Pajero Manual

ELECTRICAL
SYSTEM
CONTENTS
SPECIFICATIONS .............................................. 2 IGNITION COIL . . .. . . .. . . .. . . .. .. .. . . . . . . . . . . . . . . . . . . . . . . . . . 101

GENERAL SPECIFICATIONS ....................... 2 WIRING HARNESS . . . .. . .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 15 FUSES . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . ‘131
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . .. 16 IGNITION SWITCH . .. . .. . . . .. . . . . . . . .,:. . . . . . . . . . . . . . . . . . . . 133
METERS AND GAUGES .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
TROUBLESH-OOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
LIGHTING SYSTEM . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
SERVICE ADJUSTMENT PROCEDURES ..I..... 73 WINDSHIELD WIPERS AND WASHER . . . . . . . 149
BATTERY . . . . . . . . . . . . . .. . . .. . . . . . . .. . . . . .. . . .. .. .. .. . . .. . .. . . .. . 73 REAR WINDOW WIPER AND WASHER . . . . 152
CHARGING SYSTEM . . .. .. .. .. .. . . .. .. . . .. . . . . . . .. . . .. . . 74 HEADLIGHT WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. 154
IGNITION SYSTEM . . . . .. . . . . .. . . . .. . . . . . . . . . . . . . . . . . . . . . . 77 HORN . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 156
CLOCK .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .. 158
COMPONENT SERVICE .................................... 79
REAR WINDOW DEFOGGER . . . . . . . . . . . . . . . . . .. . .. . 159
CHARGING SYSTEM .................................... 79
RADIO AND STEREO . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . . 161
STARTING SYSTEM ..................................... 84
POWER WINDOW . . .. . . . . . . . . . .. . . .. . . .. . . . . . .. . . . . . . . . . . . . . 166
IGNITION SYSTEM ....................................... 97
3-POINT ELR SEAT BELTS WITH’
TENSION RELIEFERS . .. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 169
8-l
SPECIFICATIONS
GENERAL SPECIFICATIONS
Starter Motor
Engine with M/T Engine with A/T
Model No. M3T25882 M2T53083

Type Direct drive Reduction drive
Output (nominal) kW/V 0.9112 1.2/12
Turning direction (as viewed from pinion side) Clockwise Clockwise
No. of teeth of pinion 8 9
No-load characteristics
Terminal voltage V 11.5 11.5
Current A 60 or less 100 or less
Speed rpm 6,500 or more 3,000 or more
Under-cut depth mm (in.) 0.5-l (.020-.039) 0.5-l (.020-.039)
Service limit 0.2 (.008) or less 0.2 (.008) or less
Commutator diameter mm (in.) 38.7 (1.524) 32 (1.260)
‘Service limit 37.7 (1.484) 31(1.220)
Pinion gap mm (in.) 0.5-2.0 (.020-.079) 0.5-2.0 (.020-.079)
Distributor
Federal California
Model No. T3T61971 T3T61972

(MD073074) (MD073075)
Type Contact-pointless type Contact-pointless type
Igniter Built-in type Built-in type
Turning direction Clockwise Clockwise
Firing order l-3-4-2 l-3-4-2
Centrifugal advance
(distributor angle at distributor rpm)
Initial 0’ at 750 0” at 750
Middle 7” at 1,900 7’ at 1,900
8.5” at 2,500 8.5” at 2,500
Final
Vacuum advance
(distributor angle at mm (in.) of mercury)
Initial 0” at 130 (5.12) 0” at 130 (5.12)
Middle 6.5” at 180 (7.09) 5.3’ at 180 (7.09)
15’at 300 (11.81) 11.5” at 280 (11.02)
Final
8-2
-+
SPECIFICATIONS cl
Ignition Coil
Identification model No. E-089 .; .

-
Primary resistance fi 1.2
Secondary resistance kfl 13.7
External resistor resistance a 1.35
,
Spark Plugs
Model No: NGK BPSES-11

NIPPONDENSO W16EPR-UlO
Plug gap mm (in .) 1.0-l .l (.039-.043)
Alternator
Model No. A5T2 1077 A2T41377

(MD064068) (MD074645)
Output (nominal) V/A 12150 12/55
Regulated voltage V 14.4 f 0.5 at 20°C (68°F) 14.4 + 0.5 at 20°C (68’F)
Polarity Minus (-) ground Minus (-) ground
Turning direction (as viewed from pulley) Clockwise Clockwise
Voltage regulator Electronic, built-in type Electronic, built-in type _’
Battery ~
Type NXlOO-S6 (S)-MF NX120-7-MF

(Maintenance free battery) (Maintenance free battery)
Capacity (20HR) Ab 45 80
Voltage V 12 12
Electrolyte specific gravity [2O”C (60”F)] 1.280 1.280 .
NOTE
If the specific gravity of the battery electrolyte falls 0.06 or more, recharge the battery.
8-3
SPECIFICATIONS
Fuses
Fusible links For Federal For California

(not available (can also be sold in Federal states)
in Califo:rnia)
Main
Cable color Red Red .Green
Fusible link size mm’ (ini) 0.85 (.d013) 0.85.(.0013) 0.5 (.OOOS)
Permissible continuous current A 34 34 27
Fusing current A 150 150 100
Sub Ignition circuit Power window Headlight, headlight

circuit washer circuit
Cable color Green Green Brown
Fusible link size mm2 (in.“) 0.5 (.0008) 0.5 (.OOOS) 0.3 (.0005)
Permissible continuous current A 27 27 19
Fusing current A 100 100 65
Fuse capacity A 10 -15 . 20 -

Color Red ’ Light blue Yellow
,’
Ignition Switch .
.I
Ignition switch
!
Type Rotary switch with steering wheel lock
and key-reminder switch
Load capacity A
AM-ACC 15
AMGIG 30
AM-ST .i 15
‘M-R 15
Key-reminder switch
Load capacity W 1
,
8-4
-+
SPECIFICATIONS cl
Meters and Gauges

.
Speedometer
Speed indication range mph (km/h) O-85 (O-1 37)
Indication ratings (range of allowable error)
Meter with “mph” indication mph
+2.5
0
t3.5
50 mph to.3
+5
75 mph +1
Tachometer
Type Pulse type
Detection source Ignition coil
Red zone rpm 6,000~8,000
Indication ratings (range of allowable error) rpm
1,000 rpm i f 100
2,000 rpm + 100
3,000 rpm f 150
4,000 rpm f 200
-5,000 rpm f 250
Fuel gauge
Bi-metal type
5pe (built-in constant voltage relay)
Constant voltage relay resistance value Q. 68-72
Fuel gauge unit
7-V resistance type
5Pe
Standard resistance value fi
Float position “F” point 14.9-19.1
Float position “E” point 113.5-126.5
Float vertical movement range mm (in.) 222-220 (8.81-8.97)
Water temperature gauge
Bi-metal type
Type
Water temperature gauge unit
Thermistor type
Type
Standard resistance value a
70°C (158°F) 90.5-l 17.5
115°C (239’F) 21.3-26.3
8-5
SPECIFICATIONS
Oil pressure gauge

Type Bi-metal tyPe
Oil pressure gauge unit
Type Bi-metal type
Standard resistance value i-2
0 kPa (0 psi) 0
588 kPa (85 psi) 136
Inclinometer
Type Gravity type
Damping system Oil-fdled system
Indication angle
Forward, backward 45” max.
Right, left 49 max.
Voltage meter
Type Bimetal type
Indication ratings (range of allowable ,error) V
IOV f 0.5
:
14v + 0.5
8-6
SPECIFICATIONS
Indicator and Warning Lights W (ME trade numbers)
1. Upper-beam and passing indicator light 1.4 (74)

2. Turn-signal indicator lights 1.4 (74)
3. Brake warning light 1.4 (74)
4. Oil pressure warning light 1.4 (74)
5. Charging warning light 1.4 (74)
6. Fasten-seat-belt warning light 1.4 (74)
7. Door-ajar warning light 1.4 (74)
8. 4WD indicator light 1.4 (74)
I , 16W735
4
Sensor and Switches
Parking brake switch

Rated load W 5
Voltage drop (at 12 V, rated load) V 0.1 or less :
Brake fluid lever sensor
Rated load W 3.6 ,
Voltage drop (at 12 V, rated load) V 0.1 or less
Door switch
Rated load W 15
Voltage drop (at 12 V, rated load) V 0.2 or less
Belt switch
‘Me Normally closed type
Seat Belt Warning Timer
Rated load 3.4 W (light) and 24 TL” s2 (buzzer)
Operating voltage V 8.0-16.0
8-7
SPECIFICATIONS
Buzzer
Rated voltage V 13.5

Operating voltage range V 11-15
While buzzing (Terminal voltage at 13 V)
Sound pressure dB 70 f 5
Fundamental frequency Hz 700
Lighting Systern
Main lights W (SAE trade numbers)

Headlights 60150
Front combination lights
Turn-signal lights 27 (1156)
Front side marker and position lights 3.8 (194)
Rear combination lights
Turn-signal, stop and tail lights 27/8 (1157)
Rear side marker lights 3.8 (194)
Back-up lights 27 (1156)
License.$ate lights 6
Sub lights W (SAE trade number)

Dome light 10
Combination meter illumination light 3.4 (158)
Cigarette lighter illumination light 4 . 1.4 (74)
Heater panel illumination light 1.4 (74)
Rear window defogger switch illumination light 0.9
Ashtray illumination light 1.4 (74)
Turn-signal flasher unit

Type Condenser type :
Rated load W 82.9-84.2
Blinking freguencx cycle/min 85 f 10
[12.8 V, 20 C (68 F)]
Hazard warning flasher unit

Type Heat-band type
Rated load W 49.4-168.8
Blinking frequency cycle/min 90* 10
[12.8 V, 20 C (68”F)]
8-8
SPECIFICATIONS III-+
Column switch
Turn-signal switch
Rated load A 6.1-7.1
Voltage drop (at 12 V and the rated load) V 0.2 or less
Dimmer switch
Rated load A
High beam 16.1-18.7.
Low beam 9.4-10.8
Passing switch
Rated load A
High beam 16.1-18.7
Low beam 9.4-10.8
Voltage drop (at 12 V and the rated load) 0.2 or less
Lighting switch
Rated load A 0.17-0.27
Headlight washer switch
Rated load A 0.5
.
Hazard warning switch

Voltage drop (at 12 V and the rated load) V 0.2 or less I
Light control relay

Rated load W 200
Range of voltage used V lo-16
Voltage drop between terminals V 0.2 or less
Dimmer control switch

Type Variable-resistance type
Rated load W 15 (Min.)-26.6 (Max.)
Stop light switch ..

Rated load W 150
8-9
cl-+ SPECIFICATIONS
Windshield Wipers and Washer
Wiper motor
Type Permanent-magnet type
Speed control system 3-brush system
Braking system Dynamic brake system ,’
Revolution under load rpm
Low speed [ 1.9 Nm (1.4 ftlbs.)] 35 *4
High speed [1.3 Nm (0.9 ft.&.)] 45 f 8
Nominal torque Nm (ftlbs.) 13 (9)
Wiper blades
Wiping angle
Driver’s side 85.5’
Passenger’s side 114”
Blade length mm (in.) 401 (16)
Washer motor and pump
Motor type Direct current ferrite magnet type
Pump type Centrifugal type
Power consumption A 3.5 or less
Time of continuous use sec.
With washer fluid Max. 60
Empty operation Max. 20 .
Nozzle jet pressure kPa (psi) 69 (10.0) or more
Tank capacity lit. (U.S.qts., Imp.qts.) 1.5 (1.6, 1.3)
1.
Intermittent wiper relay
Intermittent cycle sec. 1.5 + 0.7-10.5 f 3
Delay time in combined intermittent wiper and washer operation 0.4-l .2
Load current A 5 (motor load)
Wiper switch
Rated load A 0.5
Intermittent 0.22 f 0.05
Low speed 3.5
High speed 4.5
Lock 18
Washer switch
Rated load A 3
8-10
SPECIFICATIONS cl-+
Rear Window Wiper and Washer
Wiper motor
Motor type Ferrite magnet type
Braking system Dynamic braking system
Revolution under no-load rpm 50 + 5
Nominal torque Nm (ft.lbs.) 6 (4) or more
No-load current A 2 or less
Wiper blade
Wiping angle 108’
Blade length mm (in.) 334 (13)
Window washer motor and pump
Motor type Direct current ferrite magnet type
Power consumption A 3.5 or less
Allowable period of continuous use sec.
With washer fluid Max. 60
Empty operation Max. 20
Nozzle jet-spray pressure Wa (psi) 78 (11.4) or more
Tank capacity lit. (U.S.qts., Imp.qt.) 1.1 (1.2, l.O)or more
Wiper and washer switch
Rated load A
Wiper switch 3
Washer switch 5
Headlight washer
Headlight washer motor

Motor type Ferrite magnet type
Power consumption A 21 or less
Nozzle injection pressure kPa (psi) 177 (25.6) or more :
Tank capacity lit. (U.S.qts., Imp.qts.) 3.0 (3.2,26)
’ I
Headlight washer control relay
Timer setting sec. 0.52 + 0.1
Check valve
Valve opening and closing pressure kPa (psi) 49-108 (7.1-15.6)
8-11
SPEW CATIONS
Horn
Type Flat type

Effective sounding voltage V 1 l-14.5
Power consumption .A 3.5 or less
Sound level dB 100-110
Fundamental frequency Hz
“low” sound 340-380
“high” sound 400-440
Clock
Type Crystal oscillating type

Display type Fluorescent digital display (12 hour display)’
Daily variation seconds/day k2
[at a power supply of 9 to 16V,
20”C(68’F) ambient temperature]
:, I,
Cigarette Lighter
Rated input W 120

Timing of plug pop-up Within 18 seconds
Cigarette lighter light bulb capacity W 1.4.x 1 ,
Ashtray light bulb capacity W. 1. ’ 1.4x 1
Rear Window Defogger
Rear window defogger switch

Type Seesaw type
Rated current A 12
Indicator light W 0.9
Rear window glass with defogger ., .’
No. of printed heater lines 11
Power consumption [2O”C (68’ F)] W 102-138
8-12
SPECIFICATIONS III-+
Radio and Stereo
Radio
Model AR-8729 SEKR-Y
Receiving bands AM/FM-MPX
Circuitry AM High frequency: 1 step; mid frequency:
I step, superheterodyne amplification
FM High frequency: 1 step; mid frequency:
1 step, superheterodyne amplification
Ratio detection, PLL, FM stereo demodulation,
and noise killer circuits
Reception frequencies AM kHz 5251,615
FM MHz 88-108
Tape player
Model RX-750 SY-RY
Playback system 4-track auto-reverse stereo playback
Adaptable tape Normal, C-90 or shorter tape ..
output w 4
Tape speed cm/set. 4.76
Tuning system Manual search tuning, Mechanical memory tuning
Frequency coverage AM kHz 525-1,615
FM MHz 88-108
Speakers
Model SG-28A8 SG-3K44-G, SG-3K44-R
Rated input power W 5 (Max. 7) 5 (Max. 7)
Output sound pressure level dB 88-92 88-92
Mounting position Instrument panel, driver’s side Left and right center pillars
Antenna
Type Whip antenna (Fender-mounted)
8-13
cl-+ SPECIFICATIONS
Power Windows
Power window motor

Type Permanent magnet type (built-in circuit breaker)
Revolutions under load rpm
At 1 Nm (.72 ft. lbs.) : . 60-90
At 2 Nm (1.45 ft. lbs.) 50-80
Bound current A . 34 or less
Direction of rotation
Power window main switch
Type
,
.I t
!.
Clockwise and counterclockwise
Automatic reset type

Rated load current A :
Lock switch 30
L.H. switch ‘: 11
R.H. switch .i ,. 11
Power window sub switch ,I
Type Automatic reset type
Rated load current A 11
Power window relay ‘I I .‘L
Maximum contact current A 20
Rated coil current A 0.13-0.19
-Voltage drop between terminals V 0.2 or less - -
(at 12 V and the rated load current)
_ ,’
i
3-Point ELR seat belts with tension reliefers .
Belt switches Normally open type

Seatbelt solenoids
Operating voltage V B-16
Continuous rating (50 fl, 240 mA) 2.88.W
Insulation resistance(measuredwith SOO-VDCmegger) 100 Ma
8-14
-+
SPECIFICATIONS cl
SERVICE SPECIFICATIONS
Engine
General
Basic ignition timing 7 f 2”BTDC
Meters and Gauges
Fuel gauge indication test

When resistance is 17 s2 Scale indication A
When resistance is 120 Q Scale indication B
Fuel gauge continuity test
Resistance value R Approx. 25
Water temperature gauge indication test
When resistance is 23.8 a Scale indication C
\
When resistance is 104 Q Scale indication D
Water temperature gauge continuity.test
Resistance value 52 Approx. 55
Water temperature gauge unit operation check
When water temperature is 70°C (158’F) SI 104
Oil pressure gague indication test
When resistance is 120 s2 Scale indication E
Oil pressure gauge continuity test
Resistance value fi Approx. 42
Voltage meter continuity test
Resistance value 52 420
Fuel gauge .A
68WOO3
Water temperature gauge
W68003
Oil pressure gauge
161764
I&15
SPECIFICATIONS
Lighting System
Standard value
Headlight intensity 20,000 cd or more
Windshield Wipers and Washer
Standard value
Wiper blade stopping position mm (in.) 37-47 (151.9)
(distance between blade tip and front deck garnish)
Rear Window Wiper and Washer 1
Standard value
Wiper blade stopping position mm (in .) 20 (.8)
(distance between blade tip and back door window weatherstrip)
TORQUE SPECIFICATIONS
Fuel Gauge Unit Nm (ft.lbs.)
Fuel gauge unit 1 1 (0.7)
Windshield Wipers and Washer Nm (ft.lbs.)
Wiper pivot shaft mounting nut 7 (5)

Wiper arm locking nut IO-16 (7-12)
Wiper motor 3 (2)
Rear Window Wiper and Washer Nm (ft.lbs.)
Rear wiper pivot shaft mounting nut 8-12 (6-9)

Rear wiper arm locking nut 7-10 (5-7)
Rear wiper motor 7-10 (S-7)
8-16
TROUBLESHOOTING III-+
BATTERY
t
I Run-down battery
I
I
TEST 1
With the engine at curb idle, measure the voltage at the “B”,terminal
of the alternator. Next, measure the voltage at the “B” terminal
when the engine speed is increased to about 2,000 rpm, and compare that
1 measurement with the measurement during idling.
1 Is voltage higher at 2,000 rpm?
I
$
I
1
I Go to TEST 6.
TEST 2
With the engine stopped and the ignition switch in the “ON” position, measure
the voltage at the “L” terminal of the alternator. In other words, check whether
or not field current flows.
1
I Go to TEST 6. ~~ t0 TEST 5.
TEST 3
Short-circuit the “B” terminal and the “R” terminal of the alternator with a
jumper wire, and then repeat TEST 2.
I I
oto1v 1 to3V
I
I
Poor ignition
switch ground
TEST 4
Remove the connector from the alternator, and then check for continuity
between the “L” and “R” terminals of the alternator.
I
Continuity (35 to 100 52) No continuity
Malfunction of the regulator, Malfunction of the regulator

or (t) side brush is grounded
CAUTION
While engine is running (alternator generating power), make sure that
Lterminal is not grounded. If Ltenninal is grounded, auxiliary diode
will be short-circuited and no voltage will be available at Lterminal, so
no power will be generated. Therefore, CHARGE lamp will remain lit.
8-17
TROUBLESHOOTING
TEST 5
With the engine stopped and the ignition switch in the “ON” position, measure
the voltage at the “F” terminal (for testing the alternator).
With the ignition switch in the “OFF” position, puIl the connector from the
alternator. Then, measure the voltage at the “L” terminal. If the voltage
battery voltage, the (t) diode is short-circuitd.
, CAUTION
When measuring the’ voltage of the “F” terminal (for testing), be
careful not to let the voltmeter probe contact the rear bracket. If
by chance it does contact it, there’s no problem if it’s immediately
pulled away.
8-18
TROUBLESHOOTING n-+
TEST 6
Output current test
Disconnect the wiring from the “B” terminal of the alternator, and
connect an ammeter (60 A or higher) between the wires and the terminal.
Start the engine. Then immediately increase the engine speed to 2,500 to 3,000
rpm and quickly read the maximum value shown by the ammeter. Note that
all loads on the electrical system should be “ON” when this test is made.
I
70% or less of nominal 70% to 90% of nominal 90% or more of nominal
output output output
Normal function of alternator Alternator is normal
I
1 TEST 7
Output current test (recheck)
Check for poor contact of the wiring between the “B”
terminal of the alternator and the positive (+) terminal of the battery.
After slightly discharging the battery make TEST 6 once again.
I I
Less than 90% of nominal More than 90% of nominal
output output
1
Remove the alternator from
the engine and check it. Alternator is normal
NOTE
Make TEST 8 if it is necessary after finishing TESTS 6 and 7.
1 TEST8 I
Regulated voltage test
(See p.8-76.)
I
I Electronic voltage regulator

is normal I
I Malfunction of alternator I
8-19
cl-+ TROUBLESHOOTING
-Overcharge I
Not 15.5 V or more 15.5 V or less
Malfunction of alternator
(malfunction of electronic
voltage regulator, or negative
(-) brush is grounded)
r TEST 2
Measure and compare the voltage of the “F” terminal (for checking the
alternator) at idle speed and at approx. 3,000 rpm.
Is the voltage higher at 3,000 rpm?
I I
Higher Not higher, or no change

