CAB AND CHASSIS ELECTRICAL

CAB AND CHASSIS ELECTRICAL 8-1

CAB AND CHASSIS ELECTRICALSECTION 8

CAB AND CHASSIS ELECTRICALContents

GENERAL INFORMATION..................................... 8-2General Information............................................. 8-2Notes for Working on Electrical Items ................. 8-2Symbols and Abbreviations ................................. 8-8Parts for Electrical Circuit .................................. 8-11Reading The Circuit Diagram ............................ 8-19

MAIN DATA AND SPECIFICATIONS ................... 8-22Bulb Specifications ............................................ 8-22Fuse and Fusible Link Location......................... 8-25Reference Table of Fuse and Circuit Breaker ... 8-36Relay Location................................................... 8-42Diode Location................................................... 8-48Reference Table of Grounding Point ................. 8-49Grounding Point Location .................................. 8-49Cable Harness Routing ..................................... 8-50

SYSTEM REPAIR ................................................. 8-54Start and Charging ............................................ 8-54QOS (Quick On Start) II System (4HF1 and 4JB1 En-gine Model)........................................................ 8-68Exhaust Brake System ...................................... 8-74Exhaust Brake System and Engine Control ...... 8-84Engine Stop System ........................................ 8-126Headlight, Fog Light, Rear Fog Light and Cornering Light................................................................. 8-133Headlight Leveling ........................................... 8-159Clearance Light, Taillight, License Plate Light and Illu-mination Light .................................................. 8-168Turn Signal Light, Hazard Warning Light, and Stop-light .................................................................. 8-183Horn, Backup Light and Backup Buzzer.......... 8-197Dome Light and Key Remind Buzzer .............. 8-209Power Door Lock ............................................. 8-219Power Window................................................. 8-231Windshield Wiper and Washer ........................ 8-247Audio and Cigar Lighter................................... 8-266Meter and Warning/indicator Light................... 8-274Heater and Air Conditioning ............................ 8-330Fuel Heater and Rear Heater .......................... 8-3424WD Transfer (Vacuum Control) ..................... 8-348ABS (Anti-lock Brake System, Without ASR) .. 8-354ABS/ASR System ............................................ 8-363Transmission Control System (Smoother)....... 8-368Electronic Control Type PTO........................... 8-386

8-2 CAB AND CHASSIS ELECTRICAL

GENERAL INFORMATIONGeneral InformationThe chassis electrical system is of 12-volt specificationswith a negative ground polarity.Wire sizes are appropriate to respective circuits, andclassified by color. (The classification of harnesses bycolor is shown on the circuit diagram for ease of harnessidentification.)The wire size is determined by load capacity and thelength of wire required.The vehicle harnesses are: body harness, floor harness,engine harness, frame front harness, frame rear har-ness, rear body harness, dome light harness, door har-ness and battery cable.The harnesses are protected either by tape or corrugat-ed tube, depending on harness location.The circuit for each system consists of the powersource, wire, fuse, relay switch, load parts and ground,all of which are shown on the circuit diagram.In this manual, each electrical device is classified bysystem. For major parts shown on the circuit based onthe circuit diagram for each system, a summary, diagno-sis of troubles, inspection and removal and installationprocedures are detailed.

Notes for Working on Electrical Items

Battery CableDisconnecting The Battery Cable

1. All switches should be in the “OFF” position.2. Disconnect the battery ground cable 1.3. Disconnect the battery positive cable 2.4. Disconnect the battery cable 3.

Caution:It is important that the battery ground cable be discon-nected first.Disconnecting the battery positive cable first can resultin a short circuit.

Connecting The Battery CableFollow the disconnecting procedure in the reverse or-der.

Caution:Clean the battery terminal and apply a light coat ofgrease to prevent terminal corrosion.

Connector HandlingDisconnecting The ConnectorsSome connectors have a tang lock to hold the connec-tors together during vehicle operation.Some tang locks are released by pulling them towardsyou 1.Other tang locks are released by pressing them forward2.Determine which type of tang lock is on the connectorbeing handled.Firmly grasp both sides (male and female) of the con-nector.Release the tang lock and carefully pull the two halvesof the connector apart.

N8A0001E

N8A0002E


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

Connecting the ConnectorFirmly grasp both sides (male and female) of the con-nector. Be sure that the connector pins and pin holesmatch. Be sure that both sides of the connector arealigned with each other. Firmly but carefully push thetwo sides of the connector together until a distinct clickis heard.

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

N8A0003E

N8A0004E

N8A0005E

N8A0006E


Never insert the circuit tester test probes into the con-nector open end to test the continuity. Broken or openconnector terminals will result.

Waterproof Connector InspectionIt is not possible to insert the test probes into the con-nector wire side of a waterproof connector.Use one side of a connector 1 with its wires cut to makethe test. Connect the test connector 2 to the connectorto be tested. Connect the test probes to the cut wires tocheck the connector continuity.

Connector Pin RemovalConnector Housing Tang Lock Type

1. Insert a slender shaft into the connector housingopen end.

2. Push the tang lock up (in the direction of the arrowin the illustration). Pull the wire with pin free fromthe wire side of the connector.

Pin Tang Lock Type1. Insert a slender shaft into the connector housing

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

connector). Pull the wire with pin free from the wireside of the connector.

N8A0007E

N8A0008E

N8A0009E

N8A0010E


Connector Pin Insertion1. Check that the tang lock is fully up.2. Insert the pin from the connector wire side.

Push the pin in until the tang lock closes firmly.3. Gently pull on the wires to make sure that the con-

nector pin is firmly set in place.

Parts HandlingBe careful when handling electrical parts. They shouldnot be dropped or thrown, because short circuit or otherdamage may result.

Cable HarnessWhen installing the parts, be careful not to pinch orwedge the wiring harness.All electrical connections must be kept clean and tight.

Use a grommet or guard tube to protect the wiring har-ness from contacting a sharp edge or surface.N8A0011E

N8A0012E

N8A0013E

N8A0014E


Position the wiring harness with a enough clearancefrom the other parts and guard the wiring harness with avinyl tube and clips to avoid direct contact.

The wiring harness between engine and chassis shouldbe long enough to prevent chafing or damage due tovarious vibrations.

Splicing Wire1. Open the Harness

If the harness is taped, remove the tape. To avoidwire insulation damage, use a sewing “seam rip-per” (available from sewing supply stores) to cutopen the harness.If the harness has a block plastic conduit, simplypull out the desired wire.

2. Cut the wireBegin by cutting as little wire off the harness aspossible. You may need the extra length of wire lat-er if you decide to cut more wire off to change thelocation of a splice. You may have to adjust splicelocations to make certain that each splice is at least

1-2/2″ (40 mm) away from other splices, harnessbranches, or connectors.

3. Strip the insulationWhen replacing a wire, use a wire of the same sizeas the original wire. Check the stripped wire fornicks or cut stands. If the wire is damaged, repeatthe procedure on a new section of wire. The twostripped wire ends should be equal in length.

4. Crimp the WiresSelect the proper clip to secure the splice. To de-termine the proper clip size for the wire beingspliced, follow the directions included with yourclips.Select the correct anvil on the crimper. (On mostcrimpers your choice is limited to either a small orlarge anvil.) Overlap the two stripped wire endsand hold them between your thumb and forefinger.Then, center the splice clip under the strippedwires and hold it in place.

• Open the crimping tool to its full width and restone handle on a firm flat surface.

• Center the back of the splice clip on the properanvil and close the crimping tool to the pointwhere the back of the splice clip touches thewings of the clip.

• Make sure that the clip and wires are still in thecorrect position. Then, apply steady pressureuntil the crimping tool closes.

N8A0015E

N8A0016E

N8A0017E


Before crimping the ends of the clip, be sure that:• The wires extend beyond the clip in each direc-

tion.• No strands of wire are cut loose, and• No insulation is caught under the clip.

Crimp the splice again, once on each end. Do notlet the crimping tool extend beyond the edge of theclip or you may damage or nick the wires.

5. SolderApply 60/40 rosin core solder to the opening in theback of the clip. Follow the manufacturer's instruc-tions for the solder equipment you are using.

6. Tape the SpliceCenter and roll the splicing tape. The tape shouldcover the entire splice. Roll on enough tape to du-plicate the thickness of the insulation on the exist-ing wires. Do not flag the tape. Flagged tape maynot provide enough insulation, and the flaggedends will tangle with the other wires in the harness.

N8A0018E

N8A0019E

N8A0020E

N8A0021E


If the wire does not belong in a conduit or other har-ness covering, tape the wire again. Use a windingmotion to cover the first piece of tape.

Symbols and Abbreviations

Symbols

Symbol Meaning of Symbol

Fuse

Fusible link

Fusible link wire

Switch

N8A0022E

N8A5501E

N8A5502E

N8A5503E

N8A5504E

Switch

Switch(Normal close type)

Contact wiring

Battery

Diode

Electronic Parts

Resistor


N8A5505E

N8A5506E

N8A5507E

N8A5508E

N8A5509E

N8A5510E

N8A5511E


Speaker

Buzzer

Circuit breaker

Bulb

Double filament bulb

Motor

Variable register Rheo-stat


N8A5512E

N8A5513E

N8A5514E

N8A5515E

N8A5516E

N8A5517E

N8A5518E

Coil (inductor), solenoid,magnetic valve

Relay

Connector

Light emitting diode

Reed switch

Condenser

Horn


N8A5519E

N8A5520E

N8A5521E

N8A5522E

N8A5523E

N8A5524E

N8A5525E


Abbreviations

Vacuum switching valve


N8A5526E

Abbreviation Meaning of Abbreviation Abbreviation Meaning of Abbreviation

A Ampere (S) kW kilowatt

ABS Anti-lock brake system LH Left hand

ASM Assembly LWB Long wheel base

AC Alternating current M/T Manual transmission

A/C Air conditioner OD Over drive

ACC Accessories OPT Option

C/B Circuit breaker QOS Quick on start

CSD Cold start device RH Right hand

DIS Direct ignition system RR Rear

EBCM Electronic brake control module RWAL Rear wheel anti-lock brake system

ECGI Electronic control gasoline injection ST Start

ECM Electronic control module STD Standard

ECU Electronic control unit SW Switch

EFE Early fuel evaporation SWB Short wheel base

4X4 Four-wheel drive V Volt

FL Fusible link VSV Vacuum switching valve

FRT Front W Watt (S)

H/L Headlight WOT Wide open throttle

IC Integrated circuit W/ With

IG Ignition W/O Without


Parts for Electrical Circuit

WiringWire ColorAll wires have color-coded insulation.Wires belonging to a system’s main harness will have asingle color. Wires belonging to a system’s subcircuitswill have a colored stripe. Striped wires use the followingcode to show wire size and colors.

Abbreviations are used to indicate wire color within a cir-cuit diagram.Refer to the following table.

Wire Color Coding

Distinction of Circuit by Wire Base Color

Wire SizeThe size of wire used in a circuit is determined by theamount of current (amperage), the length of the circuit,and the voltage drop allowed. The following wire sizeand load capacity, shown below, are specified by AWG(American Wire Gauge) (Nominal size means approxi-mate cross sectional area).

N8A5023E

Color-Coding Meaning Color-Coding Meaning

B Black BR Brown

W White LG Light green

R Red GR Grey

G Green P Pink

Y Yellow LB Light blue

L Blue V Violet

O Orange

Base color Circuits Base color Circuits

B Starter circuit Y Instrument circuit

W Charging circuit L, O, BR,LG, GR,P, LB, V

Other circuitR Lighting circuit

G Signal circuits


Wire Size Table

Fuse, Fusible Link and Circuit BreakerFuseFuses are the most common form of circuit protectionused in vehicle wiring. A fuse is a thin piece of wire orstrip of metal encases in a glass or plastic housing. It iswired in series with the circuit it protects. When there isan overload of current in a circuit, such as a short of aground, the wire or metal strip is designed to burn outand interrupt the flow of current. This prevents a surgeof high current from reaching and damaging other com-ponents in the circuit.Determine the cause of the overloaded before replacingthe fuse.The replacement fuse must have the same amperagespecifications as the original fuse.Never replace a blown fuse with a fuse of a different am-perage specification.Doing so can result in an electrical fire or other seriouscircuit damage. A blown fuse is easily identified.

N8A0025E

Nominal size Cross sectional area (mm2)

Outside diameter (mm)

Allowable current (A)

AWG size(cross reference)

0.30.50.851.25

23581520

0.3720.5630.8851.2872.0913.2965.2277.95213.3620.61

1.82.02.22.52.93.64.45.57.08.2

9121621 28

37.553677597

22201816141210864

N8A0026E


Fusible LinkThe fusible link is primarily used to protect circuits wherehigh amounts of current flow and where is would not bepractical to use a fuse. For example, the starter circuit.When a current overload occurs, the fusible link meltsopen and interrupts the flow of current so as to preventthe rest of the wiring harness from burning.Determine the cause of the overload before replacingthe fusible link. The replacement fusible link must havethe same amperage specification as the original fusiblelink.Never replace a blown fusible link with fusible link of adifferent amperage specification. Doing so can result inan electrical fire or other serious circuit damage.A blown fusible link is easily identified.

Fusible Link Specifications

Circuit BreakerThe circuit breaker is a protective device designed toopen the circuit when a current load is in excess of ratedbreaker capacity. If there is a short or other type of over-load condition in the circuit, the excessive current willopen the circuit between the circuit breaker terminals.The reset knob pops out when the circuit is open. Pushthe reset knob in place to restore the circuit after repair-ing it.

RelayBattery and load location may require that a switch beplaced some distance from either component. Thismeans a longer wire and a higher voltage drop 1.The installation of a relay between the battery and theload reduces the voltage drop 2.Because the switch controls the relay, amperagethrough the switch can be reduced.

N8A0027E

Type Rating Case Color Maximum Circuit Current (A)

Connector 30 A Pink 15

Connector 40 A Green 20

Bolted 50 A Red 25

Bolted 60 A Yellow 30

Bolted 80 A Black 40

N8A0028E

N8A0029E


Relay Specification, Configuration and Inspection

Name/Color

Rated voltage/Coil resistance Internal circuit Name/

ColorRated voltage/Coil resistance Internal circuit

MR5C(1T)/Black

12 V/Approx. 90 Ω

Minimumoperating

voltage: 7 Vat 25°C (77°F)

MR82C/Whitelabel

12 V/Approx. 23 Ω

Minimumoperating

voltage: 7 Vat 20°C (68°F)MR5C

(1T)/Brown

12 V/Approx. 90 Ω

Minimumoperating

voltage: 10.5 Vat 25°C (77°F)

MR5C(1T)/

Green

24 V/Approx. 266 Ω

Minimumoperating

voltage: 16 Vat 25°C (77°F) MR82C/

Greenlabel

24 V/Approx. 100 Ω

Minimumoperating


MR5C(1T)/Grey

24 V/Approx. 266 Ω

Minimumoperating


(connector face) (connector face)

Inspec-tion

The way

Check to see ifthere is any conti-nuity between therelay terminals.

