ELECTRICAL SYSTEM

SECTION EL
When you read wiring diagrams:
Read GI section. "HOW TO READ WIRING DIAGRAMS" .
.
CONTENTS
HARNESS CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EL- 2
STANDARDIZED RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .EL- 3
POWER SUPPLY ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EL- 5
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .EL- 9
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . e1-17
STARTING SYSTEM . Starter ............................................ E 1-20
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E1-27
CHARGING SYSTEM . Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E1-28
COMBINATION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E 1-37
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E1-39
EXTERIOR LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E1-42
INTERIOR LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
METER AND GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARNING LAMPS AND CHIME . . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . .
WIPER AND WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HORN, CIGARETTE LIGHTER AND CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR WINDOW DEFOGGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUDIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOCATION OF ELECTRICAL UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HARNESS LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAM REFERENCE CHART

Engine control system ........ EF & EC SECTION

Ignition system . . . . . . . . . . . . EF & EC SECTION
Chickglow system . . . . . . . . . . EF & EC SECTION
Injection pump control syrtem . . . E F & EC SECTION
AIT control system . . . . . . . . . . . . . AT SECTION
Power window and p w w door lock . . . . BF SECTION
Heater m d air conditioner . . . . . . . . . HA SECTION
. . . . . . . . . . . . . . BF SECTION
E l c t r i i l run roof
Electricalwinch . . . . . . . . . . . . . . . SE SECTION
 HARNESS CONNECTOR

Description
HARNESS CONNECTOR
a All harness connectors prevent accidental looseness or disconnection.
The connector can be disconnected by pushing or lifting the locking section.
CAUTION:
Do not pull the harness when disconnecting the connector.

[Example]

,a
UFT

PUSH

PUSH
(For combimtion motor) 6krmbt)
- -- -
-
- - -
-
 STANDARDIZED RELAY -
--~- -- -

Normal Open, Normal Closed and

Mixed Type Relays

- -
Relays can mainly be divided into three types: normal open,
normal closed and mixed type relays.

NORMAL OPEN RELAY NORMAL CLOSED RELAY MIXED TYPE RELAY

- -
Flows Flows

LL
LL
0
C

3,
SMTl BAlTERY SWl BATTERY SW1 BAITERY

Flows
Does not
T

SW1 BAITERY SWI BATTERY SWI BATTERY

Type of Standardized Relays

1M .......... 1 Make 2M .......... 2 Make
IT .......... 1 Transfer 1M.lB .......... 1 Make 1 Break
 STANDARDIZED RELAY
--- --
POWER SUPPLY ROUTING

Fuse
a. If fuse is blown, be sure to eliminate cause of problem before
installing new fuse.
b. Use fuse of specified rating. Never use fuse of more than
specified rating.
c. Do not install fuse in oblique direction; always insert it into
fuse holder properly.
d. Remove fuse for clock if vehicle is not used for a long period
of time.

Fusible Link
A melted fusible link can be detected either by visual inspection
or by feeling with finger tip. If i t s condition is questionable, use
circuit tester or test lamp.
CAUTION:
a. If fusible link should melt, it is possible that critical circuit
(power supply or large current carrying circuit) is shorted. In
such a case, carefully check and eliminate cause of problem.
b. Never wrap periphery of fusible link with vinyl tape. Extreme
care should be taken with this link to ensure'that it does not
come into contact with any other wiring harness or vinyl or
rubber parts.
IGNITION SWITCH

IGN ACC BLOW

~udto~CIook
9 I o w r LOW
I

l n h l b l l ~ 1 m 1 v Wmedml)
Auta-abamk.I.C.D.0. ne1mnold
WT
Warnlno IUC, a o n ~ r o lu n l t
Rear de+Ioser
Warnlnr luom,Yltar 4 &uoe
eaok-ur IUP
Pow* vtfldll) p a l w
Hazmrl wbrnlnm
n8.1 I.Y L.n.
AA centPo8 u n l t
Hand 1- R.Y.

ClaarmCtb IImhIor
roar WI-r -her
Rear u l o e r L u**hrr
Wlnoh
BODY GROUND Rear WE

Fog t M P
s t o p I*
Her*
AudlO,CI~Oh, lnt9PlOP I W m
H a z b r l w.ralna
II ~u*tmmslm.ct.ar.nm
F09 ~UBI

* Wagon and Hard too model

(ME).A/Tm o d e l f o r G u t f s t a n d a r d ( M i d d l e E a s t )
(EX) E x c e p t A/T m o d e l f o r G u l f s t a n d a r d ( M 1 d d l e East)

(L L . H . d r i v e m o d e l
BATTERY
 I G N I T I O N SWITCH

IGN ACC BLOW

RELAY RELAY RELAY

AudIo,EIeok
O l a o r rotor
I~J*UtlOfp #ulp o o u l ~ o u
l nit
69.1 O u t aol.nold
BlW m.LI*OI W l t
*Arnlno 1-
Raw d o l l s o a r
V I r n l n m I-., Motor A aauob
0.OhYD 8 . U
P W O ~ w t n 8 w PSIW

H m n r d wornln@
Yoad 1-• L.H.

Hard Immo R.H.

C l m 8 ~ m I I mI l#htnr
W o n t wlawor 4 workor
R o w WIPCF L r h . h o r
Wln&
RSU m
Foe Inmr
FUSIBLE L I N K SIOP 1 . y
HOLDER norm

hudlo. Clnck. I n t u I e r I...

H a r a r l warnlne
II I u m l n a t l o n . c I ~ ~ r o n o ~
Pea 1 ~ 1 . 0

*nWmOon and Hmrd t o p model

(L L . H . d r i v e model
 POWER SUPPLY ROUTING

Note:
 BATTERY

CAUTION:
a. If it becomes necessary t o start the engine with a booster
battery and jumper cables, use a 12-volt booster battery.
b. After connecting battery cables, ensure that they are tightly
clamped t o battery terminals for good contact.
c. Never add distilled water through the hole used t o check
specific gravity.

How to Handle Battery

METHODS O F PREVENTING OVER-DISCHARGE
The following precautions must be taken t o prevent over-dis-
charging a battery.
The battery surface (particularly its top) should always be
kept clean and dry.
I f the top surface of a battery is wet with electrolyte or
water, leakage current will cause the battery t o discharge.
Always keep the battery clean and dry.

When the vehicle is n o t going t o be used over a long period

o f time, disconnect the negative battery terminal. (If the
vehicle has an extended storage switch, turn it off.)

Check the charge condition o f the battery.

Periodically check the specific gravity o f the electrolyte.
Keep a close check on charge condition t o prevent over-
discharge.
0- - - - --=

How t o Handle Battery (Cont'd)

CHECKING ELECTROLYTE LEVEL
WARNING:
Do not allow battery fluid t o come in contact with skin, eyes,
fabrics, or painted surfaces. After touching a battery, d o not
touch or rub your eyes until you have thoroughly washed your
hands. I f the acid contacts the eyes, skin or clothing, immediate
l y flush with water for 15 minutes and seek medical attention.
Normally the battery does not require additional water. How-
ever, when the battery is used under severe conditions, adding
distilled water may be necessary during the battery life.

Remove the cell plug using a suitable tool.

Add distilled water up t o the MAX level.

SULPHATION
----- When a battery has been left unattended for a long period of
Charging voltage time and has a specific gravity of less than 1.100, it will be com-
pletely discharged, resulting in sulphation on the cell plates.
Compared with a battery discharged under normal conditions,
the current flow in a "sulphated" battery is not as smooth
Charging current
although its voltage is high during the initial stage of charging,
as shown in the figure at the left.
-
Duration of charge SE L709E

SPECIFIC GRAVITY CHECK

1. Read hydrometer and thermometer indications at eye level.
 BATTERY
How to Handle Battery (Cont'd)
a When electrolyte level is t o o low, tilt battery case t o raise it
for easy measurement.

