Sec 08 Electrical - Body & Chassis-fb

8/9/2019 Sec 08 Electrical - Body & Chassis-fb

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WORKSHOP MANUAL

TBR SERIES

ELECTRICAL-BODY AND CHASSIS

SECTION 8


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NOTICE

Before using this Workshop Manual to assist you in performing vehicle

service and maintenance operations, it is recommended that you

carefully read and thoroughly understand the information contained in

Section - 0A under the headings “GENERAL REPAIR

INSTRUCTIONS” and “HOW TO USE THIS MANUAL”.

All material contained in this Manual is based on the latest product

information available at the time of publication.

All rights are reserved to make changes at any time without prior

notice.


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ELECTRICAL-BODY AND CHASSIS 8-1

SECTION 8

ELECTRICAL-BODY AND CHASSIS

TABLE OF CONTENTS

PAGE

General Information ..........................................................................................................8- 3

Notes for Working on Electrical Items .......................................................................8- 4

Symbols and Abbreviations ........................................................................................8- 10

Symbols ..................................................................................................................8- 10

Abbreviations .........................................................................................................8- 11

Parts for Electrical Circuit ...........................................................................................8- 12

Wiring ......................................................................................................................8- 12

Fuse .........................................................................................................................8- 13

Fusible Link ............................................................................................................8- 13

Relay ........................................................................................................................8- 14

Diode .......................................................................................................................8- 15

Connector ...............................................................................................................8- 16

Battery .....................................................................................................................8- 17

Reading the Circuit Diagram .......................................................................................8- 20

Main Data and Specifications ..........................................................................................8- 22

Bulb Specifications ......................................................................................................8- 22

Relay and Fuse Box Location .....................................................................................8- 24

Relay Location (Relay and Fuse Box) ........................................................................8- 25

Fuse and Fusible Link Location (Relay and Fuse Box) ............................................8- 26

Fuse Location (Fuse Box) ...........................................................................................8- 27

Reference Table of Fuse, Fusible Link........................................................................8- 28

Grounding Point ...........................................................................................................8- 29

Reference Table .....................................................................................................8- 29

Location ..................................................................................................................8- 30

Main Cable Harness Routing ...........................................................................................8- 32

Fuse Block Circuit ........................................................................................................8- 34

System Repair ...................................................................................................................8- 35

Start and Charging .......................................................................................................8- 35


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8-2 ELECTRICAL-BODY AND CHASSIS

PAGE

Lighting .........................................................................................................................8- 39

Hazard Warning Flasher, Turn Signal Light, Back Up Light,

Horn and Stop Light .....................................................................................................8- 55

Windshield Wiper and Washer ....................................................................................8- 73Meter, Warning Light and Indicator Light ..................................................................8- 93

Air Conditioning ...........................................................................................................8- 135

Power Door Lock .........................................................................................................8- 138

Power Window .............................................................................................................8- 147

Audio, Clock and Cigarette Lighter ............................................................................8- 161

Power Door Mirror ........................................................................................................8- 170

Transmission Control Module (A/T) ............................................................................8- 180

Connector List ..................................................................................................................8- 184


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GENERAL INFORMATION

The body and chassis electrical system operates on a twelve volt power supply with negative ground polarity.The main harness consists of the engine harness, the instrument harness, the body harness, and the chassis

harness.The harnesses use a split corrugated tube to protect the wires from the elements.

Wire size is determined by current flow, circuit length, and voltage drop.All wires have color-coded insulation.Wire color-codes are shown in the circuit diagrams.

This makes it easier to trace circuits and to make the proper connections.

Each circuit consists of the following:

1. Power source - The battery and the alternator

2. Wires - To carry electrical current through the circuit

3. Fuses - To protect the circuit against current overload

4. Relays - To protect voltage drop between the battery and the circuit parts and to protect the switch points against

burning

5. Switches - To open and close the circuit

6. Load - Any device, such as a light or motor, which converts the electrical current into useful work7. Ground - To allow the current to flow back to the power source


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NOTES FOR WORKING ON ELECTRICAL ITEMS

Ground cable Positive cable BATTERY CABLEDisconnecting the Battery Cable

1. All switches should be "OFF" position.

2. Disconnect the battery ground cable.

3. Disconnect the battery positive cable.

CAUTION:

It is important that the battery ground cable bedisconnected first.

Disconnecting the battery positive cable first can result ina short circuit.

Connecting the Battery CableFollow the disconnecting procedure in the reverse order toconnect the battery cables.

CAUTION:

Clean the battery terminal and apply light coat of grease toprevent terminal corrosion.

CONNECTOR HANDLINGDisconnecting the Connectors

Some connectors have a tang lock to hold the connectors

together during vehicle operation.Some tang locks are released by pulling them towards you 1 .

Other tang locks are released by pressing them forward 2 .Determine which type of tang lock is on the connector being

handled.

Firmly grasp both sides (male and female) of the connector.Release the tang lock and carefully pull the two halves of theconnector apart.

Never pull on the wires to separate the connectors.This will result in wire breakage.


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Connecting the Connectors

Firmly grasp both sides (male and female) of the connector.

Be sure that the connector pins and pin holes match.Be sure that both sides of the connector are aligned with each

other.Firmly but carefully push the two sides of the connector

together until a distinct click is heard.

Connector Inspection

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

CAUTION

Never insert the circuit tester test probes into theconnector open side to test the continuity.

Broken or open connector terminals will result.

Waterproof Connector Inspection

It is not possible to insert the test probes into the connector

wire side of a waterproof connector.Use one side of a connector 1 with its wires cut to make the

test.Connect the test connector to the connector 2 to be tested.

Connect the test probes to the cut wires to check the connectorcontinuity.

Connector Pin Removal

Connector Housing Tang Lock Type

1. Insert a slender shaft 3 into the connector housing open

end 4 .

2. Push the tang lock 5 up (in the direction of the arrow in the

illustration).

Pull the wire 6 with pin 7 free from the wire side of the

connector.


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Pin Tang Lock Type

1. Insert a slender shaft 3 into the connector housing open

end 4 .

2. Push the tang lock 8 flat (toward the wire side of the

connector).

Pull the wire 6 with pin 7 free from the wire side of the

connector.

Connector Pin Insertion

1. Check that the tang lock 8 is fully up.

2. Insert the pin 7 from the connector wire side 9 .

Push the pin in until the tang lock closes firmly.

3. Gently pull on the wires 6 to make sure that connector pin

is firmly set in place.

Fuse Replacement

The replacement fuse must have the same amperage

specification as the original fuse.Never replace a burn out fuse with a fuse of a differentamperage specification.

Doing so can result in an electrical fire or other serious circuitdamage.

Parts HandlingBe careful for parts handling and any part should not bedropped or thrown, otherwise short circuit or disorder may

result.

Wiring Harness

1. When assembling the parts, be careful not to bite or wedgethe wiring harness.

2. All electrical connections must be kept be kept clean and

tight.


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3. Use a grommet or guard tube to protect the wiring harness

from contacting a sharp edge or surface.

4. Position the wiring harness with enough clearance from the

other parts and guard the wiring harness with a vinyl tube to

avoid direct contact.

5. The wiring harness between engine and chassis should be

long enough to prevent chafing or damage due to various

vibrations.


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SPLICING WIREOpen the Harness

If the harness is taped, remove the tape.To avoid wire insulation damage, use a sewing "seam ripper"

(available from sewing supply stores) to cut open the harness.If the harness has a black plastic conduit, simply pull out the

desired wire.Cut the wire

Begin by cutting as little wire off the harness as possible.You may need the extra length of wire later if you decide to cut

more wire off to change the location of a splice.You may have to adjust splice locations to make certain that

each splice is at least 1-1/2" (40 mm) away from other splices,harness branches, or connectors.

Strip the insulation

When replacing a wire, use a wire of the same size as the

original wire.

Check the stripped wire for nicks or cut stands.If the wire is damaged, repeat the procedure on a new sectionof wire.

The two stripped wire ends should be equal in length.

Crimp the Wires

Select the proper clip to secure the splice.To determine the proper clip size for the wire being spliced,

follow the directions included with your clips.Select the correct anvil on the crimper.