Inspec-tion

The way


Result (When no voltage isapplied relay terminals 2-4)3 -5 → continuity1 -5 → No continuityInspection

Result(When no voltage isapplied relay terminals 4-5)2 -3 → No continuity

Normal Normal

Abnormal

(When minimum operat-ing voltage is appliedrelay terminals between2 -4)3 -5 → continuity1 -5 → No continuity

Abnormal

(When minimum operat-ing voltage is appliedrelay terminals between4 -5)2 -3 → No continuity

Normal

(When minimum operat-ing voltage is appliedrelay terminals between2 -4)3 -5 → No continuity1 -5 → continuity

Normal

(When minimum operat-ing voltage is appliedrelay terminals between4 -5)2 -3 → continuity

N8A0431E N8A0433E

1

3

5

1

3

5

42

N8A0432E N8A0434E


Name/Color

Rated voltage/Coil resistance Internal circuit

ACM13221M04/Black

12 V/Approx. 120 Ω

Minimumoperating


ACM13222M01/Green

24 V/Approx. 320 Ω

Minimumoperating


(connector face)

Inspec-tion

The way


Result (When no voltage isapplied relay terminals 3- 5)1 - 4 → continuity1 - 2 → No continuityInspection

Normal

Abnormal

(When minimum operat-ing voltage is appliedrelay terminals between3 - 5)1 - 4 → continuity1 - 2 → No continuity

Normal

(When minimum operat-ing voltage is appliedrelay terminals between3 - 5)1 - 4 → No continuity1 - 2 → continuity

N8A5571E

N8A5572E


DiodeDiode Specifications and Configurations

Maximum Rating (Temp. = 25°C)

Items Rating Remarks

Peak reverse voltage 400 V

Transient peak reverse voltage 500 V

Average output current 1.5 A Temp. = 40°C

Working ambient temperature −30°C — 80°C

Storage temperature −40°C — 100°C

SHAPE MARK/COLOR

CONSTRUCTION CHECKING

BLACK

BLACK

CONNECTIONPATTERN

2 1

BLACK

3 2 1

4 3 2 1

BLACK

4

3

2

1

THERE SHOULD BE CONTINUITY INEITHER A OR B WHEN A CIRCUITTESTER IS CONNECTED WITHDIODE TERMINAL

TERMINAL NO.

AB

TERMINAL NO.

CONNECTIONPATTERN

A

B

3 2 1TERMINAL NO.

CONNECTIONPATTERN

A

B

A

B

CONNECTIONPATTERN

TERMINAL NO.

N8A0032E


ConnectorThe connector pin shape determines whether the con-nector is male or female.The connector housing configuration does not deter-mine whether a connector is male or female.

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

Connector is identified with a number.

The applicable terminal number is shown for each con-nector.

Connector terminal numbers are clearly shown.Male side connector terminal numbers are in sequencefrom upper right to lower left.Female side connector terminal numbers are in se-quence from upper left to lower right.

N8A0033E

N8A0034E

N8A0035E

N8A0036E


Notice:For those connectors on which specific terminal num-bers or symbols are shown (such as ECM), the terminalnumbers or symbols are used in the circuit diagram, ir-respective of the above rule.

The connectors used for relays have their own terminalnumber assignment, irrespective of the above rule.

N8A0037E

N8A0038E

N8A5038E


Reading The Circuit DiagramIn this manual, each system has its own parts location illustration, circuit diagram and connector configuration usedin the circuit diagram.Parts LocationThe parts location shows the location of the parts 1 and the connector 2 used in each harness routing 3.

N8A0040E


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

N8A5040E


Connector ListThe connector list shows each connectors' configuration 7 and the pin number 8.

Connector Symbol

Connector Symbol Harness name Connector

Symbol Harness name

B Body harness L Dome Light harness

D Door harness N Floor harness (LH & RH)

E Engine harness P Battery harness

H For joint between harnesses R Rear body harness

J Front frame & Rear frame harness

B-341

B-232

B-51

B-52

No. Connector Face

002-009

1

2

002-009

1

2

014-001

1 2 3 4 5 6 7 8 9 1011121314

012-003

1 2 3 4 5 6

7 8 9 10 11 12

E-5

E-16

E-110

E-76

No. Connector Face

000-009

002-014

1 2

009-003

16

27

34

859

1

3

2

4

78

N8A0430E


MAIN DATA AND SPECIFICATIONSBulb Specifications

Light Name Rated Power No. of Bulb Lens Color Remarks

Halogen Headlight60 W / 55 W 2

Clear12 V

75 W / 70 W 2 24 V

Front combi-nation light

Turn signal light 21 W 2 Amber 12 V, 24 V

Cornering light / Clearance light 21 W / 5 W 2 Clear 12 V, 24 V

Fog lightFront

55 W2 Clear

12 V

70 W 24 V

Rear 21 W 1 Red 12 V, 24 V

Rearcombinationlight

Stoplight / Taillight 21 W / 5 W 2 Red 12 V, 24 V

Turn signal light 21 W 2 Amber 12 V, 24 V

Backup light 21 W 2 Clear 12 V, 24 V

License plate light 5 W 1 Clear 12 V, 24 V

Dome light 10 W 1 White 12 V, 24 V

Roof marker light 5 W 2 White 24 V

Side turn signal light 21 W 2 Amber 24 V

Dome light

License plate light

Backup light

Stoplight/Taillight

Turn signallight

Turn signal light

Cornering light / Clearance lightFog light

Headlight

N8A0475E


Light NameRated Power

No. of Bulb RemarksExcept 4HK1-TC 4HK1-TC

Indicator /WarningLight(In the meterassembly)

Glow1.4 W —

112 V

1.4 W 1.8 W 24 V

Engine oil pressure1.4 W —

112 V

1.4 W 1.8 W 24 V

Fuel sedimenter1.4 W —

112 V

1.4 W 1.8 W 24 V

Brake fluid level / Parking brake1.4 W —

112 V

1.4 W 1.8 W 24 V

Charge1.4 W —

112 V

1.4 W 1.8 W 24 V

Exhaust brake 2 W — 1 12 V

High beam1.4 W —

112 V

1.4 W 1.8 W 24 V

Turn signal1.4 W —

112 V

1.4 W 1.8 W 24 V

Fuel level2 W —

112 V

1.8 W 1.8 W 24 V

Seat belt2 W —

112 V

1.8 W 1.8 W 24 V

4WD 1.8 W 1.8 W 1 24 V

Rear fog1.4 W —

112 V

1.4 W 1.8 W 24 V

Brake booster1.4 W —

112 V

1.4 W 1.8 W 24 V

ABS1.4 W —

112 V

1.4 W 1.8 W 24 V

Check engine1.4 W —

112 V

1.4 W 1.8 W 24 V

P.T.O.1.4 W —

112 V

1.4 W 1.8 W 24 V

Smoother — LED 1 24 V

1st start — LED 1 24 V

ECONO — LED 1 24 V

ASR — 1.8 W 1 24 V


Illumination

Illumination light for meterassembly

3.4 W1

12 V

3 W 24 V

Hazard warning Switch2 W

112 V

1.8 W 24 V

Dome light switch2 W

112 V

1.8 W 24 V

Front fog light switch2 W

112 V

1.8 W 24 V

Rear fog lightswitch

For indicator 60 mA 112 V

For illumination 60 mA 1

Cigar lighter1.4 W

112 V

1.8 W 24 V

Heater bezel 1.4 W 1

Ashtray 1.4 W 1

Light NameRated Power

No. of Bulb RemarksExcept 4HK1-TC 4HK1-TC


Fuse and Fusible Link LocationFuse and Circuit Breaker

Fuse Label-for 12 Volt (4JB1)

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

Fuse label

Relay box No. 2

Fuse( )F-1 F-24

Fuse pullerSpare fuse

-

Fuse( )F-25 F-28-

Fuse( )F-29 F-31-

N8A0531E

10 A(1) AIR CON

15 A(2) EXH. BRAKE, FUEL HEATER

15 A(3) REAR HEATER

15 A(4) AUDIO (B), DOOR LOCK

10 A(5) STOP LIGHT

10 A(6) FRT FOG LIGHT, CORNERING LAMP

10 A(7) TAIL LIGHT

10 A(8) EGR

10 A(9) FUEL CUT

15 A(10) FRONT WIPER & WASHER

10 A(11) TURN LIGHT

10 A(12) H/LAMP LEVEL

(13) —

(14) —

15 A(15) AUDIO (IG), CIGAR LIGHTER

10 A(16) METER

(17) —

(18) —

15 A(19) HORN, HAZARD

10 A(20) ABS (IG)

15 A(21) GENERATOR

10 A(22) STARTER

10 A(23) HEAD LIGHT RH


Fuse Label-for 12 Volt (4HG1 / 4HE1)Fuse Label-for 12 Volt (4JH1)

10 A(24) HEAD LIGHT LH

15 A(25) MARKER LAMP

15 A(26) COND. FAN

10 A(27) RR FOG

(28) —

10 A(1) AIR CON

15 A(2) EXH. BRAKE

(3) —


10 A(5) STOP LIGHT

(6) —

10 A(7) TAIL LIGHT


10 A(9) ENG.(IG)


10 A(11) TURN LIGHT

(12) —

10 A(13) ENG. STOP

(14) —


10 A(16) METER

(17) —

(18) —

15 A(19) ENG.(B)


(21) —

10 A(22) STARTER




(26) —

10 A(27) RR FOG

(28) —

10 A(1) AIR CON

15 A(2) FUEL HEATER

15 A(3) REAR HEATER


10 A(5) STOP LIGHT


10 A(7) TAIL LIGHT

15 A(8) ENG.(B1)

15 A(9) ENG.(B2)


10 A(11) TURN LIGHT


(13) —

(14) —


10 A(16) METER

(17) —

(18) —


10 A(20) ABS (IG)


Fuse Label-for 24 Volt (4HF1 / 4HG1 / 4HE1)

Fuse Label-for 24 Volt (4HK1)

(21) —

10 A(22) STARTER




15 A(26) COND. FAN

10 A(27) RR FOG

(28) —

15 A(1) HEATER, AIR CON

10 A(2) EXH. BRAKE, FUEL HEATER

15 A(3) REAR HEATER


10 A(5) STOP LIGHT

20 A(6) POWER WINDOW

10 A(7) TAIL LIGHT


10 A(9)

ENG. (IG)

FUEL CUT


10 A(11) TURN LIGHT


10 A(13) ENG. STOP

(14) —


10 A(16) METER

(17) —

15 A(18) GENERATOR

15 A(19) ENG. (B)


10 A(21) ABS (IG)

10 A(22) STARTER




15 A(26) COND. FAN

10 A(27) RR FOG

(28) —

20 A(29) PTO

10 A(30) PTO

10 A(31) PTO

15 A(1) HEATER, AIR CON

10 A(2) FUEL HEATER

15 A(3) REAR HEATER


10 A(5) STOP LIGHT


10 A(7) TAIL LIGHT

10 A(8) FRT FOG LIGHT

10 A(9) ENG. (IG)



Notice:The fuse numbers (1) — (31) indicated on the fuse la-bels are expressed as — in the circuit dia-grams of this manual.

10 A(11) TURN LIGHT


10 A(13) NEES (B)

(14) —


10 A(16) METER

10 A(17)

NEES (IG)

HSA

10 A(18) SRS

10 A(19) ENG. (BACK UP) HSA


10 A(21) ABS (IG)

10 A(22) STARTER




15 A(26) COND. FAN

10 A(27) RR FOG

10 A(28) ECM. ENG.

F-1 F-31


Fusible Link

For 12 Volt (4JB1)

For 12 Volt (4HG1 / 4HE1)


1

Fusible link

Fusible link

2 3 4 5

6 7 8 9

26

FU

SE

PU

LLER

25

N8A0047E

100 A(1) MAIN

50 A(2) KEY

60 A(3) GLOW

30 A(4) HEAD LAMP

(5) —

(6) —

(7) —

60 A(8) STARTER

60 A(9) ABS

30 A(25) HEATER


100 A(1) MAIN

50 A(2) KEY

60 A(3) GLOW


For 12 Volt (4JH1)

For 24 Volt (4HF1 / 4HG1 / 4HE1)

For 24 Volt (4HK1)

Notice:The fusible link numbers (1) — (26) are expressed as

— in the circuit diagrams of this manual.