J
Malfunction of alternator
(malfunction of electronic
voltage regulator, or negative
(-) brush is grounded)
NOTE
The voltage of the “F” terminal
may not increase if the battery
is discharged.
TEST3
Regulated voltage test.
(See p.8-76.)
I
I
Alternator normal I
I
1
I
Malfunction of alternator 1
I
S-20
TROUBLESHOOTING
ENGINE
P
Unsmooth
idling
Ignition system
wiring con-
nections loose
Starter motor faulty Spark plug gap Spark plug gap

l Faulty switch contacts incorrect incorrect
l Burnt or defective magnetic switch contact plate
l Magnetic switch pull-in coil broken
l Magnetic switch holding coil broken
l Magnetic switch plunger is released at improper
position
l Faulty brush contact
l Brush spring tension insufficient

Loose or Loose or
defective spark defective spark
l Burnt commutator
plug cable plug cable
0 Large amount of mica on commutator
l Field coil grounded
l Armature grounded
l Clutch pinion tip worn
l Clutch races I
1
l Clutch drive spring weakened
Defective Defective Insufficient
. Motor does not rotate in overrun direction ignition coil ignition coil acceleration
l Spline section does not slide smoothly
0 Bearing worn
l Improper soldering of field coil
1
1
Wiring broken Primary wiring Primary wiring Defective

between starter connections connections spark plug
switch and faulty faulty
magnetic switch
terminal
Faulty contact
between battery
and ground
strap
TROUEILESHOOTING
cInsufficient
power
n
Overdisch&e
Battery
0 Insufficient !
electrolyte’,
0 Defective plate
(internal short)
Drive belt loose
I I
Alternator ’ Electrical Poor contact
0 Stator coil overload starting switch
1:
grounded or l Addition of
wire broken non-standard
aQ
l Rotor coil electrical loads
L
wire broken
0 Loose contact
between brusl Blown charging Faulty ‘wiring,
and slip ring circuit fuse connectors
f-2hnot
come down
fully)
l Diode open .
: ’
(noise emitted Defective’

by radio) I.C. regulator
I
I,
vr-l
Defective
I.C. regulator
Battery
connected in
reverse polarity
r-l strange sound
from alte’inator
(emitted by
radio)
Alternator
0 Defective
bearing
l Open diode
0 Stator coil
grounded or
winding
shorted
8-22
TROUBLESHOOTING n-+
STARTING SYSTEM
The troubles of starting system may be divided into Generally, starting difficulty, aside from inoperative
“Starting motor does not turn”, “Starting motor starting -motor, is often attributable to defective
turns but engine does not start” and “It takes some ignition system, fuel system, battery, electrical
time before engine starts”. When there is something wiring, etc. If makeshift corrective steps are taken
wrong with starting system, therefore, it is important without locating the cause, same trouble will develop
to determine which part of starting system is defec- again.
tive with starting motor attached to engine.
Starting motor turns but engine does

not start
Set ignition switch to “ST”. Does

switch make operating sound?’ 1 Does initial explosion occur?
Is starting motor pinion
I moving away from flywheel teeth too

early? I
--
Starting motor defective 1 1 ~~~$t~~~$e~:ive 1
Defective wiring between

battery and switch I
8-23
TROUBLESHOOTING
j _rethi’;” wrong I 1 Nothin;,w,ntig 1
IRecharge battery or replace

I I
j--A,Check .,
ignition system, fuel system
Check voltage drop per 100 A betwe&

, / switch B-andM-teyals. /
I j--J I- I
Point to Note when Checking I

1. To measure a voltage drop across contacts B titd M, make
connections as shown. (1 EL030)
If there is a voltage drop of more than 0.3 V per 100 A,
hard starting could result, when engine resistance in-
creases as in very cold weather. In such a case, replace
switch assembly.
I lEL030 1
8-24
TROUBiESHOOTlNG
IGNITION SYSTEM
The cause of hard engine starting is not always in the For on-vehicle troubleshooting of the ignition system,
ignition system. Defective parts may exist in the fuel the short cut is to determine on the basis of symptoms
system, exhaust emission control system, starting which is defective: the power supply, primary low-
system or the engine itself. tension circuit or high-tension circuit. For example,
The role of the ignition system is to generate suffi- when all spar& plugs fail to produce sparks, the pro-
cient electric sparks at the proper time. To check the bable cause is in power. supply or primary circuit.. If
ignition system, therefore, ,it is. necessaiy that the misfiring occurs only at a specific spark plug, the high
spark check and timing measurement are carefully tension circuit is likely to be defective.. If misfiring
performed. _ occurs ‘octiasionally, loose leads or spark plugs may_. be
suspected.
Check
starting system
‘S-25
TROWLESHOOTING
I I
No spark produced Spark produced
TEST 2. With ignition key at ON position, measure ’ Check cap, rotor,

voltage of(+) terminal of ignition coil. spark plugs, cables
and ignition timing
Voltage equal
to battery voltage
Defective wiring
between battery
and ignition coil
TEST 3. With ignition key at ON position, measure

voltage of (-) terminal of ignition coil.
1
Voltage equal
to battery voltage
Faulty igniter or
opened ignition
coil
TEST 4. Remove ignition coil, and install normal ignition

coil. Make a spark test as in the same manner
shown in TEST 1. 1
No spark Spark produced
produced
I I
Faulty distributor Defective
pickup coil ignition coil
8-26
TROUBLESHOOTING
Poor low speed performance

(Backfiring or hard starting)
IDistributor improperly installed

1
IImproper ignition timing
1
I Incorrect spark plug gap 1
Incorrect spark plug
heat value -
I Faulty distributor or igniter I Defective governor

advance mechamsm I Faulty advance
mechanism I
I I
advance mechanism
Engine stalls or misfires

occasionally
I
I
Faulty insulation of hi&r- I
tension cables, cap, rot& and/or
spark plugs
Faulty primary circuit

(Damaged primary wire
or ignition coil, or
overheated ignition coil)
8-27
TROUBLESHOOTING
SPEEDOMETER
ometer cable or replace the cable
The speedometer pointer will not

return to “0” or will not move Deformed hair spring ,
above a certain speed _I
Foreign matter caught onthe magnet
The speedometer pointer moves Flexible shaft improperly routed Repair the routing’of the speed- ’
ometer cable or replace the cable
Gear malfunction ins<de the speedometer
NOTE
If oil is inside the meter, replace the speedometer cable as well. Check the transmission fluid quantity and check for clogged
breather plug, too.
0.
. .
.. ..’
.- .
8-28
TROUBLESHOOTING
GAUGES
Fuel Gauge and Unit
t-
Is the fuel gauge indicator below Fuel gauge malfunction Check or replace the fuel gauge
the lowest marking on the scale No .
while the ignition key is in the
“LOCK” or “ACC” position?
Yes
Set the ignition key to the
Is the No. 4 fuse OK? No Short-circuited wiring harness Repair the harness and replace
* (damaged wiring harness, burnt m the fuse
cover, etc.)
Yes
.
Does the tester needle remain Constant voltage relay mal- Replace the fuel gauge
with in the area between 2 V function (Constant voltage relay is built
and 7 V when the voltage No . into the fuel gauge)
.
between the Y wire on the
fuel gauge side and ground is
measured?
I
t
Yes
Does the fuel gauge needle go Fuel gauge malfunction Replace the fuel gauge
above the scale’s highest marking No
when a 17-a resistance is con- * .
netted between the Y wire on
the fuel gauge side and ground?
Yes
Fuel gauge unit malfunction
8-29
TROUBLESHOOTING
Water Temperature Gauge and Unit
No indicator movement
Incorrect indication
Is the water temperature gauge

indicator below the lowest mark-
No j=zraty gauge , . Check or replace the water
temperature gauge
ing while the ignition key is in
the “LOCK” or “ACC” uosition?
I Yes
1
Set the ignition key to the
“ON” position
1
Is the No. 4 fuse OK? No Short-circuited wiring harness Repair the harness and replace
* (damaged wiring harness, burnt * the fuse
cover, et&)
Yes
-1 No *Itage relay mal- Replace the fuel gauge

w (Constant voltage relay is built
into the fuel gauge)
I Yes
Does the water temperature gauge Water temperature gauge Replace the water temperature
indicator move to approximately malfunct’ion - gauge
the second marking from the No
bottom of the scale when a 100-a * *
resistance is connected between
the water temperature gauge unit
and ground?
Yes
Water temperature gauge unit Replace the water temperature

malfunction gauge unit
8-30
TROUBLESHOOTING
INCLINOMETER
Symptom Probable cause Remedy
When vehicle inclines forward or Internal parts such as pointer and pendulum Replace inclinometer assembly
backward, pointer does not move up defective
or down
When vehicle inclines to right or left, Internal parts such as dial and pendulum
spherical dial does not perform defective
follow-up operation.
Oil-like fluid flows out from bottom Seal of oil case broken
of case
Pointer and spherical dial frequently Oil case broken and oil leaking
swing during vehicle operation
8-31
TRblBLESHOOTlNG
INDICATORS AND WARNING LIGHTS

Oil Pressure Warning Light
Is fuse No. 4? Repair harness and replace fuse

c
Yes
Is there 12 V between RL wire No Open circuit in harness between Repair the harness
at back of connector of combi- w fuse block and combination w
nation meter and ground? meter ;
Yes
When YB wire at back of con- Open circuit in light bulb Replace light bulb
nectar of combination meter is No c c
grounded, does the indicator
light illuminate?
Yes
Does the indicator light illuminate No Open circuit in harness between Repair the harness
when oil pressure switch harness * combinat:ion meter and oil *
is grounded? pressure’ switch
Yes
Oil pressure switch defective Replace the oil pressure switch
Correct the oil circulation system
8-32
TROUBLESHOOTING
I
The warning light remains
illuminated
1 .
Check with engine idling
..
- .
I
Does warning light go out when Short circuit in harness Repair the harness between the
oil pressure switch harness is No ) (damaged harness, burnt combinatibn meter connector
disconnected? covering, etc.) and oil pressure gauge unit
-. terminal
Yes
Does oil pressure switch operate NO Oil pressure switch defective Replace the switch
properly?
Yes
I Check oil circulation system

I
: “,
8-33
TROUBLESHOOTING
Charging Warning Light
Do oil pressure warning light Repair harness and replace, fuse

and other indicator/warning
lights illuminate?
I __
IYes
,
Does the indicator light illuminate No Is light No Light bulb Replace the light bulb,
when alternator harness connector I b bulb good? - defective .
“I” is grounded?
#
4
.IYes IYes
in harness between Repair the harness

fuse block and alternator .
t
Is there continuity between No Alternator malfunction Repair or replace the alternator
alternator “I” and alternator .
harness connector “I”?
I Yes
I IC (electronic voltage) regulator

malfunction
Replace the regulator assembly
8-34
TROUBLESHOOTING cl-+
,
The warning light does not
go off
No
- V belt defective Adjust or replace the V belt
Remove fuse No. 4 from fuse
Check the connection of the Loose contact terminal

alternator terminals No c _
Is each terminal correctly
connected?
IYes
Check alternator terminal B Check continuity of fusible Repair harness and replace
No No
Is about 12 V indicated? + link c fusible link
Is 0 fl indicated?
1
Yes
8-35
u-+ TROUBLESHOOTING
Door-Ajar Warning Light
. __.. .
,_ ..
1
Does the dome light illumi- No ) No’ ’ Repair the harness &d replace
.
nate? th6 fusible link
Yes
., . :’.
No Repair the harness or replace
-thefuse’ ...-
_
.: ,,.’
.__ Repair the hai%ess or correct.
the connection ’
No . _
_. .
Yes -:
..,
+
Does the, indidator light Replace the light . .’
illuminate when one end of
the test bar is iqserted
1
No
into the 9.3-RG wire from the
back of the combination meter
connect& and ‘the other end
of the test bar is grounded?
IYes
Repair the harness
II
Yes
Replace the door switch I
8-36
Brake System Warning Light
zi
light under following conditions.
; 1
Is fuse No. 4 good? No Short circuit in harness (damaged *
* harness, burnt covering, etc.)
1
Is there 12 V between combina- No Open circuit in harness RL wire Repair the harness
tion meter RL wire and ground? ’ * between fuse block and combina- b
tion meter
L
Yes
Is brake warning light bulb No Open circuit in brake warning

good? - light bulb
IYes
8-37
TROUIBLESHOOTING
Brake warning light remains lit

NOTE
Check the brake fluid level and make sure it is correct.
Caution
:Make sure that.vehicle is maintained in level position and wheels chocked.
Does light remain lit after discon- Parking brake switch defective Replace the parking brake switch
IYes
Does light remain lit after Brake fiuid level sensor defective Replace the brake fluid sensor
disconnection of brake fluid
level sensor connector?
Yes
Ground side of brake warning Repair the harness

- light circu:it short circuited
L
I
Brake warning light does not light
when parking brake lever is pulled I
th ignition key in “ON” posi

tion, check by pulling parking
I
Does the indicator light illuminate
when parking brake switch con- No
nectar is disconneted and YG
wire grounded?
Yes
Replace the parking brake switch
8-38
TROUBLESHOOTING
Brake warning light does not Caution

illuminate when brake fluid level Be sure the vehicle is level and the
is low. wheels are chocked.
I
(T)
Inspect with parking brake lever
Disconnect connector of brake Is 12 V indicated

fluid level sensor and short at harness0.3-Y(
circuit harness 0.3-YG and 0.3-B wire of sensor
wires. Does warning light connector?
illuminate?
I-.
Yes
Yes
I
Damaged0.3-YG Repair the harness
* wire in ground w
harness
c Brake fluid level Replacethe brake fluid level

sensordefective sensor
A
8-39
TROUBLESHOOTING
Fasten Seat Belt Warning Light and Buzzer ;
Fasten seat belt warning light

does not illuminate when
ignition key is turned to “ON”
with driver’s seat belt not
buckled.
Check with ignition key in

“OFF” position
1 t
Is fuse No. 7 good? No .Repair harness and replace fuse
*
Yes
Is there continuity between CR No Open circuit in harness between Repair the harness
wire of key-reminder switch * fuse block and key-reminder *
connector and ground? switch
Yes
Is there continuity between-G No Key-reminder switch defective Replace the key-reminder switch
wire of key-reminder switch w *
connector and ground?
IYes
-7
Is there 12 V between G wire No Open circuit in harness between Repair the harness
at back of connector of corn-’ w key-reminder switch and combina- c
bination meter and ground? tion meter
IYes
When 0.3-YB wire at back of Open circuit in light bulb Repair the light bulb
connector of combination No
e *
meter is grounded, does the
warning light illuminate?
4.
Yes
Is there 12 V between 0.3-YB Repair the harness
wire at back of connector of No combinatifon meter and seat belt
.
seat belt warning timer and
ground
t
I Yes
NOTE
Set ignition key to “ON” If the malfunction is in the following circuits, in addition to the warning light
not illuminating, the buzzer will not sound.
1
Is fuse No. 3 good? ?&No -jmFI -71
Yes
. * .
Is there 12 V between 0.3-RL Open circuit in harness between Repair the harness
wire at back of connector of No fuse block. and seat belt warning t
seat belt warning timer and * timer
ground?
,
Yes
Replace the belt warning timer
8-40
TROUBLESHOOTING

\ “OFF” position
/
IS fuse NO. 7 good? No Short circuit in harness
D (damaged harness, burnt
cover, etc.)
Does buzzer sound when driver’s No Faulty key-reminder switch or

door is opened? buzzer
1Yes
Is there 12 V between 0.3-Y No Open circuit in harness between Repair the harness
wire at back of seat belt switch . buzzer and seat belt switch c
connector ma ground?
Yes
1
. Ground 0.3-RB wire from back Seat belt switch defective Replace the buckle
of belt switch connector (with No c c
buckle unlocked). Does buzzer
sound?
Yes
Is there 12 V between 0.3-RB Open circuit in harness between Repair the harness
wire at back of seat belt warning No seat belt switch and seat belt *
timer connector and ground warning timer
(with buckle unlocked)?
NOTE
Set ignition key to “ON” If the malfunction is in the following circuits, in addition to warning buzzer
not sounding, the warning light will not illuminate.
Repair harness and replace fuse

w
Is there 12 V between 0.3-RL Open circuit in harness between Repair the harness
wire at back of connector of No fuse block and seat belt warning .
seat belt warning timer and timer
ground? .
I
Yes
I P Seat belt warning timer defective Replace the seat belt warning
8-41
TROUl3LESHOOTING
Disconnect connector of driver’s
I
Disconnect connector of driver’s No c Replace the door switch
door switch. Does buzzer sound?
Yes
in ground of buzzer Repair the harness
-1 ‘:
Disconnect timer connector.
Does warning light go out?
IYes
No
rShort circuit of 0.3-YB wire

* between combination meter
and timer
w
Repair the harness
Seat belt warning timer defective Replace the seat belt warning
\
I
a-42
-+
TROUBLESHOOTING cl
Lighting System
Check the illumination of all lights; if there are any problems,
use the following chart to check the appropriate location.
(For trouble symptom Nos. 3, 4, and 7, refer to the corre-
sponding yes/no troubleshooting chart.)
Trouble symptoms
Location 2 3 4 5 6 7
Headlights
[Both left and right lights should illuminate in both high and o x o A o A
low beams]
Passing lights
[Both left and right lights should illuminate in high beams 0 X X 0 0 A A
when the passing switch is at “ON” position]
Position, tail, rear side marker and license plate lights

[All of these lights should illuminate when the lighting switch o o o x o o A
is at the first stage]
Probable cause
Light control relay
Column switch l l 0 l
Dimmer switch segment
Passing switch segment - 0 0 - - l - a
Lighting switch segment l - 0 0 - - 0
Body ground points - - l - - 0

Front pillar, inner
Left side of engine compartment - - 8 - - l
Between battery and body - - - - l
Fuse block (No. 2 fuse) - 0 -
Light bulb e - 0 e 0 - l
Remarks
The symbols used in the table indicate the following:
o : Normal illumination
a : Dim illumination
x : No illumination
l : Parts requiring check
8-43
TROUHLESHOOTING
Trouble Symptom 3
‘m)
\ lower position
I 1
Do the headlights illuminate Light relay defective Replace the light control relay
.
when 0.5-R wire located on
back of light control relay
I _
connector is grounded? No .
Caution
Be sure not to ground 2-R,
1.25-R and OS-GW wires.
Replace the column switch
I-+zly grounded Correct the ground connection

I-l
8-44
-+
TROUBLESHOOTING cl
Trouble symptom 4
-1
Are main and sub fusible links No Short circuit in harness Repair the harness and replace
good? w (damaged harness, burnt t the fusible link
covering, etc.)
Yes
No Short circuit in harness Repair the harness and replace

* (damaged harness, burnt -t the fuse
covering, etc.)
1Yes
,
Do tail and rear side marker Open circuit in coil of light Replace the light control relay
lights illuminate when 0.5GW No
e control relay and poor relay t
wire at back of light control contacts
relay connector is grounded?
- I
I Yes
Do tail and rear side marker

Caution
Be sure not to ground the other wires.
Open circuit in 0.5GW wire Repair the harness
?
lights illuminate when OS-GW No c between relay and switch
wire at back of column switch r
connector is grounded?
Yes
-Caution I
Be sure not to ground the other wires.
Do position, tail, rear side Column switch defective Replace the column switch
marker and license plate lights
illuminate when 0.3-B wire No t
c
at back of column switch
--r-
I 1 1 1
Improperly grounded Correct the ground point
t I
8-45
TROUEILESHOOTING
Trouble Symptom 7
rBoth R.H. and L.H. headlights

upper and lower betims dark
at all times (including when
passing)
Check ivith lighting switch at/