(On most crimpers your choice is limited to either a small orlarge anvil.)

Overlap the two stripped wire ends and hold them between

your thumb and forefinger.Then, enter the splice clip under the stripped wires and hold it

in place.

• Open the crimping tool to its full width and rest one handle

on a firm flat surface.

• Center the back of the splice clip on the proper anvil and

close the crimping tool to the point where the back of the

splice clip touches the wings of the clip.

• Make sure that the clip and wires are still in the correct

position. Then, apply pressure until the crimping tool closes.

Before crimping the ends of the clip, be sure that:

• The wires extend beyond the clip in each direction.

• No strands of wire are cut loose.

• No insulation is caught under the clip.

Crimp the splice again, once on each end.Do not let the crimping tool extend beyond the edge of the clip

or you may damage or nick the wires.


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Solder

Apply 60/40 rosin core solder to the opening in the back of the

clip.Follow the manufacturer's instructions for the solder equipment

you are using.

Tape the Splice

Center and roll the splicing tape.The tape should cover the entire splice.

Roll on enough tape to duplicate the thickness of the insulationon the existing wires.Do not flag the tape.

Flagged tape may not provide enough insulation, and theflagged ends will tangle with the other wires in the harness.

If the wire does not belong in a conduit or other harness

covering, tape the wire again.Use a winding motion to cover the first piece of tape.


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SYMBOLS AND ABBREVIATIONS

SYMBOLS

Symbol Meaning of Symbol Symbol Meaning of Symbol

Fuse Bulb

Fusible link Double filament bulb

Fusible link wire Motor

Switch Variable resistor Rheostat

SwitchCoil (inductor),solenoid,

magnetic valve

Switch (Normal close type)

Contact wiring Relay

Battery

Diode Connector

Electronic Parts Light emitting diode

Resistor Reed switch

Speaker Condenser

Buzzer Horn

Circuit breaker Vacuum switching valve


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ABBREVIATIONS

Abbreviation Meaning of Abbreviation Abbreviation Meaning of Abbreviation

A Ampere (S) kW kilowatt

ABS Anti-lock brake system LH Left hand

ASM Assembly LWB Long wheel base

AC Alternating current M/T Manual transmission

A/C Air conditioner OD Over drive

ACC Accessories OPT Option

A/T Automatic transmission RH Right hand

C/B Circuit breaker RR Rear

CSD Cold start device RWAL Rear wheel anti-lock brake system

DIS Direct ignition system SRS Supplemental restraint system

EBCM Electronic brake control module ST Start

ECGI Electronic control gasoline injection STD Standard

ECM Engine control module SW Switch

ECU Electronic control unit SWB Short wheel base

EFE Early fuel evaporation TCM Transmission control module

4A/T 4-speed automatic transmission V Volt

FL Fusible link VSV Vacuum switching valve

FRT Front W Watt (S)

H/L Headlight WOT Wide open throttle

IC Integrated circuit W/ With

IG Ignition W/O Without


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PARTS FOR ELECTRICAL CIRCUIT

WIRINGWire Color

All wires have color-coded insulation.

Wires belonging to system's main harness will have a singlecolor.Wires belonging to a system's sub-circuits will have a colored

stripe.Striped wires use the following code to show wire size and

colors.

Example: 0.5 G / R

Red (Stripe color)

Green (Base color)

Wire size (0.5mm2)

Abbreviations are used to indicate wire color within a circuit

diagram.

Refer to the following table.

Wire Color-Coding

Color-Coding Meaning Color-Coding Meaning

B Black BR Brown

W White LG Light green

R Red GR Grey

G Green P Pink

Y Yellow LB Light blue

L Blue V Violet

O Orange

Distinction of Circuit by Wire Base Color

Base color Circuits Base color Circuits

B Starter circuit and grounding circuit Y Instrument circuit

W Charging circuit L, O, BR,

R Lighting circuit LG, GR, Other circuits

G Signal circuit P, LB, V

Wire Size

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

area measured in square millimeters.


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Wire Size Specifications

Normal sizeCross sectional area

(mm2)

Outside diameter

(mm)

Allowable current

(A)

0.3 0.372 1.8 9

0.5 0.563 2.0 12

0.85 0.885 2.2 16

1.25 1.287 2.5 21

2 2.091 2.9 28

3 3.296 3.6 37.5

5 5.227 4.4 53

8 7.952 5.5 67

15 13.36 7.0 75

20 20.61 8.2 97

Normal Blown FUSEFuses are the most common form of circuit protection used in

vehicle wiring.A fuse is a thin piece of wire or strip of metal encased in a

glass or plastic housing.It is wired in series with the circuit it protects.

When there is an overload of current in a circuit, such as ashort of a ground, the wire or metal strip is designed to burnout and interrupt the flow of current.

This prevents a surge of high current from reaching anddamaging other components in the circuit.

Determine the cause of the overloaded before replacing the

fuse.Never replace a blown fuse with a fuse of a different amperagespecification.

Doing so can result in an electrical fire or other serious circuitdamage.A blown fuse is easily identified.

Normal BlownFUSIBLE LINKThe fusible link is primarily used to protect circuits where highamounts of current flow and where is would not be practical to

use a fuse.For example, the starter circuit.

When a current overload occurs, the fusible link melts openand interrupts the flow of current so as to prevent the rest ofthe wiring harness from burning.

Determine the cause of the overload before replacing thefusible link.

The replacement fusible link must have the same amperagespecification as the original fusible link.

Never replace a blown fusible link with fusible link of a differentamperage specification.Doing so can result in an electrical fire or other serious circuit

damage.A blown fusible link is easily identified.


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Fusible Link Specifications

Type Rating Case Color Maximum Circuit Current(A)

Connector 30A Pink 15

Connector 40A Green 20

Bolted 50A Red 25

Bolted 60A Yellow 30

Bolted 80A Black 40

RELAYBattery and load location may require that a switch be placedsome distance from either component.

This means a longer wire and a higher voltage drop 1 . Theinstallation of a relay between the battery and the load reduces

the voltage drop 2 .Because the switch controls the relay, amperage through the

switch can be reduced.

Relay Specifications and Configurations

Name/

Color

Rated

voltage/ Coil

resistance

Internal circuit

1T

(MR5C)

/Black

12V

Approx. 90Ω

Minimumoperating

voltage:7V at

25°C (77°F)

1T

(MR5C)

/Brown

12V

Approx. 90Ω

Minimum

operating

voltage: 10.5V

at 25°C (77°F)

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


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DIODE

Diode Specifications and Configurations

SHAPEMARK/

COLORCONSTRUCTION CHECKING

THERE SHOULD BE CONTINUITY IN

EITHER A OR B WHEN A CIRCUITTESTER IS CONNECTED WITH

DIODE TERMINAL

BLACK

2 1

CONNECTION A + -

PATTERN B - +

TERMINAL NO.

BLACK

3 2 1

- +

CONNECTION + -

PATTERN + -

- +

B

A

TERMINAL NO.

BLACK

3 2 1

- +

CONNECTION + -

PATTERN + -

- +

B

A

TERMINAL NO.

BLACK

4 3 2 1

+ -

A - +

CONNECTION - +

PATTERN - +

B + -

+ -

TERMINAL NO.

Maximum Rating (Temp.=25

C)

Items Rating Remarks

Peak reverse voltage 400V

Transient peak reverse voltage 500V

Average output current 1.5A Temp.=40°C

Working ambient temperature -30°C∼80°C

Storage temperature -40°C∼100°C


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CONNECTORThe connector pin shape determines whether the connector is

male or female.The connector housing configuration does not determine

whether a connector is male or female.

The symbol illustrated in the figure is used as connector in the

circuit this section.

Connector is identified with a number.

The applicable terminal number is shown for each connector.

Connector terminal numbers are clearly shown.

Male side connector terminal numbers are in sequence fromupper right to lower left.

Female side connector terminal numbers are in sequence fromupper left to lower right.

NOTE:

For those connectors on which specific terminal numberson symbols are shown, the terminal numbers or symbols

are used in the circuit diagram, irrespective of the aboverule.