Therrnorneter

2. Convert i n t o specific gravity at 20°C (68" F).

Example:
a When electrolyte temperature is 35°C (95°F) and specific
gravity o f electrolyte is 1.230, converted specific gravity at
20" 0 (68" F ) is 1.240.
a When electrolyte temperature is 0°C (32°F) and specific
gravity o f electrolyte is 1.210, converted specific gravity a t
20" 6 (68" F ) is 1.196.

- - - . - - - -. ..
Converted specific gravity (S20)
. .

1.30
--
V, 1.28

1.26
t

--E,
m
1.24

1.22
-
>
g 1.20
-
0

m
>
- 1.18

r 1.16
t
-
=
1.14

g 1.12
V)

1.10

-30 -20 -10 0 10 20 #) 4O 80

(-22) (-4) (14) (32) 1501 (681 ((16) (1011 (122)
Electrolyte temperature O C (OF)

SE LO420
 BATTERY

Battery Test and Charging Chart

VISUAL INSPECTION
Check banery case for cracks or bends.
Check battery terminals for damage.
If the difference between the max. and min. electrolytelevel in cells is within 10 m m (0.39 in),
it is O.K.

1
O.K. I
4
Replace battery.

Refer to "Specific Gravity Check".

t
+
SLOW CHARGE
CAPACITY TEST
Refer t o "A: Slow
STANDARD CHARGE Refer t o "Chart 11".
Charge".
Refer t o "B. Standard Refar PD "C:(lulck
J

4
t
Refer t o "Chart 11". Ready for use
CAPACITY TEST
Mount banery again
Refer t o "Chart 11".
and check loose ter-
minals. Also, check
O.K. 1 N.G.
1
other related circuits.
I
Ready Replace
for use banery.
4
CHECKING SPECIFIC GRAVITY
1 Refer t o "Specific Gravity Check". I Refer t o "C: Quick

RECHARGE
Refer t o "C: Quick Charge". Refer t o "Chart 11".
~f w a r y tompraturm rises & o v a 60°C
(1400 F), stop charping. Always chrg. o.K.~ ~N.G.
briery whmn its tunciemturr is b l o w
60.c ~ ~ w F I . Ready Replace
for use battery.

CAPACITY TEST
Refer t o "Chart II ".

Ready Replace
for use battery.

'STANDARD CHARGE" is r-rnmondd in -that tho M i d o & in norm &wing.

 Battery Test and Charging Chart (Cont'd)

Check battery type and

Q CAPACITY TEST
determine the specified
current using the following
table.

Fig. 1 DISCHARGING CURRENT

(Load tester)

I Test using load tester.

I TY~e
28619R(L)
Current (A)
90
34B19R(L) 99
46B24R(L) 135
Follow manufacturer's Read load tester voltage
when specified discharging 55B24R(L) 135
instructions to check and
determine if battery is current {Refer to Fig. 1) 50D23R(LI 150
serviceable. flows through battery for 55D23R(L) 180
15 seconds. 65D26R(LI 195
80D26R(L) 195
75D31R(L) 210
Ready for use Go to next step.
95D31R(L) 240
95E41R(L) 300
130E41R(L1 330

Redy for Go t o next step.

 BATTERY
Battery Test and Charging Chart (Cont'd)

I A: SLOW CHARGE I Fig. 2 I N I T I A L CHARGING CURRENT SETTING (Slow charoel

I Determine initial charging current from

specific gravity referring t o Fig. 2.
I
Charge battery. Check battery type and determine the specified current using tho
Check charging voltage 30 minutes after table shown above.
starting the battery charge. Aftar starting charging, adjustment of charging current is not
-.

12 t o 15 volts Below 12 volts or above

I Fig. 3 ADDITIONAL CHARGE (Slow charge)

12 hours. A h -
Charge for 5 hours.
at initial charging
current setting.
II Charge for 4 hours
at i n ~ t i acharging
l
current setting.
I Charge for 2 hours
at initial charging
current setting.

CHECKING SPECIFIC GRAVITY

Refer to "Specific Gravity Check".
+
Go t o "CAPACITY TEST".

CAUTION:
Conduct additional charge as per a. Set charging current t o value specified in Fig.
Fig 3. if necessary.
2. I f charger is not capable o f producing speci-
fied current value, set its charging current as
close t o that value as possible.
b. Keep battery away from open flame while it is
being charged.
c. When connecting charger, connect leads first,
then turn o n charger. D o not turn on charger
first, as this may cause a spark.
d. If battery temperature rises above 60°C
(140°F). stop charging. Always charge battery
when its temperature is below 60°C (140"F).
- B: STANDARD CHARGE

Determine initial charging curient from

specific gravity, referring t o Fig. 4.

( Charge battery for 8 hours.

. .-
I
I
BATTERY
Battery Test and Charging Chart (Cont'd)

Fig. 4 I N I T I A L CHARGING CURRENT SETTING

(Standard charge)
-

Check battery type and determine the specified current using the table

CHECKING SPECIFIC GRAVITY

Refer t o "Specific Gravity Check".
I shown above.
After starting charging, adjustment of charging current is not necessary.

I Conduct additional charge as per

Fig. 5, if necessary. 1
Fig. 5 ADDITIONAL CHARGE (Standard charge)

Go t o "CAPACITY TEST ".

I I II
Charge for 3.5 hours Charge for 2.5 hours Charge for 1.5 hours
at initial charging at initial charging at initial charging
current setting. current setting. current setting.

1 GO t o "CAPACITY TEST".

CAUTION:
a. Do not use standard charge method o n a battery whose specific gravity i s less than 1.100.
b. Set charging current t o value specified i n Fig. 4. I f charger is not capable o f producing specified current
value, set its charging current as close t o that value as possible.
c. Keep battery away from open flame while it is being charged.
d. When connecting charger, connect leads first, then turn on charger. Do not turn on charger first, as this
may cause a spark.
e. I f battery temperature rises above 60°C (140" F), stop charging. Always charge battery when its tempera-
ture is below 60°C (140" F).
 Battery Test and Charging Chart (Cont'd)

I C: QUICK CHARGE I Fig. 6 I N I T I A L CHARGING CURRENT S E l T l N G AND

CHARGING TIME (Quick charge)

Determine initial charging current setting and

charging time from specific gravity, referring
t o Fig. 6.

+
Go t o "CAPACITY TEST"
Check battery type and determine the specified current using the table
shown above.
After starting charging, adjustment of charging current is not necessary.

CAUTION:
a. Do n o t use quick charge method on a battery whose specific gravity is less than 1.100.
b. Set initial charging current t o value specified i n Fig. 6. If charger is not capable of producing specifid
current value, set its charging current as close t o that value as possible.
c. Keep battery away from open flame while it is being charged.
d. When connecting charger, connect leads first, then turn on charger. Do not turn on charger first, as this
may cause a spark.
e. Be careful o f a rise in battery temperature because a large current flow i s required during quick-charge
operation.
If battery temperature rises above 60°C (140" F), stop charging. Always charge battery when its tem-
perature is below 60°C (140" F).
f. Do not exceed the charging time specified in Fig. 6, because charging battery over the charging time can
cause deterioration o f the battery.

Service Data and Specifications (S. D. S.)