30 A(4) HEAD LAMP

(5) —

(6) —

(7) —

60 A(8) STARTER

(9) —

30 A(25) HEATER


100 A(1) MAIN

50 A(2) KEY

60 A(3) GLOW

30 A(4) HEAD LAMP

(5) —

(6) —

(7) —

60 A(8) STARTER

60 A(9) ABS

30 A(25) HEATER


100 A / 120 A

(1)MAIN

40 A(2) KEY

60 A(3) GLOW

30 A(4) HEAD LAMP

(5) —

(6) —

(7) —

60 A(8) STARTER

40 A(9) ABS

100 A / 120 A

(1)MAIN

40 A(2) KEY

60 A(3) GLOW

30 A(4) HEAD LAMP

40 A(5) ECM. ENG.

60 A(6) CERAMIC HEATER

60 A(7) NEES

60 A(8) STARTER

40 A(9) ABS

FL-1 FL-26


Fuse Block CircuitFor 12 Volt-4JB1 Engine

HEATER &A/C RELAY

10A

HEAD LIGHT LHF-24

10A

HEAD LIGHT RHF-23

10A

STARTERF-22

15A

GENERATORF-21

10A

ABS (IG)F-20

15A

HORN, HAZARDF-19

F-18

F-17

10A

METERF-16

15A

AUDIO (IG), CIGAR LIGHTERF-15

F-14

F-13

10A

H/LAMP LEVELF-12

10A

TURN LIGHT

15A

F-11

15A

FRONT WIPER & WASHERF-10

10A

FUEL CUTF-9

10A

EGRF-8

10A

TAIL LIGHTF-7

F-2510A

FRT FOG LIGHT, CORNERING LAMPF-6

10A

STOP LIGHTF-5

15A

AUDIO (B), DOOR LOCKF-4

15A

REAR HEATERF-3

15A

EXH. BRAKE, FUEL HEATERF-2

10A

AIR CONF-1

30A

POWER WINDOW

FL-26

30AHEAD LAMP

FL-4

30A

FL-25

HEATER

INDICATION ON LABEL

INDICATION ON LABEL

KEY ONRELAY

EXH.BRAKERELAY

TAILRELAY

HEAD LIGHTRELAY

COMBINATION SWITCH

STARTER

STARTERRELAY

CONDENSER FAN

ABS UNIT

GLOW PLUG

GLOW PLUGRELAY

CONDENSER FANRELAY

KEY SW OFF

ACCON

ST

60AGLOW

FL-3

60AABS

FL-9

60ASTARTER

FL-8

50AKEY

FL-2

REAR FOGRELAY

REAR FOG

COMBINATIONSWITCH

CHARGEWARNING

RELAY

MARKER LIGHT

100AMAIN

FL-1

MARKERLIGHTRELAY

15AF-26

10AF-27

F-28

GENERATOR

GENERATOR B

RR FOG

COND. FAN

MARKER LAMP

N8A0506E


For 12 Volt-4HG1 / 4HE1 Engine

HEATER &A/C RELAY

10A

HEAD LIGHT LHF-24

10A

HEAD LIGHT RHF-23

10A

STARTERF-22

F-21

15A

HORN, HAZARDF-20

15A

ENG. (B)F-19

F-18

F-17

10A

METERF-16

15A

AUDIO (IG), CIGAR LIGHTER

ENG. STOP

F-15

F-14

F-13 10A

F-12

10A

15A

F-11

15A


10A

ENG. (IG)F-9

10A


10A

TAIL LIGHT

TURN LIGHT

F-7

F-25F-6

10A

STOP LIGHTF-5

15A


F-3

15A

EXH. BRAKEF-2

10A

AIR CONF-1

30A

POWER WINDOW

FL-26

30AHEAD LAMP

FL-4

30A

FL-25

HEATER

INDICATION ON LABEL

INDICATION ON LABEL

KEY ONRELAY

EXH.BRAKERELAY

TAILRELAY

HEAD LIGHTRELAY

COMBINATION SWITCH

STARTER

STARTERRELAY

GLOW PLUG

GLOW PLUGRELAY

KEY SW OFF

ACCON

ST

60AGLOW

FL-3

FL-9

60ASTARTER

FL-8

50AKEY

FL-2

REAR FOGRELAY

REAR FOG

COMBINATIONSWITCH

CHARGEWARNING

RELAY

MARKER LIGHT

100AMAIN

FL-1

MARKERLIGHTRELAY

F-26

10AF-27

F-28

GENERATOR

GENERATOR B

RR FOG

MARKER LAMP

N8A0507E


For 12 Volt-4JH1 Engine

HEATER &A/C RELAY

10A

HEAD LIGHT LHF-24

10A

HEAD LIGHT RHF-23

10A

STARTERF-22

F-21

10A

ABS (IG)F-20

15A

HORN, HAZARDF-19

F-18

F-17

10A

METERF-16

15A


F-14

F-13

10A

H/LAMP LEVELF-12

10A

TURN LIGHT

15A

F-11

15A


15A

ENG. (B2)F-9

15A

ENG. (B1)F-8

10A

TAIL LIGHTF-7

F-2510A


10A

STOP LIGHTF-5

15A


15A

REAR HEATERF-3

15A

FUEL HEATERF-2

10A

AIR CONF-1

30A

POWER WINDOW

FL-26

30AHEAD LAMP

FL-4

30A

FL-25

HEATER

INDICATION ON LABEL

INDICATION ON LABEL

KEY ONRELAY

HEATERRELAY

TAILRELAY

HEAD LIGHTRELAY

COMBINATION SWITCH

STARTER

STARTERRELAY

CONDENSER FAN

ABS UNIT

GLOW PLUG

GLOW PLUGRELAY

CONDENSER FANRELAY

KEY SW OFF

ACCON

ST

60AGLOW

FL-3

60AABS

FL-9

60ASTARTER

FL-8

50AKEY

FL-2

REAR FOGRELAY

REAR FOG

COMBINATIONSWITCH

CHARGEWARNING

RELAY

MARKER LIGHT

100AMAIN

FL-1

MARKERLIGHTRELAY

15AF-26

10AF-27

F-28

GENERATOR

GENERATOR B

RR FOG

COND. FAN

MARKER LAMP

N8A0508E


For 24 Volt-4HF1 / 4HG1 / 4HE1 Engine

HEATER &A/C RELAY

10A

HEAD LIGHT LHF-24

10A

HEAD LIGHT RHF-23

10A

10A

20A

STARTERF-22

F-31

F-30

F-29

10A

ABS (IG)

PTO

PTO

PTO

10A

F-21

15A

HORN, HAZARDF-20

15A

ENG. (B)

GENERATOR15A

F-19

F-18

F-17

10A

METER

ENG. STOP

F-16

15A


F-14

F-13

10A

H/LAMP LEVEL10A

F-12

10A

TURN LIGHT

15A

F-11

15A


10A ENG. (IG)FUEL CUT

F-9

10A


10A

TAIL LIGHTF-7

F-2520A

POWER WINDOWF-6

10A

STOP LIGHTF-5

15A


15A

REAR HEATERF-3

10A

EXH. BRAKE, FUEL HEATERF-2

15A

HEATER, AIR CONF-1

FL-26

30AHEAD LAMP

FL-4

FL-25

INDICATION ON LABEL

INDICATION ON LABEL

KEY ONRELAY

EXH.BRAKERELAY

TAILRELAY

HEAD LIGHTRELAY

COMBINATIONSWITCH

STARTER

STARTERRELAY

CONDENSER FAN

ABS UNIT

GLOW PLUG

GLOW PLUGRELAY

CONDENSER FANRELAY

KEY SW OFF

ACCON

ST

60AGLOW

FL-3

40AABS

FL-9

60ASTARTER

FL-8

40AKEY

FL-2

REAR FOGRELAY

COMBINATIONSWITCH

CHARGEWARNING

RELAY

100A or 120AMAIN

FL-1

MARKERLIGHTRELAY

15AF-26

10AF-27

F-28

GENERATOR

GENERATOR B

RR FOG

COND. FAN

MARKER LAMP

REAR FOG

MARKER LIGHT

N8A0509E


For 24 Volt-4HK1 Engine

HEATER &A/C RELAY

10A

HEAD LIGHT LHF-24

10A

HEAD LIGHT RHF-23

10A

STARTERF-22

10AABS (IG)

F-21

15AHORN, HAZARD

F-20

10A

ENG. (BACK UP) HSAF-19

F-18

F-17

10A

METER

NEES (B)

SRS

F-16

15AAUDIO (IG), CIGAR LIGHTER

F-15

F-14

F-13

10AH/LAMP LEVEL

10A

F-12

10ATURN LIGHT

15A

F-11

15AFRONT WIPER & WASHER

F-10

10AF-9

10A

FRT FOG LIGHTF-8

10A

TAIL LIGHT

ENG. (IG)

F-7

F-2520A

POWER WINDOWF-6

10A

STOP LIGHTF-5

15A


15A

REAR HEATERF-3

10A

FUEL HEATERF-2

15A

HEATER, AIR CONF-1

FL-26

30AHEAD LAMP

FL-4

FL-25INDICATION ON LABEL

INDICATION ON LABEL

NEES (IG)HSA

KEY ONRELAY

HEATERRELAY

TAILRELAY

HEAD LIGHTRELAY

COMBINATION SWITCH

STARTER

STARTERRELAY

CONDENSER FAN

ABS UNIT

GLOW PLUG

GLOW PLUGRELAY

CONDENSER FANRELAY

KEY SW OFF

ACCON

ST

60AGLOW

FL-3

40AABS

FL-9

60ASTARTER

FL-8

40AKEY

FL-2

REAR FOGRELAY

COMBINATIONSWITCH

CHARGEWARNING

RELAY

100A or 120AMAIN

FL-1

MARKERLIGHTRELAY

15AF-26

10AF-27

F-28

GENERATOR

GENERATOR B

RR FOG

ECM. ENG.

COND. FAN

MARKER LAMP

METER(BOOST IND)

10A

10A

ECM

ECM

ECM MAINRELAY

ECM

40AECM. ENG.

FL-5

STARTER CUTRELAY

ECMECM

NEUTRAL SWITCH

TCM

GEAR SHIFTERRELAY

TCM

60ANEES

FL-7

CERAMIC HEATER60A

CERAMIC HEATER

FL-6

REAR FOG

MARKER LIGHT

N8A0510E


Reference Table of Fuse and Circuit BreakerFuse12 Volt 4JB1 Engine

Fuse No. Capacity Indication on label Main parts (Load)

F-1 10 A AIR CON A/C switch, A/C thermo relay, Pressure switch, Magneticclutch, VSV: FICD, Electronic thermostat

F-2 15 A EXH. BRAKE, FUEL HEATER

Exhaust brake switch, Exhaust brake control relay, Exhaustbrake magnetic valve, Clutch switch, Accel switch, Fuel heater

F-3 15 A REAR HEATER Rear heater, Rear heater switch

F-4 15 A AUDIO (B), DOOR LOCK

Radio & clock, Dome light switch, Dome light, Door switch(RH & LH), Door lock switch, Door lock actuator, Door lockcontroller, Speedometer, Key cylinder switch, Key remindbuzzer

F-5 10 A STOP LIGHT Stoplight switch, Stoplight

F-6 10 A FRT FOG LIGHT, CORNERING LAMP

Fog light switch, Fog light, Lighting switch, Cornering lightrelay, Cornering light, Cornering light switch

F-7 10 A TAIL LIGHT Tail relay, Illumination light(s), Clearance light(s), Tail light(s)

F-8 10 A EGR ECM ignition

F-9 10 A FUEL CUT Fuel cut solenoid

F-10 15 A FRONT WIPER & WASHER

Wiper & Washer switch, Wiper motor, Washer motor, Intermit-tent relay

F-11 10 A TURN LIGHT Flasher unit, Front turn signal light, Rear turn signal light, Turnsignal light switch, Hazard warning switch

F-12 10 A H/LAMP LEVEL Headlight leveling switch, Headlight leveling motor (actuator)

F-13 — — —

F-14 — — —

F-15 15 A AUDIO (IG), CIGAR LIGHTER Radio, Cigar lighter

F-16 10 A METER

Exhaust brake control relay, CSD Relay, Key remind buzzer,Backup light switch, Backup light, Neutral switch, Starter relay,QOS-II controller, QOS-III controller, Glow relay, Glow-1 relay,Glow-2 relay, Glow indicator (Meter), Coolant temperaturegauge, Thermo unit, Vehicle speed sensor (Installed on themeter assembly & Transmission), Meter assembly, Powerwindow relay, Cornering light relay

F-17 — — —

F-18 — — —

F-19 15 A HORN, HAZARD Horn, Horn relay, Horn switch, Flasher unit, Hazard warningswitch

F-20 10 A ABS (IG) ABS

F-21 15 A GENERATOR Generator

F-22 10 A STARTER Starter relay, QOS-II controller, QOS-III controller

F-23 10 A HEAD LIGHT RH Headlight (RH), Dimmer relay, High beam indicator light

F-24 10 A HEAD LIGHT LH Headlight (LH), Dimmer relay

F-25 15 A MARKER LAMP Marker light, Marker light relay

F-26 15 A COND. FAN Condenser fan

F-27 10 A RR FOG Rear fog light switch, Rear fog light relay


12 Volt 4HG1 / 4HE1 Engine

F-28 — — —



F-2 15 A EXH. BRAKE Exhaust brake switch, Exhaust brake control relay, Exhaustbrake magnetic valve, Clutch switch, Accel switch

F-3 — — —




F-6 — — —




F-9 10 A ENG. (IG) ECM ignition




F-12 — — —

F-13 10 A ENG. STOP Engine stop motor

F-14 — — —


F-16 10 A METER

Exhaust brake control relay, CSD Relay, Key remind buzzer,Backup light switch, Backup light, Inhibitor switch, Neutralswitch, Starter relay, QOS-II controller, QOS-III controller,Glow relay, Glow-1 relay, Glow-2 relay, Glow indicator (Meter),Coolant temperature gauge, Thermo unit, Vehicle speed sen-sor (Installed on the meter assembly & Transmission), Meterassembly, Power window relay, Cornering light relay

F-17 — — —

F-18 — — —

F-19 15 A ENG. (B) ECM battery


F-21 — — —

F-22 10 A STARTER Starter relay, Inhibitor switch, QOS-II controller, QOS-III con-troller






12 Volt 4JH1 Engine

F-26 — — —


F-28 — — —



F-2 15 A FUEL HEATER Fuel heater








F-8 15 A ENG. (B1) ECM battery

F-9 15 A ENG. (B2) ECM battery





F-13 — — —

F-14 — — —


F-16 10 A METER


F-17 — — —

F-18 — — —



F-21 — — —







24 Volt 4HF1 / 4HG1 / 4HE1 Engine



F-28 — — —


F-1 15 A HEATER, AIR CONBlower motor, Blower resistor, Fan switch, A/C switch, A/Cthermo relay, Pressure switch, A/C cut relay, Thermo switch(A/C cut), VSV: FICD, Electronic thermostat

F-2 10 A EXH. BRAKE, FUEL HEATER

Exhaust brake switch, Exhaust brake control relay, Exhaustbrake magnetic valve, Clutch switch, Accel switch, Fuel heater





F-6 20 A POWER WINDOW Power window




F-9 10 AENG. (IG) ECM ignition (EXCEPT 4HF1-2)

FUEL CUT Fuel cut solenoid (4HF1-2)





F-13 10 A ENG. STOP Engine stop motor

F-14 — — —


F-16 10 A METER


F-17 — — —

F-18 15 A GENERATOR Generator

F-19 15 A ENG. (B) ECM battery (4HG1-T)






24 Volt 4HK1 Engine






F-28 — — —

F-29 20 A PTO PTO main relay (Electronic control type PTO)

F-30 10 A PTO PTO cut relay (Electronic control type PTO)

F-31 10 A PTO PTO cut relay (Electronic control type PTO)


F-1 15 A HEATER, AIR CON

Blower motor, Blower resistor, Fan switch, A/C switch, A/Cthermo relay, Pressure switch, VSV: FICD, Electronic thermo-stat, A/C compressor, A/C thermo relay, Condenser fan, ECM(A/C compressor SIG.)

F-2 10 A FUEL HEATERExhaust brake magnetic valve, Clutch switch, Accel switch,Fuel heater, VSV: Intake throttle, ABS (Exhaust brake SIG.),Ceramic heater relay



Radio & clock, Dome light switch, Dome light, Door switch(RH & LH), Door lock switch, Door lock actuator, Door lockcontroller, Speedometer, Key cylinder switch, Key remindbuzzer, Side turn signal light(s)

F-5 10 A STOP LIGHT Stoplight switch, Stoplight, ABS (Stop on SIG.), ECM (brakeon SIG.)

F-6 20 A POWER WINDOW Power window

F-7 10 A TAIL LIGHT Tail relay, Illumination light(s), Clearance light(s), Tail light(s),Roof marker light, License light(s), Marker light relay

F-8 10 A FRT FOG LIGHT Fog light switch, Fog light, Lighting switch, Cornering lightrelay, Cornering light, Cornering light switch

F-9 10 A ENG. (IG)ECM (IG SIG.), Starter cut relay, ECM (Exhaust brake SIG.),Exhaust brake indicator, ECM (brake off SIG.), ECM (clutchon SIG.), ALDL connector



F-11 10 A TURN LIGHTFlasher unit, Front turn signal light, Rear turn signal light, Turnsignal light switch, Hazard warning switch, Side turn signallight relay


F-13 10 A NEES (B) Smoother

F-14 — — —

F-15 15 A AUDIO (IG), CIGAR LIGHTER Radio, Cigar lighter, Digital clock



F-16 10 A METER

CSD Relay, Key remind buzzer, Backup light switch, Backuplight, Neutral switch, Starter relay, QOS-II controller, Glowrelay, Glow indicator (Meter), Coolant temperature gauge,Thermo unit, Vehicle speed sensor (Installed on the meterassembly & Transmission), Meter assembly, Power windowrelay, Cornering light relay, Backup buzzer, ABS indicatorrelay, Charge relay, Heater A/C relay, VSV: 2WD (4WD), VSV:4WD (4WD), 4WD relay

F-17 10 ANEES (IG) Smoother (IGN SIG.)

HSA —

F-18 — SRS —

F-19 10 A ENG. (BACK UP) HSA ECM (Back up)

F-20 15 A HORN, HAZARD Horn, Horn relay, Horn switch, Flasher unit, Hazard warningswitch, Turn light(s), Side turn signal light relay

F-21 10 A ABS (IG) ABS (IGN SIG.)