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BATTERYInspection

1. Check the battery terminals 1 for corrosion.

2. Check the battery cables 2 for looseness.

3. Check the battery case 3 for cracks and other damage.

4. Check the battery electrolyte level.

If the electrolyte level is excessively low, the battery must be

replaced.

5. If the battery has a built-in hydrometer, perform the

following steps.

1) Carefully clean the battery upper surface.

2) Check the hydrometer.

The hydrometer design will vary with the battery

manufacturer.

Refer to the illustration shown on the battery.

Battery Replacement

1. Disconnect the battery ground cable 1 .

2. Disconnect the battery positive cable 2 .

3. Remove the battery clamp 3 .

4. Remove the battery

Caution:

It is important that the battery ground cable be removed

first.Removing the battery positive cable first can result in a

short circuit.

Jump Starting the Engine with a Booster Battery

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

battery charging equipment.


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Caution:Never push or tow the vehicle in an attempt to start it.

Extensive damage to the emission system and othervehicle parts will result.(only catalytic converter vehicle)

Treat both the discharged battery and the booster batterywith great care when using jumper cables.

Carefully follow the procedure outlined below.Always be aware of the dangers of sparking.

Failure to follow the following procedure can result in:

a. Serious personal injury, specially to your eyes.

b. Extensive property damage from a battery explosion,

battery acid discharge, or electrical file.

c. Extensive damage to the electronic components of

both vehicles.

Do not use a 24 volt booster battery.

Serious damage to the vehicle's electrical system andelectronic components will result.

Jump Starting Procedure1. Set the parking brake on both vehicles.

2. If one or both vehicles is equipped with a manual

transmission, place the gear shift in the "NEUTRAL"

position.

3. Turn off the ignition on both vehicles.

4. Turn off all vehicle lights and accessories.

5. Check the built-in hydrometer on the discharged Battery (If

so equipped).

If there is no hydrometer indication abandon the jump start

procedure.

6. Be sure that the two vehicles are not touching.

Attach the end of one jumper cable to the booster battery

positive terminal.

7. Attach the other end of the same cable to the discharged

battery positive terminal.

8. Once again, check that the booster battery has a 12 volt

rating.

9. Attach one end of the remaining booster cable to the

booster battery negative terminal.

10.Attach the other end of the booster cable to a solid ground

(such as the air conditioner compressor mounting bracketor the alternator mounting bracket) in the engine room of

the vehicle with the discharged battery.

Be sure that the ground connection is at least 500 mm (20

in) from the discharged battery.


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Caution:Do not attach the booster cable to the discharged battery

negative terminal.

11.Start the engine of the vehicle with the booster battery.

Check that all unnecessary electrical accessories are off.

12.Start the engine of the vehicle with the discharged battery.

13.Remove the jumper cables in the reverse order to which

they were attached.

Caution:

Be absolutely sure to remove the negative jumper cable

from the vehicle with the discharged battery first.


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READING THE CIRCUIT DIAGRAM

In this manual, each system has its own parts location illustration and circuit diagram.And connector configurations used in the circuit diagram are shown at the end of this manual.

PARTS LOCATION: The parts location shows the location of the connectors 1 and the harnesses 2 used in theeach system.

CIRCUIT DIAGRAM: The circuit diagram shows the power supply 3 , the load or loads 4 and the groundingpoint(s) 5 .CONNECTOR LIST: The connector configuration shows each connector's number 6 , configuration 7 and the pin

numbers 8 .

PARTS LOCATION

ER-11

RELAY&FUSE BOX

(X-2,X-7)

P-7

P-8

P-2

ER-7

TE-4 TE-7 P-5

P-4

P-9 ER-9

H-5,6H-4*

H-2

H-3

ER-16

I-3

*=M/T

P-1P-6

1

2


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CIRCUIT DIAGRAM

P-8

P-6

BATT

P-1

P-9 P-7

P-7 : EARTH ; BODYP-8 : EARTH ; FRAMEP-9 : EARTH ; ENGINE

3 0 B / Y

9 B / Y

3 W / B

3B/Y 0.5YO/D RELAY etc.

WIPER

3B/W

0.5W/G(M/T)

0.5W/R(A/T)

0.5W/G(A/T)

5 B / Y

MAINEB-360A

8B/R

IGNEB-240A

ALT

BACC

IG

ST

ER-161

METERC-110A

ENGINEC-215A

FRT WIPERC-320A

ER-163

ER-165

SW ; STARTER

X-74

ER-91

X-72

X-73

X-71

ER-71

H-44

X-21

X-25

X-75

RELAY ;CHARGE

0.5W/L

3W

3 W

5 W

3 0 B / R

3B/W 3B/W

5W

0 . 8 5 B / Y

0 . 5 Y

0 . 8 5 W / R

0 . 5 B

0.85B/Y

0.5B

0.5B

S IG.

LBACG

RELAY ;STARTER

STARTER

X-24

X-22

H-22

H-67

H-35

TE-42

P-5 P-2

FUEL CUT

ER-11EARTH ; E/R (RH)0.85B 0.85B

P-4

STARTERE-110A

TE-7

(M/T)

H-51(A/T)

0.85B/Y

0.85B/Y

0.85B/Y

1.25LG/W

0.85B/Y

H-3

14

I-3

10

ER-7

2

ER-7

3

M E T E R

C H G .

I-3

5

TE-43

H-66

H-21

SW ; INHIBITOR(A/T)

M

3

4

5

CONNECTOR LIST


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MAIN DATA AND SPECIFICATIONS

BULB SPECIFICATIONS

HEAD LIGHT

FRONT ROOM LIGHT

FRONT COMBINATION LIGHT

BACK UP LIGHT

TAIL & STOP LIGHT

LICENSE PLATE LIGHT

REAR ROOM LIGHT

REAR TURN SIGNAL LIGHT

Light Name Bulb No.Rated Power

V-W

Number

of Bulbs

Lens

ColorRemarks

H4 12-60/55 2 White Halogen

R2 12-45/40 2 White

Front turn signal light - 12-21 2 White

Rear turn signal light P21W 12-21 2 Amber

Tail and stop light P21/5W 12-21/5 2 Red

Back up light P21W 12-21 2 White

License plate light W5W 12-5 1 or 2 White

Clearance light W5W 12-5 2 White

A/C-Heater control light - 12-0.7 1 -

Dome light (FRT) - 12-10 1 White

Dome light (RR) - 12-10 1 White

Inspection light - 12-5 1 White

Headlight


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Light NameBulb No. Rated Power

V-W

Number

of Bulbs

Lens

ColorRemarks

Charging

systemGasoline engine - 14-3.0 1 Red

Check engine 74 14-1.4 1 Red

Turn W/O Tachometer 158 14-3.4 2

signal W/Tachometer 74 14-1.4 2

High W/O Tachometer 158 14-3.4 1

Indicator/ beam W/Tachometer 74 14-1.4 1

Warning Low W/O Tachometer - 14-3.0 1

light fuel W/Tachometer 74 14-1.4 1

Oil pressure 74 14-1.4 1 Red

Brake system 74 14-1.4 1 Red

Overdrive off 74 14-2.0 1 Amber A/T

Sedimenter 74 14-1.4 1 Red

Check trans 74 14-1.2 1 Red A/T

Illumination light - 1.4-3.4 4 - Meter

Green

Blue

Amber


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RELAY AND FUSE BOX LOCATION

RELAY & FUSE BOX FUSE BOX


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RELAY LOCATION (RELAY AND FUSE BOX)

RELAY & FUSE BOX

X-1X-3

X-4

X-5

X-6

X-7

X-8

X-9

X-10

X-11

X-2

X-13

X-12

RELAYEngine

modelNO.