2nd stage, and dimmer switch
at beam position >
Is there 12 V between 2-R wire Check battery voltage,

and ground when test probe connector or battery defective correct connector
which contacts the 2-R wire is connection or replace
inserted from back of
light control relay connector?
Is 0.5 V or less indicated on Poor light control relay contact Replace. the light control relay
voltmeter (about 20-V range)
when (t) and (-) test probes are No
connected to 2-R (B) and
1.25RL wires respectively at
back of light control relay
connector? t-
Yes
I
Is there 0.5 V or less between Improperly grounded Correct the ground connection
test probe and ground when test :
No I
probe is inserted into 2-B wire
from back of column switch
connector?
1~~~~~ Replace the column switch 1
8-46
TROUBLESHOOTING
Stop Light
Stop light does not illuminate
Is fuse NO. 7 good? No Short circuit in harness Repair harness and replace fuse
c (damaged harness, burnt c
covering, etc.)
Yes
Is there 12 V between 0.85-CR No Open circuit in harness between Repair the harness
wire of stop light switch and w fuse block and stop light switch t
ground?
Yes
Is there 12 V between 0.85 wire No Stop light switch defective Replace stop light switch
of stop light switch and ground . Stop light switch mounted at w Adjust stop light switch
when brake pedal is depressed? incorrect position mounting position
Yes
heck with stop light switch 0
, 1
Is there 12 V between 0.85-G ~~ Open circuit in harness between Repair the harness
wire of hazard warning switch e stop light switch and hazard *
and ground? warning switch
1 Yes
.
Is there 12 V between 0.85-WC No Hazard warning switch defective Replace the hazard warning
wire of hazard warning switch c - switch
aa ground?
1Yes
1
Is there 12 V between 0.85-WG No Open circuit in harness between Repair the harness
wire of column switch and * hazard warning switch and a
ground? column switch
Yes
Is 12 V indicated between Column switch defective Replace the column switch
column switch connector’s WL No w w
wire and ground and VR wire
ma ground? I
Yes
*
Left stop light: Open circuit in harness between Repair the harness
Is 12 V indicated between 0.3- column switch and stop light
GY wire of rear combination bulb
light (left) aa ground? No c e
Right stop light
Is 12 V indicated between 0.3-
GL wire of rear combination
light (right) and ground?
IYes
Is there 12 V in B wire of stop No Open circuit in stop light bulb
light bulb connector?
Yes
Ground circuit defective
8-47
TROUElLESHOOTlNG
Stop light does not go out
Stop light switch improperly Adjust stop light switch position

adjusted.or defective
Turn-signal and hazard lights ,
Incorrect connector connection
Improper ground connection - Correct the iround connection

*
i
Light bulb malfunction Replace the light bulb

I / I
i
TROUBLESHOOTING
I Turn-signal light does hot

illuminate I
Set ignition key to “ON”

position
+
Are the battery and fusible No Short circuit in harness
links (main, sub) normal? c (damaged harness, burnt
covering, etc.)
Yes
Battery defective Charge or replace the battery
p Charging system defective * Check and correct charging
system
7
Is fuse No. 3 good? No Short circuit in harness ,pj
t (damaged harness, burnt
covering, etc.)
Yes
Remove the turn-signal flasher

unit
Is there continuity between Open circuit in harness between Repair the harness
0.85RL wire of turn signal No fuse block and turn signal flasher c
flasher unit connector and unit
fuse block?
/Yes
With hazard warning switch No Hazard warning switch defective Replace the hazard warning
OFF, is there continuity c . switch
between GR wires? I
Yes
Is there continuity between GR Open circuit in harness between Repair the harness
wire of turn-signal flasher unit No turn-signal flasher unit and
.
connector and GR wire of hazard ) hazard warning switch
warning switch?
4
1Yes
Is there continuity between GR No Open circuit in harness between Repair the harness
wire of hazard warning switch , c hazard warning switch and L
and GR wire of column switch? column switch
Yes
Is there continuity between Poor column switch contact Correct or replace the column
GR wire and 0.85GY and No or open circuit in harness of switch
0.85GL wires of turn signal * column switch .
switch connector (12P) when
switch lever is operated?
Yes
h Turn signal flasher unit defective . , Replace the flasher unit I
8-49
TROUBLESHOOTING
I
All lights illuminate, but flashing
is irregular
All lights illuminate without
flashing I
No _ Replace the light bulb

Is each bulb the specified type? .
,
1Yes
Is 12 V indicated as battery No
terminal voltage?
I Yes
1
Are lights properly grounded No
and bulbs properly mounted?
8-50
TROUBLESHOOTING
Hazard lights and indicator

lights do not illuminate
Do both the left and right No Are the battery, charging system No
turn-signal lights function + and fusible links (main, sub)
properly? normal?
Is fuse No. 1 good? No Short circuit in harness Repair the harness and replace
N (damaged harness, burnt - the fuse
covering, etc.)
Yes
Pull out the hazard warning
I
Is there continuity between No Open circuit in harness between Repair the harness
1.25GB wire and fuse block? w fuse block and hazard warning c
flasher unit
4
IYes I
Is there continuity between Open circuit in harness between Repair the harness
1.25GO wire of hazard warning No hazard warning flasher unit and
flasher unit connector and 1.25- I . hazard warning switch .
GO wire of hazard warning
switch?
Yes
*
With the hazard warning switch Poor contact of the hazard -
ON, is there continuity between No warning switch
the 1.25-GO wire and the WL,
GL, GY, WR wires?
6
Yes
Hazard flasher unit defective - Replace the flasher unit
8-51
TROUBLESHOOTING
WINDSHIELD WIPERS AND WASHER
1 Wipers do not operate I
, I ,’
Are the main fusible link and No Repair the harnessand
the sub fusible link OK? replace the fusible link
I
Yes
Is fuse No. 8 OK? Repair the harnessand

replace the fuse
I
Yes
Is 12 V indicated between each. Correct the connector or repair

of the various wires (0.85-L, the harness
LO, LB) and ground when a No
test probe is inserted from the
back of the wiper motor
connector?
Yes
Replacethe $iper motor

I
I
Is 12 V indicated between each

wire (LO and LB) and ground No
when a test probe is inserted
from the back of the column
switch connector? _ _ I
Yes
Is there 12 V between 2-B wire Correct connector or replace

of column switch connector column switch
and ground when wiper switch
is set to “1” and “2”?
1 {F between wiper Correct harnessor ground

switch and ground or improperl) * connection
8-52
TROUBLESHOOTING
1 Washer does not operate I
Check while the ignition key

is in the “ACC” position
I 1 1
Are the main fusible link and No A short-circuited wiring Repair the harness and
the sub fusible link OK? w harness (damaged wiring . replace the fusible link
harness, burnt cover, etc.) I
Yes
4 1
Is fuse No. 8 OK? No A short-circuited wiring Repair the harness and
+ harness (damaged wiring * replace the fuse
harness, burnt cover, etc.)
Yes
t
Is 12 V indicated between the A broken harness between Correct the connector or repair
L wire and ground when a test No the fuse block and washer the harness
probe is inserted from the back * motor, or an improperly .
of the washer motor connected connector
connector?
I I J
lYes
I--
Does the washer function Replace the washer motor
when the YL wire of the
washer motor connector is
grounded?
1””
Frl
Does the washer function A broken harness between Correct the connector or repair
when the YL wire of the No I the washer motor and the
column switch connector is column switch or an impro-
grounded? perly connected connector I----
Yes
II 1
Does the washer operate A poor connection in the Replace the column switch
when the washer switch is No column switch
turned on while the 2B wire I
of the column switch con-
nector is grounded? I--
Yes
I 1 I 1
Open circuit between Repair harness or correct the
c washer switch and ground I ground connection
or improperly grounded I
8-53
The wipers do not operate
when the washer switch is
turned on, but washer
operates properly
Refer to the troubleshoot-

ing section, “The wipers do
not operate at all when the
wiper switch is set to the
star mark”
Replace the wiper control
8-54
TROUBLESHOOTING

Do the wipers operate when No Refer to the troubleshooting

the wiper switch is set to c section, “Wipers do not
the “1” postion? operate”
Yes
Set wiper switch to the star

mark.
I
Is there 12 V between LW wire Open circuit in harness between Correct harness
and ground when test probe is No intermittent wiper control unit
inserted from back of inter- . and wiper motor c
mittent wiper control unit
connector?
I I
J’“” -
1
-I
I
Does wiper perform inter- Malfunction in intermittent Replace intermittent wiper
I
mittent operation when test wiper control unit control unit
probe is inserted from back of No
intermittent wiper control unit . I
and grounds: -
1. 0.3-BY wire?
2. B wire?
2. Yes 1. Yes
Open circuit in harness between Correct harness or correct 1
1’“‘““““’
intermittent wiper control unit
and wiper switch, or loose
connector t
Improperly grounded Correct ground connection

I
8-55
Check with ignition key at

“ACC” position.
r
Do wipers operate continu-
ously when intermittent wiper
control unit connector is
disconnected and wiper switch
is set to the star mark?
No
I
Intermittent
defective
wiper control unit
--.-A
Replace intermittent
control unit
wiper
Yes
Replace column switch

I
]I ,’ -,
(-g+zy-) , ,.
t
Disconnect wiper switch Faulty wiper switch variable
connector and operate time resistor
adjustment switch. Does No *
resistance between 0.3-Y wire
and 2-B wire vary between
0 and 50 ohms?
._, Yes,
1.
Yes
Faulty intermittent wiper relay c Replace intermittent wiper

relay
8-56
-+
TROUBLESHOOTING cl
REAR WINDOW MPER AND WASHER
Rear wiper does not operate I

Is fuse No. 9 OK? A short-circuited wiring Repair the harness and

No e replace the fuse
+ harness (damaged wiring
harness, burnt cover, etc.)
I Yes
Is 12 V indicated between the A broken wire between fuse ’ Correct the connector or repair
L wire and ground when a test No No. 9 and the wiper motor the harness
probe is inserted from the back . connector, or a poor Con- *
of the rear wiper motor con- nectar connection
nector?
Yes
Is 12 V indicated between the A malfunction in the wiper Replace the wiper motor
BrW wire and ground when a No motor brush, or a broken
test probe is inserted from . wire in the coil t
the back of the rear wiper
motor connector?
Yes
Does the wiper motor func- Correct the connector or repair

tion when a test probe is the harness
inserted from the back of the No 1-1 ,
rear wiper and washer switch
connector and the BrW wire
is grounded?
Yes
Set the igniton key to the
Does continuity exist between Repair the connector or replace

the 0.3-B wire and ground No the wiper and washer switch
when the rear wiper switch is .
turned on?
Yes
Correct the ground connection
847
cl-+ TROUEILESHOOTING
I Rear window washer does

not operate I
1 IsfuseNo.‘“;:, :1 Repair the harness and

t replace the fuse
IS 12 V indicated between the Correct the connector or repair

0.3-L wire and ground &hen a No
test probe is inserted from
the back of the rear window
washer motor?
Yes
Does the washer function No

when a test probe is inserted
from the back of the rear c
window washer motor and
the 0.3-WB wire is grounded?
Yes
Does the washer motor func- A broken harness between Correct the connector or repair
tion when a test probe is the rear window washer the harness
inserted from the back of No motor and the rear wiper t
the rear window wiper and c and washer switch, br a
washer switch connector and poor connector connection
the 0.3-WB wire is grounded?
Yes
SEE NEXT PAGE
8-58
TROUBLESHOOTING cl-+
CONTINUED FROM
PREVIOUS PAGE
Does continuity exist between A poor connection of the rear Repair the connector or replace
the 0.3B-wire and ground No wiper and washer switch the wiper and washer switch
when the rear washer switch + connector, or a malfunction
is turned on? in the rear wiper and washer
switch
Yes
Improperly grounded Correct the ground connection
8 -59
TROUBLESHOOTING
HEADLIGHT WASHER
Disconnect the headlight washer NOTE

control relay connector, and The headlight washer should operate when all of the following conditions are
check with ignition key at fulfilled i
“AU.7 (1) The ignition key is at either the ACC position or the ON position.
(2) The lighting switch is at the ON position.
(3) The headlight washer switch is at the ON position.
I
Does continuity exist between An improper ground connection Repair the harness or correct
the 1.25-B wire and ground when No between the headlight washer the ground connection
a test probe is inserted from the P control relay and ground, or a *
back of the headlight washer broken harness
control relay connector?
Is 12 V indicated between the Is fuse No. 8 OK? Repair the harness and
0.3-Lw wire and ground when a No No replace the fuse
test probe is inserted from the P m
back of the headlight washer
control relay connector? ,
Yes I Yes
Repair the harness between

the fuse block and the headlight
washer control relay connector
+
Does the headlight washer A malfunction in the headlight Replace the headlight
motor operate when the No washer motor washer motor
1.25-L wire of the headlight I c
washer control relay connector
is grounded?
Yes
Does continuity exist between A malfunction or poor Correct connector, replace

the terminals when a test probe is connection in the headlight column switch, or correct
inserted between the 0.3-LB wire No washer switch or a broken harness or ground connection
and ground from the back of the * harness between the ground
headlight washer control relay branch points of the headlight
connector and the headlight washer switch
washer switch is pressed?
I
Yes
( ChEcitNhthe 17, )
SEE NEXT PAGE I

8-60
TROUBLESHOOTING
CONTINUED FROM
PREVIOUS PAGE
I
+
Is 12 V indicated between GW Do the tail lights, position Refer to p. 845, “Position, tail,
wire and ground when a test No lights, meter illumination No rear side marker and license
probe is inserted from the back - I lights, etc., illuminate - plate lights do not illuminate
of the headlight washer control on either side”
relay connector?
IYes /Yes
the fuse block and the headlight

washer control relay connector,
A malfunction in the headlight Replace the headlight

washer control relay washer control relay
Disconnect the main hose from NOTE

the check valve Have a receptacle prepared in order to avoid spilling the washer fluid.
Are the hoses free from.clogging, No Correct the hose installation,

No c remove the clogging, or
-c twisting, leakage, etc.?
replace the hose
Yes Yes
Inspect the washer motor
Y (for pump blockage), and
repair or replace it
Does the washer fluid spray Blockage inside the check valve,
from both the left and right No j=
discharge ports when the

headlight washer switch is
pressed?
Yes
Fluid leakage or pressure loss Repair or replace the hose
1 ~,$~::::%?$k No due to a cracked or clogged hose c
valve free from cracks, cloggmg,
Repair or replace the nozzle

I
43-61
TROUBLESHOOTING
HORN
Symptom Probable cause 1 Remedy
Sound volume of horn is low A loose or bent adjustment screw Adjust the horn
or fluctuates
Water, dirt, or other foreign matter lodged inside Replace the horn
A loose horn or bracket mounting bolt Tighten the bolt
A drop in battery:voltage Check the battery
A poor connection of the horn switch Repair or replace the horn switch
A poor connection of the horn ground terminal Repair
Horn does not sound
Inspect while the ignition key

is in the “AU? position
, /
I
Is fuse block No. 8 OK? A short-circuited wiring Repair the harness and
No w replace the fuse
m harness (damaged wiring
harness, burnt cover, etc.)’
Yes
t
Is 12 V indicated between the Does horn sound when it is dis- Repair the harness
0.85-B wire of the horn connec- No connected and connected to No
.
tor terminal and ground? * different battery of specified
voltage?
Yes Yes
Adjust. or replace the horn as

necessary ’
I
Dose the horn sound when
the column switch connector No
is disconnected and the .
0.85-B wire of the connector-
~terminal is grounded?
Yes
Repair the horn switch or

-{~~$&r?~t&~und w correct
’ the ground
’ connection
8-62
TROUBLESHOOTING
Key-Reminder Switch
I Key-reminder buzzer does not

sound.

“OFF” position
1
Is fuse No. 7 good?
I
No Short circuit in harness
(damaged harness, burnt
1 cover, etc.)
I
Repair the hamess.and
b replace fuse
Yes
c
Is there continuity between CR No Open circuit in harness Repair the harness
wire of key-reminder switch * between fuse block and *
connector and ground? key-reminder switch
Yes
1
Is there continuity between G No Key-reminder switch defective Replace the key-reminder switch
wire of key-reminder switch c w
connector and ground?
I I I I I
1 Yes
No Open circuit in harness between Repair the harness

c key-reminder switch and buzzer c
Yes
Does buzzer sound when 0.3-Y No Buzzer defective Replace the buzzer
wire of buzzer connector is b *
grounded?
Yes
t
Does buzzer sound when m No Open circuit in harness between Repair the harness
wire of driver’s door switch * buzzer and door switch +
Yes
Replace the door switch

I
8-63
TROUBLESHOOTING
yehxkeith ignition key
Does buzzer sound when YW No Door swit’ch defective Replace door switch
wire of driver’s door switch * *
connector is disconnected?
Yes
Does buzzer sound when seat No Belt switch or timer defective

belt switch connector of driver’s
seat belt is disconnected? *
Yes
Short circuit at ground side of Repair the harness

c
8-64
-+
TROUBLESHOOTING cl
Defogger dok not operate

I
Inspect while the ignition key

is in the “ON” position
I
Does the indicator light Is fuse A short-circuited wiring Repair the harness and
illuminate? No No.5 No harness (damaged w replace the fuse
*OK? . *wiring harness, burnt
cover, etc.)
I 1 I
Yes Yes
T
Is 12 V indicated between the No Repair the harness between

2-RR wire of the rear window c fuse block and rear window
defogger switch and ground? switch
Yes
I-
4
Does continuity exist between A malfunction in the rear Replace the rear window
the terminals when the rear No w window defogger switch * defogger switch
window defogger switch is
removed and then operated?
<
Yes
Check with the rear window

defogger switch ON
I
Is there 12 V between printed No Open circuit between rear Repair the harness
heater (t) terminal and ground? w window defogger switch and *
printed heater
i
Yes
Improperly connected printed Correct the connector or

c heater (-) terminal connector c ground connection
or improperly grounded
8-65
cl-+ TROU13LESHOOTING
POWERWINDOWS
Symptom Probable cause Remedy
None of the door windows will Burnt-out main fu.sible link Replace the main fusible link and
operate isolate cause
Burnt-out sub f&:ible link Replace the sub fusible link and
isolate cause
Burnt-out fuse Replace the fuse and isolate cause
Correct grounding
Replace the relay
Replace the main switch
Break in harness, or poor connection Correct or replace the harness
The front door windows cannot be Malfunctioning main switch Replace the main switch
operated by using the main switches
Malfunctioning motor Replace motor
The door windows can be operated Malfunctioning main switch Replace the main switch
by using the main switches, but
cannot be operated by using the : Malfunctioning sub switch Replace the sub switch
sub switches
The door windows can be operated Malfunctioning main switch Replace the main switch
even though the lock switch is
at “ON”
8-66
TROUBLESHOOTING
RADIO AND STEREO
Poor sensitivity
Adjust the tuning settings

t
Is the antenna trimmer pro- No The trimmer is improperly Adjust the trimmer
.
perly adjusted? adjusted
F
Yes
Does the sensitivity improve The radio itself is malfunc- Repair or replace the radio
when a different antenna and No tioning t itself
w
lead-m are connected to the
radio?
[
Yes
1 I
The antenna is improperly Correct the ground connection
grounded or replace the antenna lead-m
The antenna lead-in is
malfunctioning
I
t--
1 i
8-67
TROUEILESHOOTING
Noise is produced
Start the engine
1
Is there noise when any of the No Does the noise cease when No Repair or replace the radio
electrical equipment is the antenna lead-in is dis-
operated? 1 connected from;hekfadio? 1 1
Yes
Is the antenna lead-in routed No Correct the ground connection

too close’tb a harness? of replace the antenna lead-in
/
Yes
There is no malfunction
Reroute the antenna lead-in

I
Beeping ‘. .......................... Horn the ground connection

Irregular cracking ..................... or replace the noise filter
Tachometer
Popping .......... Stop light switch
Sputtering ........ Ignition system
c
Whining ......................... Motor
Whining ............... Wiper motor
Whining .................. Alternator
Intermittent clattering ..............
\ 8-68
-+
TROUBLESHOOTING cl
Does the problem disappear No Improperly connected harness Correct the connection of the
when switched from the * or connector w harness or the connector
stereo to the radio?
Yes
t
IS the tape player head OK?
I-
Yes
Improperly connected tape Correct the connection or re-

player head lead wire, or a * place the malfunctioning parts
malfunction in either a
w capacitor or in the tape
player itself
The tape being used was Use tapes which have been
recorded monaurally recorded in stereo
1
The auto reverse does not
function
t
The program changes No A malfunction in the Repair or replace
when the direction selector + reverse circuit c
button is pressed
Yes
A malfunction in the auto- Repair or replace the radio

reverse circuit itself
8-69
TROUBLESHOOTING
No automatic tuning,
excessive noise
Is antenna lead-in properly . No Antenna-improperly installed

installed?
Yes
Is everything in order be- Short or bpen circuit in Correct short or open