Except Australia
Applied area All Middle East All
and Middle East

Diesel engine
Gasoline engine model
model
Applied model Optional for side
Standard Option facing rear seat Standard
model

Type 48D26L 55D23L 80D26L 95031 L

Capacity V-AH 12-50 1280 1285 1280

 STARTING SYSTEM

Wiring Diagram
GASOLINE ENGINE MODEL
A/T model

IGNITION SWITCH INHIBITOR RELAY

ON o r S T A R T

IGNITION S W I T C H

I1
I
I
,(Eng I ne 8 Transrnl ss i on harness)

(L L.H. drlve model

(R R . H . dr lve model

BATTERY
SEL851 K

M/T model

IGNITION S W I T C H
6
ndm

Wt n harness)

(Eng i ne 8 Transm~ss i on harness)

f
b o

SELSWK
 STARTING SYSTEM:- -= - - -
--

Wiring Diagram (Cont'd)

DIESEL ENGINE MODEL

STARTER RELAY

I G N I T I O N SWITCH
0

rww--[13 -W w Ovhin harness) @ @

@ L I N K HOLDER

BODY 5 (Eng i ne & Transrn i s s i on harness)

GROUND

BATTERY
STARTER MOTOR SEL853K
 lgnltion switch
Clutch interlock switch or Inhibitor

return spring for fatigue and pinion

for sliding condition.

Chacklum Problem or
ConWtiwIctkn'

Starter motor does not If my obnotmdity h b n d . lnwndktrty

dicoo- bttw W W t h trm-1.
- -- - -
STARTING SYSTEM -Starter-

Construction
 STARTING SYSTEM -Starter-
Construction (Cont'd)
S13-118
STARTING SYSTEM -Starter-

Magnetic Switch Check

Before starting to check, disconnect battery ground cable.
Disconnect "M" terminal of starter motor.
1. Continuity test (between "S" terminal and switch body).
No continuity ... Replace.

2. Continuity test (between "S" terminal and "M" terminal).

No continuity ... Replace.
STARTING SYSTEM -Starter- -

Pinion/Clutch Check
1. Check to see if pinion locks in one direction and rotates
smoothly in the opposite direction.
If it does not lock (or locks) in either direction or unusual
resistance is evident ... Replace.

2. Check pinion movement.

If it is hard to move, apply grease or, if necessary, replace.

3. Check ball bearing.

Spin outer race of ball bearing to ensure that it turns smooth-
ly without binding.
Abnormal resistance ... Replace.
4. Inspect pinion teeth.
Replace pinion if teeth are worn or damaged. (Also check
condition of ring gear teeth.)
5. lnspect reduction gear teeth.
Replace reduction gear if teeth are worn or damaged. (Also
check condition of armature shaft gear teeth.)
Brush Check
BRUSH
Check wear of brush.
Wear limit length:
Refer to "Service Data and Specifications."
a Excessivewear ... Replace.

BRUSH HOLDER
1. Perform insulation test between brush holder (positive side)
and its base (negativeside).
Continuity exists ... Replace.
2. Check brush to see if it moves smoothly.
a If brush holder is bent, replace it; if sliding surface is
dirty, clean.
STARTING SYSTEM -Starter-

Field Coil Check

1. Continuity test (between field coil positive terminal and
positive brushes).
No continuity ... Replace field coil.

2. Insulation test (between field coil positive terminal and

yoke).
Continuity exists ... Replace field coil.

Armature Check
1. Continuity test (between two segments side by side).
No continuity ... Replace.

2. lnsulation test (between each commutator and shaft).

Continuity exists ... Replace.

3. Check commutator surface.

Rough ... Sand lightly with No. 500 - 600 sandpaper.
STARTING SYSTEM -Starter-
Armature Check (Cont'd)
4. Check diameter of commutator.
Commutator minimum diameter:
Refer to ""SewiceData and Specifications."
Less than specified value ... Replace.

5. Check depth of insulating mold from commutator surface.

Less than 0.2 mm (0.008 in) ... Undercut to 0.5 - 0.8 mm
(0.020 - 0.031 in)

Assembly
Carefully observe the following instructions.
HIGH TEMPERATURE GREASE POINT
Frictional surface of pinion
Moving portion of shift lever
Plunger of magnetic switch

PIN ION PROTRUSION LENGTH ADJUSTMENT

Measure movement "9" in height of pinion when pinion is
pushed out with magnetic switch energized and when pinion is
pulled out by hand until it touches stopper.
Movement "P":
Refer to "Service Data and Specifications."
 STARTING SYSTEM -Starter-
Assembly (Cont'd)
1 Not in the specified value ... Adjust by adjusting plate.

Service Data and Specifications (S. D. S.)

TYpe
S174471
I 5114472

Reduction gear type

I S13-118

Applied model h & o I i i n m errpine opbio~!teP H i m wlgtm Diesel engine

System voltage V 12

No-load
Terminal voltage V 11.O

Curnnt
Revolution rpm More than 3.900

Outer diameter of commutator

More than 29.0 (1.142) More than 35.5 (1398)
rnm (in)

Minimum length of brush mm (in) 1f a (0,4331 9.0 (0.354)

Brush spring tension N (kg. Ib) 15.7 - 19.6 (1.6 - 2.0.3.5 -4.4) -
26.5 32.4 (2.7 - 3.3.6.0 - 7.3)
Clearance of bearing metal and
armature shaft mm (in)
hor rhsn 0.2 40-1 -
- -
Movement "Q" in height of pinion
assembly mm (in)
0.3 - 1.5 (0.012 - 0.059)
 CHARGING SYSTEM

Wiring Diagram
GASOLINE ENGINE MODEL

AUTO-CHOKE

0 . m model
@ :U/T model
a : F o r A u s t r a l la
FUSE BLOCK

model
a ~ x c e p tf o r
I N A T I O N METER
A u s t r a l l a model

ALTERNATOR

DIESEL ENGINE MODEL

I G N I T I O N SWITCH
ON o r START
FUSIBLE L I N K

COMBINATION METER

CONDENSER

BODY
GROUND SEL855K
 CHARGING SYSTEM -Alternator-

Construction

I to32 om,2.3 2.B) -

m3~.m
w.o-a.O,m-4w
( 0 3 2 - 0.40.23 - 2.9)

( 0 3 2 - 0.40.23 - 2.9)
: N.m (kg-m, ft-lb) SEL583A
A

;'
Replace with a new one.
/
I

-
II
I

I
I I.C. voltage regulator

I
II
1, v
/I
:I

Oil seals
Check oil seal for wear. cracks or deformation.
Raplace if mcrmry.
D o not rwso oil sual onox removed. : N.m (kg-m, ft-lb) SELZ24D
 -.- -- - CHARGING SYSTEM -Alternator- .. -

Construction (Cont'd)
LR 150428E
- - --. -

Slip ring dia.: more than 30.6 (1.205)

-
(4.0 LO, 28 43)
I.C. voltage regulator
- *Refar to BR M i o n
tor m u u m pump
u ~ l wintormotion.
I

I
!
- -
(0.32 0 . 4 4 2 3 2.8)

I
vmuum pump* 4.3.6.1)
1
Unit: mrn (in)
: N.m (kern, h-ib) S E L ~ ~ ~ D
 CHARGING SYSTEM -Alternator-
-

Before conducting an alternator test, make sure that the battery i s fully charged. A 30-volt voltmeter and
suitable test probes are necessary for the test. The alternator can be checked easily by referring to the
Inspection Table.
Before starting troubleshooting, inspect the fusible link.

WITH
0
IC REGULATOR

Ignition
switch "ON"
(Check light
fw o ~ m i o n )
With alternator side L terminal
grounded, internal short occurs
when +diode is short-circuited.

connector (S,
L) and ground
L lead wire
(Check light
---------------------
Connect con-
n
Burnsd-wt
bulb. Replace
and P r o d
t o "A"

-
nector (S, L)
for operation) and ground F
Engim idling - .
terminal <~i~ht OFF^-{-^
(Checkmt --r:
(Check light
for operation1
for opsntbnb

Dim light
Light flickers
Bright light

Contact positive lead (+) of voltmeter on B

terminal and negative lead (-1 t o L terminal.