F-22 10 A STARTER Starter relay, QOS-II controller






F-28 10 A ECM. ENG. ECM



Relay Location

X-16 X-15 X-14 X-13

X-8 X-9 X-10 X-11 X-12X-7X-6X-5

Relay box No.2

Relay box No.1

X-28X-27X-26X-25X-24X-23X-22

X-21

X-20X-19X-18


X-4X-3X-1 X-2

N8A0054E


Relay List: Standard, : Option

X-1 X-2 X-3 X-4 X-5 X-6

Charge warning Key ON Horn Lamp Tail ABS

IND.Smoother

main Dimmer

12 V

NHR55 — — —

NKR55 — — —

NKR69 — — —

NPR71 — — —

NKR77 — —

NPR77 — —

NKR77 for Taiwan — — —

24 V

NKR66 — — —

NPR66 — —

NQR66 — —

NPR70 — — —

NQR70 — — —

NKR71 — — —

NQR71with turbocharger — —

NPS71 — — —

NPR71 — — —

NQR71w/o turbocharger — — —

NPR75 — —

NQR75 — —


* : Except EC / Turkey

X-7 X-8 X-9 X-10 X-11 X-12

Power window

Exh. brake Heater Corner-

ing lampThermo

A/CCharge warning Key ON Heater

& A/C

12 V

NHR55 — —

NKR55 — —

NKR69 — —

NPR71 — —

NKR77 — — —

NPR77 — — —

NKR77 for Taiwan — — —

24 V

NKR66 — —

NPR66 — —

NQR66 — —

NPR70 — —

NQR70 — —

NKR71 — —

NQR71with turbocharger — —

NPS71 — —

NPR71 — —

NQR71w/o turbocharger — —

NPR75 — * —

NQR75 — * —


X-13 X-14 X-15 X-16

Heater Buzzer cancel ECM PTO

main TimingSmoother

emer-gency

PTO solenoid,

M/TPTO cut

12 V

NHR55 — — — — — — — —

NKR55 — — — — — — — —

NKR69 — — — — — — — —

NPR71 — — — — — — — —

NKR77 — — — — — —

NPR77 — — — — — —

NKR77 for Taiwan — — — — — —

24 V

NKR66 — — — — — — — —

NPR66 — — — — — — —

NQR66 — — — — — — —

NPR70 — — — — — —

NQR70 — — — — — —

NKR71 — — — — — — — —

NQR71with turbocharger — — — — — — —

NPS71 — — — — —

NPR71 — — — — — — —

NQR71w/o turbocharger — — — — — — —

NPR75 — — — — —

NQR75 — — — — —


*1 : For EC*2 : For Turkey*3 : For EC / Turkey

X-18 X-19 X-20 X-21 X-22 X-23 X-24

ECM main

Gear shifter Glow 2 Glow

plug Starter Marker lamp Rear fog A/C

COMP

12 V

NHR55 — — — — — —

NKR55 — — — — —

NKR69 — — — — —

NPR71 — — — — — —

NKR77 — — — *1 *1

NPR77 — — — *1 *1

NKR77 for Taiwan — — — — —

24 V

NKR66 — — — — — —

NPR66 — — — *2 *2 —

NQR66 — — — — — —

NPR70 — — — — — —

NQR70 — — — — — —

NKR71 — — — — — —

NQR71with turbocharger — — — *2 *2 —

NPS71 — — — — — —

NPR71 — — — — — —

NQR71w/o turbocharger — — — — — —

NPR75 — *3 *3 —

NQR75 — *3 *3 —


X-24 X-25 X-26 X-27 X-28

4WD ind. lamp

Exh. brake control

CSD A/C ON SIGNAL

Starter cut

Con-denser

fan

Exh. brake

cut

12V

NHR55 — — — — —

NKR55 — — — — —

NKR69 — — — — — —

NPR71 — — — — — —

NKR77 — — — — — —

NPR77 — — — — — —

NKR77 for Taiwan — — — — —

24V

NKR66 — — — — — —

NPR66 — — — — —

NQR66 — — — — —

NPR70 — — — — —

NQR70 — — — — —

NKR71 — — — — — —

NQR71with turbocharger — — — — —

NPS71 — — — — —

NPR71 — — — — —

NQR71w/o turbocharger — — — — — —

NPR75 — — — — —

NQR75 — — — — —


Diode Location

Connector No. B-17 B-18 B-25 J-23 L-1 L-3

Usage A/CDoor switch Lighting

QOS-III(Except GCC and Taiwan)

VSV: FICD(Except GCC and Taiwan)

Dome lightDome light(Except Tai-

wan)

N8A0055E


Reference Table of Grounding PointNotice:Abnormal phenomena of electrical components are considered resulted from defective grounding.In repair, be sure to inspect grounding points and to tighten all fastening parts surrounding the grounding points.

Grounding Point Location

Connector No. Cable harness name Location Main parts (Load)

B-1

Body harness

Frame-LH (FRT)Vehicle speed sensor, QOS-III control unit, Turn signalindicator light, Meter, High beam indicator light, PTOlever, TCM

B-7 Headlightbracket-LH

Charge relay, Exhaust brake relay, QOS-II control unit,QOS-III control unit, Dome light switch, Key remind andback up buzzer, Meter, Brake fluid switch, Tail relay,Cornering light switch, Cornering light, Cornering lightrelay, Fog light switch, Fog light, Dimmer relay, Doorlock switch, Door lock relay, Power window switch(RH), Power window relay, Stoplight switch, Mirrorswitch, Wiper motor, Washer motor intermittent relay,Radio, Cigar lighter, Heater & A/C relay, Fan switch,Horn relay, Rear heater switch, Rear heater, Radio &clock, Cigar lighter, Fan switch, Blower resistor, A/Cswitch, Blower motor, Electronic thermostat, Accelswitch, Door lock switch, Door lock controller, Headlightleveling switch, Headlight leveling motor, Power win-dow relay, Power window switch, QOS-III control unit,Ceramic heater relay, Emergency relay, Select switch,Emergency adjust switch, PTO-Smoother switch

J-9 Frame front har-ness Frame-LH (CTR)

Marker light relay, Marker light, Water sedimenterswitch, Fuel tank unit, Starter relay, Neutral switch, Fuelheater, Pressure switch, A/C thermo relay, VSV: FICD,Exhaust brake control relay, Exhaust brake magneticvalve, Accel switch, Clutch switch, VSV: intake throttle,Engine stop motor, ECM, ECM main relay, Starter cutrelay, Shift 1,3,5 solenoid, Shift 2,4,R solenoid, SelectsolenoidLicense plate light, Taillight, Rear fog light, Rear turnsignal light, Stoplight, Stoplight switch, Backup light

N8A5054E

B-7

N8A5055E


Cable Harness Routing

N8A5056E

FLOOR HARNESS (RH)

FLOOR HARNESS (LH)

N8A0060E


BODY HARNESS

DOOR HARNESS (RH)

DOME LIGHT HARNESS

DOOR HARNESS (LH)

N8A0061E


For Taiwan

RE

AR

FR

AM

E H

AR

NE

SS

FRO

NT

FR

AM

E H

AR

NE

SS

RE

AR

BO

DY

HA

RN

ES

S

N8A0062E


For GCC

RE

AR

FR

AM

E H

AR

NE

SS

FRO

NT

FR

AM

E H

AR

NE

SS

RE

AR

BO

DY

HA

RN

ES

S

N8A0063E


SYSTEM REPAIRStart and ChargingGeneral DescriptionThe system consists of the starter switch, starter, AC generator, starter relay, charge relay and heater and A/C relay.When the starter SW is set to the “ST” position, the battery voltage is applied to the starter solenoid coil through thestarter relay to start the starter.

• On the 4HK1 engine, the function that ECM controls STARTER RELAY is added.Starting Circuit

N8A0064E


Parts LocationFor 12 Volt

B-7

<4JB

1, 4

JG2>

N8A0065E


For 24 Volt

FU

SE

BO

X A

SM

F-1

6, F

-22

X-1

CH

AR

GE

RE

LAY

B-7

B-1

J-1,

J-2

GE

NE

RA

TO

R

FL-

1, F

L-2,

FL-

8 F

US

IBLE

LIN

KX

-21

ST

AR

TE

R R

ELA

YX

-26

ST

AR

TE

R C

UT

RE

LAY

(4H

K1)

N8A0066E


Circuit DiagramFor 4JB1, 4JB1-TC, 4JG2 Engine & 12 Volt

X-2

1X

-21

X-2

1

X-2

1

J-26

J-27

H-7

B

ST

AC

C

ON

B-6

7

B-6

7B

-67

H-1

4

H-1

4

X-1

1

X-1

1

X-1

1

H-5

X-1

4

H-5

X-1

1

E-1

7

E-1

8

E-1

8

E-1

8

B-7

J-9

P-1

P-2

P-5

1

1

12

32 4

5

3 4

8

1 3 4

5

2

11

15 10

1

23

1

30B

8B

3B/W

3W/B

3B/Y

3B/Y

0.3B/W

0.85

W

0.3B

0.3B

0.3B

0.5W

/R

0.5W

/R

0.5W

/R

0.5W

/R

1.25

B3B

0.85W/L

3W

0.85W

8 W

2B

0.5B

0.5B

/W

FRA

ME

ST

AR

TE

R

FL-1

100

AM

AIN

FL-2

50A

KE

Y S

W

FL-8

60A

ST

AR

TE

R

ST

AR

TE

R S

W

F-21

15A

GE

NE

RA

TO

R

RE

LAY

; CH

AR

GE

RE

LAY

; EX

HA

US

T

RE

LAY

; HE

AT

ER

& A

/C(2

)

BR

AK

E(2

)

CH

AR

GE

WA

RN

ING

LIG

HT

B-5

2 (

3)(M

ET

ER

)

QO

S II

I CO

NT

RO

LU

NIT

(6)

GE

NE

RA

TO

R

IGS

LB

HE

AD

LIG

HT

BR

AC

KE

T (

LH)

RE

LAY

; ST

AR

TE

R

F-22STARTER

10AQOS III CONTROL UNIT(11)QOS II CONTROL UNIT (4)

B

C

P-6

E-7

2

0.85W0.5W/L

B-1

5BFR

AM

E-L

H(F

RO

NT

)

FRA

ME

-LH

(CE

NT

ER

)

H-814

0.5B

/W

2L

2L

3W/B

FUS

E B

LOC

K

N8A0067E


For 4HG1-T Engine & 12 Volt

X-2

1X

-21

X-2

1

X-2

1

J-26

J-27

H-7

B

ST

AC

C

ON

B-6

7

B-6

7B

-67

H-1

4

H-1

4

X-1

1

X-1

1

H-5

X-1

1

H-5

X-1

1

E-1

7

E-1

8

E-1

8

E-1

8

J-9

P-1

P-2

P-5

1

1

12

32 4

5

3 4

8

3 4

5

2

11

15 10

1

23

1

30B

8B

3B/W

3W/B

3B/Y

3B/Y

0.3B/W

0.5B

/Y

0.5B

/Y

0.5B

/Y

0.5W

/R

0.5W

/R

0.5W

/R

0.5W

/R

0.85W/L

3W

0.85W

8W

2B

0.5B

0.5B

/W

FRA

ME

ST

AR

TE

R

FL-1

100

AM

AIN

FL-2

50A

KE

Y S

W

FL-8

60A

ST

AR

TE

R

ST

AR

TE

R S

W

F-16

10A

ME

TE

R

RE

LAY

; CH

AR

GE

RE

LAY

; EX

HA

US

T

RE

LAY

; HE

AT

ER

& A

/C(2

)

BR

AK

E(2

)

CH

AR

GE

WA

RN

ING

LIG

HT

B-5

2 (

3)(M

ET

ER

)

QO

S II

I CO

NT

RO

LU

NIT

(6)

GE

NE

RA

TO

R

IGS

LB

RE

LAY

; ST

AR

TE

R

F-22STARTER

10AQOS III CONTROL UNIT(11)QOS II CONTROL UNIT (4)

B

C

P-6

E-7

2

0.85W

FRA

ME

-LH

(CE

NT

ER

)

H-814

0.5B

/W

2L

2L

3W/B

FUS

E B

LOC

K

N8A0068E


For 4JH1 Engine & 12 Volt

X-2

1X

-21

X-2

1

X-2

1

J-26

J-27

H-7

ST

AC

C

ON

B-6

7

B-6

7B

-67

H-1

4

X-1

1

X-1

1

X-1

1

H-5

X-1

1

E-1

8

E-1

8

J-9

P-1

P-2

P-3

P-4

P-5

12

15 10

30B

8B

3B/W

3W/B

3W/B

3B/Y

3B/Y

0.3B/W

0.5B

/Y

0.5B

/Y

0.5W

/R

0.5W

/R

0.85W/L

3W

8W

2B

0.5B

0.5B

/W

FRA

ME

(12V

)

ST

AR

TE

R

FL-1

100

AM

AIN

FL-2

50A

KE

Y S

W

ST

AR

TE

R S

W

F-16

10A

ME

TE

RR

ELA

Y; C

HA

RG

E

ME

TE

R

RE

LAY

; FU

EL

RE

LAY

; HE

AT

ER

& A

/C(2

)

HE

AT

ER

(2)

GE

NE

RA

TO

R

RE

LAY

; ST

AR

TE

R

F-22STARTER

10A

P-6

E-7

2

0.85W/L0.85W/L

0.5W

/R

E-1

7

FRA

ME

-LH

(CE

NT

ER

)

H-814

43

4

2

53

0.5B

/W

2L

2L

FL-8

60A

ST

AR

TE

R

FUS

E B

LOC

K

1

2

2 4

3

5

1

1

N8A0069E


For 4JH1 Engine, NKR77 for Taiwan

X-2

1X

-21

X-2

1

X-2

1

J-26

J-27

H-7

B

ST

AC

C

ON

B-6

7

B-6

7B

-67

H-1

4

X-1

1

X-1

1

X-1

1

H-5

X-1

1

E-1

7E

-18

E-1

8

J-9

P-1

P-2

P-5

1

1

12

32 4

5

3 4

3 4

5

2 15 10

1

2

1

30B

8B

3B/W

8W3W

/B

3B/Y

3B/Y

0.5B

/Y

0.5W

/L

0.5W

/R

0.85W/L

8W/B

8W/B

3W/L

2B

0.5B

0.5B

/W

FRA

ME

ST

AR

TE

R

FL-1

100

AM

AIN

FL-2

50A

KE

Y S

W

FL-8

60A

ST

AR

TE

R

ST

AR

TE

R S

W

F-16

10A

ME

TE

R

RE

LAY

; CH

AR

GE

RE

LAY

; HE

AT

ER

& A

/C(2

)

CH

AR

GE

WA

RN

ING

LIG

HT

B-5

2 (

3)(M

ET

ER

)

GE

NE

RA

TO

R

S

LB

RE

LAY

; ST

AR

TE

R

F-22STARTER

10A

B

C

P-6

E-7

2

0.85W/L

0.5W

/L

FRA

ME

-LH

(CE

NT

ER

)

H-814

0.5B

/W

2L

2L

3W/B

FUS

E B

LOC

K

N8A0379E


Connector List For 12 Volt

No. Connector Face

X-11

B-67

B-67

E-17

E-18

E-18 (4JH1)