No t antenna lead-in t circuit in antenna lead-in
tween antenna lead-in and
body ground?
) Yes I
Correct or replace radio

I
1 No sound -.
I
Repair the harness and replace

- the fuse

.
I
Is radio power supply Main body fuse blown Check main body for improper
available? No c grounding or loose connector
connections before replacing
fuse
Yes
r No d-r in loose contact ) Connect connector
~,No-i=)~~
Is speaker connector securely *r-““^
Repair or replace tape player

I
8-70
-+
TROUBLESHOOTING cl
I
Poor radio sensitivity,
excessive noise I
Is antenna lead-in properly

installed?
Yes
No Antenna improperly installed Install antenna properly
I
*
Is everything in order between No Antenna lead-in defective Replace antenna lead-in
antenna lead-in and body * *
ground?
Yes
7
Is antenna trimmer properly No Timmer out of adjustment Adjust trimmer
adjusted?
Yes
Radio proper defective Repair or replace radio

I
8-71
3-POINT ELR SEAT BELTS

WITH TENSION RELIEFERS
GSeat belt tension defer system
.Short-circuited wiring harness Repair the harness and replace

k]gyring harness, burnt c the fuse
lYes
1
Is 12 V indicated between the A broken harness between the Repair the harness or correct
0.3-RL wire (LH.) or RL wire fuse block: and the seat belt the connection
(R.H.) and ground when the solenoid; or a poor connection
seat belt solenoid is removed
No
and a test probe is inserted from
the‘back of the connector?
i””
1
Does tension reliefer system Replace the seat belt assembly
operate when one end of test
probe is inserted into the 0.3-YB
wire from the back of the seat
belt solenoid connector and the
other end of the test probe is
grounded?
I
Does tension reliefer system A broken harness between the Repair the harness or correct
seat belt’solenoid and the belt the connection
operate when the belt switch is
disconnected and the 0.3-YB
No switch, or a poor connection c
wire is grounded?
Yes
r 1 r 1
A poor connection of the belt Correct the connection or
switch connector, or belt switch replace the belt switch
malfunction
t-
8-72
SERVICE ADJUSTMENT PROCEDURES cl-+
BAIITERY
General Information
The maintenace-free battery is, as the name implies, totally
maintenance free and has no removable battery cell caps.
Water never needs to be added to the maintenace-free battery.
The battery is completely sealed,:except for small vent holes
in the cover. These vent holes allow what small amount of
gasses are produced in the battery to escape. The special
chemical composition inside the battery reduces the produc-
tion of gas to an extremely small amount at normal charging
voltages. The battery contains a visual test indicator which
indicates the condition of the battery.
Battery Visual Inspection

1. Make sure ignition switch is in OFF position and all
battery feed accessories are OFF.
2. Disconnect battery cables from battery (negative first).
3. Remove battery from vehicle.
Caution
Care should be taken in the event battery case is cracked or
leaking to protect hands from the electrolyte. A suitable
pair of rubber gloves (not the household type) should be
worn when removing battery by hand.
4. Inspect battery carrier for damage caused by loss of
acid from battery. If acid damage is present it will be
necessary to clean area with a solution of clean warm
water and baking soda. Scrub area with a stiff bristle
brush and wipe off with a shop towel moistened with
ammonia or baking soda in water.
5. Clean top of battery with same solution as described in
Step 4.
6. Inspect battery case and cover for cracks. If cracks are
present battery must be replaced.
7. Clean the battery posts with a suitable battery post
cleaning tool.
8. Clean the inside surfaces of the terminal clamps with a
suitable battery terminal cleaning tool. Replace damaged
or frayed cables and broken terminal clamps.
9. Reinstall the battery in vehicle.
10. Connect cable clamps to battery post making sure top of
clamp is flush with top of post.
11. Tighten the clamp nut securely.
12. Coat all connections with light mineral grease after
tightening.
8-73
SERVICE ADJUSTMENT PROCEDURES
Charge Rate
If the test indicator is white, the battery should be charged
as outlined below. When the dot appears or wheri ‘maximum
charge shown below is reached, charging should be’ stopped. Blue
I
Charge Rate Chart
,I
Battery NXlOO-S6(S)MF NX120-7-MF

(420 amps) (600 amps)
Charging necessary OK
Slow charging 5 amps 10amps 5 amps 10 amps
10hrs. 5 hrs. 12 hrs. 16hrs.
16Vl81
Fastcharging 20 amps 30 amps $0 amps 30 amps
2.5 hrs. 1.5 hrs. ,‘i
3 hrs. 2 hrs.
CHARGING SYSTEM
Problems in charging system could be due to improper fan
belt deflection, faulty wiring or connector, or a discharged
battery. A defective electronic voltage regulatbr is not
always the cause. What is important in troublesli’ooting of
charging system, therefore, is to determine whether the
problem is due to a run-down or overcharged battery. Then
check previously mentioned items before checking alternator.
In this manner a fault in a circuit other than alternator
might also be detected.
This alternator has an “F” terminal for checking,, as shown
in the illustration (6EL068), which is provided in order to
make troubleshooting easier. The (F) in the circuit in the “F’‘-terminal
illustration (lEL042) is the “F” terminal for checking.
The voltage of this terminal can be checked from outside
the -alternator through the access hole provided in the rear
bracket. ’ .,
The voltage readings of the “F” terminal indicatk as follows:
1. Ignition switch at “OFF”
Normal if voltage is 0 V. If voltage is close to battery
voltage, the (+) diode is short-circuited, and, moreover,
there is a malfunction of the electronic voltage regulator.
If the voltage is 0.5 to 2.0 V, the (+) diode is short-
circuited. ccess hole
or “F”-terminal
2. Ignition switch “ON”
Under normal conditions, only voltage equivalent to the
voltage drop (0.5 to 2.0 V) of the power transistor within
the electronic voltage regulator will appear.
If a voltage close to battery voltage is noted, current
is not flowing to the field coil, which means that there
is a malfunction of the electronic voltage regulator. In
this instance, there should be no voltage generation, so
start the engine and confirm that there is none. Also
check to be sure that field current flows and there is
voltage generation at the instant when, with the engine
running, the “F” terminal for checking is grounded to
the rear bracket.
8-74
If the voltage reading is 0 V, the possible causes could

be wiring damage of the field coil, poor contact of the
brushes, a malfunction of the electronic voltage regulator,
poor contact of the connector, and/or poor contact in
the ignition switch. In any case, the alternator will
not generate. In addition, if the negative (-) brush is
grounded, or if there is a short-circuit inside the elec-
tronic voltage regulator, the voltage of the “F” terminal
will be 0 V, which means that there is an overcharge.
3. While engine is running

Under normal conditions, the voltage will increase as
the engine rpm is increased. If, with the battery fully
charged, there is no load on the alternator, voltage will
be close to output voltage. !ter
Stator
If the voltage remains low even though the engine rpm is coil ieter
increased, the regulator has not yet reached the operating @-3-t “A?
voltage, or current is continuing to flow to the regulator. f!!Jv / -
If the latter, an overcharge will result.
I
Vehicle-borne
ammeter
CURRENT OUTPUT TEST

1. Place the ignition switch at OFF. ~ Charqinq
2. Disconnect the battery ground cable.

3. Disconnect the cable from terminal “B” of the alternator
and connect a 60 A ammeter between the terminal “B”
and cable.
4. Connect a voltmeter between terminal “B” (+) and
ground (-).
5. Set the engine tachometer.
6. Reconnect battery ground cable to the battery. The LEJ
Voltmeter
Ammeter
voltmeter should indicate the battery voltage.

7. Start the engine.
8. Turn on all electrical loads, accelerate the engine speed
to 2,500 to 3,000 rpm and read the output current.
Output current:
Over 90% of nominal output: Alternator is good.
70 to 90% of nominal output: Recheck output current.
Less than 70% of nominal output: Alternator defective.
8-75
nI.+ SERVICE ADJUSTMENT
NJ
PROCEDURES
NOTES
1. After the engine has been started, the ammeterindication
will drop as the battery reaches the fully charged con-.
dition.
Read the indication at its maximum value while in-
creasing the engine revolution.
2. If the battery is in the fully charged condition, current
will not flow, resulting in a no-flow condition of the
nominal output current., In this case, measure l;he output
current after the battery has been discharged by cranking
the engine or increase the electrical load by @ding new
parallel circuits.
REGULATED VOLTAGE TEST

..
1
Charging
1. Turn ignition switch OFF. indicator Ignition
2. Disconnect the battery ground cable. light
Altp,#b 9, ,‘f!-fy To load
3. Disconnect the battery positive cable and: connect a
60 A ammeter between the battery positive terminal
and ‘cable.
4. Connect a voltmeter between terminal “L” of -alternator
and ground.
5. Set the engine tachometer.
6. Reconnect the battery ground cable to the battery. LtJ Azer
Voltmeter
The voltmeter should indicate 0 V; if it is, not, the alter-
nator or wiring is’defective.
7. Short circuit the ammeter-terminals and start the engine.
NOTE
Make sure that the starter current does not flow through
the ammeter while starting the engine.
8. Increase the engine speed to 2,000 to 3,090 rpm and
check the ammeter reading. If the reading is .5 A or less,
check the voltmeter reading. This reading is the regulated
voltage. If the ammeter reading is more than. 5 A, either
continue charging until the reading drops below 5 A or
replace the battery with one that is fully charged and
then repeat the test.
Regulated voltage . . . . . 14.4 V f. 0.5 at 20°C (68°F)
HANDLING PRECAUTIONS
1. Make sure that alternator, battery, etc., are connected
properly. If battery polarity is reversed, excessive current
will flow from battery to alternator, and damage to
diodes or wiring harness could result.
2. Do not disconnect battery terminals while engine is
running. Surge voltage will be produced which could
cause deterioration of diodes or transistors.
3. When battery is to be quick-charged, be sure to disconnect
battery terminals first. If terminals are not disconnected,
damage to diodes could result.
4. When a steam cleaner is used, make sure that alternator is
not directly exposed to steam.
8-76
IGNITION SYSTEM
Ignition Timing Adjustment
Adjustment condition
Coolant temperature: 80 to 90” C ( 170 to 190” F)
Lights and all accessories: OFF
Transmission: N (Neutral)
1. Start engine and run at curb idle speed.
2. Connect tachometer and timing light.
3. Check basic ignition timing and adjust if necessary.
Basic ignition timing . . . . . . . . . . . . . . . 7 + 2” BTDC
4. To adjust ignition timing, loosen distributor mounting

nut and turn distributor housing. (1 EL002)
5. After adjustment, securely tighten mounting nut.
SPARK PLUG CABLE TEST

1. Disconnect spark plug cable from spark plug.
When spark plug cable is pulled out, be sure to pull by
the cable cap. If spark plug is removed by pulling on
cable only open circuit might result.
2. Hold the spark plug cable about 6-8 mm (.24-,3 1 in.)

away from engine proper (grounding portion such as
cylinder block) and crank engine to verify that sparks
are produced.
Cylinder
block
6-8 mm
(.24-.31 in.)
1 E L03:
8-77
SPARK PLUG INSPECTION AND TEST

1. Remove the spark plugs from the engine.
2. Visually check the spark plugs for the following and Spark plug
replace if defective.
l Broken insulator.
l Worn electrode.
l Deposited carbon. Use a plug cleaner for cleaning.
Clean porcelain insulator above shell as well.
l Damaged or broken gasket.
l Burnt condition of porcelain insulator at spark gap.
If black carbon deposit is evident, probable cause is
too rich a fuel mixture or extremely low air intake.
Misfiring due to excessive spark gap is also suspected.
If insulator is burnt white, too lean a fuel mixture,
excessively advanced ignition timing, improperly
tightened plug, etc. are suspected.
3. Connect the spark plug to the high tension cable, ground Defective insulation
outer electrode (main body), and crank engine. In the
atmosphere, only short sparks are produced because of
small discharge gap. If the spark plug is good, however,
sparks will occur in discharge gap (between electrodes).
In a defective spark plug, no sparks will occur because
of leak of insulation puncture. Defective insuktion
4. Check plug gap with plug gap gauge. If it is .not within

specified limit, adjust by bending ground electrode.
Make sure that the gap of even a new spark plug is
checked before spark plug is mounted to engine. 1 E LO3,
Spark plug gap . . . .’ . . . . 1.0-1.1 mm (.039-.0’43 in.)

I”-\.
lllllllllllllllillllllllllll
5. Install the spark plug and tighten to specified torque.

If it is overtorqued, damage to threaded ,portion
/ of
cylinder head might result.
Spark plug . . . . . . . . . . . . . 20-29 Nm (15-21 ft.lbs.)
Gap
lELO2
Spark Test Without Cranking

If spark test is performed by cranking while the catalyst is
hot, unburned gas will be supplied to the catalyst, and this is
not desirable to the catalyst.
For this reason, use the following methods which;allow spark
test to be performed without cranking.
High tension cable

5-10 mm
(.2-.4 in.)
lEL03
8-78
SERVICE ADJUSTMENT PROCEDURES/ -+
COMPONENT SERVICE-CHARGING SYSTEM n
1. Remove the distributor cap.

2. Check signal rotor position in relation to the pick-up. If
it is not the position shown in the illustration (6EL069),
turn the crankshaft manually so that the projection of
the signal rotor is moved away from the center part of
the pick-up. In other words, the signal rotor should be
positioned so that current can flow to the ignition coil.
3. Disconnect the high-tension cable from the center tower
of the distributor cap, and hold the end of the cable
about 5 to 10 mm (.2 to .4 in.) away from the cylinder
block of the engine. (lEL038)
4. Turn the ignition switch to “ON”. Then, when a piece of
Pick-up
metal (the tip of a screwdriver for instance) is inserted
into the detection coil of the pick-up and then moved
away, a spark can be generated. (6EL069)
CHARGING SYSTEM
COMPONENTS
1. Through bolt (3)

2. Nut
3. Spring washer
4. Pulley
5. Fan
6. Collar
7. Screw (3)
8. Seal (2)
9. Front bracket
10. Bearing
11. Retainer
12. Rotor
13. Stator
14. Screw
15. Insulator
16. Plate “L”
17. Brush holder and regulator
18. Rectifier
19. Rear bracket
20. Nut
21. Washer
22. Condenser
23. Plate “6”
24. Screw (“B’‘-terminal)
REMOVAL
1. Disconnect battery ground cable.
2. Remove the drive belt. See “Cooling system”, Group 7,
for detailed procedure.
3. Disconnect wiring and connector from the alternator.
4. Remove the brace bolt and support bolt and remove
alternator from engine.
8-79
COMPONENT SEIRVICE-CHARGING SYSTEM
DISASSEMBLY
1. Remove the three through bolts.
2. Insert plain screwdriver between front bracket and-stator
core and pry downward. (3EL029)
Caution
Do not insert screwdriver too deep, as there is danger of
damage to stator coil.
3. Clamp the rotor in a vise with pulley side up (protect
rotor from vise jaws).
4. Remove pulley nut. Then remove spring washer, pulley,
fan and collar.
5. ,Remove front bracket and two seals.
6. Remove the rotor from vise.
I 3E LO2! 3
'I
7. Remove the nut from “B” terminal and remove the
washer and condenser.
Unsolder
8. Remove the brush holder screw and rectifier screws. hree rectifiers
9. Remove the stator assembly from the rear bracket.
10. When stator is to be removed, unsolder three stator
leads soldered to main diodes on rectifier. (3EL046)
Caution
1. When soldering or unsoldering, use care to make sure
that heat of soldering iron is not transmitted to diodes
for a long period. Finish soldering or unsoldering in as
short a time as possible.
2. Use care that no undue force is exerted to leads of diodes.
11. When separate the rectifier from brush holder, unsolder. I 3EL04f 3
two plates soldered to rectifier.
INSPECTION
Rotor
1, Check rotor coil for continuity. Check to ‘ensure that
there is continuity between slip rings.
Resistance value . . . . . . . . . . . . . . . . . . . . . . . 2.5-4s
If resistance is extremely small, it means that there is a

short. If there is no continuity or if there is short circuit,
replace rotor assembly.
3E LOO1 3
2. Check rotor coil for grounding. Check to ‘ensure that

there is no continuity between slip ring and core. If
there is continuity, replace rotor assembly.
8-80
COMPONENT SERVICE-CHARGING SYSTEM
stator
1. Make continuity test on stator coil. Check to ensure that
there is continuity between coil leads.
If there is no continuity, replace stator assembly.
I 3ELOlC
21 Check coil for grounding. Check to ensure that there is

I
no continuity between coil and core. If there is con-
tinuity, replace stator assembly.
3ELOll
Ret tifier
1. (+) HEATSINK ASSEMBLY TEST (+) heatsink assembly
Check for continuity between (+) heatsink and stator Connection terminal
nf stator coil lead
coil lead connection terminal with a circuit tester. If
there is continuity in both directions, diode is shorted.
Replace rectifier assembly.
2. (-) HEATSINK ASSEMBLY TEST
Check for continuity between (-) heatsink and stator I
coil lead connection terminal. If .there is continuity in L-terminal Die% trio / B-tkrminal
both direction, diode is shorted, and rectifier assembly I-) heatsink assembly
must be replaced.
3ELOl:
3. DIODE TRIO TEST
Check three diodes for continuity by connecting a
circuit tester to both ends of each diode. If there is no
continuity or no continuity in both directions, diode
is defective and heatsink assembly must be replaced.
8-81
COMPOMENT SEIRVICE-CHARGING SYSTEM
BRUSH REPLACEMENT
1. Brush worn down to wear limit line should be replaced.
2. If pigtail is unsoldered, brush and spring will come off.

Unsolder this portion
/ ..,’
3. When only brush or brush spring is to be replaced, it can

be replaced without removing stator, etc. I With brush ,,
holder assembly raised as illustrated, unsolder pigtail of Brush holder assembly
brush.
NOTE
If L- and B-terminals of rectifier assembly are bent, damage
to rectifier moulding might result. Therefore, plates “B” and
“L” should be gently bent at center.
4. When installing new brush, solder pigtail so that brush

will be pressed into holder about 5 mm (.2 in,)l..
I 3E LO3f
8-82
COMPONENT SERVICE-CHARGING SYSTEM
REASSEMBLY
Perform reassembly jn reverse procedure of disassembly, pay
attention to the following item:
1. Before rotor is attached to rear bracket, insert wire I nsel ‘t wire throw
through small hole made in rear bracket to lift brush.
After rotor has been installed, the wire can be removed.
Rear bracket
3EI nlF
INSTALLATION
1. Install the alternator to the engine front case and insert
the support bolt through the alternator leg into front
2: *,$I!!.
case. Do not install the nut.
2. Install the brace bolt but do not tighten the bolt.
3. Push alternator toward front of engine and check clear-
ance “A” between alternator leg and front case or timing
Alternator
chain case. If clearance is.more than 0.2 mm (.008 in.),
insert spacers [O. 198 mm (.0078 in.). thick] as required. Support bolt
If support bolt is tightened without reducing clearance I -A
Front case or
“A”, alternator leg might be broken. timing chain case
4. Install the washer and nut to the support bolt.
3ELOlE
5. Install drive belt and adjust the drive belt tension.
6. Tighten first the brace bolt and then tighten the support
bolt nut to the specified torque.
Tightening torque:
Alternator brace bolt . . . . . . 12-14 Nm (9-10 ft.lbs.)
Alternator support bolt nut . . . . . . . . . . . . . . . . . ,
20-24 Nm (15-l 8 ft.lbs.)
7. Connect wiring and connector to the alternator.