Engine idling
(Measure the
voltage across
"B" and "L" than 0 . 5 9 --- v]
1) Use fully charged battery
2) Light : Charge warning light terminal volt-
A.C.G. : Alternator parts e x a p t IC regulator
lC-RG : IC regulator Make sure "S"
0.K. : IC-alternator is i n good condition
3) When reaching "Damaged A.C.G.", remove
alternator from vehide and disassemble, inspect
and correct or replace faulty parts
4) Method of grounding F terminal

Gasoline engine model Diesel engine model

Contact t i p of wire with brush and attach Remove vacuum and connect tip
w i n t o alternator body. of wire with brush and attach wire to

Brush l i f t wire

5) Terminals "S", "L", "BAT" and "E" mrk.d SEL63iBC

on rear cover of alternator.
 CHARGING SYSTEM -Alternator-

Disassembly
ROTOR SLIP RING CHECK
1. Continuity test
No continuity ... Replace rotor.

2. Insulator test
Continuity exists ... Replace rotor.
3. Check slip ring for wear.
Slip ring minimum outer diameter:
Refer t o "Service Data and Specifications."

BRUSH CHECK
1. Check smooth movement of brush.
Not smooth ... Check brush holder and clean.
2. Check brush for wear.
Replace brush if it is worn down to the limit line.

3. Check brush lead wire for damage.

2 mm (0.08 in)
Damaged ... Replace.
4. Check brush spring pressure.
Measure brush spring pressure with brush projected approxi-
mately 2 mm (0.08 in) from brush holder.
Spring pressure:
Refer t o "Service Data and Specifications."
Not within the specified values ... Replace.
E €049

STATOR CHECK
To test the stator or diode, you must separate them by un-
soldering the connecting wires.
CAUTION:
Use only as much heat as required t o melt solder.
Diodes will be damaged by excessive heat.
CHARGING SYSTEM -Alternator- - - - -
- - -

Disassembly (Cont'd)
1. Continuity test
N o continuity ... Replace stator.

2. Ground test
Continuity exists ... Replace stator.
 CHARGING SYSTEM -Alternator- --

Diode Check

MAIN DIODES
Use an ohmmeter to check condition of diodes as indicated in chart below.
If any of the test results are not satisfactory, replace diode assembly.

Ohmmeter probes
Continuity
Positive @ Negative @

Positive diode plate Diode terminals Yes

Diodes check (Positive side)
Diode terminals Positive diode plate No

Negative diode plate Diode terminals No

Diodes check (Negative side)
Diode terminals Negative diode plate Yes
- . --. .--

hSitb6 side Negative side

Ohmmatar r-\

SUB-DIODES
Attach ohmmeter's probe to each end of diode to check for
continuity.
...
Continuity is N.G. Replace diode-assembly.
 CHARGING SYSTEM -Alternator- -

Assembly
Carefully observe the following instructions.
When soldering each stator coil lead wire to diode assembly
terminal, carry out the operation as fast as possible.

WHEN SOLDERING BRUSH LEAD WIRE

(1) Position brush so that it extends 10.5 to 11-5 mm (0.413 to
0.453 in) from brush holder.

SEL595A

(2) Coil lead wire 1.5 times around terminal groove. Solder out-
side of terminal.
When soldering, be careful not to let solder adhere t o insulating
tube as it will weaken the tube and cause it to break.

pl6m Inwlating t u b

Quantity of protrusion: RING FITTING IN REAR BEARING

Fix ring at the position
of minimum protrusion.
Fit ring into groove in rear bearing so that it is as close to
the adjacent area as possible.

SE L633D
- . - - -. --
 CHARGING SYSTEM -Alternator-
-

Assembly (Cont'd)
REAR COVER INSTALLATION
(1) Before installing front cover with pulley and rotor with rear
cover, push brush up with fingers and retain brush, by in-
serting brush lift into brush' lift hole from outside.
Brush lift wire
After installing, remove wire for brush lift.
(2)After installing front and rear sides of alternator, pull brush
liftby pushing toward center.
Do not pull brush lift by pushing toward outside of cover as it
will damage slip ring sliding surface.
- Diesel engine model
Use serration cap (Attach vinyl ta

SEL642C

bush lift wire

 CHARGING SYSTEM -Alternator-
- -

Service Data and Specifications (S. D. S.)

ALTERNATOR
Type LR150-218 LR160-165 LR160437 LR 150428E LR160426E

Diesel engine
Optional for
Applied model Gasoline engine
gasoline engine Optional for
Australia Except Australia
except Australia

Nominal rating VA 1260 12-60 12-50 12-60

Ground polarity Negative

Minimum revolution under no-load

Less than 1,000 Less than 900 Less than 1,000
(When 14 volts is applied) rpm

More than More than More than More than

More than 2611,300 2611,300 1611.300 2611,300
4012,500 More than More than More than More than
Hot output current Alr prn
More than 5212,500 5012,500 4212,500 5012.500
5015,000 More than More than More than More than
6015,000 5815,000 5015,000 5815,000

Regulated output voltage V 14.1 - 14.7 14.4 - 15.0

Minimum length of brush mrn (in) 6.0 (0236)

1.569 - 3.334 2.501 -3.383 1-569 - 3.334

2.305 - 3.383
Brush spring pressure N (g, 02) (160 - 340, (255 - 345, (160 - 340,
(235 - 345.8.29 - 12.17)
5.64 - 1199) 8.99 - 12.17) 5.64 - 11.99)

Slip ring outer diameter mm (in) 30.6 (1.205) 33.6 (1.323) 30.6 (1205) 33.6 (1.323)
 COMBINATION SWITCH

Check

-LIGHT
TURN WIPER
&

L.H. drive
L.H. drive R.H. drive

Light and Turn

WIPER SWITCH
Without intermittent With intermittent
LIGHTING SWITCH wiper wiper

INTERMITTENT
WIPER VOLUME

T U R N SIGNAL
SWITCH
-
HORN SWITCH
COMBINATION SWITCH

Replacement
Lighting switch and wiper & washer switch can be replaced
without removing combination switch hose.

To remove combination switch base, remove base attaching

screw and turn after pushing on it.
 HEADLAMP

Wiring Diagram
 HEADLAMP

Aiming Adjustment
When performing headlamp aiming adjustment, use an aiming
machine, aiming wall screen or headlamp tester. For operating
instructions o f any aimer, it should be in good repair, calibrated
and used according t o respective operation manuals supplied
with the unit.
I f any aimer is not available, aiming adjustment can be done as
follows:
For details, refer t o the regulations i n your own country.
CAUTION:
a. Keep all tires inflated t o correct pressures.
b. Place vehicle and tester o n one and same flat surface.
c. See that there is n o load i n vehicle (coolant, engine oil filled
u p t o correct level and full fuel tank) other than the driver
(or equivalent weight placed i n driver's position).

LOW BEAM
1. Turn headlamp low beam on.
2. Use adjusting screws t o perform aiming adjustment. ,
First tighten the adjust screw all the way and then make
adjustment b y loosening the screw.

a. Adjust headlamps so that main axis o f light is parallel t o

center line of body and is aligned with point P shown i n
illustration.
b. Figure t o the left shows headlamp aiming pattern for driving
o n right side o f road; for driving o n left side o f road, aiming
pattern is reversed.
c. Dotted lines in illustrationshow center of headlamp.
"H-: Horizontal center line o f headlamps
'WL": Distance between each headlamp center
"L": 5,000 m m (196.85 in)
.
"C"- 50 m m (1.97 in)

& = ACCEPTABLE RANGE

 HEADLAMP

Installing Headlamp Rubber Cap

When installing the rubber cap, set the "TOP" or "A" mark so
it is facing up.