H-14

H-14

005-001

1

32 4

5

004-001

1 23 4

004-002

2

4

1

3

001-001

1

004-003

21

43

002-003

1 2

016-001

1 2 3 4

5 6 7 8

9 10 11 12

13 14 15 16

016-002

4 3 2 1

8 7 6 5

12 11 10 9

16 15 14 13

X-21

E-17 (4JH1)

J-26

P-6

J-27

P-1

P-4

P-2

No. Connector Face

005-003

1

2 3

54

000-002

000-002

000-002

001-002

1

000-004

000-004

000-006


H-5

H-6, H-7, H-8

P-3 (4JH1)

P-5

No. Connector Face

000-006

000-007

1 2 37 8 9

13 14 1519 20 2125 26 2731 32 33 34 35 36 37

4 5 610 11 1216 17 1822 23 2428 29 3038 39 40

6 5 412 11 1018 17 1624 23 2230 29 2840 39 38

3 2 19 8 715 14 1321 20 1927 26 2533 32 3134353637

N8A5488E

1 2

1 2

1 2 3 4

5 6 7 8

9 10 11 12 13

14 15 16 17 18

2 1

2 1

4 3 2 1

8 7 6 5

13 12 11 10 9

18 17 16 15 14

H - 6

H - 7

H - 8

N8A5489E


Circuit Diagram 4H Type Engine & 24 Volt (Except 4HK1 Engine)

X-1

X-1

H-5

X-1

X-1

J-1

J-2

B-6

7H

-7B

ST

AC

C

ON

J-26

B-6

7

B-6

7

H-8

X-2

1

X-2

1X

-21

X-2

1

J-9

P-1

P-2

P-3

P-4

P-5

1

23 4

3 4

5

2 15

11

14

2 4

3

1

1

5

J-1

2

30B

8B

3W/B

3B/W

3W/B(NPR70)

3B/Y

3W/B

3B/Y

2B

0.5B

0.5B

/W

5W

0.5W

/R

0.5W

/L

0.5W

/R

0.5B/W

FRA

ME

FL-1

100

A o

r 12

0AM

AIN

FL-2

40A

KE

Y S

W

FL-8

60A

ST

AR

TE

R

ST

AR

TE

R S

W

F-22 10ASTARTER

RE

LAY

; ST

AR

TE

R

ST

AR

TE

R

FRA

ME

-LH

(C

EN

TE

R)

BL

GE

NE

RA

TO

R

RE

LAY

; HE

AT

ER

&

A/C

(2)

RE

LAY

; CH

AR

GE

0.85W/LB

C

3W(NPR66/71)

P-6

QOS IICONTROL UNIT (4)

ME

TE

R

J-27

F-16

10A

RE

LAY

; EX

HA

US

TB

RA

KE

(2)

CH

AR

GE

WA

RN

ING

LI

GH

T B

-52

(3)

3W/B

0.85W/L

0.5B

0.5B

/W

2L

FUS

E B

LOC

K

N8A0070E


4HK1 Engine

X-1

X-1

H-5

X-1

X-1

J-1

J-2

B-6

7H

-7B

ST

AC

C

ON

J-26

B-6

7

B-6

7

H-8

X-2

1

X-2

1X

-21

X-2

1

P-1

P-2

P-3

P-4

P-5

1

23 4

4 3

1

5

15

11

14

3 4

2

1

1

5

J-1

2

30B

2B0.5B8B

3W/L

3B/W

3W/B

3B/Y

0.5B

/Y

3W/L

3B/Y

0.3B

/W

8W/B

1.25

W/L

0.5W

/R

0.5W

/L

0.3B/W

FR

AM

E

FL-

1 1

00A

or

120A

MA

INF

L-2

40A

KE

Y S

W

FL-

8 6

0AS

TA

RT

ER

ST

AR

TE

R S

W

F-22 10ASTARTER

RE

LAY

; ST

AR

TE

R

X-2

6

X-2

6X

-26

X-2

6

4 3

1

5

RE

LAY

;S

TA

RT

ER

CU

T

ST

AR

TE

R

FR

AM

E-L

H(C

EN

TE

R)

BL

GE

NE

RA

TO

R

RE

LAY

; CH

AR

GE

0.85W/L

B

C

P-6

QOS IICONTROL UNIT (4)

ME

TE

R

J-27

F-1

6 1

0A

RE

LAY

;H

EA

TE

R&

A/C

(2)

CH

AR

GE

WA

RN

ING

LI

GH

T B

-52

(3)

3W/L

0.5W/L

0.5R

/W

0.85

LG0.

5LG

0.5R

2L

FU

SE

BLO

CK

J-9

EC

M M

AIN

RE

LAY

EC

M

F-2

8 1

0AE

CM

N8A0521E


Connector List For 24 Volt

No. Connector Face

B-7

X-1

B-67

B-67

J-1

J-2

J-9

X-21

000-012

005-006

004-001

1 23 4

004-002

2

4

1

3

002-003

1 2

000-001

000-001

005-003

1

2 3

54

X-26 (N*R 75)

J-26

P-5

J-27

P-1

P-4

P-2

P-3

No. Connector Face

005-006

000-002

000-002

000-009

000-004

000-004

000-006

000-006


H-5

H-6, H-7, H-8

Starter SwitchThe starter switch positions are LOCK, ACC, ON andSTART. Turning the starter key to these positions a cir-cuit for starting the engine, the operation of accessories,or stop the engine.

P-6 (N*R 66)

No. Connector Face

000-008

1 2 37 8 9

13 14 1519 20 2125 26 2731 32 33 34 35 36 37

4 5 610 11 1216 17 1822 23 2428 29 3038 39 40

6 5 412 11 1018 17 1624 23 2230 29 2840 39 38

3 2 19 8 715 14 1321 20 1927 26 2533 32 3134353637

N8A5488E

1 2

1 2

1 2 3 4

5 6 7 8

9 10 11 12 13

14 15 16 17 18

2 1

2 1

4 3 2 1

8 7 6 5

13 12 11 10 9

18 17 16 15 14

H - 6

H - 7

H - 8

N8A5489E

N8A0072E


InspectionCheck the continuity between the starter switch connector terminals.Repair or replace the switch when the result of inspection is found abnormal.

RemovalPreparation:Disconnect the battery ground cable.

1. Steering CowlRemove four screws and take off the steering cowl.

2. Starter Switch1) Disconnect the connector.2) Remove the screw.

N8A0073E

N8A0074E


QOS (Quick On Start) II System (4HF1 and 4JB1 Engine Model)General DescriptionThe circuit consists of starter switch, QOSII control unit, glow relay, thermo switch, glow plug, fuel cut solenoid, CSDrelay, CSD solenoid and glow indicator light.The QOS-II controller controls glow plug relay by the ON or OFF signal of QOS thermo switch.Immediately when the starter switch turns “ON”, the glow plug relay indicator light turns on to start preheating.The engine should be started after the indicator light is off. However, the glow plug relay keeps preheating for a fixedperiod even after the indicator light turns off. When the fixed time is over, QOS-II controller performs to switch theglow plug relay off to stop preheating.For details, refer to “PREHEATING SYSTEM”.System Circuit

N8A0075E


Parts Location

F-16

, F-2

2

X-2

0 G

LOW

RE

LAY

X-2

6 C

SD

RE

LAY

(55

)

B-7

N8A0076E


Circuit DiagramNHR55, NKR55

H-5

1

B-5

1

B-5

1

B-1

0

H-5

B-1

0

7

B

ST

AC

C

ON

1

B-6

7B

-67

H-7

B-1

0

H-8

B-1

0B

-10

B-7

P-1

P-2

P-5

B-6

7

23 4

22

3

E-3

5

B-1

0

13

6

8 6

371

4

FR

AM

E

FL-

1 1

00A

MA

IN

FL-

2 5

0AK

EY

SW

FL-

3 6

0AG

LOW

5B/L

3W/L

ST

AR

TE

R S

W

3B/Y

F-1

6 1

0AM

ET

ER

F-2

2 1

0A

ST

AR

TE

R

GLO

W P

LUG

3B

0.3B/R

0.3B

/R

0.5B/Y 0.3O/L

0.5B/Y 0.3B/Y

0.5GR

0.5B/W

THERMO SW(GLOW)

GLOW INDICATOR LIGHT (METER)

QO

S II

CO

NT

RO

L U

NIT

0.5B

0.5G

R

HE

AD

LIG

HT

BR

AC

KE

T (

LH)

B-1

FR

AM

E-L

H (

FR

ON

T)

5B

1

CSD SOLENOID2

3

45

X-2

6X

-26

X-2

6X

-26

H-1

415

0.5B/Y

0.5B/Y

RELAY; STARTER (4)

3W/B

3B/Y

0.5GR

H-1

45

0.5Y

0.5L

1.25L

RELAY; CSD

0.5B/W

E-8

E-2

4

0.5B

/Y0.

3B/Y

RE

LAY

;GLO

W

X-2

0 2

X-2

03

X-2

0 5

X-2

04

5B/Y

0.5B/Y

2L

FU

SE

BLO

CK

N8A0077E


NKR66, NPR66, NQR66

B-5

1

B-5

1

B-1

0

E-8

H-1

4

H-5

B-1

0

7

B

ST

AC

C

ON

1

B-6

7B

-67

H-5

H-7

B-1

0

B-1

0

B-7

P-1

P-2

P-3

P-4

P-5

B-6

7

23 4

B-1

0

13

6

8 6

8 37

1

4

FR

AM

E

FL-

1 1

00A

or

120A

MA

IN

FL-

2 4

0AK

EY

SW

FL-

3 6

0AG

LOW

3B/Y

ST

AR

TE

R S

W

3B/Y

3B/Y

F-1

6 1

0AM

ET

ER

F-2

2 1

0AS

TA

RT

ER

GLO

W P

LUG

HE

AD

LIG

HT

BR

AC

KE

T (

LH)

3B

0.5B/Y

0.3O/L

0.3B/Y

0.5Y

0.5B/W

0.5B/W

RELAY; STARTER (4)

THERMO SW (GLOW)

GLOW INDICATOR LIGHT (METER)

QO

S II

CO

NT

RO

L U

NIT

0.5B

0.5Y

0.5Y

3W/B

B-1

FR

AM

E-L

H (

FR

ON

T)

5B

3W/L

0.5B

/Y22

H-1

4 1

H-8

B-1

0

163

E-3

50.3B/R

0.3B

/R

RELAY;GLOW

X-2

0 2

X-2

03

X-2

0 5

X-2

04

3B/L 3B/Y

2L

FU

SE

BLO

CK

0.5B/Y

0.5B/Y

N8A0380E


Connector List

No. Connector Face

B-1

B-7

B-10

B-51

B-67

B-67

E-3

E-8

000-001

000-012

007-001

64

1

7

3

5

2

014-001

1 2 3 4 5 6 7 8 9 1011121314

004-001

1 23 4

004-002

2

4

1

3

000-009

000-010

E-8

E-15

E-15

E-24

E-24

H-14 (4H/4JH1 type

ENGINE)

H-14 (4H/4JH1 type

ENGINE)

X-20

No. Connector Face

000-011

001-002

1

001-003

1

001-002

1

001-003

1

016-003

1 2 3 4

5 6 7 8 9

11 12 13 14

15 16

10

016-004

4 3 2 1

9 8 7 6 5

13 12 11 10

16 15

14

005-003

1

2 3

54


H-5

H-7, H-8

Starter SwitchRefer to “START AND CHARGING” in this section.

Glow Indicator Light Thermo SwitchRefer to “METER AND WARNING/INDICATOR LIGHT”in this section.

X-26

P-1

P-4

P-2

P-3

P-5

H-14 (4J type

ENGINE)

(Except 4JH1)

H-14 (4J type

ENGINE)

(Except 4JH1)

No. Connector Face

005-006

000-004

000-004

000-006

000-006

000-002

016-001

1 2 3 4

5 6 7 8

9 10 11 12

13 14 15 16

016-002

4 3 2 1

8 7 6 5

12 11 10 9

16 15 14 13

1 2 37 8 9

13 14 1519 20 2125 26 2731 32 33 34 35 36 37

4 5 610 11 1216 17 1822 23 2428 29 3038 39 40

6 5 412 11 1018 17 1624 23 2230 29 2840 39 38

3 2 19 8 7

15 14 1321 20 1927 26 2533 32 3134353637

N8A5488E

1 2

1 2

1 2 3 4

5 6 7 8

9 10 11 12 13

14 15 16 17 18

2 1

2 1

4 3 2 1

8 7 6 5

13 12 11 10 9

18 17 16 15 14

H - 6

H - 7

H - 8

N8A5489E


QOSII Control Unit

Exhaust Brake System

General DescriptionThis circuit consists of starter switch, exhaust brakeswitch (combination switch), accelerator switch, clutchswitch, vacuum switching valve, neutral switch and re-lay.Exhaust brake is a system to increase exhaust pressureby means of squeezing exhaust gas from engine andexert engine brake.Turn the exhaust brake SW on, and the exhaust brakevalve starts to work by the function of the magnetic valveto enable the exhaust bake to operate, when the ex-haust brake indicator light will be on.When either the accelerator pedal or the clutch pedal isdepressed while driving, the switch of the depressedpedal will turn off, subsequently the exhaust braking willstop working.

Terminal No. Connected to

1 Starter switch (ON)

2 —

3 Thermo switch

4 Starter switch (ST)

5 Glow relay

6 Ground

7 Glow indicator (Meter)

N8A0079E


Parts LocationNHR55, NKR55

F-2

, F-1

6, F

-21

X-8

EX

HA

US

T B

RA

KE

RE

LA

Y

B-5

2 E

XH

AU

ST

BR

AK

E IN

DIC

AT

OR

LIG

HT

(M

ET

ER

)

X-1

1

X-2

5

B-7

EX

HA

US

T B

RA

KE

MA

GN

ET

IC V

ALV

E(N

HR

/NK

R55

(T

OR

TC

) O

NLY

)

(NH

R/N

KR

55 (

NIA

) on

ly)

N8A0084E


NKR66, NPR66, NQR66

N8A0085E


Circuit DiagramNHR55, NKR55

B

ST

ACC

ON

1

B-67B-67H-7

B-7

P-1

P-2

P-5

2

3

FRAME

FL-1 100AMAIN2L

FL-2 50AKEY SW

STARTER SW

3B/Y

HEADLIGHT BRACKET (LH)

3W/B

J-9FRAME-LH (CENTER )

3B

3W/L

1

X-8

X-8

X-8

X-8

2

RE

LAY

;E

XH

AU

ST

BR

AK

E

2

H-6

5 4

3W3W

/B5W

OFF

X-11 X-11

X-11

23

X-11

22

H-5

J-50B-69

B-69 J-50

H-8

X-25

5

X-25

X-25

3 2

X-25

4

B-89

H-8

B-89

B-75

B-75

H-5

J-31

J-31

1

2

EX

HA

US

T B

RA

KE

MA

GN

ET

IC V

ALV

E

J-40

J-40

1

2

F-2F-

21

0.5B

0.5B

2B

2B

VS

V; I

NT

AK

E T

HR

OT

TLE

0.5LG

0.5L

G

32

1

2

2

1

0.5L

G/B

0.5L

G/R

CLU

TC

H S

WA

CC

EL.