4JA1-NA, 4JA1-L

X-1 RELAY; HVAC

X-2 RELAY; STARTER

X-3 RELAY; (A/C COMP)

X-4 RELAY; (POWER WINDOW)

X-5 RELAY; TAIL LIGHT

X-6 RELAY; (SHIFT LOCK)

X-7 -

X-8 RELAY; FOG LIGHT

X-9 RELAY; (A/C CUT)

X-10 RELAY; DIMMER

X-11 RELAY; HEAD LIGHT

X-12 RELAY; CHARGE

X-13 -


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FUSE AND FUSIBLE LINK LOCATION (RELAY AND FUSE BOX)

RELAY & FUSE BOX

E-8E-1E-9E-2E-10E-3E-11E-4E-12E-5E-13E-6E-14E-7

EB-2

EB-3

EB-5

FUSE FUSIBLE LINK

Fuse No. Capacity Indication on lable Fuse No. Capacity Indication on lable

E-1 10A STARTER EB-2 40A IGN:B1

E-2 10A H/LIGHT LH EB-3 60A MAIN

E-3 10A H/LIGHT RH EB-5 30A (POWER WINDOW)

E-4 15A HORN HAZARD

E-5 15A (FOG LIGHT)

E-6 - -

E-7 - -

E-8 15A D/LOCK

E-9 15A AUDIO (B) DOME L.

E-10 10A STOP LIGHT

E-11 10A TAIL LIGHT

E-12 10A A/C

E-13 20A BLOWER

E-14 20A (RR. COOLER)


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FUSE LOCATION (FUSE BOX)

C-1 C-4

C-2 C-5

C-3 C-6

FUSE

No. Capacity Indication on label No. Capacity Indication on label

C-1 10A METER C-4 10A RR. WIPER

C-2 15A ENGINE C-5 15A TURN, BACK

C-3 20A FT. WIPER C-6 15A AUDIO (ACC), CIGAR

FUSE BOX


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REFERENCE TABLE OF FUSE, FUSIBLE LINK

FUSE

(Relay and fuse box)

Fuse No. Capacity Indication on lable Parts (Load)

E-1 10A STARTER Ignition SW, Starter relay

E-2 10A H/LIGHT LH

Headlight LH, High beam indicator light,

Dimmer-passing SW

E-3 10A H/LIGHT RHHeadlight RH, High beam indicator light,

Dimmer-passing SW

E-4 15A HORN HAZARD Hazard SW, Flasher unit, Horn relay, Horn SW, Horn

E-5 15A FOG LIGHT Fog light

E-6 - - -

E-7 - - -

E-8 15A D/LOCKDoor lock SW-driver side, Door lock SW-driver side,Door lock actuator

E-9 15A AUDIO (B) DOME L. Audio, Clock, Room light

E-10 10A STOP LIGHTStop light SW, Stop light, High mounted stop light,TCM (B)

E-11 10A TAIL LIGHTTail relay, Clearance light, Tail light, License plate light,Illumination lights, Lighting SW

E-12 10A A/CPressure SW, Electronic thermostat, Fan SW,

Magnetic cluch, VSV; FICD, A/C relay

E-13 20A BLOWER Blower motor, A/C relay, Blower resistor

E-14 20A RR COOLER -

FUSE

(Fuse Box)

Fuse No. Capacity Indication on lable Parts (Load)

C-1 10A METERVehicle speed sensor, Meter gauges,

Indicator and Warning lights

C-2 15A ENGINEIgnition SW, Fuel cut solenoid, Thermo SW,AC Generator, Charge relay, TCM (IG)

C-3 20A FT. WIPERWindshield wiper & washer SW,Windshield wiper motor, Windshield washer motor,

Windshield intermittent relay

C-4 10A RR. WIPER -

C-5 15A TURN, BACK

Power window relay,

FRT power window & door lock SW-driver side,RR power window SW, Hazard SW, Flasher unit,

Turn signal SW, Back up light SW, Back up lightC-6 15A AUDIO (ACC), CIGAR Audio, cigar lighter

FUSIBLE LINK

(Relay and fuse box)

Fusible link No. Capacity Indication on label Remarks

EB-2 40A IGN-B1 -

EB-3 60A MAIN -

EB-5 30A (POWER WINDOW) Power window & door lock SW, Power

window motor, Power window relay


31/202


GROUNDING POINT

REFERENCE TABLE

Connector No. Cable harness Location Parts (Load)

I-13

Instrument panel

Body-RH

(at driver’s feet)

FRT power window SW-driver side, Door lock SW,Door mirror control SW, Flasher unit, Illumination

light (Meter, Hazard SW), Cigarette lighter, Fog

SW, Clock, RR wiper SW, RR washer SW

I-2Body-LH

(at passenger’sfeet)

FRT Fan SW, Door lock controller, Heater bezel,

Illumination light (Bezel)

ER-11 Engine roomharness

Fender-RH

(behind enginecoolant

reservoir)

Vehicle speed sensor, Power window relay,FRT washer motor, Starter relay, Charge relay,

Fog relay, Dimmer relay, A/C relay, A/C comp relay,Combination SW, Fog light-RH, Position light-RH,

FRT turn signal light-RH, Meter interface

B-9 Body harnessFender-LH

(back of watersedimenter)

Windshield wiper motor (FRT, RR),

RR windshield washer motor, RR fan SW,Shift lever SW, Fuel filter SW, OD/OFF SW,

FRT turn signal light-LH, RR turn signal light (RH,LH),

Back up light (RH, LH), Stop light (RH, LH),Hi-mount stop light, Position light-LH, Fog light-LH,License plate light, Tail light (RH, LH), A/C amplifier,

Diagnosis connector, TCM

P-7Body-RH

(behind battery)Battery (-)

P-8Battery harness

Frame(near power

steering gearbox)

Engine

P-9

Engine

(at coolercompressor

bracket)

Battery (-), Frame


32/202


LOCATION

P-8

B-9

ER-11

P-7


33/202


P-9


34/202


MAIN CABLE HARNESS ROUTING

P-7

P-8

P-6P-1

P-9

I-13

H-1

H-2

H-8

H-7

H-3

H-15

I-2

ENGINE ROOM

HARNESS

BODY HARNESS

BATTERY POSITIVE CABLE

BATTERY NEGATIVE CABLE

INSTRUMENT HARNESS

TRANSMISSION &ENGINE HARNESS

ER-11

H-9

H-14

H-5

H-6

H-4*

RELAY &

FUSE BOX

FUSE BOX

*=M/T

B-9


35/202


H-3

H-15

CHASSIS HARNESS

DOME LIGHT

HARNESS

REAR COOLER

HARNESS

FRONT DOOR

HARNESS-RH

REAR DOOR HARNESS-RH

BACK DOOR

HARNESSREAR DOOR

HARNESS-LH

FRONT DOOR

HARNESS-LH

P-7

P-8

P-6P-1

P-9

I-13

H-1

H-2

H-8

H-16H-7

I-2

H-13

ER-11

H-10

H-11H-12

H-9

H-14B-9

RELAY &

FUSE BOX


36/202


FUSE BLOCK CIRCUIT

3 0 B / Y

9 B / Y

3W/B

5 B / Y

MAIN60A

8B/R

IGN40A

ACC

OFF

B

ST IG

E-11 TAIL10A

SW ; STARTER 1

2

5 3

RELAY ; TAIL

RELAY ; STARTER

RELAY ; FOG

RELAY ; A/C

0.5B

1.25W

3W

5W

3W

1.25W

1.25W1.25G/R

0.5G/R0.85B/Y

0.85W/R

0.5W/L

0.5G/Y

E-5 FOG15A 0.85R/G

0.5Y/L

E-12 A/C10A

0.5BR

E-13 BLOWER20A

2L/WE-14 RR COOLER20A 2L/R

E-8 DOOR LOCK15A 0.85B/L

E-10 STOP10A 0.5G/W

E-9 AUDIO(B) CLOCK ROOM15A 0.85R

C-1 METER10A 0.5Y

C-2 ENGINE15A

0.85B/Y 0.85B/Y

C-3 FT WIPER20A 1.25LG/W

C-4 RR WIPER10A 0.5W/L

C-5 TURN,BACK15A 0.85R/B

E-1 STARTER10A3B/W

30B/R

3B/W

0.5W/G

0.5W/R 0.5W/G

C-6 AUDIO,CIGAR15A 0.85L

0.5LG/R

0.85R/B

1.25W/L

3L/R

3L/B

3B/Y

3B/Y

0.85B

RELAY ; CHARGE

0.5B

0.5B

0.5B

RELAY ; P/W

2G/Y

3W

3W

2B/L

0.85R/B0.5B

P.N SW(A/T)

P/W30A

(M/T)

RELAY ; LIGHTING

3R/W

3R

0.5R/L1.25R

E-2 H/LAMP-LH10A 0.5R/G

E-3 H/LAMP-RH10A 0.5R/W

1.25R

E-4 HORN,HAZARD15A 0.85G

BS

B

C

IG+B

IG.