Press the rubber cap firmly so the lip makes contact with the
headlamp body.
 EXTERIOR LAMP
- -

Clearance, License, Tail and Stop LampsIWiring

Diagram

P C L L
O J U U
0
- - -- -- -
EXTERIOR LAMP

Back-up LampIWiring Diagram

CQMB I NATI ON

:wagon and H a r d to^ model

- P i c k u p model
.L.H.drive model

Fog Lamp/Wiring Diagram

FOG LAMP
SW ITCH

I fghting
sys tsm

FOG LAMP R . H . s
,- - W i n harness)

(13H)
@
FOG LAMP L . H . es-'
* - SEL865K
3 0 D Y GROUND
-- -- .- -
EXTERIOR LAMP
--

Turn Signal and Hazard Warning Lampsiwiring

Diagram
 EXTERIOR LAMP
- -

Test lamp (21W)

Combination Flasher Unit Check
Before checking, ensure that bulbs meet specifications.
Connect a battery and test lamp to the combination flasher
unit, as shown. Combination flasher unit is properly func-
tioning if it blinks when power is supplied to the circuit.

Battery SEL122E

Bulb Specifications

HEADLAMPS

bb
Sealed beam type

semi-sealed beam wpe

OTHER LAMPS
Wattage (Wl
50140.45140 (Yellow type)

Wattage (W)

Front turn signal light 21

Front clearance light 5
Side turn signal light
5
(Pickup)
Rear combination light
Turn signal 21
Stop~Tail 2115
Back-up 21
License plate light 10
Interior light 10
Fog light
35
(H3 type halogen)
 ILLUMINATION
f
FUSE BLOCK
., UP CONTROL SWITCH 1
F A N SWITCH
(LHS I L L U M I N A T I O N
11111111 t -P,

I*
\ C I G LIGHTER
mC3(IH)
I IN ILLUMINATION
ATTE R Y
4*
ASH TRAY
N
I -- l L L U M l N A T l ON

4m @$a A/T I N D I C A T O R
LAMP
P/B

RAD I 0
To Fog lamp switch

-- 0
47Mm
)
41 B'P -#jsJ DECK
Il

DIGITAL
CLOCK
P/B
I
<132)10

Ei METER ILL.

COMBINATION METER
170
-GI=
05eM>
BODY GROUND
=
('O'R)
( 1

(Room lamp harness)

or
(Sunroof harness)
or
0With

(Rear c o o l e r harness)
C L I N O METER
5) (3LLUMINATION
c l i n o meter

(:DX model

L I G H T I N G SWIl-CH ~ : D m oXd e l Except for Gul f s t a n d a r d ( M i d d l e E as t )

(AU):DX
model for Austral i a
(:A/T model
~ : R . H d. r i v e m o d e l
(L:L.H.
d r i v e model
INTERIOR LAMP

Interior LampIWiring Diagram

 METER AND GAUGES -
- - -- - -

Combination Meter
TYPE A
 METER AND GAUGES
Combination Meter (Cont'd)
TYPE B
 METER AND GAUGES
Combination Meter (Cont'd)
TYPE C
METER AND GAUGES

Wiring Diagram
 - --
METER AND GAUGES

Inspection/Fuel Gauge and Water Temperature

Gauge
INSPECTION START

O.K.
I
11
CHECK POWER SOURCE Check the following items.
1) Turn ignition switch "ON". N.G. 1) Harness continuity between
2) Check voltage between
I
Battery terminal and
terminal @ and ground. combination meter !
Battery voltage should exist. 2) Ignition relay
3) Fusible link and fuse
O.K. 4) Ignition switch
N.G.
-
- - -

CHECK GAUGE OPERATION Repair or Replecs gwge.

1) Turn ignition switch "ON".
2) Connect terminal @ and
ground with wire for lessthan
10 seconds.
3) Check operation of gauge.
Gauge should move smoothly
to full scale.

between gauge units and

I O.K..
I
@
: w a a temperature gauge
: Fuel gauge
4 Refer t o FE section. (Fuel gauge)
SEL820K Refer to "Fuel Tank Gauge Unit
Check" or "Thennal
Transmitter Check".

+Rainrtall any part r e m o d .

'
 METER AND GAUGES - . - -
. --
-
-

Fuel Tank Gauge Unit Check

- - - - - - -- -- - - - -

Hardtop and Wagon Pickup

Ohmmeter
Float position Resistance value
(+I (-1
Full Approx. 4.3 - 5.7a
0 0 Approx. 74.3 - 84.8Q
Empty

Thermal Transmitter Check

Check the resistance between the terminals of thermal transmit-
ter and body ground.
METER AND GAUGES

Oil Pressure Sending Unit Check

Check the resistance between the terminals of oil preosure
sending unit and body ground.
- - -

Oil pressure
Resistance value
kPa (bar, kglan2,psi)
0 (0.0.0) (Engine is stopped.) 71-7# -
- -

392 (3.9, 4, 57) -

24 31Q

588 (5.9, 6, 85) 13 - 2051

Oil Pressure Switch Check

Check the continuity between the terminals of oil pressure
switch and body ground.

Oil pressure
Continuity
kPa (bar, kg/cm2, psi)
-

More than
Engine running 10 - 20 (0.10 - 0.20, NO
0.1 - 0.2, 1.4 - 2.8)

Less than
Engine n o p p d 10 - 20 (0.10 - 0.20, YES
0.1 - 0.2, 1.4 - 2.8)

Speed Sensor Signal Check

1. Remove speed sensor from transmission.
Location: Refer to "Location of Electrical Units".
2. Turn speedometer pinion quickly and measure voltage across
@ and @ .
--- ..-
r
:- - WARNING LAMPS AND CHIME _--- - - - - - -
-
. .

Warning Lamps/Schematic
I
U
CCC
4-1-

K
A $::
t%-gr,
r$:FA
I FILTER O? F U E L F I L T E R SWITCH

- -
0) 0

BRAKE P A R K I N G BRAKE S W I T C H
 WARNING LAMPS AND CHIME

Warning LampsIWiring Diagram

GASOLINE ENGINE MODEL
 -- - - - - - -, WARNING LAMPS AND CHIME - --
- - -

Warning LampsIWiring Diagram (Cont'd)

DIESEL ENGINE MODEL
WARNING LAMPS AND CHIME

Diode Check
Check continuity using an ohmmeter.
Diode is functioning properly i f test results are as shown in
the figure on the left.

Diodes for warning lamps are built into the combination

meter printed circuit.
(Refer to "Combination Meter".)

Seat Belt Timer Check

Connect as shown in the figure to the left.
If chime and test lamp come on for 4-8 seconds when connecting
terminal @ to battery O terminal, seat belt timer is normal.
 WIPER AND WASHER

Front Wiper and WasherIWiring Diagram

L.H. DRIVE MODEL
-
IGNITION SWITCH
ACC o r ON

NTERMITTENE

WIPER SWITCH

WIPER MOTOR

WASHER MOTOR

BODY GROUND
(I):with intermitter wiper
@ : ~ i thout i n t e r m i t t e r wiper
SEU374K