8. Connect the battery ground cable.
8-83
cl-+ COMPONENT SERVICE-STARTING SYSTEM
COMPONENTS
I Direct drive type
9 8,
1. Screw (2)
2. Front bracket
3. Washer
4. Snap ring
5. Stop ring
6. Overrunning clutch
7. Armature
8. Magnetic switch
9. Packing
10. Spring retainer
11. Lever spring
12. Spring seat
13. Lever
14. Washer
15. Yoke assembly
16. Brush holder
17. Brush spring
18. Rear bracket
19. Screw (2)
20. Through bolt (2)
NOTE
Numbers show order of disassembly.
For reassembly, reverse order of disassembly.
Reduction drive type
. ’ -8
., : : .. 7 I 20
1. Screw (2)
2. Front bracket
3. Lever
4. Spring
5. Spring retainer -
6. Center bracket
7. Packing
8. Magnetic switch
9. Snap ring
10. Stop ring
11. Pinion gear
12. Spring
13. Pinion shaft and ‘overrunning clutch
14. Reduction gear
15. Adjusting washer
16. Washer
17. Retaining ring 26 I
.B.
18. Cover
19. Screw (2)
20. Bolt
21. Front ball bearing
22. Armature
23. Rear bail bearing
24. Yoke assembly
25. Brush holder
26. Rear bracket
27. Screw (2)
28. Through bolt (2)
6ELO02
8-84
COMPONENT SERVICE-STARTING SYSTEM cl-+
REMOVAL
1. Disconnect battery ground cable.
2. Disconnect starting motor harness from the starter
motor.
3. Remove the two starting motor mounting bolts and
remove starter motor.
INSPECTION (after removal)

Pinion Gap Adjustment
1. Disconnect field coil wire from M-terminal of magnetic
switch.
2. Connect a 12 V battery between S-terminal and M-
terminal. (6EL050)
3. Set switch to “ON”, and pinion will move out.
Caution
This test must be performed quickly (in less than 10 seconds)
Field coil wire
to prevent coil from bourning.
4. Check pinion to stopper clearance (pinion gap) with a 1 Direct drive type
feeler gauge. (6EL003)
If pinion gap is out of specification, adjust by adding or
removing washers between magnetic switch and front
bracket.
Pinion gap . . . . . . . . . . . 052.0 mm (.020-.079 in.)
5. Lightly push back the pinion, and measure the amount Reduction drive type
of travel, which represents the pinion gap. Adjust the
thickness (number) of washers at switch area so that the Pinion
gzipbecomes 0.5 to 2.0 mm (-020 to .079 in.).
Amount of I
DELOO:
COMPONENT SERVICE-STARTING SYSTEM
Pm&in Test of Magnetic Switch

switch.
2. Connect a 12 V battery between S-terminal and M-
terminal. (6EL004)
Caution
This test must be performed quickly (in less than 10 seconds) 12 V battery
to prevent coil from burning.

3. If pinion moves out, then pull-in coil is good. If it doesn’t,
replace magnetic switch.
Hold-m Test of Magnetic Switch

switch.
2. Connect a .12 V battery between S-terminal
(6EL005)
and body.
p
b S
@”
Caution
12V battery
This test must be performed quickly (in less than 10 seconds)
to prevent coil from burning. Starter
motor
3. If pmion remains out, everything is in order,, If pinion Field coil wire
moves in, hold-in

switch.
circuit is open. Replace magnetic
:8
6E LOO5
Return Test of Magnetic Switch

1. Disconnect field coil wire from “M” terminal ocf magnetic
switch.
2. Connect a 12 V battery between M-terminal and body.
(6EL006)
Caution
This test must be performed quickly (in less than ‘10 seconds) 12 V battery
to prevent coil from burning.
3. Pull pinion out and release. If pinion quickly returns to
its original position, everything is in order. If it doesn’t
replace magnetic switch.,
LOO6
Free Running Test

1. Place starter motor in a vise equipped with soft jaws and Carbon pile rheostat
connect a fully-charged, 12 volt battery to starter motor

as follows: r 1
2. Connect a test ammeter (100 amperes scale)’ and carbon
pile rheostat in series with battery positive, post and
starter motor terminal.
3. Connect a voltmeter (15 volt scale) across starter motor.
4. Rotate carbon pile to full-resistance position. (6EL071)
8-86
COMPONENT SERVICE-STARTING SYSTEM n-+
5. Connect battery cable from battery negative post to
starter motor body.
6. Adjust rheostat until battery voltage shown on voltmeter
reads 11.5 volts.
7. Check specifications for maximum amperage draw and
minimum rpm .
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5 Volts

Amperage draw . . . . . . . . . . . . . . . . , . . . . 60 Amps
Minimum rpm . . . . . . . . . . . . . . . . . . . . . 6,800 rpm
DISASSEMBLY-DIRECT DRIVE TYPE

1. Disconnect field coil wire from “M” terminal of magnetic I Magnetic switch
“S”
I
terminal
switch.
& “B” terminal
Field coil wire
/ &EL07
2. Remove two magnetic switch mounting screws and

remove magnetic switch. Magnetic switch
Magnetic switch
I Mounting screw
3. Remove two through bolts and two screws. Through bolts Screws
4. Remove rear bracket.
ear bracket
I 6EL074
8-87
-+
El COMPONENT SERVICE-STARTING SYSTEM
5. Slide the two brushes from brush holder’ bjr prying

retaining springs back. Retaining sying
6. Remove brush holder.
7. Remove yoke assembly. Brush
I / 6EL075
8. Remove washer from rear end of armature.
6E LO76
9. Remove spring retainer, spring and spring seat from

front bracket.
Y 6EL077 1
10. Remove armature assembly and lever from front bracket.
Clutch shift lev
clutch
8-88
COMPONENT SERVICE-STAF?TI&~ SYSTEM,
! 1. Remove washer from front bracket.
12. Press stop ring off snap ring with suitable socket.
6E LO80
13. Remove snap ring with snap ring pliers and then remove
stop ring and overrunning clutch.
Snap ring
Snap ring
\ Cal iers
‘-Armature
6E LO81
8-89
DISASSEMBLY-REDUCTION
Drive Type
1. Disconnect the field coil wire from “M” terminal
I, of
magnetic switch.
Field coil wire
2. Remove the two magnetic switch mounting screws and ’ Magnetic switch
remove the magnetic switch.
3. Remove the two through bolts and two screws, and then I /
remove the rear bracket. I
k---/l 5EL018
4. Slide the two brushes from brush holder by prying

Retaining spring
retaining springs back, and then remove the brush holder
assembly.
5. Remove the yoke assembly.
6. Remove the armature.
8-90
7. Remove the pinion shaft end cover from the center cover.
8. Measure the pinion shaft end play using feeler gauge for
reassembly.
9. Remove the retaining ring and washer from the pinion
shaft.
10. Remove the center bracket.
11. Remove the lever spring retainer and spring.

12. Remove the adjusting washer and reduction gear.
13. Remove the clutch shift lever and two lever holder.
Lever holder
5E LO22
14. Press the stop ring off the snap ring with suitable socket.
COMPONENT SE,RVICE-‘STARTING SYSTEM
15. Rt%ove the snap ring with screwdriver, and then remove.
the stop ring.
16. Remove the pinion and spring from pinion shaft.
I 5EL024
17. Reiove the overrunning clutch from the front bracket.
CLEANING STARTER MO:TOR PARTS

1. Do not immerse parts in cleaning solvent. Immersing
the yoke and field coil assembly and/or armature will
damage .insulation. Wipe these parts with a cloth only.
2. Do not immerse drive’ tinit in cleaning. solvent. Over-
running clutch is pre-lubricated at the factory and solvent
will wash lubrication from clutch.
3. The drive tinit may be cleaned with a brush moistened
with cleaning solvent and wiped
0 dry with a cl@h.
Z.’
8-92 ,. .
COMPONENT’ SERVICE-STARTING SYSTEM III-+
BRUSHES AND SPRINGSREPI;ACEMENT
1. Brushes that are worn beyond wear limit line, or are
oil-soaked, should be replaced.
2. When replacing field coil brushes, crush worn brush with
pliers, taking care not to damage pigtail.
3. Sand pigtail end with sandpaper to ensure good soldering.
4. Insert pigtail into hole provided in new brush and solder
it. Make sure that pigtail and excess solder do not come
out onto brush surface. E861 Wear limit line
5. When replacing ground brush, slide the brush from brush

holder by prying retaining spring back.
lEL0101
New brush
Soldered
(Make sure that there
is no excess solder
on brush surface.)
Surface marked A
I 1 E L04E
TESTING ARMATURE
Testing Armature for Short Circuit
1. Place armature in a growler.
2. Hold a thin steel blade parallel and just above while
rotating armature slowly in growler. A shorted armature
will cause blade to vibrate and be attracted to the core.
Replace shorted armature.
Testing Armature for Grounding

1. Touch armature coil core and the end of each commu- Growler
I
tator bar with a pair of test lamp prods.
2. If lamp lights, it indicates a grounded armature. Replace
grounded armature..
/ VII I6E L08:
8-93
Testing Commutator Runout

1. Place armature in a pair of “V” blocks and check runout
with a dial indicator.
2. Check both shaft and commutator. A bent shaft requires
replacement of armature.
,3. If commutator runout exceeds 0.05 mm (002 in.),
commutator should be refaced. Remove only enough
metal to provide a smooth; even surface. /
Commutator runout . . . ‘. . . Max 0.05 mm (.002 in.)

Under cut depth . . . . . . . . . . . . . . . 0.5 mm (.02 in.)
TESTING FIELD COILS FOR GROUNDING

1. Touch one probe of test lamp to series field coil lead
and other probe to yoke. Lamp should not light.
If lamp lights, coils are grounded. If field coils are ground-
ed, replace field coil and yoke assembly.
Yoke ,
6E LO85
TESTING BRUSH HOLDER

1. Touch. each of the insulated brush holders with one test
probe, while holding other test probe against brush
holder plate.
2. The lamp should not light during this test since the brush
holders are insulated. If the lamp lights brush holders
on brush holder plate are grounded. Replace brush
holder assembly if brush holders are grounded.
SERVICING DRIVE UNIT Direct drive type

\ /
Overrunning Clutch
1. While holding clutch housing, rotate the pin:ion. Drive
pinion should rotate smoothly in one direction, but
should not rotate in opposite direction. If clutch does
not. function properly, replace overrunning clutch as-
sembly.
2.’ Inspect pinion for wear or burrs. If pinion ,i:sworn or
burred, replace overrunning clutch assembly. If pinion
is damaged, also inspect ring gear for wear or burrs.
lEL012
8-94
Reduction drive typ
5EL026
FRONT AND REAR BRACKET BUSHINGDIRECT DRIVE

TYPE
1. Inspect bushing for wear or burr. If bushing is worn or
burred, replace front bracket assembly or rear bracket
assembly.
REASSEMBLY Direct drive tvDe

Reassemble starter motor in the reverse order of disassembly
with the following exception.
1. Using a suitable pulling tool, pull overrunning clutch
stop ring over snap ring.
Snab ring
lEL013
Reduction drive type
gear v 5EL027
COMPONENT SE:RVICE-STARTING SYSTEM
INSTALLATION
1. Clean both surfaces of starter motor flange and rear plate.
2. Install starter motor to engine and tighten two bolts to
specified torque. 1
Starter motor mounting bolts. . . . . . . . . . . 1. . .

22-3 1 Nm (16-23 ft.lbs.)
3. Connect battery cable and switch wire to starter motor.

4. Connect battery ground cable.
8-96
COMPONENT SEl?VlCE-IGNITION SYSTEM
COMPONENTS
1. Breather
2. Cap
3. Contact carbon
4. Rotor
5. Lead wire
6. Earth wire
7. Igniter
8. Pin
9. Rotor
10. Breaker base
11. Vacuum controller for dual diaphragm
12. Vacuum controller for single diaphragm
13.
14.
15.
Rotor
Spring
shaft
Governor
retainer
spring
(2)
(2)
T
24
16. Governor weight (2)
17. Distributor shaft
18. Oil seal
19. Packing I
20. Distributor housing
21 : O-ring
22. Washer
23. Gear
24. Pin
NOTE
Numbers show order of disassembly.
For reassembly, reverse order of disassembly.
6E LO87
DISASSEMBLY r
1. Lightly clamp distributor in a vise equipped with soft
jaws.
2. Remove retaining clips and lift off distributor cap and
seal ring.
3. Pull-off rotor from rotor shaft.
4. Remove two,vacuum controller mounting screqs.
5. Remove link of controller from pin on the bf&aker base,
and then remove vacuum controller.
8-97
COMPONENT SERVICE-IGNITION SYSTEM
6. Remove two screws and remove igniter.

7. Remove lead wire (black).
8. Remove signal rotor shaft tightening screw and two

breaker plate retaining screws.
9. Remove signal rotor shaft and breaker plate assembly.
10. Remove signal rotor shaft from signal rotor.
11. Remove, two spring ret&ers with pliers and th.en remove Spring retainer
I
two governor springs.
12. Remove two governor weights.
Governor
I spring 6ELO92 I
8-98
13. Mark location of drive gear on distributor shaft.

14. Place drive gear on soft base (wood block) SO that roll
pin can be removed.
15. Using a pin punch, remove roll pin.
16. Remove drive gear and washer.
17. Remove distributor shaft from housing.
I 6EL093
REASSEMBLY
J--.--Pin punch
1. Clean and inspect all parts.
2. Install shaft into housing.
3. Install drive gear into distributor shaft at previously
II
marked location. Then install new roll pin.
4. Install governor weights on the governor plate.

Spring retainer
5. Install governor springs and spring retainer.
=3?-- -
Governor spring
6EL092
6. Install signal rotor shaft into distributor shaft.

7. Install breaker plate to housing. Position the breaker
plate so that the projection (A) fits into the groove (B).
8. Tighten two breaker plate retaining screws.
6E LO94
9. Install. signal rotor to rotor shaft. Position the signal rotor

so that the dowel pin fits into the groove. (
1 6EL09E
10. Install igniter to breaker plate and install two screws.

1.1.Connect one end of lead wire to igniter mounting screw
and other end to breaker plate.
12. Adjust air gap between signal rotor and pick-up of igniter.
13. Connect vacuum control link to breaker plate and tighten

two vacuum controller screws.
14. Install rotor to rotor shaft. ,.
15. Install seal ring and distributor cap to housing and set
the retaining clips.
8-100
INSTALLATION
1. Turn crankshaft until piston of No. 1 cylinder is at top
dead center of compression stroke.
2. Align mating mark on distributor housing with mating
mark (punch) on distributor driven gear. (lEL0 18)
3. Install distributor to cylinder head while aligning mating

mark on distributor attaching flange with center of
distributor installing stud and tighten nuts. (lELO19)
4. Adjust ignition timing.
IGNITION COIL
(+I terminal
INSPECTION f-1 terminal
1. Using a circuit tester, measure resistance. An open- or d
short-circuited coil should be replaced.

Model No.
Primary resistance E-064 . . . . . . . . . . . . . . . . . . . .
1.1-1.3 a at 20°C (68’F)
Secondary resistance . . . . . . . . . . . . . . . . . . . . . . . resistor
11.6-15.8 kn at 20°C (68’F)
External resistor resistance . . . . . . . . . . . . . . . . . . .
1.2-1.5 G! at 20°C (68’F) 3E LOO’
2. Check resin portion for cracks. If there are cranks, replace.

3. Check for fluid (oil) leaks. If there are leaks, replace.
8-101
Wiring harness locations
Dome light wiring harness

(for canvas-top)
Dome light wiring harness /

Back door
Control wiring harness

For California
(can also be sold in
c--l-..-, -A-s-.\
\
Front wiring harness
wiring harness
\ Door wiring harness (L.H.)

Door wiring harness (R./H.) ,.
Back-up light and 4WD
-Center oanel indicator ligh t wiring harness
SW763
wiring harness
Engine compartment - Front
Brake fIrrid
.._._ To back-uo liaht and Diode” Ground
level sensor 4WD indicator I
wiring harness ight 1 Solenoid \ Front combination C-^..A ^^-L.:^^r:^^ Gr0Llnd
rl”lll l.“lll”llldll”ll
Idle-up solenoid I valve- \ light (L.H.1 linht IR H 1 I
/alve” Sub fus
I \ / \ Iink I
E.S.S
\\ \ temperature \ \ \ /\i \
/ / \\I \
Carburetor \ \\ \sensor* \ /?C’Power relav** Oil pressure switch
E.S.S. solenoi d Water temperature \ --’
/ or Magnet clutch** 16W760
Tn
,”
frrY”t
. . . . . .
Wirinn
..“‘..J
T? air conditioner
w
,I
harness** wi. rinn,..= harness**

.._. .._- Air temperature Water temperature
Ground gauge unit”
Throttle position
sensor*
NOTE
l
: For California (can also be sold in Federal States).
l * : indicates connection for vehicles with an air conditioner.
Engine compartment - Rear
Wiper motor
Battery cable (+I Main fusible link
16W755
ain fusible link* arter motor
Battery cable (-1
NOTE
* : For California (can also be sold in Federal States)
Instrument panel
Combination
meter Heater relay
Defogger
switch Power
relay** Speaker
Buzzer \ \\ I
I
Combination gauge To dome light
Therm0 wiring
switch** harnesstfor metal-top)
Blower switch**
Rear wiper and

washer switch
Fuse \ I \ I,,
\ \ / I
, 1
\ \ \ Column /
Intermittent r wiring
wiper
relay
IF
To rear heater
switch wiring tlarness
\
Turn-signal
flasher unit
/ To ddor
/ control unit*
wiring harness
16W761
Seat belt brake -

switch (I-H) switch
NOTE
l
: For California (can also be sold in Federal States).
** : indicates connection for vehicles with an air conditioner.
COMPONENT SERVICE-WIRING HARNESS
-
.
1
8-106
COMPONENT SERVICE-WIRING HARNESS n-+
z.n
-
i
0”
Frame
Rear combination
light (R.H.1
I
Back door wiring harness
Rear combination
light (L.H.)
\
16W696
Back door - Vehicles without a rear wiper and washer Back door - Vehicles with a rear wiper and washer
Frame wiryg harness Frame wiring

harness
Rear wiper
motor
Rear washer
motor
COMPONENT SERVICE-WIRING’ HARNESS
CENTRALIZED GROUND POINTS

yq
16W722
ILI Fender
inner
side)
shield,
(right
Front
(right
pillar,
side)
inner
I k--J I 16K774
Fender
inner
side)
shield,
(left 04 Engine
(left side)
block
Frame
(left side)
Fender shield
(left side)
Front pillar, inner

(left side)
NOTE
l : For California (can also be sold in Federal States).
8-111
I3-+ COMPONENT SERVICE-WIRING HARNESS
RELAY MOUNTING LOCATIONS
16W722
7
A Front pillar (right side)
El Fender shield, inner (left side)
16W626
a Front pillar, inner (left side) Dash panel, upper
1. Light control relay 7. Intermittent wiper relay

2. E.S.S. relay 8. Carbul-etor control unit
3. Headlight washer relay For, California
4. Turn-signal flasher unit I (can also be sold in Federal States) 1
5. Hazard warning flasher unit 9. Seat belt timer
10. Heater relay -..
6. Power window relay
8-112
SPARE TERMINALS
Y
r-
El
71 Front speaker 4 ACC spare terminal
i-l Rear wiper and washer switch

El Rear speaker
-eft side Right side
16W726 16W72#
d Radio %I Headlight washer motor and relay
ieadlight washer motor Headlight washer relay
161111717 16W728 16W738
NOTES
(1) If ACC spare terminal 1 is used, it must not be used for more than 5 A.
(2) If the vehicle is not equipped with the optional equipment corresponding to a spare
terminal, that spare terminal will be secured to the main line with blue tape.
8-l 13
COMPONENT SERVICE-WlRlNG.HARNESS
16W722
Air conditioner compressor and low pressure switch d Air conditioner unit
-
Left side Right
I I
side
’ 1
-
31 Rear
A
Heater
-
-
1101 Power Window
-
\’ 16W768
For California
11 11 Air conditioner switch (can also be sold in Federal stat&
-
25
-
a-114
READING THE HARNESS DIAGRAMS

Harness Diagram Example
16E962
How to Read the Accompanying
1 2 3 4 5
I I
NO. WIRE CIRCUIT
,
1 -2FB- IGNITION SWITCH <ST> INSTRUMENT PANEL WIRING HARNESS
2 RL FUSE BLOCK (I) STOPLIGHT SWITCH
3 GY HORN <E> III
4 GL HORN - *
5 0.85GB -
6 7 8 9
1. The connector terminal number indicated in the diagram.