SW

0.5B

12

0.5L

G/B

RE

LAY

;E

XH

AU

ST

BR

AK

E

CO

NT

RO

L

17

0.5L

G/R

0.5L

G/R

0.5G

/B

2 1

5 2

NE

UT

RA

L S

W

EX

HA

US

T B

RA

KE

SW

(C

OM

BIN

AT

ION

SW

)

0.5LG

F-16

15A

15A

10A

FUEL HEATEREXH. BRAKE

GE

NE

RA

TO

R(N

*R55

)

0.5B

/Y0.

5B/Y

METER

3B/Y

0.85

W

GENERATOR (L)

0.85

W/L

RE

LAY

; C

HA

RG

E

45

3B/R

0.5B

0.5W

/R0.

85W

/R

N8A0086E


NKR66, NPR66, NQR66

B

ST

ACC

ON

1

B-67B-67H-7

B-7

P-1

P-2

P-3

P-4

P-5

2

3

FRAME

FL-1 100AMAIN2L

FL-2 40AKEY SW

STARTER SW

3B/Y


3W/B

J-9FRAME-LH (CENTER )

3B

3W/L

1

X-8

X-8

X-8

X-8

2R

ELA

Y;

EX

HA

US

T B

RA

KE

2

H-6

5 4

3W5W

OFF

X-1 X-1

X-1

23

X-1

22

H-5

B-69

B-69

H-8

X-25

5

X-25

X-25

3 2

X-25

4

B-89

H-8

B-89

B-75

B-75

H-5

J-31

J-31

1

2

EX

HA

US

T B

RA

KE

MA

GN

ET

IC V

ALV

E

J-40

J-40

1

2

F-13

0.5B

0.5B

2B

2B

VS

V; I

NT

AK

E T

HR

OT

TLE

0.5LG

0.5L

G

32

1

2

2

1

0.5L

G/B

0.5L

G/R

CLU

TC

H S

WA

CC

EL.

SW

0.5B

12

0.5L

G/B

RE

LAY

;E

XH

AU

ST

BR

AK

E

CO

NT

RO

L

170.

5LG

/R0.

5LG

/R

0.5G

/B

2

5

EX

HA

US

T B

RA

KE

SW

(C

OM

BIN

AT

ION

SW

)

0.5LG

F-16

10A

10A

FUEL HEATEREXH. BRAKE

0.5B

/Y0.

5B/Y

METER

0.85

W

GENERATOR (L)0.

85W

/L

RE

LAY

; C

HA

RG

E

45

3B/R

0.5B

0.5W

/R0.

85W

/R

E-11

E-11

H-14

H-14

1

2

NE

UT

RA

L S

W

5

10

N8A0381E


Connector List

No. Connector Face

X-1

X-8

X-11

X-25

B-69

B-69

B-75

B-75

005-006

005-006

005-001

1

32 4

5

005-006

008-001

1

5

2

6

3

7

4

8

008-002

1

5

23

67

4

8

002-022

1 2

002-023

2 1

B-89

B-89

E-11

E-11

J-50

J-50

H-14

H-14

No. Connector Face

002-009

1

2

002-010

1

2

002-001

1 2

002-002

12

002-001

1 2

002-002

12

016-003

1 2 3 4

5 6 7 8 9

11 12 13 14

15 16

10

016-004

4 3 2 1

9 8 7 6 5

13 12 11 10

16 15

14


H-5

J-31

J-31

J-40

P-1(12 V)

P-1(12 V)

P-2

P-2

P-2(24 V)

No. Connector Face

002-011

1 2

002-012

12

002-014

1 2

000-003

000-004

000-003

000-004

000-006

P-3

P-1(24 V)

P-4

P-5(12 V)

P-5(24 V)

No. Connector Face

000-006

000-004

000-004

000-007

000-002

1 2 37 8 9

13 14 1519 20 2125 26 2731 32 33 34 35 36 37

4 5 610 11 1216 17 1822 23 2428 29 3038 39 40

6 5 412 11 1018 17 1624 23 2230 29 2840 39 38

3 2 19 8 7

15 14 1321 20 1927 26 2533 32 3134353637

N8A5488E


H-6, H-7, H-8

Neutral SwitchRefer to “START AND CHARGING” in this section.

Starter RelayRefer to “START AND CHARGING” in this section.

Charge RelayRefer to “START AND CHARGING” in this section.


Accel SwitchInspection

1. Check the continuity between the switch connectorterminals.

2. Check to see if switch plunger operates smoothly.Repair or replace the accel switch when result ofinspection is found abnormal.


1. Accel Switch1) Disconnect the connector.2) Remove the two screws.

InstallationTo install, follow the removal steps in the reverse order,noting the following points.

1. Check to see if the accel pedal has been returnedby the return spring to the specified position.

Clutch SwitchInspection

1. Check the continuity between the switch connectorterminals.

2. Check to see if switch push rod operates smoothly.Repair or replace the switch when result of inspec-tion is found abnormal.

1 2

1 2

1 2 3 4

5 6 7 8

9 10 11 12 13

14 15 16 17 18

2 1

2 1

4 3 2 1

8 7 6 5

13 12 11 10 9

18 17 16 15 14

H - 6

H - 7

H - 8

N8A5489E

N8A0087E

N8A0088E

N8A0089E



1. Clutch Switch1) Disconnect the connector.2) Loosen the lock nut of the switch.3) Remove the switch by turning it.


1. Check to see if the clutch pedal has been returnedby the return spring to the specified position.

2. Turn the clutch switch clockwise until the tip of thethreaded portion of the switch contacts the pedalarm.

3. Tighten the lock nut to the specified torque.

Tighten:Lock nut to 13 N⋅m (130 kg⋅cm / 115 lb⋅in)

Exhaust Brake SwitchInspectionCheck the continuity between the terminals of the exhaust brake switch.Repair or replace the switch when the result of inspection is found abnormal.

N8A0088E

N8A0091E


Removal and InstallationRefer to “HEADLIGHT, FOG LIGHT AND CORNERINGLIGHT” in this section.

Exhaust Brake Magnetic Valve (4H Series En-gine)InspectionConnect the magnetic valve connector terminal No. 1 tothe battery (+) terminal and terminal No. 2 to the (−) ter-minal and then check the continuity among each port.

Vacuum Switching Valve: Intake Throttle (4HSeries Engine)InspectionConnect the magnetic valve connector terminal No. 1 tothe battery (+) terminal and terminal No. 2 to the (−) ter-minal and then check the continuity among each port.Repair or replace the vacuum switching valve when theresult of inspection is found abnormal.

N8A0094E

N8A0096E


Exhaust Brake System and Engine ControlParts LocationFor 4HE1-TC Engine

N8A0097E


For 4JH1 Engine

P-5 P

-4P-3

BA

TT

ER

Y (

12V

)

P-1

P-2

B-5

1, B

-52

EX

HA

US

T B

RA

KE

IND

ICA

TO

R L

IGH

T(M

ET

ER

)B

-55

SP

EE

DO

ME

TE

R

X-1

4 E

CM

RE

LAY

X-1

0 A

/C T

HE

RM

O R

ELA

Y

RE

LAY

BO

X A

SM

(No.

1)

B-1

8 D

IOD

EX

-12

HE

AT

ER

A/C

RE

LAY

X-1

1 C

HA

RG

E R

ELA

Y

B-3

1 E

NG

INE

WA

RM

ING

SW

EX

HA

US

T B

RA

KE

SW

ST

AR

TE

R S

W

H-1

4

J-17

7 A

BS

; C

/U

J-50

NE

UT

RA

L S

W

J-32

VE

HIC

LE S

PE

ED

SE

NS

OR

J-9

B-6

6 B

RA

KE

SW

B-8

9 C

LUT

CH

SW

B-7

9D

AT

A L

INK

CO

NN

EC

TO

R

B-8

0 T

HR

OT

TLE

PO

SIT

ION

S

EN

SO

R B-3

40 ID

LE L

SW

B-3

41

RE

SIS

TO

R ID

LE L

SW H

-5~

H-8

B-2

33, B

-234

EC

M B-7

B-2

32JO

INT

CO

NN

EC

TO

R-2

B-2

9JO

INT

CO

NN

EC

TO

R-1

B-3

42 N

EU

TR

AL

SW

RE

SIS

TO

R

B-3

39 A

/C O

NS

IGN

AL

RE

SIS

TO

R

B-3

43 J

OIN

T C

ON

NE

CT

OR

RE

LAY

BO

X A

SM

(No.

2)

FU

SE

BO

X A

SM

F-1

, F-5

,F

-8, F

-9,

F-1

6

J-6

PR

ES

SU

RE

SW

B-6

7

B-6

9

H-1

4

RE

LAY

BO

XS

BF

1, S

BF

2, S

BF

3, S

BF

25 F

US

IBLE

LIN

KX

-20

GLO

W R

ELA

YX

-24

A/C

CO

MP

RE

SS

OR

RE

LAY

X-2

6 A

/C S

IGN

AL

RE

LAY

J-10

5 E

VR

V :

EG

RJ-

40

VS

V

: IN

TA

KE

TH

RO

TT

LE

J-31

EX

H B

RA

KE

MA

GN

ET

IC V

ALV

E(B

)

E-5

MA

GN

ET

IC

CLU

TC

H

J-18

2 M

AS

S A

IR F

LOW

SE

NS

OR

J-18

3 T

DC

E-1

6C

OO

LAN

TT

EM

PE

RA

TU

RE

SE

NS

OR

J-12

2 G

LOW

PLU

G

E-1

10 IN

JEC

T P

UM

P

FR

AM

EH

AR

NE

SS

N8A0099E


For 4HK1-TC Engine

RE

LAY

BO

X A

SM

(N

o. 2

)

FU

SE

BO

X A

SM

F-2

, F-7

,F

-9, F

-16,

F-2

2

B-4

31R

ES

IST

OR

2

B-3

87R

ES

IST

OR

1B-7

9D

AT

A L

INK

CO

NN

EC

TO

R

B-5

1, B

-53

ME

TE

R

B-6

7 S

TA

RT

ER

SW

B-1

B-7

H-1

5

P-5

P-1

P-2

BA

TT

ER

Y

P-3

P-4

F-2

8 F

US

ES

BF

1, S

BF

2, S

BF

3, S

BF

5, S

BF

8F

US

IBLE

LIN

KX

-18

EC

M M

AIN

RE

LAY

X-2

1 S

TA

RT

ER

RE

LAY

X-2

6 S

TA

RT

ER

CU

T R

ELA

Y

RE

LAY

BO

X A

SM

H-1

2

H-4

, H-5

, H-6

,H

-7, H

-8

RE

LAY

BO

X A

SM

(N

o. 1

)S

TA

RT

ER

SW

MA

FS

EN

SO

R

MA

PS

EN

SO

R

RE

V S

WJ-

50N

EU

TR

AL

SW

J-31

EX

H B

RA

KE

MA

GN

ET

IC V

ALV

E (

B)

X-1

4 S

MO

OT

HE

RE

ME

RG

EN

CY

RE

LAY

X-1

CH

AR

GE

RE

LAY

X-3

3 D

IOD

E

J-9

B-4

25, B

-426

,B

-427

, B-4

28T

CM

B-3

1E

NG

INE

WA

RM

ING

SW

J-19

1 E

CM

N8A0530E


Circuit Diagram4HE1-TC Engine (1)

N8A0100E


4HE1-TC Engine (2)

SW

:LO

W(N

-SP

EC

ON

LY)

RE

LAY

:GLO

W

J-131

2

J-145 VSV:VSS

J-145

0.5B/Y

0.5B/Y

0.5B/Y

3B/L

0.5B/Y

2

1

B-233

X-20

B-233

B-11VSV:VSS

11

H-14

4

E-76

THERMO SENSOR

HEAD LIGHTBRACKET-LH

RACK SENSOR ENGINE SPEED SENSOR EVRV:EGR

2

X-20

4

7

H-5

26

B-233

H-14

8

E-76

1

8

H-5

27

5

X-20

2

B-233

J-146

B-13VSV:

ANECON

VSV:ANEROIDCOMPENSATOR

13

0.5B

R/B

0.5B

R/Y

0.5

BR

/W

0.5B

R/B

0.5B

R/Y

0.5B

R/W

0.3B

R/B

0.3B

R/Y

0.3B

R/W

0.3Y

0.3B

/Y

0.3L

J-146

2

1

B-233

J-147

B-1VSV:EGR

VSV:EGR

1

H-13

1

B-234

2

H-8

8

H-13

3

H-13

5

H-8

9

H-8

18

H-5

40

X-14

2

J-147

2

1

H-1311

B-234

B-79

DATA LINKCONNECTOR

0.5B

/Y

0.5B

/Y

0.5B

/Y

0.5B

/Y0.

5B/Y

0.3B

/R0.

3B/R

0.5L

G/B

0.3G

R/B

0.3G

R

0.5B

0.5W

0.5R

0.3G

R/B

0.3G

R

0.5B

0.5W

0.5R

0.3V

0.3L

G

0.3G

R/B

0.3G

R

0.5B

0.5W

0.5R

0.3V

0.3L

G

0.85

BR

/R

0.5R

/W

0.5O

0.5B

R/R

0.5R

/W

0.3B

0.5O

0.5B

0.5B

R/R

RE

LAY

:TIM

ING

0.5R

/W

0.3B

R/Y

0.5O

0.3L

G

0.3V

0.3V

0.5L

G/B

3B/Y

5B/Y

A-1CHECKER

1

7

B-234

B-79

A-15GND

15

3

B-234

B-79

A-16DIAG

A-27

ECMB-2

GLOWRELAY

16

B-234

27

H-5

29

B-233

2

6

J-131

1

J-105

2

J-105

1

MA

GN

ET

IC V

ALV

E:T

IMIN

G

E-74

1

H-14

11

H-522

X-20

3

H-8

3

H-14

GLOW PLUG

16

1

E-3

B-234

H-14

1

E-43

1

21

H-5

13

B-234

RACKSIGA-7

H-14

2

E-43

2

7

H-5

7

B-234

H-14

3

E-43

3

6

H-5

1

B-233

H-14

12

E-2

1

9

H-8

16

B-233

ENG SIGB-10

ENG-B-9

RACK+A-6

RACK-A-21

THERMO SIGB-8

THERMO GNDB-7

B-234

H-14

13

E-2

2

10

B-234

1411

B-234

EVRV+A-13

EVRV-A-14

MVTIMING

A-11

13

B-234

GNDA-22

22

5

X-14

4H-8

15X-14

12H-8

H-13

10

6H-8

H-13

4

5H-8

X-14

1

A

B-7

INT

AK

ET

EM

PS

W

N8A0101E


4JH1 Engine (1)S

BF

-1M

AIN

100A

F-8

EN

G.(

B1)

15A

F-5

ST

OP

LIG

HT

10A

F-9

EN

G.(

B2)