R.H. DRIVE MODEL

IGNITION SWITCH
ACC o r ON

INTERMITTENE
WIPER AMPLIFIER

WIPER SWITCH

WASHER MOTOR

(I) W ~ t hlnterrn~tterw~per BODY GROUND

(El) WI thout interm1 tter w ~ p e r SEL876K

 WIPER AND WASHER

Rear Wiper and WasherIWiring Diagram

-- - - . -- - -
REAR WIPER AND REAR W I P E R MOTOR
WASHER SWITCH
I G N I T I O N SWITCH
ACC o r ON

1
harness R.H. 1
FUSE BLOCK

REAR WASHER BODY GROUND @:L.H. d r i v e model

MOTOR
SEL876K
 WIPER AND WASHER

Windshield Wiper Installation

Adjustment
1. Prior to wiper arm installation, turn on wiper switch to operate wiper motor and then turn it "OFF"
(Auto Stop).
2. Lift the blade up and then set it down onto glass surface to set the blade center. to clearance "C" im-
mediately before tightening nut.
3. Eject washer fluid. Turn on wiper switch to operate wiper motor and then turn it "OFFf'.
4. Ensure that wiper blades stop within clearance "C".
Clearance "C": 20 - 30 m m (0.79 - 1.18 in)
Installation
Tighten windshield wiper arm nuts to specified torque.
-
(cl 13 - 18 N-m (1.3 1.8 kg-m, 9 - 13 ft-lb)
Windshield wiper and washer
L.H. drive model R.H. drive model
240 367 367 240
(9-45) (14.45) (14.45) 19.45)

I
All the diameters of these circles are less than 80 mm (3.15 in). Unit: mm {in)
. -- - ---- .

r
I
I
I
I
I

J
I

- Lower windshield molding SEL825K

 WIPER AND WASHER
Windshield Wiper Installation (Cont'd)
4

Rear Wiper and Washer

289 ( 11.38)
4 *

I 70 12.76)

I
I
-
55 65 (2.17 - 256)

*\ Nozzle
*: All the diameters of these c~rclesare less than 50 mm (1 9 7 in).
Unlt: mm (in) SEL826K

Before reinstalling wiper arm, clean up the pivot area as illus-

trated. This will reduce possibility of wiper arm looseness.

Washer Nozzle Adjustment

Adjust washer nozzle with suitable tool as in the figure
below.
Details of tool are shown below.

+
\,\, 0.9 (0.035)O x 1 .O (0.039)
.\\>,
:.',\
4
2
@
.J
*

- -- -
SEL24SI
- - --
@
0.85 (0.0335)
0.85 850.0335)

Unit: mm (in)
SEL0881
 WIPER AND WASHER

Check Valve
2

A check valve is provided in the washer fluid line. Be careful

not to connect check valve to washer tube in the wrong
From Check valve
reservo0r To direction.
nozzle

SEL411H

Wiper Relay Check

1. Connect as shown in the figure to the left.
2. If test lamp comes on when connect to terminal @ and
battery ground, wiper relay is normal.

SEL827K
HORN, CIGARETTE LIGHTER AND CLOCK

Wiring Diagram
 REAR WINDOW DEFOGGER

Wiring Diagram
-- -

I G N I T I O N SWITCH
ON o r START

UP

IIIHIIIU' t
F I

(Main h a r n e s s )
G

C
[I W~ w, Qrwl
FUSE BLOCK REAR
W INDOW
DEFFOGER
REAR
WINOW
DE FFOGER

DEFFOGER

(228) (Back
door
harness
(Back
door
sub
a L.H . d r t v e model

BODY L .H.) harness0

GROUND L.H.)
SEL878K
 REAR WINDOW DEFOGGER

[+I I- I Filament Check

1. Attach probe circuit tester (in volt range) t o middle portion
of each filament.

6 volts (normal filament) SEU63

2. I f a filament is burned out, circuit tester registers 0 or 12

volts.

Burnedout point

3. To locate burned out point, move probe to left and right

I-] along filament to determine point where tester needle swings
abruptly.

SEL266
 REAR WINDOW DEFOGGER

Filament Repair
REPAlR EQUIPMENT
1. Conductive silver composition (Dupont No. 4817 or equiv-
alent)
2. Ruler 30 cm (11.8 in) long
3. Drawing pen
4. Heatgun
5. Alcohol
6. Cloth

s sg REPAIRING PROCEDURE

Hmt wire
6
- a m r , Brwek
1. Wipe broken heat wire and i t s surrounding area clean with a
cloth dampened in alcohol.
2. Apply a small amount of conductive silver composition to tip
of drawing pen.
Shake silver composition container before use.
3. Place ruler on glass along broken line. Deposit conductive
Unit: mm (in)
silver composition on break with drawing pen. Slightly over-
Drawing pen
BE540 lap existing heat wire on both sides [preferably 5 mm (0.20
in)] of the break.
4. After repair has been completed, check repaired wire for
continuity. This check should be conducted 10 minutes after
silver compositon is deposited.
Do not touch repaired area while test is being conducted.

5. Apply a constant stream of hot air directly t o the repaired

area for approximately 20 minutes with a heat gun. A
minimum distance of 3 cm (1.2 in) should be kept between
repaired area and hot air outlet. I f a heat gun is not available,
let the repaired area dry for 24.hours.
. - .
AUDIO __
Audio/Wiring Diagram
 AUDIO

Location of Antenna
I I

1 SE L828K

Radio Fuse Check

Antenna Trimmer Adjustment

The antenna trimmer should be adjusted in the following cases:
Fading and weak MW (AM) reception.
After installation of new antenna, feeder cable or radio
receiver.
Before adjusting, be sure to check harness and antenna feeder
cable connectors for proper connection.
1. Extend antenna completely.
2. Turn radio on, and turn volume control to increase speaker
volume.
3. Tune in the weakest station (barely audible) on dial at the
range around 14 (1,400 kHz).
4. Turn antenna trimmer to left or right slowly, and set it in the
position where reception is strongest.
CAUTION:
Do not turn antenna trimmer more than one-half turn.
 Gasoline engine model
Horn relay (Blue)

F.I.C.D. solenoid
Bulb check relay (Blue) Brake fluid switch (R.H.D. model) Wiper motor (R.H.D. model)
Auto choke relay (Black) (Located on the opposite side for L.H.D. mod

Rear wiper amplifier

Dropping resistor

Diesel engine model

Fuel filter sensor (L.H.D. model)
(Loceted on the opposite side for R.H.D. model)

Horn relay (Blue)

Air conditioner relay (Blue)

Bulb check relay (Blue

Windshield wiper amplifier

Glow relay (Black)

Injection pump contr

Rear air condition8

Neutral indicator r
 LOCATION OF ELECTRICAL UNITS

Passenger Compartment
L.H. DRIVE MODEL

A
 LOCATION OF ELECTRICAL UNITS
Passenger Compartment (Cont'd)
R.H. DRIVE MODEL
 LOCATION OF ELECTRICAL UNITS
Passenger Compartment (Cont'd)
HARDTOP AND WAGON
 LOCATION OF ELECTRICAL UNITS

Note:
 HARNESS LAYOUT

HARDTOP
Outline
L.H. drive model

Back door sub-harness R.H.

Room lamp harness

Back door harness R.H.

Back door harness

Door harness R.H.

Main-harness

ack door sub-harness

Chassis harness

Door harness L.H.

SEL894K

R.H. drive model

r

Back door sub-harness R.H.

Room lamp harness Back door harness R.H.

Back door harness L.H.

Door harness R.H.

Back door
sub-harness L.H.

Chassis harness

Door harness L.H.

8EL806K
 HARNESS LAYOUT
WAGON Outline (Cont'd)
L.H. drive model
Room lamp harness
Sun roof harness Back door sub-harness R.H.
(High-roof Wagon)
Back door harness R.H.
Door harness rear R.H

Back door harness L.H.

Ooor h.maslfront R.H.

Back door sub-harness L.H.

Chassis harness

Door harness rear L.H.

Door harness front L.H.

Rwu air conditioner SELSQSK

-
R.H. drive model

Sun roof harness

(High-roof Wagon)

Back door harness L.H.

Door harness rear R.H.

Door harness front R.H.

Main harness

Back door subharness L.H.

Chassis harness

Door harness rear L.H.

Rear air conditioner

 HARNESS LAYOUT
Outline (Cont'd)
PICKUP
L.H. drive model

Door harness R.H.

I
I
I
I
I
Daor bun- L.H.

