Check 10A fuse (No. 14 , located in fuse block), 30A
fusible link (letter b , located in fusible link and fuse
operated using any switch.
M52 circuit breaker
box) and M52 circuit breaker. Turn ignition switch
ON and verify battery positive voltage is present at
terminal q
1 of power window main switch and terminal
q
5 of sub-switch.
2. Grounds M1 and M54
2. Check grounds M1 and M54 .
3. Check power window relay.
3. Power window relay
4. Open/short in power window 4. Check W wire between power window relay and power
window main switch for open/short circuit.
main switch circuit
Driver side power window cannot be 1. Driver side power window regula- 1. Check harness between power window main switch
and power window regulator for open or short circuit.
tor circuit
operated but other windows can be
2. Driver side power window regula- 2. Check driver side power window regulator.
operated.
tor
Passenger power window cannot be 1. Power window sub-switches
operated.
2. Passenger side power window
regulators
3. Power window main switch
4. Power window circuit
1. Check power window sub-switch.

2. Check passenger side power window regulator.
3. Check power window main switch.
4-1. Check harnesses between power window main
switch and power window sub-switch for open/short
circuit.
4-2. Check harnesses between power window subswitch and power window regulator for open/short
circuit.
Passenger power window cannot be 1. Power window main switch

operated using power window main
switch but can be operated by power
window sub-switch.
Driver side power window auto func- 1. Power window main switch
tion cannot be operated using power
window main switch.
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
EL-151
POWER DOOR LOCK

System Description
Power is supplied at all times
I through 30A fusible link (Letter b , located in the fusible link and fuse box)
I to circuit breaker terminal q
1
I through circuit breaker terminal q
2
I to door lock timer terminal q
3 .
Ground is supplied to door lock timer terminal q
1 through body grounds M1 and
M54
INPUT
When the door lock & unlock switch (power window main switch) is in LOCKED position, ground signal is
supplied
5
I through door lock & unlock switch terminal q
14
I to door lock & unlock switch terminal q
3
When the door lock & unlock switch (power window main switch) is in UNLOCKED position, ground signal is
supplied
8
I through door lock & unlock switch terminal q
7
I to door lock & unlock switch terminal q
3
Driver side door key cylinder and driver side lock knob are connected to lock knob switch with a rod. When
lock knob switch is in UNLOCKED position, ground signal is supplied
6
I through lock knob switch terminal q
2
I to driver side lock knob switch terminal q
1
When lock knob switch is in LOCKED position, ground signal is interrupted.
Door lock operates according to the conditions of the door lock & unlock switch (power window main switch)
and lock knob switch.
OUTPUT
Unlock
Ground is supplied
I to passenger side door lock actuator, rear door lock actuator LH and RH terminal q
1 (double cab models)
I through door lock timer terminal q
2 .
Power is supplied
2 (double cab models)
4 .
Then, the doors are unlocked.
Lock
Ground is supplied
2
4 .
Power is supplied
1
2 .
Then, the doors are locked.
EL-152
POWER DOOR LOCK

Wiring Diagram D/LOCK
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL961
EL-153
POWER DOOR LOCK

Wiring Diagram D/LOCK (Contd)
HEL962
EL-154
POWER DOOR LOCK

Trouble Diagnosis
SYMPTOM CHART
GI
EL-155
EL-156
None of the doors lock/unlock when operating any switch.
EL-158
Diagnostic procedure 3
(Driver side lock knob switch check)
(Door lock actuator check)
(Door lock and unlock switch check)
SYMPTOM
EL-157
MA
Main power supply and ground circuit check
REFERENCE PAGE
EM
LC
EC
FE
CL
One or more doors are not locked and/or

unlocked.
MT
Door lock and unlock switch does not operate.
TF
Lock knob switch on drivers door does not

operate.
PD
FA
MAIN POWER SUPPLY AND GROUND CIRCUIT CHECK

Main power supply for door lock timer
Terminal
RA
BR
Ignition switch
OFF
ACC
ON
q
3
Ground
Battery
voltage
Battery
voltage
Battery
voltage
ST
RS
SEL154V
BT
Ground circuit for door lock timer
Terminals
Continuity
q
1 - Ground
Yes
HA
IDX
SEL155V
EL-155
POWER DOOR LOCK

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

unlock switch
condition
Lock
N and Unlock
Unlock
N and Lock
OK
Door lock and unlock

switch is OK.
Replace door lock and

unlock switch.
Continuity
Yes
No
Yes
No
NG
H
CHECK DOOR LOCK AND UNLOCK

SWITCH.
1. Disconnect door lock and unlock switch
connector.
2. Check continuity between power window main switch (Door lock and unlock
switch) terminals.
Condition
Lock
N
Unlock
Terminals
7
3
q
14
q
No continuity
q
OK
H

I Ground circuit for door lock and unlock
switch
I Harness for open or short between door
lock and unlock switch and door lock
timer connector
SEL157V
EL-156
NG
POWER DOOR LOCK

(Door lock actuator check)
CHECK DOOR LOCK ACTUATOR CIRCUIT.
Check voltage for door lock actuator.
Lock knob switch
condition
SEL158V
Lock
Unlock
Terminals
@
q
2
ground
q
4
ground
GI
NG
Replace door lock timer.