15A

2L8B

LK

8 WH

T/

BLK

30 BLK

8 WH

T/

BLK

3 WH

T/

BLK

0.5

WH

T/

RE

D

3 WH

T/

BLK

0.5

WH

T/

BLU

3 BLK

/B

LU

3 BLU

0.5

BLK

0.5

GR

Y/

YE

L

2 WH

T/

BLK

3 BLK

/Y

EL

0.5

BLK

/Y

EL

0.5

BLK

/Y

EL

0.5

BLK

/Y

EL

0.5

BLK

/Y

EL

3 BLK

/Y

EL

3 BLK

/Y

EL

EC

M M

ain

Rel

ay

0.85

BR

N2 B

LU

A/C

The

rmo

Rel

ay

B-7

Hea

dlig

htB

rack

et

Dat

a Li

nkC

onne

ctor

Bra

keS

witc

h

30B

LK

2H

-6

Sta

rter

AC

G

Met

er

42

53

X-1

1

X-1

1 Cha

rge

Rel

ay

42

51

X-1

2

X-1

2 Hea

ter

A/C

Rel

ay

F-1

AIR

CO

N10

A

SB

F-2

5H

EA

TE

R30

A

2 BLK

3 BLK

5 BLK

Sta

rter

Rel

ay

21

ST

ON

AC

CO

FF

Igni

tion

Sw

itch

B-6

7

3B

-67

H-7

SB

F-2

KE

Y50

A

SB

F-3

GLO

W60

A

3 WH

T/

BLU

Glo

w R

elay

P-1

P-3

P-2

P-5

P-4

Bat

tery

EC

MW

/S-M

Fus

e &

Rel

ay B

ox(B

ehin

d th

e C

ab)

Fus

e &

Rel

ay B

ox(G

love

Box

)

Rel

ay B

ox(I

nstr

umen

t P

anel

)

3 WH

T/

BLU

A/C

The

rmo

Rel

ay

Fus

e &

Rel

ay B

ox(G

love

Box

)

N6A3862E


4JH1 Engine (2)

25

X-1

13

X-1

ST

ON

AC

CO

FF

Igni

tion

switc

h

3 BLK

/Y

EL

0.5

BLK

/Y

EL

21

B-6

7

31

H-7

8BLK

SB

F-2

KE

Y50

A

3 WH

T/

BLU

3 WH

T/

BLU

3 WH

T/

BLU

B-6

74

2H

-6

F-2

2S

TAT

ER

10A

F-1

6M

ET

ER

10A

F-2

0A

BS

(IG

)10

A

F-1

5A

UD

IO(I

G),

CIG

AR

LIG

HT

ER

15A

Key

ON

Rel

ay

F-1

2H

/LA

MP

LEV

EL

10A

F-1

1T

UR

NLI

GH

T10

A

F-1

0F

RO

NT

WIP

ER

&W

AS

HE

R15

A

F-2

5M

AR

KE

RLA

MP

15A

F-2

7R

R F

OG

10A

F-2

6C

ON

D.F

AN

15A

SB

F-1

MA

IN10

0A

SB

F-2

6P

OW

ER

WIN

DO

W30

A

SB

F-8

STA

RT

ER

60A

SB

F-9

AB

S60

A

SB

F-3

GLO

W60

A

SB

F-4

HE

AD

LAM

P30

A

Hea

ter

Rel

ay

Glo

w P

lug

Rel

ay

F-4

AU

DIO

(B

),D

OO

R L

OC

K15

A

F-5

ST

OP

LIG

HT

10A

F-8

EN

G.

(B1)

15A

F-9

EN

G.

(B2)

15A

F-1

9H

OR

N,

HA

ZA

RD

15A

2 WH

T/

BLK

3 WH

T/

BLK

3 WH

T/

BLK

3 WH

T/

BLU

3 BLU

0.5

BLK

W/S

-GW

/S-H

W/S

-A

Bat

tery

2BLK

/YE

L

Fus

e &

Rel

ay B

ox(B

ehin

d th

e C

ab) F

use

&R

elay

Box

(Glo

ve B

ox)

Hea

ter

Rel

ay

N6A3863E


4JH1 Engine (3)

Ref

er to

Pow

er D

istr

ibut

ion

Ref

er to

Pow

er D

istr

ibut

ion

SB

F-2

KE

Y50

A

30 BLK

3 BLK

/W

HT

3 WH

T/

BLK

3 WH

T/

BLK

E-7

2P

-6J-

26

3 BLK

/W

HT

SB

F-8

STA

RT

ER

60A

3 WH

T/

BLU

3 WH

T/

BLU

P-1

P-2

P-3

P-2

P-5

P-4

Bat

tery

J-9

Fra

me2 BLK

0.5

BLK

Sta

rter

Rel

ayF

-22

STA

RT

ER

10A

4B

-67

14H

-82B

-67

1H

-7

30B

LK8B

LK

2L

Fus

e &

Rel

ay B

ox(B

ehin

d th

e C

ab)

Fus

e &

Rel

ay B

ox(G

love

Box

)

313

H-3

2P

-81

P-8

P-9

3 WH

T

0.85

WH

T/B

LU

0.85

WH

T/B

LU

0.5

WH

T/B

LU

8 WH

T

H-6

SB

Gen

erat

or

L

ST

ON

AC

CO

FF

Igni

tion

switc

h

Rel

ay B

ox(I

nstr

umen

t P

anel

)

53

4

X-8X-8

2

0.5

BLK

/Y

EL

0.5

BLK

/Y

EL

42

53

X-1

1

X-1

1 Cha

rge

Rel

ay

Fus

e &

Rel

ay B

ox(G

love

Box

)

F-1

6M

ET

ER

10A

Hea

ter

A/C

Rel

ayW/S

-M

Rel

ay B

ox(I

nstr

umen

t P

anel

)

Sta

rter

B C 1J-

27

1

M

N6A3864E


4JH1 Engine (4)

CA

Nhi

ghC

AN

low

ES

Oso

leno

idsi

gnal

outp

ut

12V

Bat

tery

volta

ge

EC

Mm

ain

rela

yco

ntro

l

3 BLU

/R

ED

3 BLU

/R

ED

0.5

BLU

/B

LK

2 BLU

/R

ED

583

B-2

33

EC

M

1H

-615

H-1

4

7E

-110

1056 11

100

9912

CA

Nhi

ghC

AN

low

BA

T (

+)

16

6

2 BLK

2 BLK

0.5

RE

D0.

5Y

EL

0.5

BLU

0.5

YE

L

127

138

105

918

H-8

H-1

4

E-1

105E

SO

sole

noid

sign

al

CK

Pse

nsor

sign

al

J-9

Fra

me

PC

U

CK

Pse

nsor

sign

alou

tput

Exh

aust

Bra

ke S

olen

oid

Val

veIn

take

Thr

ottle

Sol

enoi

d V

alve

Neu

tral

Sw

itch

A/C

Com

pres

sor

Rel

ayA

/C S

igna

l Rel

ayM

AF

& IA

T S

enso

r

Glo

w R

elay

1.25

BLK

/Y

EL

3 BLK

/Y

EL

3 BLK

/Y

EL

EC

MM

ain

Rel

ay

F-8

EN

G.(

B1)

15A

Fus

e &

Rel

ay B

ox(G

love

Box

)

Rel

ay B

ox(I

nstr

umen

t P

anel

)

45

2

X-1

4

X-1

41

2BLU

/RE

D

2 RE

D/

WH

T 0.5

PN

K

0.5

PN

K

0.5

PN

K

0.5

OR

N

0.5

OR

N

0.5

OR

N

0.5

BLU

0.5

YE

L

F-1

6M

ET

ER

10A

0.5

BLK

/Y

EL

Met

er

39B

-234

Igni

tion

volta

ge

W/S

-M

2 BLU

/R

ED

F-9

EN

G.(

B2)

15A

N6A3866E


4JH1 Engine (5)G

roun

dG

roun

d

2 BLK

3 BLK

/Y

EL

2 WH

T/

BLK

2 WH

T/

BLK

0.5

BLK

/Y

EL

2 BLK

5 BLK

0.5

BLU

0.5

YE

L

F-8

EN

G.(

B1)

15A

EC

M

Dat

aLi

nkC

onne

ctor

(DLC

)

451

B+

235

B-2

34

Key

wor

d20

00

Dia

gnos

ticre

ques

tsw

itch

Key

wor

d20

00

616

7B

-79

5 5 9

4B

-79

B-7

Hea

dlig

ht B

rack

et

0.5

BLK

0.5

BLK

0.85

BLK

0.85

BLK

Gro

und

Gro

und

EH

CU

429

J-17

7

212

43

H-1

5

2627

H-5

0.3

WH

T/

BLK

0.3

WH

T/

BLK

0.3

WH

T/

BLK

0.3

WH

T/

GR

N

0.3

WH

T/

GR

N

0.3

WH

T/

GR

N

J185

0(C

lass

2)D

iagn

ostic

requ

est

switc

h

F-9

EN

G.(

B2)

15A

W/S

-C

J/C

-E

Fus

e &

Rel

ay B

ox(G

love

Box

)D

iagn

ostic

requ

est

switc

h

Dia

gnos

ticre

ques

tsw

itch

B-1

Fra

me

EC

MM

ain

Rel

ay

J185

0(C

lass

2)

N6A3867E


4JH1 Engine (6)

12V

VS

Ssi

gnal

Exh

aust

brak

ela

mp

cont

rol

Glo

win

dica

tor

lam

pco

ntro

l

MIL

cont

rol42

43B

-234

6827

EC

M

Inst

rum

ent

Pan

el C

lust

er(I

PC

)M

ILG

low

31

J-32

VS

S

Eng

ine

spee

dsi

gnal

outp

ut

4B

-51

68

0.5

GR

N/

YE

L

0.5

OR

N/

BLU

0.5

BLU

/G

RN

0.85

BLK

0.5

YE

L/G

RN

0.5

BLK

0.85

BLK

2 BLK

0.5

YE

L/G

RN

Tach

omet

er

1B

-55

8 2J-

32

10

Spe

edom

eter

0.5

BLK

/YE

L

F-1

6M

ET

ER

10A

19H

-525

31

B-7

Hea

dlig

htB

rack

et

1B

-51

0.5

LT G

RN

/B

LU

Exh

aust

Bra

ke

Exh

aust

Bra

keS

witc

h

60

0.5

GR

N/

RE

D

2B

-52

3

0.5

BLK

0.85

BLK

9

B-1

Fra

me0.3

BLK

Fus

e &

Rel

ay B

ox(G

love

Box

)

0.3

BLK

/Y

EL

0.3

BLK

/Y

EL

0.5

YE

L/G

RN

N6A3868E


4JH1 Engine (7)

Res

isto

r

Eng

ine

war

m u

psw

itch

sign

al

Low

refe

renc

eS

hiel

dgr

ound

Low

refe

renc

e

Eng

ine

war

m u

psw

itch

indi

cato

rla

mp

cont

rol

AP

Pse

nsor

sign

al

Idle

switc

hsi

gnal

5V r

efer

ence

EC

ME

CM

101

1 2

B-3

40

B-3

40

69

24

98B

-233

49B

-234

18H

-5

2J-

183

1J-

183

J-18

3 3

12H

-5

90B

-233

0.5

RE

D

0.5

RE

D

0.5

WH

T

0.5

WH

T

CK

PS

enso

r

CK

Pse

nsor

sign

al

5V r

efer

ence

3857

B-2

34

Idle

Sw

itch

B-1

Fra

me0.85

BLK

0.5

BLK

/G

RN

0.5

BLK

0.5

GR

N/

BLK

0.5

GR

N/

OR

N

0.5

RE

D/

GR

N

0.5

GR

N/

BLK

32

B-8

0

AP

PS

enso

r

1B

-80

EC

M

0.5

BLK

0.5

BLK

24

4

2

0.5

LT G

RN

/R

ED

Tail

Rel

ay

1B

-31

0.5

BR

N

5B

-31

3 6EC

MM

ain

Rel

ay

4659

0.5

BLU

/R

ED

0.3

BLK

0.5

BR

N/

RE

D

0.5

BR

N/

RE

D

Eng

ine

War

m U

pS

witc

h

W/S

-C

EC

MM

ain

Rel

ay

0.5

BR

N/

RE

D

N6A3869E


4JH1 Engine (8)

N6A3870E

Low

refe

renc

eLo

wre

fere

nce

MA

Fse

nsor

sign

al

IAT

sens

orsi

gnal

5V r

efer

ence

5V r

efer

ence

EC

Tse

nsor

sign

al

5V r

efer

ence

93B

-233

1J-

182

24

5

29H

-5

16H

-14

11H

-14

37H

-5H

-81

2

0.5

BLK

/P

NK

0.5

BLK

/P

NK

0.5

BLK

/P

NK

926H

-8

0.5

BLK

/R

ED

0.5

BLK

/R

ED

84

3J-

182

89B

-233

0.5

BLK

/B

LU

0.5

BLK

/B

LU

16H

-5

0.5

GR

Y

0.5

GR

Y

0.5

GR

Y

EC

M

EC

M

8883

0.5

GR

N/

RE

D

0.5

WH

T/

RE

D

0.5

GR

N/

RE

D

0.5

WH

T/

RE

D

0.5

BLU

/R

ED

MA

F &

IAT

Sen

sor

1E

-16

2E

-16E

CT

Sen

sor

0.5

BLK

/O

RN

0.5

BLK

/O

RN

0.5

BLU

/R

ED

21J-

105

J-10

5EG

RS

olen

oid

Val

ve

7H

-8

97

EG

Rso

leno

idva

lve

cont

rol

(PW

M)

EC

MM

ain

Rel

ay


4JH1 Engine (9)

A/C

Com

pres

sor

A/C

ON

sign

alre

lay

sign

alG

low

rela

yco

ntro

l

A/C

com

pres

sor

rela

yco

ntro

l

Res

isto

r

1B

-339

2B

-339

0.5

GR

N/

YE

L

0.5

GR

N/

YE

L

0.5

GR

N/

YE

L0.