Engine hornass

R.H. drive model -

Door huMss R.H.

Chassis harness

Door hamess L.H.

SELS99K
 HARNESS LAYOUT

Main Harness
L.H. DRIVE MODEL
@ : F.I.C.D. solenoid : Fusible llnk holder @I: Front combination lamp R.H.
@ I
: F.I.C.D. solenoid : Fusible link holder @ : Fog lamp R.H.
@ : Power antenna motor : Body ground : Winch relay sub-harness
@ : Rear wiper amplifier : Fuslble llnk holder @ : Horn (High)
(@ : Fuel filter swltch : Horn relay @ Thermo switch
:
@ : Dropping resistor : AIC relay @ Low-pressureswitch
:
@ :To@ : AIC relay @ Horn (Low)
:
@ :To@ : AIC cut relay @ Not used
:
@ :To@ : Glow relay @ : Front combination lamp L.H.
:To@ : Glow relay @ : Fog lamp L.H.
@ :To@ : Glow relay @ : Thermo witch
@ : Revolqtlon sensor : lnhlbltor relay @ : Distributor
@ :To@ : Rear cooler relay @ : Cbmpressor
@ : To@ : Front wiper ampllf ier @ : Headlamp L.H.
@ :To@ : Injection pump control unit @ : Body ground
@ : To@ : injection pump control unit @ : Side turn signal lamp L.H.
@ . T o @i J : lnhibitor relay @ : Front combination lamp L.H.
@ :To@ : Inhibitor relay @@ : Compressor
@ : lnhibitor switch : Diode @ : Alternator
@ : AIT oil temperature switch : Resistor @ : Alternator
overrun clutch, : Starter relay @ : Alternator
shift solenold-A, : Starter relay @ : Condenser
shift solenoid-B, : Starter relay @ : Water temperature switch
lock-up solenoid, : Engine sub-harness @ : Thermal transmitter
fluid temperature sensor, : Engine sub-harness @ :IVecuum switch
line pressure solenold : To@ @ : lgnition coil
@ : Inhibitor swltch : To Cm @ : Ignition coil
@I : T o @ : Winch relay @ : Resistor
@ : Bettery : Winch unit @ :IResistor
@ : Battery : Front washer motor @ : Resistor
I
@ : Fusible link holder : Rear washer motor @ :IBrake fluid LEVEL switch
@@ : Fusible link holder : Headlamp R.H. @ : Wiper motor
@b : Fusible link holder : Side turn slgnal lamp R.H. @@ : AIC relay
@$ : AIC relay
@ : Wiper motor @ : AIC relay @ : Horn (High)
@O : F.I.C.D. solenoid @ : Auto-choke reley @ : Therrno switch
@ : F.I.C.D. solenoid @ : AIC relay @ : Fog lamp R.H.
@ : Rear wiper amplifier @ : Glow relay @ : Horn (Low)
@ : Dropping resistor @ : Glow relay @ : Not used
@ : Brake fluid switch @ : Glow relay @ : Front combination lamp L.H.
@:To@
I @ : lnhibitor relay @ : Fog lamp L.H.
@ :To@ @ : Rear cooler relay @ : Thermo switch
@ :To@ @ : Wiperamplifier @ : Distributor
@ :To@ @ : Injection pump control unit .
@ Compressor
@ : Revolution sensor @ : Injection pump control unit @ : Headlamp L.H.
@ :To@ @ : lnhibitor relay @ : Bodyground
6 3 :To@ @ : lnhibitor relay @ : Side turn signal lamp L.H
@ :To@ @ : Diode @ : Vacuum switch
@ :TO@ @ : Resistor @ : Compressor
@ :To@ @ : Not used @ : Alternator
@ :To@ @ : Starter relay @ : Alternator
@ :To@ @ : Starter relay @ : Alternator
63 :To@ @ : Starter relay @ : Condenser
@ : lnhibitor witch @ : Engine sub-harness @ : Water temperature sensor
@ : A/T oil temperature switch @ : Engine sub-harness @ : Thermal transmitter
@ : A/T oil temperature switch @ : Not used @ : Ignition coil
@ :TO@ I@ : Not used @ : Ignition coil
@ Battery
: @ : Not used @ : Resistor
@ Battery
: @ : Wlnch unit @ : Resistor
@ Fusible link holder
: @ : To@ @ : Resistor
@ Fusible llnk holder
: @:To@ @ : Fuel filter sensor
@ Fusible link holder
: @ : Winch relay @ : Power entenna motor
@ Fusible link holder
: I@ : HeadlampR.H. @I : AIC relay
@ Body ground
: @ . I : Rear washer motor @ : AIC reley
@ :IFusible link @ : Front washer motor @ :To@
: Horn relay @ : Low-pressure switch @ : T o @
@ : AIC relay @ : Front combination lamp R.H.
 HARNESS LAYOUT
Main Harness (Cont'd)
L.H. DRIVE MODEL
 @ : Fog lamp switch @ : Circuit breaker
@ : Check connector
@ : Rear wiper end washer switch @ : Door lock timer
: Body ground
: Body ground
@ : Rear defogger switch @ : T O O
@ :To@
@ : Kickdown switch @ : TO @I (Wagon modell
@ : Combination meter TO @(Hardtop model)
To @
: Combination meter To @ (Sun roof)
To @
8
zstm . Ignition switch @$ : To @ (Pickup model)

@ : T O G
To @
g$ : Combination switch
: Horn swltch
@ : Wiper switch
@ : To @ (Wagon model)
To @O
@ : To
(Hardtop model)
(Wagon model)
@ : AIT check switch @ : Wiper switch To @ (Hardtop model)
@ : Rear cooler switch @ : Body ground
@ : A/T control unit
: AICwitch @I : To @ (High-roof model)
@I : AIT control unit
@I : Cigarette lighter To C@ (Standerd roof model)
: To@
@ . Cigerette lighter @ : To @ (High-roof model)
@ : T O O
To @
@ : Ash tray illumination To @ (Standard roof model)
@ : Fan switch @ : Blower motor
:To@
@ : Digital clock @ : Blower motor
To @
@I : Seat belt timer @ : Fuse block
@ : Seat belt switch
@ : Hazard swltch @ : Glow control unit
@ : A.T.P. lamp
@
@
@
: AIT indicator lamp
: Parking brake switch
: To@
@ : Power antenna switch
@ - Front sun roof switch
@ : Cassette deck
8 : Solenoid valve
: To @ (Wagon model)
@ : Front R.H. door switch
@ : Radio
I @ : Rear R.H. door switch (Wagon model)
@ : Door switch (Front L.H.)
@ : Door w i t c h (Front R.H. Wagon model)
@ : Radio 0 : Body ground
@ : Combination flasher unit @ : AlC thermo control emp. @ : Power window relay
@ : Stop lamp switch
@ : Resistor (3 : Power window relay
@$ : Combination meter
@ : Circuit breaker
- --
HARNESS LAYOUT
Main ~ a r n e s s(Cont'd)
--
--

R.H. DRIVE MODEL

HARNESS LAYOUT
Main Harness (Cont'd)
 @@ : Fwl attwrknolrf,
.@: To @ (L.H. drive model) 0 : 011pre#ure #ritEh nutschoke M u ,
To @ (R.H. drive model) @ : 011p m n lending unit B.C.D.D. mrnoid
@ : To @ (L.H. drive model) @ : Ah- 0 : Fwlwtrohld
To @ (R.H. drive model) @ : Throttlr rMu 0 : Tlmml trmmlttw
@ : To @) (L.H. drlve model) @ : Throttle vlhaswltch 0 : Startar motor
@ : To @ (L.H. drive model) @ : Auto-chaka heater, @:I6mck-u~bmp witch (MIT model)
@ :ITo @ (L.H. drive model) fwl cut rokrold @o:spudmow
To @ (R.H. drive model) . @ : B.C.D.O. m h # @ : hlautralfwlteh(AK model)
@ : Battery @ : 4WDswheh
 HARNESS LAYOUT
Engine Harness (Cont'd)
TD42 ENGINE
 -
-
. --
-
-
=--A-
. -
HARNESS LAYOUT