(Before replacing control
unit, perform DIAGNOSTIC
PROCEDURE 1.)
Voltage
(V)
Battery
voltage
MA
EM
LC
EC
OK
H
CHECK DOOR LOCK ACTUATOR.

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

Unlocked , Locked
Locked , Unlocked
Terminals
! @
q
q
1
2
q
q
2
1
OK
Repair harness between door lock timer

connector and door lock actuator.
NG
Replace door lock actuator.
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
EL-157
POWER DOOR LOCK

(Driver side lock knob switch check)
CHECK LOCK KNOB SWITCH INPUT
SIGNAL.
Check voltage between door lock timer
terminal q
6 and ground.
SEL160V
Lock knob switch

condition
Lock
Unlock
OK
Driver side lock knob

switch is OK.
Voltage
(V)
Approx. 12
0
NG
H
CHECK LOCK KNOB SWITCH.

1. Disconnect driver side lock knob switch
connector.
2. Check continuity between lock knob
switch terminals.
SEL161V
Terminals
q
1 -q
2
Condition
Locked
Unlocked
Continuity
No
Yes
OK

I Ground circuit for lock knob switch
I Harness for open or short between lock
knob switch and door lock timer
EL-158
NG
Replace lock knob switch.
LOCATION OF ELECTRICAL UNITS

Engine Compartment
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL843
EL-159

Passenger Compartment
LHD MODELS
HEL844
EL-160

Passenger Compartment (Contd)
RHD MODELS
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL845
EL-161
HARNESS LAYOUT
LHD MODELS
Outline
HEL846
RHD MODELS
HEL847
EL-162
HARNESS LAYOUT
How to Read Harness Layout
GI
Example:
G2
E1
B/6
: ASCD ACTUATOR
MA
Connector color / Cavity
EM
Connector number
Grid reference
LC
The following Harness Layouts use a map style grid to help locate connectors on the drawings:
I Main Harness (Instrument Panel, Engine Compartment)
I Engine Room Harness
I Engine Control Harness
To
1)
2)
3)
4)
5)
use the grid reference

Find the desired connector number on the connector list.
Find the grid reference.
On the drawing, find the crossing of the grid reference letter column and number row.
Find the connector number in the crossing zone.
Follow the line (if used) to the connector.
CONNECTOR SYMBOL
Main symbols of connector (in Harness Layout) are indicated in the below.
Water proof type
Female
FE
CL
MT
TF
Standard type
Connector type
Male
EC
Male
I Cavity: Less than 4