L

RR WIPER WASHER

TURN,BACK

STARTER

DOOR LOCK

STOP

FRT WIPER WASHER

METER,A/T

HVAC

FOG LAMP

TAIL,ILLUMI

ACG.

AUDIO,MIRRORCIGAR LIGHTER

FUEL CUT

CLOCK

ROOM LAMP

P/WINDOW

SHIFT LOCK(A/T)

LIGHTING

HORN,HAZARD

RELAY ; A/C COMP

0.5B/R 0.5G/B

0.5G (A/T)

0 . 5

B R

1.25BR/Y (M/T)

RELAY ; A/CLUT

1.25BR/Y (A/T)

1.25BR/Y (A/T)

0.5O (A/T)

0.5R/G0.5R/W

0.5R/Y

0.5R/B

RELAY ; DIMMER

0.5W/G

0.5W

0.5G/Y

RELAY ;SHIFT LOCK

0.85R

0.85R

TCM


37/202


SYSTEM REPAIR

START AND CHARGING

PARTS LOCATION

ER-11

RELAY&FUSE BOX

(X-2,X-7)

P-7

P-8

P-2

ER-7

TE-4 TE-7 P-5

P-4

P-9 ER-9

H-5,6H-4*

H-2

H-3

ER-16

I-3

*=M/T

P-1P-6


38/202


CIRCUIT DIAGRAM

P-8

P-6

BATT

P-1

P-9 P-7


3 0 B / Y

9 B / Y

3 W / B

3B/Y 0.5YO/D RELAY etc.

WIPER

3B/W

0.5W/G(M/T)

0.5W/R

(A/T)

0.5W/G

(A/T)

5 B / Y

MAINEB-360A

8B/R

IGNEB-240A

ALT

B

ACC

IG

ST

ER-161

METERC-110A

ENGINEC-215A

FRT WIPERC-320A

ER-16 3

ER-16 5

SW ; STARTER

X-12

4

ER-91

X-12

2X-12

3

X-12 1

ER-7 1

H-4 4

X-21

X-2 5

X-12

5

RELAY ;CHARGE

0.5W/L

3W

3 W

5 W

3 0 B / R

3B/W 3B/W

5W

0 . 8 5 B / Y

0 . 5 Y

0 . 8 5 W / R

0 . 5 B

0.85B/Y

0.5B

S IG.

LBACG

RELAY ;STARTER

STARTER

X-24

X-2 2

H-2 2 H-6 7

H-3 5

TE-4 2

P-5 P-2

FUEL CUT

EARTH ; E/R (RH) 0.85B 0.85B

P-4

STARTERE-110A

TE-7

(M/T)

H-5 1

(A/T)

0.85B/Y

0.85B/Y

1.25LG/W

0.85B/Y

H-3

14

I-3

10

ER-7

2

ER-7

3

M E T E R

C H G .

I-3

5

TE-43 H-66 H-21

SW ; INHIBITOR(A/T)

M

0.5W/L

0.5B

ER-11

H-1 12

H-1 12


39/202


REMOVAL AND INSTALLATION

STARTER SWITCHRemoval

1. Steering Lock Assembly

• Refer to Section 3B" STEERING COLUMN" for steeringlock assembly removal steps.

2. Starter Switch

Installation

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

INSPECTION AND REPAIR

STARTER SWITCHSwitch Connections

Terminal No.

Starter

switch key

position

1 2

(ACC)

3

(IG)

5

(ST)

Removed

OFF

ACC Inserted

ON

START

LOCK

X-7 Charge relayCheck continuity between the relay terminals.

3 - 4 ............................Continuity3 - 5 ............................No continuity

(When battery voltage is applied between 1 and 2 )

3 - 4 ............................No continuity3 - 5 ............................Continuity


40/202


Starter relayCheck continuity between the relay terminals.

5 - 3 ............................Continuity5 - 1 ............................No continuity


5

-3

............................No continuity5 - 1 ............................Continuity


41/202


LIGHTING

PARTS LOCATION

ER-11

P-7

ER-2

ER-3

ER-4

P-8 P-9 B-2

B-1

B-4

H-3H-7

ER-14

I-14

I-4 I-3

I-13

I-6

I-12

I-11

I-10

I-9

I-2

B-9

B-28

BD-4BD-5

RELAY&FUSE BOX

(X-5,X-8,X-10,X-11)

H-1

B-26

H-16B-19

P-1P-6


42/202


CIRCUIT DIAGRAM

B - 2

3

B - 2

1

B - 2

2

P - 8

P - 6

B A T T

P - 1 P

- 9

P - 7

P - 7 : E A R T H ; B O D Y

P - 8 : E A R T H ; F R A M E

P - 9 : E A R T H ; E N G I N E

30B/Y

9B/Y

0.5B/Y

8 B / R

M A I N

E B - 3

6 0 A

X - 1 1

2

X - 1 1

1

3 R

3 R / W

0 . 5 R / G

0 . 5 R / W

0.5R/B 0.5R/B

0 . 5 R / Y

0 . 5 R / Y

0 . 5 Y / L

1 . 2 5 W

0 . 5 R / B

0 . 5 R / W

0 . 5 R / Y

0 . 5 R / Y

0 . 5 B

I N D I . ; H I - B E A M

1 . 2 5

R

R E L A Y ;

L I G H T I N G

X - 1 1

3

X - 1 1

5

X - 1 0

4

X - 1 0

2

X - 1 0

3

X - 1 0

1

X - 1 0

5

0 . 8 5 B

0 . 5 R / G

1 . 2 5 W / L

0 . 8 5 R / G

0 . 8 5 R / G

0 . 8 5 R / G

0 . 5 B

0 . 5 B

0 . 5 B

0 . 5 B

0 . 5 B

0 . 5 B

I - 1 4

4

I - 1 4

5

0 . 5 G / R

S W ;

F O G

X - 5

2

X - 5

1

1 . 2 5 G / R

1.25W

0.5R/L

1.25W

R E L A Y ; T A I L

X - 5

3

X - 5

5

H / L A M P - L H

E - 2 1 0 A

H / L A M P ; L H

H / L A M P ; R H

H / L A M P - R H

E - 3 1 0 A

F O G E - 5 1 5 A

T A I L

E - 1 1

1 0 A

L O H

I L O H

I

E R - 3

3

E R - 3

1

E R - 3

2

H-1 3

H-1 2

R E L A Y ; D I M M E R

X - 8

2

X - 8

3

X - 8

1

X - 8

5

R E L A Y ; F O G

F O G L A M P - R H

ER-4

1

ER-4

2

F O G L A M P - L H

B-4

1

H-1

23

H-3

4

H-11

H-3

7

B-4

2

0 . 5 B

T A I L L A M P - R H

T A I L L A M P - L H

L I C E N S E L A M P

P O S

I T I O N L A M P - L H

P O S

I T I O N L A M P - R H

B-26

6

B-26

1

I - 1 4

3

0 . 5 G / R

I - 1 4

6

I - 1 4

2

I-4

11

I-4

10

0 . 5 G / R

0 . 5 B

B-28

6

B-28

1

0 . 5 B

BD-4

1

BD-5

1

H-16

11

0 . 5 G / R

0 . 5 G / R

0.5G/R

0.5G/R

0 . 5 G / R

0 . 5 G / R

0 . 5 G / R

0 . 5 G / R

0 . 5 B

B-1

1

H-1

4

B-1

2

0 . 5 B

ER-2

1

ER-2

2


43/202


0.5R/L

0.5G/Y

0 . 5 G / R

0 . 5 B

M

E T E R I L L U M I

C L O C K

M

E T E R I L L U M I

H A Z A R D S W

H E A T E R B E Z E L

I-3

13

I-4

8

0 . 5 G / R

I-4

1

I-4

8

0 . 5 G / R

0 . 5 B

I-9

2

I-9

3

0 . 5 G / R

0 . 5 G / R

0 . 5 B

I-12

3

I-12

1

0 . 5 B

I-6

1

I-6

2

R

R W I P E R S W

R R

W A S H E R S W

O D

O F F S W ( A / T )