Chassis Harress
WAGON MODEL
'
@ @I (L.H. drive model)
: TO
I
To @ (R.H. drive model)
I @ : To @I (L.H.drke model)
To @ (R.H. drive model)

@ : Not used
@ : Stabilizer indicator switch
@:To@
@:To@
@:To@
@ : Fuel tank gauge unit
@:To@
@:To@
@ :To@

HARDTOP MODEL
@ : To @ (L.H. drive model)
To @ (R.H. drive model)
I @ : To @ (L.H. drive model)
To @ (R.H. drive model)
I

@ : Not used
@ : Stabilizer indicator switch
0 :To@
@ :To@
1 TO@
@ : Fuel tank gauge unit
@ : To@
I @:To@
0 :To@
 HARNESS LAYOUT
Chassis Harress (Cont'd)
'ICKUP MODEL
@ : To @ (L.H. drive model)
@ : To @ (R.H. drive model)

8
zmc : Rear combination lamp L.H.
: License lamp
@ : License lamp
@ : Rear combination lamp R.H.

SE LBO9K
 HARNESS LAYOUT

Door Harness
WAGON L.H. DRIVE- MODEL
Door harness front R.H. Door hrrn~rr w R.H.
@:To@ @ :To@
@ : To@ @@ : Raw R.H. IW. power window rsguW
@ : Door speaker R.H.
@ : R w RH. rid.paw window witch
@ : Front R.H. side power w~ndowregulator @ : RearR.H.~doorlodraetuaror
@J : Front R.H. side power window switch
@ : Front R.H. s~dedoor lock actuator

@ :To@
@ : Door speaker L.H.
@ : Power w~ndowamp.
@ : Front driver side power window regulator @: Rear L.H. s~depower w~ndowregulator
@ : Lock-unlock switch-1 @:IRear L.H. s~depower window switch
@ : Lock-unlock switch-2 @:IRear L.H. side door lock actuator SEL91OK

WAGON R.H. DRIVE MODEL

r
Door harnes rear R.H. Door harnes rear L.H.
@:TO@ @ : To@
@: Rear R.H. side power window regulator @ : Rear L.H. side power window regulator
@: Rear R.H. side power window switch @: Rear L.H. side power window switch
@: Rear R.H. side door lock actuator @ : Rear L.H. side door lock actuator

Door harness front L.H.

@ : To@ : Door speaker R.H.
@ : To@ : Power window amp.
@ : Door speaker L.H. : Front driver side power window regulator
@ : Front L.H. side power window regulator : Lockunlock switch-1
@ : Front L.H. tide power window switch @ : Front driver side power window switch
@I : Front L.H. side door lock actuator @ : Lockunlock switch-2 SEL91lK
 HARNESS LAYOUT
Door Harness (Cont'd)
HARDTOP L.H. DRIVE MODEL
Door harness L.H.
.
/
\ @ : T O @
@ : T O @
@:To@
@ : Door speaker L.H.
@ : Power window amp.
@ : Front driver side power window regulator
@ : Lockunlock switch-1
@ : Lockunlock switch-2

Door harness R.H.

@:To@
@ : To 1260)
@ : Door speaker R.H.
@ : Front R.H. side power window regulator
@ : Front R.H. side power window switch
@ : Front R.H. side door lock actuator I
SELBllK
-

HARDTOP R.H. DRIVE MODEL

Door harness L.H.
@:To@ /
@:To@
@ : Door speaker L.H.
@) : Front L.H. side power window regulator
@ : Front L.H. side power window switch
@ : Front L.H. side door lock actuator

I
Door harness R.H.

@:To@ 1
@ : To @
@ : Not used
@ : Power window amp.
i
@ : Front driver side power window regulator
@ : Lock-unlock switch-1
@ : Front driver side power window w i t c h
@ : Lock-unlock switch-2 sE~913K
 HARNESS ,LAYOUT
Door Harness (Cont'd)
PICKUP L.H. DRIVE MODEL
Door harness R.H.
@:TO@
@ : Door speaker R.H.
Door harness L.H.
@ : T o @
@ : Door speaker L.H.

'I

SEL914K

PICKUP R.H. DRIVE MODEL

Door harness R.H.

@ : T o @
@ : Door speaker R.H.

Door harness L.H.

@ : Door speaker L.H.

SELSIIK
Back door L.H. sub-harness
@ : To @ (Wagon model)
To @ (Hardtop model)
@ : TO @ (Wagon model)
TO @ (Hardtop model)
@ : To a (Wagon model)
To @ (Hardtop model)
@ : Rear combination lamp L.H.
@ :To@
@ :To@
@ :To@

Back door L.H. harness

@ :To@
@:I
TO@
@ :TO@
@ :TO@
@ : Back door actuator
@ : Body ground
@
@
: License lamp
: Rear speaker L.H.

Rear defogger harness L.H.

-
@ :To@
@I : Rear defogger L.H.
@) : Rear defogger L.H.
@Q : Body ground

@
@
@

Back door R.H. sub-harness

@I : To @ (Wagon model)
TO @ (Hardtop model)
@ : To @ (Wagon model)
TO @ (Hardtop model)
Back door R.H. harness
@ : To @ (Wagon model) @:To@
Rear defogger harness L.H.
To
- - (Hardtop model)
0 : Rear combination lamp R.H.
@ : To @
@ : Rear speaker R.H. @ : T o @
@D : Body ground @ : Rear wiper motor @ :IRear defogger R.H.
@ : T o @ @:To@ @3 : Body ground
@ : TO .@ @ : Body ground @ : Rear defogger R .H.
 HARNESS LAYOUT

Room Lamp Harness

WAGON MODEL

@ : @I (L.H. drive model)

TO
To @ (R.H. drive model)
@ : Clinometer
a : Front interior lamp
@ : Rear interior lamp SEL917K

HARDTOP MODEL
@ : To @I (L.H. drive model)
To @ (R.H. drive model)
@ : Clinometer
@ : Front interior lamp

SEL9lBK
 HARNESS LAYOUT - -

Room Lamp and Sun Roof Harness

PICKUP MODEL (Room lamp harness)

@ . To @ I
(L.H.drive model)
To @I (R.H dr~vemodel)
@ : Interlor lamp
@ : Interlor lamp
SEL919K

HI-ROOF WAGON (Sun roof harness)

I
@ : To @ (L.H. drive rnodel)
To @ (R.H. drive model)
: To @ ( L H . drive model)
To @ (R.H. drive model)
a
a
:
:
Clinometer
Front interior lamp
a :
:
Sun roof motor
Safety relay
@ : Sun roof reby-1
@ : Sun roof relay-2

@ : Sun roof switch rear (L.H. drive model)

@! : Sun roof switch rear (L.H. drive rnodel)
@ : Safety switch
@ : Sun roof switch rear (R.H. drive model)
@ : Sun roof switch rear (R.H. drive rnodel)
@ : Rear interior lamp
 HARNESS LAYOUT

Rear Air Conditioner Harness

OVERHEAD TYPE REAR COOLER (TYPE 1)
@ : To @ (L.H. drive model)
To @ (R.H. drive model)
@ : To @ (L.H. drive model)
To @ (R.H. drive model)
@ : To @ (L.H. drive model)
To @ (R.H. drive model)
@ : Clinometer
@ : Rear interior lamp

I
'1

I
I,
I1

SE W22K

3EAR COOLER (TYPE 2)

1