I Relay connector
Female
PD
FA
I Cavity: From 5 to 8
I Cavity: More than 9
I Ground terminal etc.
RA
BR
ST
RS
BT
HA
IDX
EL-163
HARNESS LAYOUT
Main Harness
INSTRUMENT PANEL LHD MODELS
HEL848
EL-164
HARNESS LAYOUT
Main Harness (Contd)
INSTRUMENT PANEL LHD MODELS
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL849
EL-165
HARNESS LAYOUT
INSTRUMENT PANEL RHD MODELS
HEL850
EL-166
HARNESS LAYOUT
INSTRUMENT PANEL RHD MODELS
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL851
EL-167
HARNESS LAYOUT
BODY SIDE LHD MODELS
HEL989
EL-168
HARNESS LAYOUT
BODY SIDE RHD MODELS
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL853
EL-169
HARNESS LAYOUT
ENGINE COMPARTMENT KA24E ENGINE (LHD models)
HEL854
EL-170
HARNESS LAYOUT
ENGINE COMPARTMENT KA24E ENGINE (LHD models)
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL855
EL-171
HARNESS LAYOUT
ENGINE COMPARTMENT EXCEPT KA24E ENGINE (LHD models)
HEL856
EL-172
HARNESS LAYOUT
ENGINE COMPARTMENT EXCEPT KA24E ENGINE (LHD models)
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL857
EL-173
HARNESS LAYOUT
Engine Room Harness
LHD MODELS GASOLINE ENGINE
HEL858
EL-174
HARNESS LAYOUT
Engine Room Harness (Contd)
LHD MODELS GASOLINE ENGINE
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL859
EL-175
HARNESS LAYOUT
LHD MODELS DIESEL ENGINE
HEL860
EL-176
HARNESS LAYOUT
LHD MODELS DIESEL ENGINE
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL861
EL-177
HARNESS LAYOUT
RHD MODELS GASOLINE ENGINE
HEL862
EL-178
HARNESS LAYOUT
RHD MODELS GASOLINE ENGINE
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL863
EL-179
HARNESS LAYOUT
RHD MODELS DIESEL ENGINE
HEL864
EL-180
HARNESS LAYOUT
RHD MODELS DIESEL ENGINE
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL865
EL-181
HARNESS LAYOUT
Engine Control Harness
HEL866
EL-182
HARNESS LAYOUT
Engine Control Harness (Contd)
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL867
EL-183
HARNESS LAYOUT
Engine Harness
NA AND Z ENGINES
HEL868
EL-184
HARNESS LAYOUT
Engine Harness (Contd)
KA ENGINE
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL870
EL-185
HARNESS LAYOUT
Engine Harness (Contd)
TD AND QD ENGINES
HEL871
EL-186
HARNESS LAYOUT
Alternator Harness
GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
HA
IDX
HEL872
EL-187
HARNESS LAYOUT
LHD MODELS
Instrument Harness
HEL873
RHD MODELS
HEL874
EL-188
HARNESS LAYOUT
LHD MODELS
Room Lamp Harness

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
HEL875
RHD MODELS
FA
RA
BR
ST
RS
BT
HA
IDX
HEL876
EL-189
HARNESS LAYOUT
Chassis Harness and Tail Harness
HEL877
EL-190
HARNESS LAYOUT
LHD MODELS
Front Door Harness (LH side)

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
HEL878
RHD MODELS
FA
RA
BR
ST
RS
BT
HA
IDX
HEL879
EL-191
HARNESS LAYOUT
LHD MODELS
Front Door Harness (RH side)
HEL880
RHD MODELS
HEL881
EL-192
HARNESS LAYOUT
LH SIDE
Rear Door Harness

GI
MA
EM
LC
EC
FE
CL
MT
TF
PD
HEL882
RH SIDE
FA
RA
BR
ST
RS
BT
HA
IDX
HEL883
EL-193

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ELECTRICAL SYSTEM

When you read wiring diagrams:

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

WIRING DIAGRAM REFERENCE CHART

Supplemental Restraint System (SRS) AIR

TYPE OF STANDARDIZED RELAYS

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

POWER SUPPLY ROUTING

POWER SUPPLY ROUTING

POWER SUPPLY ROUTING

POWER SUPPLY ROUTING

POWER SUPPLY ROUTING

POWER SUPPLY ROUTING

POWER SUPPLY ROUTING

POWER SUPPLY ROUTING

POWER SUPPLY ROUTING

POWER SUPPLY ROUTING

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

Circuit Breaker Inspection

CHECK CONNECTOR (Z engine)

COMBINATION FLASHER UNIT

IACV-FICD SOLENOID VALVE (KA engine)

REAR WINDOW DEFOGGER SWITCH

SPIRAL CABLE (2WD models with air bag)

GLOW CONTROL UNIT

COMBINATION METER (FUEL GAUGE)

ALTERNATOR (Gasoline engine)

NEUTRAL POSITION SWITCH

How to Handle Battery

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

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

Check the charge condition of the battery.

CHECKING ELECTROLYTE LEVEL

Remove the cell plug using a suitable tool.

SPECIFIC GRAVITY CHECK

CHECKING SPECIFIC GRAVITY

Ready for use

Ready for use

Ready for use

Ready for Replace

Test using battery checker.

Test using load tester.

Follow manufacturers instructions to check and determine

Read load tester voltage

Ready for use

Ready for use

Fig. 2 INITIAL CHARGING CURRENT SETTING (Slow charge)

Below 12 volts or above 15

Fig. 3 ADDITIONAL CHARGE (Slow charge)

Continue to charge for 12

CHECKING SPECIFIC GRAVITY

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

Fig. 4 INITIAL CHARGING CURRENT SETTING

Determine initial charging current from

CHECKING SPECIFIC GRAVITY

Charge battery for 8 hours.

Conduct additional charge as per Fig. 5, if

Charge for 3.5

Charge for 2.5

Charge for 1.5

CONVERTED SPECIFIC GRAVITY

0.75 hours (45 min.)

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

Service Data and Specifications (SDS)

Clearance between pinion

Movement in height of pinion assembly