0 . 5 G / R

0 . 5 B

I-10

1

I-10

3

0 . 5 G / R

0 . 5 B

0 . 5 B

0 . 8 5 B

0 . 5 B

0 . 5 B

0 . 5 B

0 . 5 B

I-11

1

I-11

3

0 . 5 G / R

0 . 5 R / G

C O M B

. S W

0 . 5 B

0 . 5 B

B-19

9

B-19

8

ER-14

10

H-7

15

ER-11

B-9

EARTH ; E/R (RH)

EARTH ; E/R (LH)

I-13EARTH ; BODY (RH) 0.85B

I-2EARTH ; BODY (LH) 2B

1.25B

0.85B

0.85B

1.25B

HI

PASS

HS1

HS2

HU

E

TS

E

ER-1412

ER-1411

ER-1413


44/202


TROUBLESHOOTING

HEADLIGHT

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

Checkpoint Trouble Cause Countermeasure

Repair the wiringPoor ground point contactNG

Repair open circuit or

connector contact

Repair open circuit

Repair or replace the

combination switch

Voltage between 12 ER-14 -

ground

Open circuit between lighting

relay and lighting switch

Open circuit between battery

positive terminal and lightingrelay

Combination switch continuityPoor switch contact or sw

faulty

Voltage between

1 X-11 - ground and5 X-11 - ground

Reinstall or replace the

lighting relayLighting relay

Poor relay contact or relay

faulty

NG

NG

NG

NG

OK

OK

OK

OK

Ground point contact (ER-11)

Repair open circuitWiring continuity between

10 ER-14 - ER-11Open circuit

NG

OK


45/202


2. High or low beam does not light on both headlights



combination switch

Dimmer⋅passing switch

continuity

Poor switch contact or switch

faulty

NG


connector contact

Voltage between

13 ER-14 - ground

Open circuit between

headlight and dimmer⋅passing

switch

NG

OK

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

Replace the headlight bulbHeadlight connector continuity Blown filament or air leakageNG

Repair or replace the wire

and/or connector

Wiring continuity between

connector 3 ER-3 - fuse No.

E-3 or 3 B-2 fuse No.

E-2

Open circuit and/or poor

connector contact

NG

OK

Reinstall or replace fuse No.

E-2 or No. E-3

Fuse No. E-2 (10A) or

No. E-3 (10A) (Relay and fuse

box)

(No. E-2: RH, No. E-3: LH)

Poor installation or blown fuseNG

OK

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

Replace the headlightassembly

Headlight connector continuity Blown filamentNG


connector contact

Wiring continuity between


switch

Open circuit between


switch

NG

OK


46/202


5. Headlight does not go out


Replace the lighting relay

Lighting relay continuity

between connector 1 X-11

- 2 X-11 (Should be nocontinuity)

Relay point fusedNG

Replay the combination switch

Lighting switch continuity

between connector 2 ER-14

-10 ER-14 when switch is

OFF(Should be no continuity)

Point fused or faultyNG

OK

OK

Repair short circuit

between 5 X-11 - 12 ER-14

Check if headlight goes out

when connector ER-14 is

disconnected

Short circuitNG

6. Insufficient headlight brightness

Replace the headlight bulbHeadlight bulb Bulb filament faultyNG

Repair the wiring

Dimmer⋅passing switch

Wire continuity between con-

nector 10 ER-14 - ER-11

Poor ground point contactNG

OK

Clean the light lensHeadlight lens Lens dirtyNG

OK


47/202


7. Passing light does not function when dimmer switch is operated


Repair or replace the dimmer

switch

Dimmer switch Poor switch point contactNG

Repair open circuit between

5 X-11 - 13 ER-14

Voltage between

13 ER-14 - ground (Should

be battery voltage present)Open circuit

NG

OK

8. Headlight beam does not change when dimmer switch is operated

Repair or replace the dimmer

switchDimmer switch

Loose beam lever or foreign

material in switch

NG


48/202


TAIL LIGHT, LICENSE PLATE LIGHT, CLEARANCE LIGHT

1. All lights do not light



combination switch

Lighting switch continuity

between connector

11 ER-14 - 10 ER-14

Poor switch point or connector

contact

NG

Reinstall or replace the tail

relayTail relay

Poor relay contact or relay

faulty

NG

OK

Reinstall or replace the fuse

No. E-11

Fuse No. E-11 (10A, Relay

and fuse box)Poor fuse contact or blown

NG

OK

2. Tail light does not light

Replace the bulb or repair

connector contactTail light bulb continuity

Bulb burned out or poor

connector contact

NG


connector contact

Continuity between connector

6 B-26 - 1 B-26 (RH)

or 6 B-28 - 1 B-28 (LH)

Open circuit or poor connector

contact

NG

OK


49/202


3. License plate light does not light



connector contact

Continuity between

connector 1 BD-4 - 1 BD-5


contact

NG


connector contact

License plate light bulb

continuity


connector contact

NG

OK

4. Clearance light does not light


connector contactClearance light bulb continuity


connector contact

NG


50/202



HEADLIGHTRemoval

1. Remove three bolts on the upper sides and bottom center

of the radiator grille, then remove the radiator grille.

2. Remove each bolt on the upper sides 1 , bottom sides 2 ,

and bottom corner 3 of the front face panel, then remove

the front defector panel.

3. Remove the headlight bolts.

4. Disconnect the headlight connector.

5. Remove the headlight.


51/202


Installation

Follow the removal procedure in the reverse order to install the

headlight.Pay close attention to the important points mentioned in the

following paragraphs.

Connector

Be absolutely sure that the headlight connector is securely

connected.This will prevent a contact and an open circuit.

LIGHTING SWITCHRemoval

1. Remove the steering wheel 1 .

Refer to the “STEERING” Section of this manual.

2. Remove the Instrument panel lower cover 2 .

3. Remove the steering column cover 3 .

4. Disconnect the connector.

5. Remove the lighting switch from the steering shaft.

Installation


lighting switch.Pay close attention to the important points mentioned in the


Connector

Be absolutely sure that the lighting switch connector is securelyconnected.

This will prevent a poor contact and an open circuit.

Wire Harness

Do not pinch the wire harnesses between the cluster and the

meter hood during the cluster installation procedure.Wire damage will result.


52/202


CLEARANCE LIGHTRemoval

1. Remove the top screw.

2. Remove the front combination light.

3. Turn the socket counterclockwise to disconnect it from the

light housing.

4. Pull the bulb from the socket.

Installation


clearance light.Pay close attention to the important points mentioned in the


Connector

Be absolutely sure that the clearance light connector is

securely connected.


LICENSE PLATE LIGHTRemoval

1. Loosen the screws 1 .

2. Remove the lens cover 2 and the lens 3 .

3. Pull the bulb to remove it.


53/202


Installation


license plate light.Pay close attention to the important points mentioned in the


Bulb

Be absolutely sure that the license plate light bulb is correctly

installed.This will prevent a poor contact and open circuit.

HEADLIGHT BEAM SWITCH(COMBINATION SWITCH)Removal

1. Remove the screws on the lower part of the steering wheel.

2. Remove the horn pad.

3. Remove the wiring connector.

4. Remove the steering wheel fixing nuts.

5. Remove the steering wheel.

Refer to the "STEERING" Section of this manual.

6. Remove the Instrument panel lower cover.

7. Remove the steering column cover.


9. Remove the headlight beam switch (lever) from the steering

shaft (combination switch).

Installation

Follow the removal procedure in the reverse order to install theheadlight beam switch(lever).

Pay close attention to the important points mentioned in thefollowing paragraphs.