Permissible current
2. The numbers indicate the nominal cross-sectional area of
the wire; refer to the table at right. If a number is not NO. Nominal SAE
size mni* In engine Other
gauge No.
used, it indicates that the cross-sectional area of the wire compart- areas
is 0.5 mm*. ment
3. “F” indicates that this is flexible wire.
0.3 0.3 AWG 22 SA
0.5 AWG 20 7A 13A
0.85 0.85 AWG 18 9A 17A
1.25 1.25 AWG 16 12A’ 22 A
2 2.0 AWG 14 16A 30 A
3 3.0 AWG 12 21 A 40 A
5 5.0 AWG 10 31 A 54 A
8-115
4. The letters indicate the color of the wire.
Symbol B G L 0 R W Y Br
Color Black Green Blue Orange Red White Yellow Brown
Wires which have two-color insulation covering are indicated by two letters. The first letter indicates the cable
color and the second letter indicates the trace maryking (color).
Example
M 16063
5. Indicates the circuits which are connected. ;

6. The letters in angular brackets indicate which part of the circuit this terminal is connected to; refer to the
following table. -
Letter Meaning Letter Meaning
I
ACC Accessory L Load
AS Auto-stop LO Low-speed terminal
B Battery LI License plate lights
BACK . Back-up lights OIL Oil pressure
BEAM Headlight upper beam indicator light RL Rear left
BK .’ Brake RR Rear iight
CHG Charging s Soft
DEF Defogger ST Starter
DR Door STOP Stop lights
E Ground TAC Tachometer
FL Front left TAIL Tail lights
FR Front right TEMP Water temperature
H Hard TUL Turn-signal light, left
HI High speed terminal TUR Turn-signal light, right
HL Headlight low beam w Washer
HU Headlight high beam + Positive terminal
IG Ignition - Negative terminal
ILL Illumination 4WD 4WD indicator light
IND Indicator light
7. Parentheses contain supplementary information; in the example, the “1” indicates the number 1 fuse of the
fuse block.
8. The boxed numbers I indicate to which terminal is connected.
9. If neither a ci!cuit .nor a number is listed, it :i:ndicates that this wire of this terminal is not connected to an-
qther terminal.
8-116
WIRING CONNECTORS 4-pole pin terminal connector
Connector Classifications Pin terminal
Electrical wiring connectors can be classified according to the

type of terminals (such as pin terminals or flat terminals), the Ah!
+;I
number of poles (terminals), whether they are male or female,
whether they have a locking device or not, etc. In this Service
1. -=
Manual, connectors will generally be classified as follows: ki B
Male Female
4-pole flat terminal connector
Flat terminal
3’ ‘4 4’ ‘3
.. Male Female
1. Classification according to terminal type

Connectors illustrated with outer lines shaped so that the Top corners are cut diagonally
‘/r(lPin terminal connector)
top comers are cut diagonally usually have pin terminals,
and those illustrated with outer lines shaped so that the
top is cut into stairsteps usually have flat terminals.
m /Top is cut into stairsteps
Note that connectors illustrated with diagonally cut (Flat terminal connector)
comers on which one section is marked with an “X”
are small flat terminal connectors. The “X” indicates the 1 I I
position of a guide to prevent the connector from being Position of guide to prevent
improper connection
improperly connected. (Small fiat terminal
connector)
36K031
i. Classification according to number of poles

The number of sections represents the number of poles
inside the connector. However, sections in the illustra-
tion marked with an “X” or blacked in do not represent
poles.
There are 18 sections; however, because

two of the sections are blacked in,
there are only 16 poles.
3. Classification according.to male and female

Connectors illustrated with double outer lines are male,
and those with single outer lines are female. ,.
Male Female
I 36KO3l
4. Classification according to the presence of a locking de-

vice
If a flat terminal connector is illustrated with ,a projection
Projections indicate
at the top, it indicates that the connector is equipped locking devices h
with a locking’device.
NOTE
(1) Because all pin terminal .connectors, small flat terminal
connectors, and sealed connectors are equipped with ELl?G!b E!iicfQ
locking devices, there, are special indications in the
(housing lance lock connectors)
graphic illustrations.
(2) Housing lance lock connectors have lances inside the con-
nector housing which securely lock the terminals
prevent them from becoming disconnected, ‘thus provid-
to
I .?tiKO?A
ing increased reliability.

5. Classification according to sealed connector
Classification of round shape-sealed connector (pin ter-
minal water-proofed connector) which is used for engine This is guide to prevent
improper connection
wiring harness is the same as above.
Double lines indicates Number of sections

male indicates the number
of poles
I 36K03C
Terminal numbers
If a pair of connectors (male and female) is illustrated as dis-
connected, the corresponding terminal numbers ‘vlrill be posi-
tioned symmetrically. Therefore when the pair of connectors
is connected, the corresponding terminal numbers on the
male and female connectors will match.
8-118
Main fusible link Seat belt solenoid
Rear !
IL.H.l
For California
(can ah be sold in Federal States1
Front cambi-
nation light
(R.H.1
Headlight
RI-.)
Air conditmne,
IIAI
Hazard Headlight Intermittent
warning washer wiper relay
flasher relay Furs block
0,
unit
Air conditioner 16W707
wiring harnerr C
NO.
:
COMPONENT SERVICE- WIRING HARNESS
CONTROL WIRING HARNESS

For California (can also be sold in Federal States)
Carburetor assembly
- Air temperature sensor Oxygen sensor
Throttle
Water temperature sensor position q Main fusible link
sensor
Ground cl35 Ground
El Ground
Air conditioner k-l
16W754
valve switch Carburetor control unit (A)
NO. WIRE T Cl RCUIT

T
1 SB CARBURETOR CONTROL UNIT (A) OXYGEN SENSOR

2 1.25GY CARBURETOR CONTROL UNIT (A) AIR TEMPERATURE SENSOR
3 G CARBURETOR CONTROL UNIT (A) THROTTLE POSITION SENSOR
4 GR CARBURETOR CONTROL UNIT (A) AIR TEMPERATURE SENSOR
5 GB CARBURETOR CONTROL UNIT (A) VACUUM SWITCH
6 1.258 CARBURETOR CONTROL UNIT (A) GROUND
7 2BW CARBURETOR CONTROL UNIT (A) IGNITION COIL (+I
8 2BW CARBURETOR CONTROL UNIT (A) 171
9 2RL CARBURETOR CONTROL UNIT (A) MAIN FUSIBLE LINK
10 SB‘ CARBURETOR CONTROL UNIT (A) IGNITION COIL (-1
11 1.258 CARBURETOR CONTROL UNIT (A) (61
12 YG CARBURETOR CONTROL UNIT (A) WATER TEMPERATURE SENSOR
13 YR CARBURETOR CONTROL UNIT (A) THROTTLE POSITION SENSOR
l 14 0.85BW CARBURETOR CONTROL UNIT (B) AIR CONDITIONER
15 YW CARBURETOR CONTROL UNIT (B) CARBURETOR ASSEMBLY
16 YL CARBURETOR CONTROL UNIT (B) CARBURETOR ASSEMBLY
18 RW CARBURETOR CONTROL UNIT(B) SOLENOID VALVE ASSEMBLY
*20 0.85L CARBURETOR CONTROL UNIT (B) AIR CONDITIONER
21 GL CARBURETOR CONTROL UNIT(B) SOLENOID VALVE ASSEMBLY
22 YG CARBURETOR CONTROL UNIT(B) CARBURETOR ASSEMBLY
23 B VACUUM SWITCH Cm
26 1.25BW CARBURETOR ASSEMBLY 171
27 1.25BW CARBURETOR ASSEMBLY
28 1.25BW CARBURETOR ASSEMBLY ;
29 1.25BW CARBURETOR ASSEMBLY 171
30 1.25BW SOLENOID VALVE
31 GY WATER TEMPERATURE SENSOR ;
32 GY CARBURETOR 121
33 B GROUND
35 1.258 GROUND
36 B GROUND
37 1.258 GROUND
NOTE
*Vehicles equipped with an air conditioner.
8-121
COMPONENT SEIRVICE- WIRING HARNESS
BACK-UP LIGHT AND 4WD INDICATOR LIGHT WIRING HARNESS
4WD indicator
II 3 I kl
light switch
I cl
1
Back-up
light
switch
q 2
16W704
NO. 1 WIRE 1 CIRCUIT
1 R FRONT ,WIRING’ HARNESS BACK‘-UP LIGHT SWITCH.

2 RL FRONT WlRlrjG HARNESS BACK-UP LIGHT iWITCH
3 BR FRONT WIRING HARNESS ( 4WD INDICATOR, LIGHT ‘SWITCH
4 YR FRONT ‘WIRING HARNESS ’ 4WD INDICATOR. LIGHT SWITCH
DOME LIGHT WIRING HARNESS
16W635
NO. 1 WIRE 1 CIRCUIT
1 RB FRONT WIRING HARNESS DOME LIGHT 

2 B FRONT WIRING HARNESS DOME LIGHT <E>
3 RG FRONT WIRING HARNESS ’ DOME LIGHT <DR>
8-122
CENTER PANEL WIRING HARNESS
Heater control
illumination light
EIEI
Ashtray
illumination
light
Front
wiring
harness
16W636
Cigarette Cigarette
lighter lighter
illumination
light
NO. WIRE 1 CIRCUIT
1 0.85LW FRONT WIRING HARNESS <ACC> CIGARETTE LIGHTER

2 GW FRONT WIRING HARNESS <ILL+> CIGARETTE LIGHTER ILLUMINATION LIGHT
3 0.858 FRONT WIRING HARNESS <E> CIGARETTE LIGHTER ILLUMINATION LIGHT
4 0.3RB FRONT WIRING HARNESS CLOCK
5 0.3GY FRONT WIRING HARNESS <ILL--> HEATER CONTROL ILLUMINATION LIGHT
6 B CLOCK <E> El
7 LW CLOCK <ACC> El
8 0.3GW CLOCK <ILL+> 121
9 0.3GW FRONT WIRING HARNESS <ILL+> HEATER CONTROL ILLUMINATION LIGHT
,I_I
10 0.3B ASHTRAY ILLUMINATION LIGHT <E> LLI
11 0.3GW ASHTRAY ILLUMINATION LIGHT <ILL> 121
8-123
n-+ COMPONENT SERVICE-WIRING
I
HARNESS
FRAME WIRING HARNESS - Vehicles without a rear wiper and washer
at ion
light (R.H.)
Back door
harness wiring harness
light (R.H.)
Side marker
light (L.H.1
16W695
Rear combination
light (L.H.1
NO. WIRE T Cl RCUIT
1 0.3GW FRONT WIRING HARNESS BACK DOOR WIRING HARNESS <LI>

2 B FRONT WIRING HARNESS BACK DOOR WIRING HARNESS <E>
3 28 FRONT WIRING HARNESS BACK DOOR WIRING HARNESS <DEF>
8 0.3GY FRONT WIRING HARNESS REAR COMBINATION LIGHT (R.H.) <TUR/STOP>
9 G FRONT WIRING HARNESS REAR COMBINATION LIGHT (R.H.)
10 FIG FRONT WIRING HARNESS REAR COMBINATION LIGHT (R.H.1 <TAIL>
11 RL FRONT WIRING HARNESS REAR COMBINATION LIGHT (R.H.) <BACK>
12 0.3GL FRONT WIRING HARNESS REAR COMBINATION. LIGHT (L.H.) <TUL/STOP>
13 Y FRONT WIRING HARNESS FUEL GAUGE UNIT
15 B . REAR COMBINATION LIGHT (R;H.) <E>
16 0.3G REAR COMBINATION LIGHT (L.H.)
17 0.3RG REAR COMBINATION LIGHT 1L.H.) <TAIL>
18 0.3RL REAR COMBINATION LIGHT (L.H.) <BACK>
19 B REAR COMBINATION LIGHT (L.H.) <E>
31 GW SIDE MARKER LIGHT (L.H.)
32 0.38 SIDE MARKER LIGHT (L.H.1
33 0.3GW SIDE MARKER LIGHT (R.H.)
34 0.38 SIDE MARKER LIGHT (R.H.)
S-124
-+
COMPONENT SERVICE-WIRING HARNESS n
FRAME WIRING HARNESS - Vehicles with a rear wiper and washer
0,
II
1’ Back door
Front wiring
harness wiring harness
43 34
33
Side marker
light (R.H.)
16W776
Rear combination
light (L.H.)
NO. WIRE T Cl RCUIT
1 0.3GW FRONT WIRING HARNESS BACK DOOR WIRING HARNESS <LIB

2 B FRONT WIRING HARNESS BACK DOOR WIRING HARNESS <E>
3 28 FRONT WIRING HARNESS BACK DOOR WIRING HARNESS <DEF>
4 L FRONT WI RING HARNESS BACK DOOR WIRING HARNESS
(REAR WIPER) <ACC>
5 0.3BrW FRONT WIRING HARNESS BACK DOOR WIRING HARNESS
(REAR WIPER) <LO>
6 0.3Br FRONT WIRING HARNESS BACK DOOR WIRING HARNESS
(REAR WIPER) <AS>
7 0.3WB FRONT WIRING HARNESS BACK DdOR WIRING HARNESS
(REAR WASHER)
8 0.3GY FRONT WI RING HARNESS REAR COMBINATION LIGHT (R.H.1 <TUR/STOP>
9 G FRONT WIRING HARNESS REAR CGMBINATION LIGHT (R.H.1
10 RG FRONT WIRING HARNESS REAR COMBINATION LIGHT (R.H.1 <TAIL>
11 RL FRONT WIRING HARNESS REAR COMBINATION LIGHT (R.H.) <BACK>
1’2 0.3GL FRONT WIRING HARNESS REAR COMBINATION LIGHT (L.H.1 <TUL/STOP>
13 Y FRONT WI RING HARNESS FUEL GAUGE UNIT
15 B REAR COMBINATION LIGHT (R.H.) <E> El
16 0.3G REAR COMBINATION LIGHT (L.H.1 El
17 0.3RG REAR COMBINATION LIGHT (L.H.1 <TAIL> 1101
18 0.3RL REAR COMBINATION LIGHT (L.H.) <BACK> 111
19 B REAR COMBINATION LIGHT 1L.H.) <E> El
31 GW SIDE MARKER LIGHT (L.H.) 1171
32 0.38 SIDE MARKER LIGHT (L.H.) m
33 0.3GW SIDE MARKER LIGHT (R.H.) 1101
34 0.3B SIDE MARKER LIGHT (R.H.) (151
8-125
COMPONENT SE.RVICE- WIRING HARNESS
BACK DOOR WIRING HARNESS - Vehicles withouta rear wiper and washer
Defogger
License
plate
light
Frame
wiring
harness
J
16W705
NO. WIRE .
1 FGW FRAME WIRING k+ARNESS

2 FB FRAME WIRING HARNESS
3 2FB FRAfvc WIRING HARNESS
7 GW LICENSE PLATE LldHP ;=Bi
8. ..B LICENSE PLATE LIGHT <E>
8-126
COMPONENT SERVICE-WIRING HARNESS -+
II
BACK DOOR WIRING HARNESS - Vehicles with a rear wiper and washer.
Rear
wiper
Defogger motor
El 4
Rear washer
motor
5 6
1
i
El
wiring
harness ’
NO. WIRE T CIRCUIT
1 FGW FRAME WIRING HARNESS LICENSE PLATE LIGHT 

2 FB FRAME WIRING HARNESS LICENSE PLATE LIGHT <E>
3 2FB FRAME WIRING HARNESS DEFOGGER
4 FL FRAME WIRING HARNESS REAR WIPER MOTOR <ACC>
5 FBrW FRAME WIRING HARNESS REAR WIPER MOTOR <LO>
6 FBr FRAME WIRING HARNESS REAR WIPER MOTOR <AS>
7 GW LICENSE PLATE LIGHT El
8 B LICENSE PLATE LIGHT <E> 121
9 3.3WB FRAME WIRING HARNESS REAR WASHER MOTOR <->
IO 3.3L REAR WASHER MOTOR <+> 141
8-127
COMPONENT SERVICE- WIRING HARNESS
DOOR WIRING HARNESS - Vehicles with a rear power window

Left side
Power
window
motor Power window main switch
Front 4 1 -
wiring
harness 5 2 3
ww
16W753
CIRCUIT
FRONT WIRING HARNESS POWER WINDOW MAIN SWITCH 

FRONT til RING HARNESS POWER WINDOW MAIN SWITCH <E>
FRONTWIRING HARNESS POWER WINDOW MAIN SWITCH
FRONTWIRING HARNESS POWER WINDOW MAIN SWITCH (R.H.-UP)
FRONT WIRING HARNESS POWER WINDOW MAIN SWITCH (R.H.-DOWN)
POWkR WINDOW MAIN SWITCA POWER WINDOW MOTOR
POWER WINDOW MAIN SWITCH POWER WINDOW MOTOR
Gght sick
Power
window
: motor
:-
3
-r
.’ 5.
R 1
,q, ,“,Tb; (/ & , 3 ;‘y&e;dow

Front 2
wiring
harness 4 1
WbJ
16W752
NO. WIRE
1 2FR FRONT WIRING HARNESS

2 2FL FRONT WIRING HARNESS
3 2RB POWER WINDOW MOTOR
4 2FG FRONT WIRING HARNESS POWER WINDOW SUB SWITCH (DOWN)
5 2GB POWER WINDOW MOTOR POWER WINDOW SUB SWITCH (DOWN)
8-128
-+
COMPONENT SERVICE-WIRING HARNESS cl
AIR CONDITIONER WIRING HARNESS A
Blower switch
DEl
Therm0 Front
switch wiring
harness
Power
relay B
Fuse 16W751
NO. WIRE CIRCUIT
1 0.85WB BLOWER SWITCH AIR CONDITIONER SWITCH

2 0.85LB AIR CONDITIONER SWITCH THERM0 SWITCH
3 B AIR CONDITIONER SWITCH El
4 0.85GB THERM0 SWITCH POWER RELAY B
5 0.85L POWER RELAY B POWER RELAY A
6 0.85LW POWER RELAY B FRONT WIRING HARNESS <ACC>
7 0.85B POWER RELAY B FRONT WIRING HARNESS <E>
8 0.85BY POWER RELAY A FRONT WIRING HARNESS
9 0.85LR POWER RELAY A FUSE
10 0.85BW POWER RELAY A FRONT WIRING HARNESS
11 3LR FUSE FRONT WIRING HARNESS
12 I 1.85L FRONT WIRING HARNESS 191
8-129
COMPONENT SIERVICE- WIRING HARNESS
41R CONDITIONER WIRING HARNIESS B
Zi~js ~+CLI<-~ i iigre
16W666
CIRCUIT
LOW PRESSURE SWITCH

LOW PRESSURE SWITCH
AIR CONDITIONER WIRING HARNESS C
I 13] pJ
Idle-up
solenoid valve
as ‘)
3
12.
Diode
Front
16W750
wiring harness
NO. WIRE CIRCUIT

.
I
1 0.85BW FRONT WIRING HARNESS MAGNETIC CLUTCH
2 0.85BW IDLE-UP SOLENOID VALVE III
3 0.858 IDLE-UP SOLENOID VALVE DIODE
4 0.85BY WATER TEMPERATURE SWITCH FRONT WIRING HARNESS
5 0.85BW E.S.S. SOLENOID VALVE DIODE
6 0.85L E.S.S. SOLENOID VALVE FRONT WIRING HARNESS

7 0.85L . POWER RELAY C FRONT WIRING HARNESS
8 0.85GB POWER .RELAY C CONDENSER FAN MOTOR
9 0.85BW POWER. RELAY ,C El

10 0.858 POWER RELAY C GROUND
11 0.85GY CONDENSER FAN MOTOR I-TJ
0.85BW < FRONT WI RING HARNESS
12 DIODE
13 0.85BW DIODE
1 1
8-130
COMPONENT SERVICE-FUSES -+
cl
FUSIBLE LINKS 1 For California

---‘-I -
(can also be sold in
The fusible links consist of main link and sub link. Every Federal States) I
I .
circuit except the starter motor uses fusible links.
Main fusible link
Connected to the positive (+) terminal of the battery.
(/I-LGIJI 16K776 1I
Sub fusible link
The sub fusible link is secured with tape to the wiring harness
at the rear of the left front fender shield.
Inspection
Check for a burnt fusible link with a circuit tester, since visual
diagnosis may be difficult.
If a fusible link bums out, the cause is a short or some other
problem in the circuit. Carefully determine the cause and
correct it before replacing the fusible link.
When replacing fusible links, be sure to use a fusible link of
the specified capacity.
8-131
cl-+ COMPONENT SERVICE-FUSES
FUSE BLOCK
The fuse block is located on the left hand side of the instru-
ment panel.
Inspection
If any of the fuses are to be replaced, be. sure to use a fuse of
the specified capacity.
NOTE
If a fuse has failed, locate the cause and completely eliminate
the problem before installing a new fuse.
Fuse Capacity Table

--r
Power supply circuit -1pplicable circuits
Battery 1
Headlight relay 2 Tail lights, License plate lights, Illumination lights, Headlight washer
relay, Position lights
Ignition switch (IG) 3 Heater relay, Seat belt warning timer, Turn-signal lights, Alternator,
Seat belt switches, power window relay
lights, Fuel and water temperature gauges, indicator and

,waming lights, oil pressure gauge, voltage meter
Rear window defogger, Rear heater
Battery
switch, Stop lights, Buzzer, Seat belt switch (L.H.)