Connector

Be absolutely sure that the headlight beam switch connector issecurely connected.


Wire Harness

Do not pinch the wire harnesses between the cluster and themeter hood during the cluster installation procedure.

Wire damage will result.


54/202


AIMING OF HEADLIGHT

Adjustment

1. Check and adjust the tire inflation pressures, clean the headlights, park the vehicle on a level surface and make

sure that vehicle is loaded. Block the wheels. Release the parking brake and shift to Neutral. (N position for AT

vehicles.)

2. Set the screen 3m away from front of the headlight. Adjust the screen so that the H-H, V-V line position is

aligned with the headlight center (mark position). Align the C-C length with B-B length for the vehicle center line.

If the cut line is not marked as shown in the figure of the following page, mark the cut line for adjustment 36mm

below H-H line.

L

Ah2

C

C

h1

B

B

1 Screen 4 V-V line of screen

2 Cut line 5 Vehicle center line

3 H-H line of screen

Screen adjusting value

Distance C: C = 543mm

Distance A: A = 0.012×3000 = 36mm (1.2% downwards)

Note:

Measure at the following conditions:

a. Carry out the aiming procedure on a level surface where it is able to darken.b. Headlight height "h1", distance from vehicle center line "B", and distance from screen "L" should be

measured from the center mark of the headlight.

c. Always set the screen base line as:h1 = h2

B = C


55/202


3. Adjust headlight aiming one side by one side. Switch the headlight to "LOW" position. Cover the headlight other

than adjustment with cloth to shade the light.

4. Adjust the headlight cut line with the screen cut line by turning the aiming screw at the rear side of the headlight.

(The Cut line is the boundary between the bright side and dark side. First adjust the vertical aiming, then the

horizontal aiming. The headlight will move diagonally when the vertical aiming is adjusted. Adjust horizontal

aiming by aligning intersection point of the 15° cut line and horizontal cut line as a target.)

LH Headlight RH Headlight

(View from rear side of headlight)

1 Vertical aiming (Turn clockwise to move headlightupward)

3 Horizontal aiming (Turn clockwise to moveheadlight to the left)

2 Horizontal aiming (Turn clockwise to moveheadlight to the right)

4 Aiming fulcrum

V

H H

V

C

15˚

LH Headlight line

V

V

C

15˚

RH Headlight line

A

Marking on screen

5. Set the screen against the other headlight and repeat Steps 3, 4 to adjust aiming.

6. Aiming is completed.


56/202



LIGHTING SWITCHLighting Switch Connections

Terminal

SW No.position 1 7 8

OFF

Tail

Headlight

HEADLIGHT BEAM SWITCHHeadlight Beam and Passing SwitchConnections

Terminal NO. 10 12 13

SW position HI PASS

HI

LO

At “Passing” Position

At “Dimmer” position

X-5 X-11LIGHTING RELAY, TAIL RELAYCheck continuity between the relay terminals.

3 - 5 .............................No continuity


3 - 5 .............................Continuity


57/202


HAZARD WARNING FLASHER, TURN SIGNAL LIGHT, BACK UPLIGHT, HORN AND STOP LIGHT

PARTS LOCATION

ER-11

P-7

ER-1

ER-5

P-8P-9 B-3

H-3H-7

ER-14ER-14

I-4 I-3

I-13

I-16

I-12

B-9

B-28

BD-3

H-1

B-26

H-16

ER-16

TE-4TE-5*,TE-6*

H-6H-4*

*=M/T

ER-13

RELAY&FUSE BOX

P-1P-6


58/202


CIRCUIT DIAGRAM

P-8

P-6

BATT

P-1

P-9 P-7


3 0 B / Y

9 B / Y

3 W / B

5 B / Y

MAINEB-360A

8B/R

3W 0.5G/W

IGNEB-2

40A

B

ACC

3B/Y

1.25R

0.85R/B

0.85G

IG

ST

ER-161

H-119

STOP ROOME-10

10A

TURN,BACKC-515A

HORN,HAZARDE-415A

ER-163

SW ; STARTER

B-9

ER-11

EARTH ; E/R (LH)

EARTH ; E/R (RH)

I-13EARTH ; BODY (RH)0.85B

0 . 5

B

0 . 5

B

0.85B

1.25B

0.85B

ER-14

6

I-12

5

I-12

3

I-12

7

ER-14

5

I-12

6

I-12

8

I-12

4

I-12

1

I-16

2

H-3

2

H-3

1

ER-14

4

RH LH

0.85G/B

0.85G/Y 0.85G/Y

0 . 8

5 G / Y

0 . 5

R / G

0 . 8

5 B / R

0 . 8

5 G

0 . 8

5 R / B

0 . 8

5 R / B

0 . 8

5 G

0.5G/R

0.5B

0.85G/W

0.85G/B

0.85G/W

0.85G/B

0.85G/W

COMB SW

BODY H,CONN(RH)

I-163

H-39

H-118

H-117

H-720

H-719

I-122

I-16

1

E B

L

FLASHER UNIT

(HAZARD)


59/202


H-166

H-1611

0.85G/B

FRT.TURN S.LAMP-LH

FRT.TURN S.LAMP-RH

0.85G/W

0.5B

0.5B

B - 3

1

B - 3

2

E R - 1 1

E R - 1 2

0.85G/W

RR TURN S.LAMP-RH

METER INDI.-LH

0.85G/B

0.5B

0.5B

B - 2 6 2

B - 2 6 1

I - 4

9 I - 4

1 1

METER INDI.-RH

0.85G/W I - 3

1 2

RR TURN S.LAMP-LH

0.85G/B 0.5B

B - 2 8 1

B - 2 8 2

0.5G/Y

0 . 5

G / Y

0.5G/Y0.5G/Y

HI-MOUNT STOP LAMP

STOP LAMP-RH

0.5G/Y

0.5B

0 . 5

B

0 . 8

5 B

0.5B

B D - 3 1

B D - 3 2

0.85R/Y0.85R/Y0.85R/B

0.85R/B

0.85R/Y

0.85R/B

0.85G

BACK UP LAMP-RH

BACK UP LAMP-LH

0.85R/Y

0.5B

0.5B

STOP LAMP-LH

0.5G/Y 0.5B

B - 2 8 1

B - 2 8 5

B - 2 6 1

B - 2 6 5

B - 2 6 1

B - 2 6 4

B - 2 8 1

B - 2 8 4

0.85B

0.85B

1.25B

0.85B

H-15

H-6

4

SW ; STOP LAMP

HORN

RELAY ; A/C

ER-51

ER-52

ER-147

SW ; HORN(COMB.SW)

0.5G/O

ER-132

ER-131

INHIBITOR SW(A/T)

TE-48

TE-4

6R

H-4

10

TE-61

TE-5

1SW ; BACK UP LAMP(M/T)

H-68

H-49

0.85R/B


60/202


TROUBLESHOOTING

STOPLIGHT AND HIGH MOUNTED STOPLIGHT

1. One side of stoplight does not light



connector contact

Burned out bulb or poor

connector contact

NG


connector contact


connector contact


contact

LH:

Continuity between

5 H-1 - 5 B-28

RH:

Continuity between5 H-1 - 5 B-26


contact

Continuity between

B-9 - 1 B-28 (LH)

T-6 - 1 B-26 (RH)

NG

NG

OK

OK

Stoplight bulb continuity

2. Both sides of stoplight do not light

Adjust the switch installation

position

Stop light switch (or brake

switch) function

Incorrect the switch installation

or adjustment

NG


connector contact

Voltage between 5 B-28

ground or 5 B-26 - ground

with brake pedal depressed

(Should be battery voltage

present)


contact between stoplight

switch (or brake switch) and

stoplight

NG

OK


E-10 (10A)