Door switch (L.H.)
Ignition switch (ACC) Windshield wipers and washer, Headlight washer relay, Intermittent
Rear window wiper and washer
Cigarette lighter, Radio, Tape player, Clock (ACC), Spare terminal
INDEPENDENT FUSE
An. independent fuse is provided behind the left-hand head-
light, for the high beam indicator light.
beam indicator
16W746
8-132
COMPONENT SERVICE-IGNITION SWITCH
COMPONENTS
Ignition switch
LOCK
16YO62
ON 0 A 0
START 0 A A 0
Key-reminder switch
Terminal
When the key is removed

When the key is inserted
16YE45
16YO62
1. Steering wheel lock cylinder

(key lock cylinder)
2. Ignition switch segment
3. Key-reminder switch segment
REPLACEMENT OF THE IGNITION SWITCH SEGMENT

1. Disconnect the negative cable from the terminal of the
battery.
2. Remove the column cover. (Refer to GROUP 19.)
3. Remove the band clip of the wiring harness, and then
disconnect the ignition switch harness connector and the
key-reminder switch harness connector.
4. Remove the ignition switch segment and key-reminder
switch mounting screws, and then pull the switch seg-
ment out of the key cylinder. (16W74 1)
cl-+ COMPONENT SERV)CE-IGNIITION SWITCH/METERS AND GAUGES
INSTALLATION
1. Secure the column switch harness and ign$ion switch
harness to the steering column with band chps-to make
sure that the harnesses are not caught in the boss or
moving portion of the column cover.
2. The ignition harness connector and the key-reminder
switch harness connector should be connected to the
front wiring harness together with the column switch
harness connector at the left side of steering support
’ bracket. (16W730)
METERS AND GAUGES

COMPONENTS
1. Speedometer cable
2. Buzzer
3. Printed-circuit board
4. Meter cover
5. Meter case
6. Meter glass
7. Meter hood
8. Speedometer
9. Fuel gauge, water temperature gauge
10. Tachometer .
11. Window plate
12. Combination meter pad
13. Voltage gauge
14. Inclinometer
15. Oil pressure gauge
16. Meter wiring harness
16W765
REMOVAL
1. Remove the meter cover.
8-134
COMPONENT SERVICE-METERS AND GAUGES
2. Remove the screws from the bottom of the case.

( 16W 740)
3. Remove the bolt from the upper part of the case.
(16W508)
4. Disconnect the speedometer cable from the meter case by

pushing the stopper of the plug on the speedometer cable
side of the connection. (16W744)
5. Disconnect the connectors of the meter harness and the
buzzer (located behind the meter case), and also of the
body harness.
. 6. Disconnect the connectors (all located behind the meter
case at the bottom) of the hazard switch, the rear window
defogger, and the rear wiper/washer switch, and then
remove the meter case.
INSTALLATION
When installing the instrument cluster, be sure to secure the
speedometer cable and connector positively.
SPEEDOMETER.
Replacement of the Speedometer Cable
1. Replace the cable assembly if there is a-malfunction.
2. When connecting the cable to the speedometer, insert the
cable until the stopper properly fits to the speedometer
groove. (16F554)
3. After installing the speedometer, pull the speedometer

cable through the grommet in the fire wall until the
cable marking is visible from the engine compartment
side.
4. Apply a drying sealant to the outside surface of the
grommet. (-16W540)
,5. Securely clamp the speedometer cable to the frame clip
at the marking (yellow) on the transmission side.
Caution
Disconnect install?tjon of the cable may cause the meter
indication to fluctuate, damage a harness, or produce noise.
/ / 16W540
COMPONENT SEFIVICE-METERS AND GAUGES
TACHOMETER
Inspection
Connect a tach-dwell meter, and then compare the meter
readings at various engine speeds,with the values indicated on
the tachometer. If there is a large error, replace the
tachometer.
rpm
Engine speed Tolerance
i,ooo * 100
2,000 + 100
‘3,000 f 150
4,000 ‘. f 200
5,000 f 250
Caution
The tachoineter is the negatik-ground type, and therefore
should not be connected in rev&k polarity to the battery. If
the tkhometer is connected in reverse polarity, the transistors
and diodes will be damaged.
FUEL GAUGE AND UNIT

Inspection
FUEL GAUGE INDICATION TEST
Disconnect the wiring connector from the fuel gauge unit
inside the luggage compartment. Connect a resistance be-
tween the terminals and confirm the gauge indications.
indication p&t Resistance value
Empty 120 !a
Full 17 a
FUEL GAUGE CONTINUITY TEST

Measure the resistance value between the terminals Iyith an
ohmmeter.
Resistance value . . . . . . . . . . . . . . . . . Approx. 25 52
,NOTE
‘If the resistance value is extremely small, there may be a
short in the coil. If it is extremely large, there may be a
broken wire or some .other problem in the coil. In either
case, replace ‘the gauge.
16W719 1
8-136
-+
COMPONENT SERVICE-METERS AND GAUGES cl
Replacement of the Fuel Gauge Unit

1. Remove the fuel gauge unit. (03W505)
Caution
Since the fuel gauge unit is mounted to the side of the tank,
drain the fuel first. The in-tank filter of the fuel gauge unit
should be handled carefully because there is the danger of the
filter coming out of position.
2. When installing the fuel gauge unit, be careful not to
bend the float arm.
3. After installation, confirm that the unit is securely
grounded.
Tightening torque
Fuel gauge unit . . . . . . . . . . . . . . . 1 Nm (0.7 ft.lbs.)
.WATER TEMPERATURE GAUGE AND UNIT

Inspection
wfmz TEMPERATURE GAUGE INDICATION TEST
1. Disconnect the wiring connector from the water tempera-
ture gauge unit inside the engine compartment.
2. Connect a resistance to the connector, and then confirm
the gauge indications.
Indication point Resistance value
(1) 115°C (239°F) 23.8 52

(2) 70°C (158°F) 104a
WATER TEMPERATURE GAUGE CONTINUITY TEST

Measure the resistance value between the terminals with an
ohmmeter.
Resistance value . . . . . . . . . . . . . . . . Approx. 55 s2
NOTE
If the resistance value is extremely small, there may be a
short in the coil; if it is extremely large, there may be a
broken wire or some other problem in the coil. In either case,
replace the gauge. 16W71t
WATER TEMPERATURE GAUGE UNIT OPERATION

CHECK
Measure the resistance with the gauge unit in hot water at
,7O”C (158°F).
Resistance value . . . . . . . . . . . . . . . . . . . . . . . 104 Q
Caution
The gauge unit should be held with its housing 3 mm (. 12 in.)
away from the surface of the hot water.
8-137
INCLINOMETER Center shaft of

pitching damper plate
Outline
The inclinometer is an instrument which indicates the
forward or backward inclination (pitching) or side to side
inclination (rolling) of vehicle.
Motion of a pendulum in the system is displayed on the
system. The pitching and rolling pointer is supported by a
double support mechanism in which the rolling fulcrum is
supported in such a way as to be rotatable around the case
and the pitching fulcrum supported on the rolling system.
Construction Zenter shaft of

,olling damper plate 16W 60C
The inclinometer consists of an outer case which inclines
with the vehicle, a pointer which is provided in an oil case’
and always maintains a level position, and a spherical dial.
The spherical dial is coupled through the dial support plate to
the rolling damper plate. The rolling damper plate is swivel
bearing coupled to a stationary frame by the center axis, so
it can incline side-to-side, but is always held in a llevel posi-
tion by a pendulum. The pointer is coupled with the pitching
damper plate.
Since the pitching damper plate is swivel bearing coupled to
the rolling damper plate by the center axis, it can incline
forward and backward, but is always maintained in a level
position by the pendulum. 68W500
6 7 8
-. 16W603
1. Outer case
2. Front panel
3. Spherical dial
4. Spherical dial horizontal centerline
5. Pointer
6. Dial support plate
7. Blind plate
8. Oil case
9. Pitching damper plate
10. Rolling damper plate
11. Stationary frame
12. Oil
13. Pendulum
8-138
Operation
Side to side inclination Forward or backward
The side-toside inclination angle should be read on a scale of angle’ inclination angle
the front panel as indicated by the horizontal centerline of
the spherical dial, whereas the forward or backward inclina-
tion angle should be read on a scale of the spherical dial as
indicated by the pointer. f&J ifi?JJ
Horizontal line Horizontal line
I 16W616
SIDE-TO-SIDE INCLINATION
The front panel inclines with the vehicle, but the spherical
dial maintains a horizontal condition, so the horizontal
centerline of the spherical dial shows the side-to-side inclina-
tion angle.
Inclined 15” to right
68WOOE
FORWARD OR BACKWARD INCLINATION

The spherical dial inclines forward or backward with the
vehicle, but the pointer maintains a level position, so the
pointer indicates the forward or backward inclination angle.
20” uphil
COMBINED FORWARD OR BACKWARD AND SIDE-

TO-SIDE INCLINATION
The forward or backward inclination angle and the side-to-
side inclination angle are indicated by the pointer and
spherical dial.
15” downhill
Inclined IO” to left
COMPONENT SERVICE-METERS AND GAUGiS
Removal
1. Remove the cqtibination nieter. (Refer to p. 8-134.)
2. Remove the pad. (16W781)
3. Remove the meter case attaching screws.
4. Disconnect the. connectors of the meter harness located
behind the meter case.
5. Remove the inclinometer from the meter case.
Caution
To prevent internal trouble, the meter must not be dropped
or subjected to shock or must not be abruptly inclined to the
extent that the maximum indication angle is exceeded.
16W76
Installation
Bubble coilming portion
1. Make sure that all water bubbles in the oil case are
collected in the upper bubble collecting portion before
installation. (16W780)
2. With the vehicle in a level p&on (unladen), check to
ensure that the spherical dial. and pointer indicate a level
position.
3. If the spherical dial and pointer do not indicate that the
vehicle is level, adjust the inclinometer by insefting shims
between it tid either the combination gauge bracket or
the instrument panel. If the pointer indication is very far
from horizontal, replace the inclinometer.
16W761
OIL PRESSURE GAUGE AND UNIT

Removal
1. Remove the combination meter.
2., Remove the pad.
3. Disconnect the oil pressure gauge from thk meter wiring
harness.
4. Remove the oil pressure gauge. td meter case attaching
screws.
Inspection
OIL PRESSURE GAUGE INDICATION TEST
Disconnect the wiring connector from the oil pressure gauge
unit inside the engine compaitment.
Connect a resistance to the connector, and then confirm
the gauge indications. (16W785, 16W597)
-
Indication point Resistance valuk
i (1) 588 kPa(85 psi) 12Oa ;
8-140
OIL PRESSURE GAUGE CONTINUITY TEST

Measure the resistance value between the terminals with an
ohmmeter.
NOTE
If the resistance value is extremely small, there may be a
short in the coil; if it is extremely large, there may be a
broken wire or some other problem in the coil.
VOLTAGE METER
Removal
1. Remove the combination meter.
2. Remove the pad.
3. Disconnect the voltage meter from the meter wiring
harness.
4. Remove the voltage meter to meter case attaching screws.
Inspection -
VOLTAGE METER CONTINUITY TEST
1. Connect an ohmmeter to the voltmeter. (16W779)
2. Contirm that the value indicated on the ohmmeter agrees I lBW779
with the standard value.
Resistance value . . . . . . . . . . . . . . . . . . . . . . . .42Oa
8-141
SEAT BELT WARNING SYSTEM

1. If the driver turns the ignition key to “ON” while his seat
belt is unbuckled, the seat belt warning system is acti- 0.3RB 3 2 0.3YB
vated to provide an audible and visual reminder through a
\ /
buzzer and light to fasten the seat belt properly.
2. The seat belt warning system consists of a belt switch,
buzzer, warning light, belt warning timer.
Seat Belt Warning Timer
\
0.38 4‘ 1 0.3RL
The timer operates when the ignition key is in the “ON”
position and terminals 2 and 3 are electrically connected to
terminal 4 (ground). (16W73 1)
16W73
Seat Belt Warning Light and Buzzer -

When the seat belt switch is ON (seat belts not buckled) with
the ignition key at the ON position, the seat belt warning
timer causes the seat belt warning light to illuminate and the
Ignition key
:zF
ON l
buzzer to sound for 4 to 8 seconds. If the seat belt switch is Seat belt switch
set to OFF (the seat belts buckled) during theseat belt wam- OFF l
4 to 8 set 4 to 8 set
ing timer interval, only the buzzer is cancelled. c
Seat belt ON ’ -
warning light I
I
OFF I -
4 to 8 set
I.
ON ’
Buzzer
OFF-. ~
16Y160!
Seat Belt Switch

CONTINUITY TEST
1. Pull back the floor mat and disconnect th.e seat belt
switch connector from where it is at the attachment to
the buckle stalk assembly.
2. Use an ohmmeter to check for a short circuit at the 0.3-Y
wire and the 0.3-RB wire of the, driver’s seat belt switch.
(16W732)
3. If the ohmmeter reads no resistance with the buckle
unlocked and indicates an open circuit when the buckle is
locked, the belt switch is operating properly.
4. If a microswitch is defective, the buckle stalk assembly l6W 732
containing microswitch should be replaced. For replace-
ment, see GROUP 23.
8-142
-+
COMPONENT SERVICE-METERS AND GAUGES cl
System Inspktion
Ignition
1. Disconnect the seat belt warning timer connector.
2. When the 0.3-YB wire (terminal 2) and 0.3-B wire (termi-
nal 4) are connected with a jumper wire, the seat belt
warning light should illuminate. If it fails to illuminate,
check the bulb, key-reminder switch and fuse. (16C953)
3. Also the buzzer should sound when the 0.3-RB wire
(terminal 3) and 0.3-B wire (terminal 4) are connected timer connector)
with a jumper wire. In this condition, fasten the buckle;
if the buzzer stops sounding, the seat belt switch is good.
(16C953)
4. If the buzzer does not sound when terminal 3 and termi-
nal 4 are connected with a jumper wire, and check con- L
16C95:
tinuity of the seat belt switch. If these is continuity in

the seat belt switch, replace the buzzer.
5. After performing the above inspections, connect the seat
belt warning timer.
6. With the ignition switch turned to IG, verify the function
of the seat belt warning system.
8-143
COMPONENT SERVICE-LIGHTING SYSTEM
.
COMPONENTS
Headlight
,
;. .,
: 3. Front combination light Rear combination light
1: .
16W720
16W62
Rear side marker light
Dome light
License plate light
l?
16W622 16w60:
HEADLIGHTS
1. The headlight system consists of two sealed-beam bulbs.
2. The bulbs are the dual filament type for low and high
beams and are marked by a number 2DI molded in the
lens.
3. The low beam is intended for use in congestgd areas and
on highways when oncoming vehicles are within a dis-
tance of 153 m (500 ft.).
4. The high beam is intended primarily for distant illumina-
tion and for use on the open highway when there are no
oncoming vehicles.
8-144
AIMING
Pre-aiming Instructions
1. Test dimmer switch operation.
2. Confirm operation of high beam indicator light moun-
ted in instrument cluster.
3. Inspect for badly rusted or faulty headlight assemblies.
These conditions must be corrected before a satisfactory
adjustment can be made.
4. Fill the fuel tank.
5. Position vehicle on a level floor.
6. Bounce the front of the vehicle up and down three
times by applying your body weight to the hood or
bumper.
7. Check tire inflation.
8. Rock vehicle sideways to allow it to assume its normal
position.
9. There. should be no other load in the vehicle except the
driver or substituted weight of approximately 70 kg
(150 lbs.) placed in driver’s seat.
10. Thoroughly clean headlight lenses.
11. Adjust headlights by following the instructions for the
headlight tester.
Removal
1. Remove the radiator grille, front combination light and
headlight bezel. (Refer to GROUP 23.)
2. Disconnect the harness connector from the bulb socket.
3. Remove the retaining ring from the mounting ring.
(16W559)
Caution
Do not disturb headlight adjusting screws.
4. Remove the headlight assembly.
16W555
LIGHT CONTROL RELAY

1. Check to ensure that when battery voltage is applied
between terminals 2 and 3 and between terminals 5 and
6 an operating sound (click) is heard. (F16077, 16W515)
2. In the above conditions, check to seeif the battery voltage
is applied to terminals 1 and 4. (F16077, 16W5 15)
4 3
24 6
5 2
6 1 F1607; 7
1 c5
1 G\A/Fi
S-145
LIGHTING SWITCH
Cancel cam
Automatic return (passing switch)
NOTE 16W734
R’ and L’ indicate lane-changing operation.
Headlight
Llghtmg Dimmer and Turn-signal Horn
Terminal ^^^^:^^ ^... :*^L. “...:+,b. washer
switch switch
switch
No. Wire Used for OFF 30 0; go ‘DI ‘Dz P L (L’) N’ R (R’) ,?FF ON OFF ON
I , I I
NOTE
The sizes for wires whose size is not specified in the “Wire” column above are 0.3 mm* for items in parentheses, and 0.5 mm2 for all others.
8-146
-+
COMPONENT SERVICE-LIGHTING SYSTEM cl
HAZARD WARNING SWITCH

Inspeciton
Move the switch to ON and OFF, and check the continuity
between the terminals.
8 d Column switch
9 0 Column switch
10 0 Front turn-signal light (R.H.)
11 0 Rear turn-signal light (R.H.)

TURN-SIGNAL AND HAZARD WARNING FLASHER To turn-signal switch

UNIT
To fusk (No. 3)
1wl558
~;:j ToLwarninQ
/
To fuse (No. 1)
8-147
COMPONENT SIERVICE-LIGHTING SYSTEM
Installation Front harness

. ground wire
1. Connect the black connector to the turn-signal flasher /
unit:( 16W747)
2. The ground wires for turn-signal flasher unit and front-
wiring harness should be tightened together. (I 6W747)
Turn-signal
flasher unit
nnector (2P)
DIMMER CONTROL SWITCH

Inspection
1. With the connector disconnected, measure the continuity
between the dimmer control switch terminals with an
ohmmeter. (F16599)
2. If the resistance value varies smoothly between 0 and 10
ohms throughout the entire operation range, .the dimmer
control switch is functioning properly. (F 16599)
I F16599
8-148
COMPONENT SERVICE-WINDSHIELD WIPERS AND WASHER
COMPONENTS
1. Wipers and washer switch assembly

2. Wiper blade
3. Wiper arm .
4. Wiper linkage
5. Wiper motor
6. Washer nozzle
7. Washer motor
8. Washer tank
9. Intermittent wiper relay
1 16W712
Nm ft.lbs.
A lo-16 7-12
B 7 5
C 3 2
3
i 16W570
WIPER MOTOR AND LINKAGE

Removal
1. Remove the wiper arms and the pivot shaft mounting
nuts, then push the pivot shafts toward the inside.
2. Loosen the wiper motor mounting bolts, and then-with
the motor pulled out slightly, disconnect the linkage and
the motor. (C16555)
3. Remove both the motor and the linkage.
Caution
Because the installation angle of the crank arm and the motor
has been set, do not separate them unless it is necessary to do
so. If they must be separated, do so only after marking the
mounting positions.
Installation
Install the wiper arms on the pivot shafts so that the stopping
position of the wiper blades is at the specified point.
(16Y1568)
Wiper blade stopping position (distance between

blade tip and front deck garnish) . . . . . . . . . . . . .
37-47 mm (1.5-1.9 in.)
16Y1561
cl-+ COMPONENT SEiRVlCE-WINDSHIELD WIPERS AhlD WASHER
WINDSHIELD WASHER mm (in.)
Inspection and Adjustment

Check the washer fluid spray pattern.
Adjust by moving the nozzle. / t (ii& _/= ci6.i)ll \
I
0 a
16Y156'
INTERMITTENT WIPER RELAY

Inspection
If the wipers do not stop in the correct position when the I
wiper switch is set to the star mark:
(1) Check whether the output of the voltage from. terminal
3 is synchronized with the operation of the wipers.
When the wipers are stopped: 12v

When the wipers are operating: ov
If the wipers do not operate intermittently when the wiper

switch is set to the star mark: I 16Y186I
(1) Perform the same check as described above. _ j
If the wipers do not operate when the wiper switch is set to
the star mark:
(1) Confirm that power is being supplied to terminals 1 and
4.
(2) Confirm that the voltage between ‘terminal 6 and ground j .
is 0 V.
(3) Confirm that the voltage between terminal 3 and ground -
is 0 V.
If the wipers do not operate when. the washer switch. is turned
.ON:
(1) Confirm that power is being supplied to terminals 1 and
4. ‘_
(2)‘Conlirm that the voltage between terminal 5 and ground
is 0 V while the washer switch is ON.
‘(3) Confirm that the voltage between terminal 3 and ground
is 1’2 V at the moment that the washer switch is .tumed
on, and that the voltage is 0 V approximately one second,
later. Also, confirm that the voltage is 0 V 2 to 5 seconds
after the washer switch is turned off.
S-150
COMPONENT SERVICE-WINDSHIELD WIPERS AND WASHER -+
cl
WINDSHIELD WIPER AND WASHER SWITCH ASSEM-

BLY (COLUMN SWITCH)
Inspection
Move the column switch to each position to check for conti-
nuity between terminals.
- SHORT 6)
LONG (L)
ON
Terminal Wiper/washer switch Intermittent time

adjusting switch
No. Wire Used for OFF INT LOW HI SHORT L LONG

c*> (1) (2) (S) (L)
1 YL Washer switch (ON)

??? ?.
I
2 LB Wiper switch (High speed) I I I I
I I I I
3 2B Ground by 60 a& 6 0
4 BY Wiper switch (Intermittent) A.

u
5 ‘BR Wiper switch (OFF)

? P
6 LO Wiper switch (Low speed) 0
7 0.3Y Intermittent time adjusting switch
Remarks
The dotted lines indicate that the automatic-return switch is ON.
8-151
cl-+ COMPONENT SERVICE-REAR WINDOW WIPER AND WASHER
COMPONENTS
1. Rear wiper and washer switch

2. Rear wiper blade
3. Rear wiper arm
4. Rear wiper motor
5. Rear washer tank lid
6. Rear washer tank
7. Rear washer motor
8. Joint
9. Rear washer nozzle
Nm ft.lbs.
A 7-l 0 5-7
0 8-12 6-9
C 7-10 5-7
REAR WIPER-MOTOR AND WIPER ARM

Removal. *.
1. Remove the spare wheel from the back door.
2. Remove ‘the wiper arm and remove the pivot shaft”lock-
ing nut.
3. Remove the back door trim and remove the waterproof
film. (Refer to GROUP 23.)
4. Remove the rear wiper motor mounting bolts: and remove
the rear wiper motor. (16W5 16)
16W51E
Installation
Adjust the mounting position of the wiper arm so that the
stopping position of the wiper blade agrees with the standard
value.
/
Wiper blade stopping position (distance between ’
blade tip and back door window weatherstrip ... .
20 mm (.8 in.)
8-152
-+
COMPONENT SERVICE-REAR WIltDOW WIPER AND WASHER cl
REAR WASHER TANK

Removal
1. Remove the right rear quarter trim.
2. Remove the rear washer tank mounting screws and then
remove the tank. (16W5 19)
REAR WASHER NOZZLE

Inspection and Adjustment
Check the washer fluid spray pattern.
Adjust the nozzle.
70 (2.8) +
I
1- 230 (g.”
I =-I\
mm (in.) 16W542
REAR WIPER AND WASHER SWITCH

Removal
Remove the switch from the instrument cluster and discon-
nect the con’nector.
,
Inspection .
operate the switch and check the continuity between the
temiinals.
Position
Wiper
Washer
16W620
8-153
COMPONENT SERVICE-HEADLIGHT WASHER
COMPONENTS
1. Headlight washer control relay

2. Headlight washer switch
3. Headlight washer motor
4. Headlight washer tank
5. Bracket
6. Main h&e
7. Clamp
8. Check valbe
9. Nozzle clamp
10. Headlight washer nozzle 16W712
HEADLIGHT WASHER TANK

‘Removal
Remove the headlight washer tank mounting bolts and
remove the tank.
8-154
COMPONENT SERVICE-HEADLIGHT WASHER
HEADLIGHT WASHER CONTROL RELAY

Continuity Test
1. Check for continuity between the terminals of the head-
light washer control relay with an ohmmeter. (Y 16696)
2. If the results obtained do not agree with the conditions
of continuity shown in the chart-below, replace the relay.
NOTE
Connect the test probe (+) to terminal 3. There should be no
continuity in the opposite direction; therefore, during inspec-
tion, pay attention to the direction of continuity when con-
necting the test probe.
HEADLIGHT WASHER NOZZLES

Removal
1. Remove the radiator grille and headlight bezels. (Refer to
GROUP 23.)
2. Remove the nozzle clamp and remove the washer nozzle
from the grille filler panel. (16W545)
16W54E
8-155
COMPONENT SERVICE-HORN
COMPONENTS ’
1. Horn (high pitch)

2. Horn (low pitch)
3. Center pad
4. Fixture
,5. Horn cable
. 6. Contact plate
7. Horn button
8. Contact cup
9. Horn spring
10. Pad
.’ ,
16W590
16D861
REMOVAL
‘1. Remove the radiator grille. (Refer to GROUP 2’3.)
2. Disconnect the horn connectors.
3. Remove the horn mounting bobs. (16W697) ”
INSPECTION
1. Check horn switch contact for burned-out or short-
circuited.
2. Check horn switch spring for broken or damaged.
3. Check horn switch hamess for damage.
4. Check horn adjustment screw for looseness.
5. Check the horn for water, dirt or other foreign matter
lodged.
8-156
COMPONENT SERVICE-HORN
HORN ADJUSTMENT
Secure the horn bracket in a vice, and then connect a battery
‘of the specified voltage (12 volts).
Sound the horn, and adjust it by turning the adjusting screw.
1. The sound volume is too low: Adjusting
Turn the adjusting screw in the “UP” direction within a
range of about 180”) and then lock it in position when a
satisfactory sound volume has been obtained.
2. The sound volume is too loud:
Turn the adjusting screw 20” to 30” in the “DOWN”
direction, and then lock it in positon when a satisfactory
sound volume has been obtained.
‘3. Horn will not sound: I 168744
Turn the adjusting screw slightly in the “UP” direction
until the horn sounds, find’a satisfactory sound volume
by continuing to turn the screw within a range of 180”,
and then lock the screw in place.
If a satisfactory volume cannot be obtained, replace the
horn.
Caution
After the adjustment, apply :lacquer to prevent the adjusting
screw from becoming loose.
8-157
COMPONENIT SERVICE-CLOCK
COMPONENTS
I 16VV543
REMOVAL
1. Remove the center console. (Refer to GROUP 23.)
2. Remove the mounting screws and disconnect the power
supply connector. (16W553)
TIME ADJUSTMENT
Adjust the clock as follows:
1. To adjust the hour, push button (1).
2. To adjust the minutes, push button (2).
3. To clear away the minutes display, push button (3).
Example of time adjustment
Before adjustment After adjustment
1O:Ol - lo:29 lo:oo

10:30 - 10:59 ll:oo
Caution
This clock is a delicate mechanism containing a crystal
oscillator, transistors, etc., and should be handled with
care. Specialized technical skill is needed to repair the inter-
nal mechanism; do not attempt to disassemble it. If the
clock itself is malfunctioning, replace the entire assembly.
When bake-finishing a paint coat, take care not to allow the
clock to be exposed to temperatures exceeding 60” C ( 140” F).
8-158
COMPONENT SERVICE-REAR WINDOW DEFOGGER
COMPONENTS
1. Rear window defogger switch

2. Rear window defogger glass
I 16W708
.PRINTED HEATER LINES

Normal characteristic curve
Inspection
Joltage
1. The printed heater lines should be tested while the engine
is running at 2,000 rpm and the battery is being charged.
2. Turn the defogger switch to the “ON” position, and use
A (Center point)
voltmeter to measure the voltage of each printed heater
line at the rear window glass center point “A”.
3. If all of the heater lines indicate approximately 6V, the
rear window printed heater lines are functioning properly.
4. If a vdltage of 12V is indicated at point “A”, the wire is
Positive Printed heater line Negative
broken between point “A” and the negative (-) terminal. terminal terminal
Move the test probe gradually toward the negative (-)
‘terminal and search for the place where there is a sudden
change in the voltage (to OV).
Abnormal characteristic curve
5. This place where the voltage suddenly changes indicates
the location of the broken wire.
Voltage
6. If OV is indicated at point “A”, the wire is broken
between point “A” and the positive (+) terminal. Find 2v
the point where there is a sudden change in the voltage
(to 12V), as described in step 4. above. 1 Open-circuit
I point
6V -
I
I
I
I I
ov ’
Positive Printed heater line Negative
terminal terminal
16Y33:
Repair
1. Prepare the following items:
I Alignment holes
l Conductive paint
l Paint thinner
l Masking tape, decal, etc.
l Unleaded gasoline
l Thin brush
Wipe the glass adjacent to the broken heater line, clean
with unleaded gasoline, and bond a decal or masking tape
as shown.
Masking tape 16F65t
8-159
cl-+ COMPONENT SERVICE-REAR WINDOW DEFOGGER
2. Shake the electroconductive paint container well, and

remove the amount of paint needed. Dilute it with a
small quantity of paint thinner, and apply three coats
with the brush at intervals of about 15 minutes.
3. Remove the tape or decal and leave the repaired defogger
unused for a while before supplying power.
4. For a better finish, scrape away excess deposits with a
knife after drying is complete (one day later).
Caution
After repair, clean the glass with a soft dry shop towel or
wipe along the printed heater line with a slightly moistened
shop towel.
REAR’ WINDOW DEFOGGER SWITCH

Removal
Remove the switch from the instrument cluster and push the
connector bar to detach the switch.
, .
Inspection
.Operate the switch and check continuity between the termi-
nals.
6 5
OFF o--@--o
ON
I 16W696
NOTE
* Denotes indicator light.
8-160
-+
COMPONENT SEWICE-RADIO AND STEREO cl
COMPONENTS
.’
1. Whip antenna ‘, .
2. Front speaker
3. Radio
4. Tape player
5. Rear speaker
16W7OQ
16W567
ANTENNA TRIMMER
The antenna trimmer is essential for matching the antenna
with the radio in order to obtain the maximum sensitivity of
the radio. It must be adjusted with the antenna actually
mounted on the vehicle. If the trimmer is not adjusted pro-
perly, the radio suffers from not only low sensitivity but also
noises, such as external noise and noise from passing
vehicles. In the following cases, therefore, adjust it as de-
scribed below:
(1) When radio is installed.
(2) If antenna is replaced.
(3) If radio has low sensitivity. -
\ ‘Y16B40
(4) If radio is noisy.
Trimmer Adjustment
Make the following preparations for adjustment.
(1) Turn the ignition key to the “ACC” position.
(2) Extend the antenna all the way.
(3) Tune accurately to a station near 1,400 kHz in order to
receive a broadcast in as weak an electric tield as can be
barely received. If there is no station near 1,400 kHz,
tune to any high-frequency station (above 1,000 kHz)
available. If there are two or more stations near 1,400
kHz, choose the stronger one.
(4) Set the volume control to the proper volume.
(5) Set the tone control to high-pitched tone.
'S-161
COMPONENT SERVICE-RADIO AND STEREO
Be sure that preparations 1 through 5 have been correctly

made.
Insert a screwdriver into the trimmer adjusting hole,
Turn the screwdriver clockwise or counterclockwise for maxi-
mum sensitivity (maximum broadcast wave sound).
If the optimum sensitivity point cannot be found, check for
an antenna malfunction or a broken wire.
NOISE SUPPRESSION
Noise interfering with radio reception may be roughly classi-
fied as follows:
(1) Noise produced by the vehicle itself
Noise from the ignition circuit, alternator circuit, etc.
(2) Noise generated in the radio itself
Thermal noise from transistors, IC, resistor, etc.
(3) Atmospheric noise
Noise from other cars, neon signs, etc.
The radio has devices to suppress noise of the radio itself and
atmospheric noise, but it is difficult to eliminate them
completely. Noise produced by the vehicle includes whining
from the alternator system, and a strong, impulsive, fast pop-
ping noise from the ignition.system.
Before .performing any checking or adjustments, tirs,t confirm
the following points.
l Adjust the antenna trimmer completely. ’
l Set the pushbuttons (tuning) properly. L
l Extend the antenna all the way. /
Prevention of Ignition Circuit Noise
A resistance-equipped cable is used for the high-tension- cable
in order to prevent noise; however, if any noise from the igni-
tion circuit does occur, check the tightness and ground con-
nection of the positive (+) terminal of the noise filter, and, if
necessary, check the noise filter.
Caution
Be careful not to connect the noise filter to the higlh-tension
cable; doing so could damage the noise filter.
Prevention 6f Other Circuit Noise
For other noises, take necessary corrective actions in actor-
dance with the following items and the NOISE SIJPPRES- .
SION CHART.
Polish the grounding cable terminal, and connect it properly.
Polish the pillar antenna ground terminal, and donnect it
properly.
Ground electric parts completely.
Keep the antenna cable and speaker lead wire away from
other electric wiring.
8-162
NOISE SUPPRESSION CHART
Symptom Noise source Remedy

Unusual noise related to Engine Securely ground the engine, frame and/or body and engine hood.
engine speed.
Engine
Ground wire
16E710
“Clatter” noise related to the Turn signals Connect a 0.5 PF noise-suppression capacitor to the B-terminal
flashing of turn signal lights. of the flasher unit.
-iuL
-
Flasher
unit
0.5pF
capacitor
noise suppression
16E712
Abnormal noise when the Horn 1. Connect a 0.5 /JF noise-suppression capacitor to the + B-
horn is operated. terminal of the horn.
2. For an FM radio, connect an LC filter to the horn terminals.
Horn LC filter
16E713
Noise when the windshield Washer motor Clonnect an LC filter between the terminal of the washer motor
washer operates. md the power source wire.
Q
16F671
Unusual noise when the Water temperature Connect a 0.1 I.IF noise-suppression capacitor to the terminal
engine is started. gauge unit If the water temperature gauge unit.
O.lpF noise suppression

capacitor
16F672
8-163
RADIO AND TAPE PLAYER

Removal
1. Remove the radio switch knobs, loosen the. mounting
nuts, and then detach the radio panel. ‘I
2. Remove the center console, loosen the mountmg screws
on the side of the radio, and then remove the radio.
(16W518)
3. Disconnect the antenna lead wire, the speaker connector,
and the power supply connector from the back of the
radio.
NOTE
The .fuse box for the radio circuits is located on the back of
the radio; -therefore, the radio must be removed ,in order to
replace a fuse. .’ .
1
FRONT SPEAKER ] _ _
Removal
1. Remove the speaker mounting screws. (16W520)
2. Remove the speaker from inside of the instrument panel.
3. Disconnect the speaker wiring connector. ’
REAR SPEAKER
Removal
..;
1. Remove the speaker mounting screws. (16W545)

2. Remove the speaker and,-- disconnect the speaker wiring
connector. .’
I
r
I .
ANTENNA
Removal
:‘1’-
. .
-. ,!. _. i
t.’ ;’
I 16W54E
1. Disconnect the antenna lead wire from the back of the

radio.
2. Remove antenna mast. (16EA96)
16EAS6
8-164
3. Remove splash shield mounting bolts and screws.

4. Detach splash shields from fender about a half of rearward.
5. Remove the antenna mounting nut. (16W709)
6. Remove the screw which mounts the antenna bracket to

the body from inside the fender. (168597)
7.. Remove the antenna toward the bottom.
16S591
8-165
COMPONENTS SERVICE-POWER WINDOW
COMPONENTS
1. Sub switch
2. Main switch
3. Power window motor
4. Power window regulator assembly 2
5. Power window relay
16W764
16W671
8-166
COMPONENTS SERVICE-POWER WINDOW -+
U’,
POWER WINDOW MOTOR
Removal
1. Detach the regulator assembly. (Refer to GROUP 23.)
2. Disconnect the power window motor from the regulator
assembly. ( 18Y4 15)
Caution
tVhen loosening the connecting screws of the regulator and
the motor assembly, the compressed force of the regulator
spring may cause the regulator arm to spring up.
lW145
Inspection
Connect the motor terminals directly to the battery and
check that the motor operates smoothly.
Next, reverse the polarity and check that the motor operates
smoothly in the reverse direction.
8-167
COMPONENTS SIERVICE-POWER WINDOW
POWER WINDOW SWITCH’

:
Inspection
MAIN SWITCH
Check for continuity in accordance with the folldlwing con-
nection table.
345 67
16K512
.
Switch
Power window switch (manual) UP 0
OFF. 0
DOWN
Lock switch ON (LOCK)
OFF (FREE)
SUB SWITCH
Check for continuity in accbrdance with the following con-
nection table.
DOWN
ISI l0K573
8-168
COMPONENTS SERVICE-POWER WINDOW/3-POINT ELR SEAT
BELTS WITH TENSION RELIEFERS
POWER WINDOW RELAY

Inspection
Check for continuity between the terminals with the power
ON and OFF.
While power is OFF

Between terminals 1 - 2 . . . . . . . no continuity
Between terminals 3 - 4 . . . , . . , . . . continuity
While power is ON
Between terminals 1 - 2 . . . . . . . . . . continuity
16Y717
3-POINT ELR SEAT BELTS WITH TENSION

RELIEFERS
SEAT BELT SWITCH
Inspection
1. Pull back the floor mat and disconnect the seat belt switch
connection from where it is at the attachment to the
buckle stalk assembly.
2. Use an ohmmeter to check the YB wire and the B wire
for breakage. (16W733)
3. If there is no continuity when the buckle is unlocked
and continuity when it is locked, the seat belt switch can
be assumed to be functioning properly.
4. If a microswitch is defective, the buckle stalk assembly
containing the microswitch should be replaced. For re-
placement. (Refer to GROUP 23.)
SOLENOID
Inspection
1. Lock the buckle and set the ignition key to “ON”.
2. Pull the seat belt out slightly from the retractor and allow
about 40 mm (1.5 in.) to be taken up.
3. Pull the seat belt out again and let go of it. If the retrac-
tor stops and there is slack in the seat belts, the solenoid
can be assumed to be funcitoning properly.
4. If the results of the above test are not satisfactory, in-
spect the seat belt switch. If no problem can be found,
replace the entire seat belt assembly in order to replace
the seat belt solenoid.
8-169

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ELECTRICAL

SPECIFICATIONS .............................................. 2 IGNITION COIL . . .. . . .. . . .. . . .. .. .. . . . . . . . . . . . . . . . . . . . . . . . . . 101

Engine with M/T Engine with A/T

Model No. M3T25882 M2T53083

Model No. T3T61971 T3T61972

Identification model No. E-089 .; .

Model No: NGK BPSES-11

Model No. A5T2 1077 A2T41377

Type NXlOO-S6 (S)-MF NX120-7-MF

Fusible links For Federal For California

Sub Ignition circuit Power window Headlight, headlight

Fuse capacity A 10 -15 . 20 -

Meters and Gauges

Oil pressure gauge

Indicator and Warning Lights W (ME trade numbers)

1. Upper-beam and passing indicator light 1.4 (74)

Sensor and Switches

Parking brake switch

Seat Belt Warning Timer

Rated load 3.4 W (light) and 24 TL” s2 (buzzer)

Operating voltage V 8.0-16.0

Rated voltage V 13.5

Main lights W (SAE trade numbers)

Sub lights W (SAE trade number)

Turn-signal flasher unit

Hazard warning flasher unit

Hazard warning switch

Light control relay

Dimmer control switch

Stop light switch ..

Windshield Wipers and Washer

Headlight washer motor

Type Flat type

Type Crystal oscillating type

Rated input W 120

Rear Window Defogger

Rear window defogger switch

Power window motor

Automatic reset type

3-Point ELR seat belts with tension reliefers .

Belt switches Normally open type

Meters and Gauges

Fuel gauge indication test

Water temperature gauge

Oil pressure gauge

Windshield Wipers and Washer

Rear Window Wiper and Washer 1

Fuel gauge unit 1 1 (0.7)

Windshield Wipers and Washer Nm (ft.lbs.)

Wiper pivot shaft mounting nut 7 (5)

Rear Window Wiper and Washer Nm (ft.lbs.)

Rear wiper pivot shaft mounting nut 8-12 (6-9)

Malfunction of the regulator, Malfunction of the regulator

Normal function of alternator Alternator is normal