Fuse No. E-10 (10A, Fuse and

Relay box)Poor fuse contact or blown

NG

OK


61/202


3. High mounted stoplight does not light


Repair or replace the high

mounted stoplight

Continuity between 1 BD-3 -

2 BD-3

High mounted stoplight

malfunction

NG

Repair an open circuit orconnector contact between

1 BD-3 - 5 H-1

Voltage between 1 BD-3 -

ground with brake pedal

depressed (Should be battery

voltage present)


contact

NG

OK

Repair grounding point

( B-9 ) contact

Grounding point ( B-9 ) Poor grounding point contactNG

OK


62/202


TURN SIGNAL LIGHT AND HAZARD WARNING LIGHT

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


Replace the flasher unitFlasher unit malfunctionNG


combination switch

Turn signal switch continuity

between connector

6 ER-14 - 4 ER-14 and

6 ER-14 - 5 ER-14 when

turn signal switch operates

Short circuit between

connector 2 I-16 - 3 I-16

when turn signal switch

operates with starter switch

in “ON” position (Turn

signal light should be ON)

Poor switch point contact or

faulty switch

NG

OK

Reinstall or replace fuse No.C-5 (15A)

Fuse No. C-5 (15A, Fuse box) Poor fuse contact or blownfuse

NG

OK

OK


connector contact

Continuity between

connector 1 I-2 -ground

(Should be continuity)


contact

NG


63/202


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



connector contact


contact

NG

(LH)

Continuity between1 B-3 - 5 ER-14 (FRT),

2 B-28 - 5 ER-14 (RR)

(RH)

Continuity between

1 ER-1 - 4 ER-14 (FRT),

2 B-26 - 4 ER-14 (RR)


combination switch

Turn signal switch continuityPoor switch point contact or

faulty switch

NG

OK

OK

Repair open circuit orconnector contact

Open circuit or poor connectorcontact

NG

3. Hazard warning light does not light

Repair or replace the hazard

SW.Hazard SW. malfunction

NG

Voltage between 2 I-12 -

ground (Should be battery

voltage present)

Hazard SW. continuity

Reinstall or replace the fuse

No. E-4 (15A)

Fuse No. E-4 (15A, Relay and

fuse box)

Poor fuse contact or blown

fuse

NG

OK

OK


connector contact

Open circuit or poor

connector contact between

fuse No. E-4 (15A) -2 I-12

NG

4. Flashing rate too fast (One side)


open circuitInspect bulb Burned out bulb

NG


64/202


BACKUP LIGHT

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


Repair grounding point contactPoor ground contactNG

Grounding point

Replace the bulb or repairconnector contact

Backup light bulb continuity Burned out bulb or poorconnector contact

NG

OK

2. Backup light does not light on both sides

Repair or replace the switchPoor switch point contact of

faulty switch

NG

Voltage between 4 B-28

(4 B-26 ) - ground with

starter switch ON and shift

lever into reverse position

(Should be battery voltage

present)

Back up light switch (mode

switch) continuity


C-5 (15A)

Fuse No. C-5 (15A, Fuse box) Poor fuse contact or blown

fuse

NG

OK

OK


connector contact


contact

NG


65/202


HORN

1. Both sides of horn do not sound


Repair the grounding pointPoor ground contactNG

Horn relay

Grounding point

Reinstall or replace fuse No.E-4 (15A)

Fuse No E-4 (15A, Relay andfuse box)

Poor fuse contact or blownfuse

NG

OK

OK

Reinstall or replace the horn

relay

Poor relay contact or faulty

horn relay

NG

OK

Remove steering pad and

steering wheel

Horn switch continuity

OK

Repair or replace the horn

switch

Poor switch point contact or

faulty switch

NG

Continuity between

7 ER-14 - 1 ER-5

E-4 (15A) - 1 ER-5

OK


connector contact


contact

NG


66/202


2. One side of horn does not blow



reconnect the connector


contact

NG

Voltage between 1 ER-5

- ground with horn switch

depressed (Should be battery

voltage present)

Replace the horn assemblyHorn continuity between

connectors

Faulty horn assemblyNG

OK

3. Insufficient horn volume

Clean and/or remove the

foreign material

Stain foreign material in the

horn

NGHorn

Recharge or replace the

batteryBattery condition Discharged battery

NG

OK


67/202



REAR COMBINATION LIGHTStoplight and TaillightRemoval

1. Open the back door.2. Remove the screws of rear combination light.

3. Remove the rear combination light assembly.

4. Turn the bulb counterclockwise to remove it.

Installation


rear combination light.Pay close attention to the important points mentioned in the


Bulb

Be absolutely sure that each bulb is correctly installed.



68/202


FRONT TURN LIGHTRemoval

1. Remove the top screw.

2. Remove the front combination light.

3. Turn the socket counterclockwise to disconnect it from the

light housing.

4. Pull the bulb from the socket.

Installation


front turn light.Pay close attention to the important points mentioned in thefollowing paragraphs.

Bulb

Be absolutely sure that the front turn light bulb is correctlyinstalled.



69/202


REAR COMBINATION LIGHTTurn Signal Light

Removal

1. Open the back door.

2. Remove the screws.



Installation


rear combination light.Pay close attention to the important points mentioned in thefollowing paragraphs.

Bulb

Be absolutely sure that the rear combination light bulb is

correctly installed.This will prevent a poor contact and an open circuit.


70/202


TURN SIGNAL SWITCHRemoval


Refer to the “STEERING” Section of this Manual.

2. Remove the instruments panel lower cover 2 .

3. Remove the steering column cover 3 .


5. Remove the turn signal switch from the steering shaft.

Installation


turn signal switch (lever).Pay close attention to the important points mentioned in thefollowing paragraphs.

Connector

Be absolutely sure that the turn signal switch connector is

securely connected.This will prevent a poor contact and at an open circuit.


71/202


REAR COMBINATION LIGHTBack Up Light

Removal

1. Open the back door.

2. Remove the screws.



Installation


rear combination light.Pay close attention to the important points mentioned in thefollowing paragraphs.

Bulbs

Be absolutely sure that each bulb is correctly installed.



72/202


HAZARD WARNING FLASHER SWITCHRemoval

1. Instrument Panel Cluster Assembly

• Refer to Section 10 “BODY” for instrument panel cluster

assembly removal steps.

2. Hazard Warning Switch

• Disconnect the switch connector.

• To remove the switch, push the lock from the back side

of the cluster assembly.

Installation

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

Connector

Be absolutely sure that the hazard warning flasher switchconnector is securely connected.


BACK UP LIGHT SWITCHRemoval

1. Disconnect the connector 1 .

2. Remove the back up light switch from the transmission 2 .

InstallationFollow the removal procedure in the reverse order to install the

back up light switch.Pay close attention to the important points mentioned in the


Back up Light Switch Threads

Apply liquid gasket to the threaded portion and install the back

up light switch.

Connector

Be absolutely sure that the back up light connector is securely

connected.This will prevent a poor contact and an open circuit.


73/202


HORNRemoval

1. Remove the radiator grille.

Refer to the “HEADLIGHT” removal procedure.

2. Loosen the horn bolt.

3. Disconnect the horn connector.

Installation

Follow the removal procedure in the reverse order to install thehorn.

Pay close attention to the important point mentioned in thefollowing paragraphs.

Connector

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

1

HORN SWITCHRemoval

1. Remove the screws on the lower part of the steering wheel.

2. Remove the horn pad 1 .

3. Remove the horn wiring connector.

3 2

4. Remove the steering wheel nut 2 .


6. Remove the connector.

7. Remove the horn switch (combination switch).

Installation


horn switch.Pay close attention to the important points mentioned in the


Steering Wheel Nut

Tighten the nut to the specified torque.

Steering Wheel Nut Torque N⋅m (kgf⋅m/lb⋅ft)

34.3±4.9 (3.5±0.5 / 25±3.6)


74/202



TURN SIGNAL SWITCHLighting Switch Connections

Terminal No.

SW position6 5 4

Left

Neutral

Right

Turning

direction

HAZARD WARNING FLASHER SWITCHHazard Warning Flasher Switch Connections

TerminalNo.

SW position

4 5 6 7 8 2 1 3

ON

OFF


75/202


WINDSHIELD WIPER AND WASHER

PARTS LOCATION

ER-11

P-7

P-8 P-9

H-3H-7

ER-15

I-13B-9

H-1

ER-10

H-16

Documents

Sec 08 Electrical - Body & Chassis-fb