5B

LK/

RE

D

0.5

BLK

25

X-2

6

X-2

6 A/C

Sig

nal

Rel

ay

3 BLK

/R

ED

0.3

BLK

/R

ED

52

X-2

0Glo

wR

elay

Glo

wP

lug

0.85

GR

N/

YE

L

0.85

GR

N/

YE

L

0.5

WH

T/

GR

N

0.5

BLK

0.85

BLK

0.5

WH

T/

GR

N

25

X-2

4

X-2

4 A/C

Com

pres

sor

Rel

ay

16H

-8

3H

-8

H-8

1H

-14

EC

M

J-9

Fra

me B-1

Fra

me

41B

-234

3394

B-2

33

SB

F-3

Glo

w60

A

43

X-2

0

1J-

122

15

41

41

Fus

e &

Rel

ay B

ox(B

ehin

d th

e C

ab)

F-1

AIR

CO

N10

A

SB

F-2

5H

EA

TE

R30

A

0.5

BLU

/R

ED

0.5

GR

N/

OR

N

US

WJO

INT

2

W/S

-C

0.5

PN

K/

GR

N

0.85

GR

N/

WH

T

1.25

LT G

RN

/B

LK

0.85

BR

N

51

42

X-1

0

X-1

0

A/C

The

rmo

Rel

ay

0.5

BLU

/R

ED

3H

-18

J-6

J-6

12

Pre

ssur

eS

witc

h

Dio

de

Ele

ctro

The

rmo

4H

-18

0.5B

LU/R

ED

2 BLU

1.25

BLU

EC

MM

ain

Rel

ay1H

-6F

use

&R

elay

Box

(Glo

ve B

ox)

Rel

ay B

ox(I

nstr

umen

t P

anel

)

EG

R S

olen

oid

Val

veP

CU

Exh

aust

Bra

ke S

olen

oid

Val

veIn

take

Thr

ottle

Sol

enoi

d V

alve

0.5

BLU

/R

ED

N6A3871E


4JH1 Engine (10)

0.5

BLU

/R

ED

US

WJO

INT

2

3 BLU

/R

ED

0.5

YE

L

0.5

WH

T/

BLK

0.5

GR

N

0.5

BLU

/R

ED

0.5

BLU

/R

ED

0.5

GR

N/

YE

L

0.5

GR

N

41

32B

-66 Bra

keS

witc

h

21

87

63

12

B-8

9

B-8

9Clu

tch

Sw

itch

EC

M

EH

CU

(AB

SM

odul

e)

65

Sto

pLi

ght

F-5

ST

OP

LIG

HT

10A

31

EC

MM

ain

Rel

ay

Glo

wR

elay

1H

-6

30

0.5

LT G

RN

0.5

BLK

21J-

31

J-31

40

0.5

LT G

RN

/W

HT

0.5

BLU

/R

ED

21J-

40

J-40

95

Inta

keT

hrot

tleS

olen

oid

Val

ve

Exh

aust

Bra

keS

olen

oid

Val

ve

MA

F S

enso

rE

GR

Sol

enoi

d V

alve

A/C

Com

pres

sor

Rel

ayA

/C S

igna

l Rel

ay

932

H-5

0.5

LT G

RN

0.5

LT G

RN

/W

HT

B-2

34

0.5

LT G

RN

/B

LU

0.5

BLU

/R

ED

21B

-69

B-6

9Exh

aust

Bra

keS

witc

h

64

IPC

12V

Bra

kepe

dal

switc

h1si

gnal

Exh

aust

brak

esw

itch

sign

al

Clu

tch

switc

hsi

gnal

Bra

kepe

dal

switc

h2si

gnal

Inta

keth

rottl

eso

leno

idva

lve

cont

rol

Exh

aust

brak

eso

leno

idva

lve

cont

rol

Fus

e &

Rel

ay B

ox(G

love

Box

)J/

C-E

PC

U

Idle

Sw

itch

Res

isto

r

Eng

ine

War

m U

pS

witc

h

87

1011

H-1

4

0.5

LT G

RN

/W

HT

0.5

LT G

RN

/W

HT

0.5

LT G

RN

/B

LK

0.5

LT G

RN

/B

LK

6232

B-2

34

J-17

7

0.5

LT G

RN

/B

LK

0.5

LT G

RN

/W

HT

3640

H-5

12V

Exh

aust

brak

e cu

tsi

gnal

inpu

t

Exh

aust

brak

e cu

tsi

gnal

feed

back

inpu

t

Exh

aust

brak

ecu

tsi

gnal

feed

back

outp

ut

Exh

aust

brak

e cu

tsi

gnal

outp

ut

0.5

LT G

RN

/B

LU

12V

N6A3872E

Neu

tral

switc

hsi

gnal

Res

isto

r

B-3

42

B-3

420.

3B

LK

0.5

BLK

/W

HT

0.5

BLK

/W

HT

0.5

BLK

/W

HT

21

J-50

J-50 N

eutr

alS

witc

h

9H

-8

87B

-233

W/S

-C

0.5

BLU

/R

ED

1 2


4HK1-TC Engine (1)S

BF

-2K

EY

40A

SB

F-1

MA

IN10

0A o

r 12

0A

2L

30 BLK

/R

ED

8 B

LK

0.3

GR

N/

OR

N

3 WH

T/

BLK

F-1

HE

AT

ER

,A

IR C

ON

15A

Hea

ter

&A

/C R

elay

12

X-1

2

54

X-1

2

F-2

FU

EL

HE

AT

ER

10A

F-7

TA

ILLI

GH

T10

A

Hea

ter

Rel

ay

12

X-8

54

X-8

Tai

lR

elay

12

X-4

54

X-4

Cha

rge

Rel

ay

3 BLK

/R

ED

3 BLU

5 WH

T

5 WH

T/

BLK

8 WH

T/

BLK

3 WH

T/

BLK

3 WH

T/

BLK

0.5

WH

T/

RE

D

0.5

WH

T/R

ED

3 WH

T

F-2

2S

TA

RT

ER

10A

F-9

EN

G.

(IG

)10

A

F-1

6M

ET

ER

10A

3 BLK

/Y

EL

W/S

-H

W/S

-E

US

WJO

INT

3

3 BLK

/Y

EL

3 BLK

0.5

BLK

2 BLK

0.5

BLK

B-6

7 4

H-6

2

H-7

1

SB

F-3

GLO

W60

A

3 BLK

/B

LU

0.5

BLK

3 WH

T/

RE

D 1.25

RE

D

Glo

wP

lug

Rel

ay

34

X-2

0

25

X-2

0

SB

F-8

ST

AR

TE

R60

A

Fus

e &

Rel

ay B

ox(B

ehin

dth

e C

ab)

Fus

e &

Rel

ay B

ox(B

ehin

dth

e C

ab)

Fus

e &

Rel

ay B

ox(G

love

Box

)

Rel

ay B

ox(I

nstr

umen

t P

anel

)

Rel

ay B

ox(I

nstr

umen

t P

anel

)

Fus

e &

Rel

ay B

ox(G

love

Box

)

Fus

e &

Rel

ay B

ox(G

love

Box

)

SB

F-5

EC

M40

A

EC

MM

ain

Rel

ay

Sta

rter

Rel

ay

EC

ME

CM

Com

bina

tion

Sw

itch

Glo

wP

lug

EC

M

0.5

BLU

/B

LK2 R

ED

0.5

BLK

/R

ED

3 BLK

/Y

EL

3 WH

T/

BLK

2 BLK

J-9

Fra

me

2

ST

ON

AC

CO

FF

B-6

7

3B

-67

Igni

tion

Sw

itch

Fus

e &

Rel

ay B

ox(B

ehin

d th

e C

ab)

P-5

B-7

H/L

Bra

cket

6

J/C

-D

1

Bat

tery

P-1

P-2

P-3

P-4

N6A6628E

0.5

YE

L/B

LK

35

X-1

8

24

X-1

8

F-2

8E

CM

10A


4HK1-TC Engine (2)

EC

MT

CM

30 B

LK/R

ED

8 B

LK8

BLK

8 B

LK

3 B

LK/Y

EL

P-1

P-2

P-3

P-4

Bat

tery

P-5

3 BLK

/W

HT

3 WH

T/

BLK

0.5

RE

D/W

HT

0.5

RE

D/W

HT

0.5

RE

D

0.5

WH

T/

BLU

0.3

BLK

/WH

T

3 WH

T/B

LU

3 WH

T/B

LU

2L

SB

F-8

STA

RT

ER

60A

SB

F-2

KE

Y40

A

F-2

2S

TAR

TE

R10

A

14H

-8

0.5

RE

D/

WH

T

0.5

WH

T/

BLU

0.5

WH

T/

BLU

J-9

Fra

me

1H-7

4

B-6

7

US

WJO

INT

32 B

LK

0.5

BLK

14J-

191

B-4

2546

Sta

rt c

utre

lay

cont

rol

Sta

rt s

witc

hsi

gnal

38H

-5

16

Sta

rter

cut

rela

yco

ntro

l

Fus

e &

Rel

ay B

ox(G

love

Box

)

F-2

8E

CM

10A

Fus

e &

Rel

ay B

ox(B

ehin

d th

e C

ab)

2B

-67

2 3J/C

-2

0.85

LT G

RN

0.5

LT G

RN

EC

MM

ain

Rel

ay

52

X-2

1

43

X-2

1 51

X-2

6

34

X-2

6

ST

ON

AC

CO

FF

Igni

tion

Sw

itch

N6A6629E

Sta

rter

B C 1J-

27

1J-

26

Fus

e &

Rel

ay B

ox(B

ehin

d th

e C

ab)

Sta

rter

Rel

ay

Fus

e &

Rel

ay B

ox(B

ehin

d th

e C

ab)

Fus

e &

Rel

ay B

ox(B

ehin

d th

e C

ab)

Sta

rter

Cut

Rel

ay


4HK1-TC Engine (3)

F-1

6M

ET

ER

10A

SB

F-8

STA

RT

ER

60A

SB

F-3

GLO

W60

A

SB

F-1

MA

IN10

0A o

r 12

0A

18 10

B-5

1

B-5

1

0.5

BLK

/Y

EL

0.5

BLK

/Y

EL

0.5

WH

T/

BLU

0.5

WH

T/

BLU

0.5

WH

T/

BLU

8 WH

T/

BLK

0.5

BLK

/Y

EL

0.5

WH

T/

RE

D

0.85

WH

T/

RE

D

Cha

rge

Rel

ay

Glo

w R

elay

8BLK

30B

LK/R

ED

2L

B

Sta

rter

Rel

ay

Cha

rge

BS

21

1

J-1

J-2

J-1

15H

-5

L

AC

G

J-26

Sta

rter

P-1

P-2

P-3

P-4

P-5

0.85

WH

T/

BLU

1.25

WH

T/

BLU

3 WH

T/

BLU

3 BLK

/Y

EL

3 WH

T/

BLU

3 WH

T/

BLU

Hea

ter

& A

/C R

elay

Fus

e &

Rel

ay B

ox

Fus

e &

Rel

ay B

ox(B

ehin

d th

e C

ab)

Fus

e &

Rel

ay B

ox(B

ehin

d th

e C

ab)

Inst

rum

ent

Pan

elC

lust

er(I

PC

)

Fus

e &

Rel

ay B

ox(G

love

Box

)

Fus

e &

Rel

ay B

ox(G

love

Box

)

15

4

X-1X-1

3 21

3

W/S

-M

J/C

-I

0.5

BLK

/Y

EL

N6A6630E

Bat

tery

2

ST

ON

AC

CO

FF

B-6

7

3B

-67

Igni

tion

Sw

itch

1H

-7

SB

F-2

KE

Y40

A


4HK1-TC Engine (4)

2 BLK

0.5B

LK3 W

HT

/R

ED

0.5

BLU

/B

LK

0.5

BLU

/B

LK

0.5

BLU

/B

LK

0.5

YE

L/B

LU

0.5

YE

L/B

LU

2 RE

D

2 RE

D

2 RE

D

EC

M

J-19

1

1.25

RE

D

2418H

-5

J-9

Fra

me

24

3

X-1

8EC

M M

ain

Rel

ay

X-1

85

SB

F-5

EC

M40

A

F-2

8E

CM

10A

212

405

Bat

tery

vol

tage

Fus

e &

Rel

ay B

ox(G

love

Box

)

F-9

EN

G. (

IG)

10A

Fus

e &

Rel

ay B

ox(B

ehin

d th

e C

ab)

Fus

e &

Rel

ay B

ox(B

ehin

d th

e C

ab)

Rel

ay B

ox(I

nstr

umen

tP

anel

)

EC

M m

ain

rela

y co

ntro

l

Igni

tion

volta

ge

US

W J

OIN

T 3

Exh

aust

Bra

ke S

olen

oid

Val

veS

tart

er C

ut R

elay

Inta

ke T

hrot

tle S

olen

oid

Val

ve

N6A6631E

SB

F-2

KE

Y40

A

3 BLK

/Y

EL

1 2

ST

ON

AC

CO

FF

B-6

7

3B

-67

Igni

tion

Sw

itch

B-6

7

3 WH

T/

BLU

3 WH

T/

BLU


4HK1-TC Engine (5)

1311

12

0.5

GR

Y

0.3

BLK

/W

HT

0.3

BLK

/WH

T

0.3

BLK

/WH

T

HS

A C

/U

EH

CU

(AB

S M

odul

e) TC

MH

SA

C/U

TC

MS

RS

C/U

0.3

LT B

LU

0.3

LT B

LU0.

3W

HT

/G

RN

2

0.3

WH

T/

BLK

0.5

LT B

LU

15238

0.5

YE

L

0.5

YE

L

7

0.5

LT B

LU

0.5

BLK

Dat

aLi

nkC

onne

ctor

(DLC

)

EC

MD

iagn

ostic

requ

est

switc

hK

eyw

ord

2000

0.5

BLK

1.25

BLK

1.25

BLK 4 Gro

und

5B

-79

Gro

und

20H

-4

4

1.25

BLK

3

1.25

BLK

1

0.75

BLK

62

0.75

BLK

43

0.5

BLK

81J-

191

9

B-1

Fra

me

2 BLK

J-9

Fra

me

Cas

egr

ound

3 12

US

WJO

INT

3

J/C

-G19

22

18

21

J/C

-B

W/S

-C

Sig

nal

grou

ndS

igna

lgr

ound

Pow

ergr

ound

Pow

ergr

ound

Pow

ergr

ound

Dia

gnos

ticre

ques

t(S

RS

)

Dia

gnos

ticre

ques

t(E

CM

)

Dia

gnos

ticre

ques

t(T

CM

or

HS

A)

Dia

gnos

tic(E

HC

U)

Cla

ss 2

seria

lco

mm

unic

atio

n(E

HC

U)

Key

wor

dse

rial

com

mun

icat

ion

(EC

M, T

CM

or

HS

A &

SR

S)

N6A6632E


4HK1-TC Engine (6)

18B

-51

0.5

BLU

/R

ED

0.5

BLU

/R

ED

0.5

OR

N/

BLU

0.5

BLU

/P

NK

0.5

OR

N/

BLU

0.5

BLU

/P

NK

Par

king

Bra

keS

witc

h

EC

M

Eng

ine

spee

dsi

gnal

outp

ut

VS

Ssi

gnal

MIL

cont

rol

Glo

win

dica

tor

lam

pco

ntro

l

Exh

aust

brak

ela

mp

cont

rol

Par

king

brak

esw

itch

sign

al

12H

-5

135

0.3W

HT

/VIO

0.3

WH

T/

VIO

0.3

WH

T/

RE

D

0.3W

HT

/VIO

5B

-51

B-5

1

3 4 10

3 5H-1

2

H-1

2

156

B-5

1B

-52

B-5

1B

-51

410

B-5

1

0.5B

RN

0.5

BLK

0.5

BLK

/YE

L

0.5

BLK

/Y

EL

0.5

BLK

/Y

EL

0.5

BLK

/Y

EL

0.5

YE

L/G

RN

0.5

YE

L/G

RN

0.5

YE

L/G

RN

0.3

YE

L/G

RN

0.3

LT G

RN

0.3

BLK

/Y

EL

0.5

BLK

0.5

BLK

1.25

BLK

0.3

WH

T/B

LK

0.3

WH

T/B

LK

WIT

HH

BB

W/O

HB

B

Par

king

Bra

keE

xhau

stB

rake

Glo

wM

IL

M/T

M/T

Sm

ooth

erS

moo

ther

0.5

WH

T/

BLK

0.5

WH

T/

BLK

0.5

WH

T/

RE

D

0.3

WH

T/

RE

D

0.5

WH

T/B

LK

0.5

WH

T/B

LU

Inst

rum

ent

Pan

elC

lust

er(I

PC

)

Cha

rge

Cha

rge

Rel

ay

Buz

zer

Rel

ay

Sho

rtC

onne

ctor

8H

-5

M/T

Sm

ooth

er

HB

BLe

vel

Sw

itch

Dio

de B

ox

2J-

32

17

7

19H

-5

4024

31H

-525

H-5

3H

-8

711

68

19

1 48J-

191

H-5

J-19

1

1N

-6

3J-

128

9X

-33

87

X-3

3

4

1J-

128

2

3J-

321

+B

B-1

Fra

meF

-16

ME

TE

R10

A

Fus

e &

Rel

ay B

ox(G

love

Box

)

Tach

omet

erS

peed

omet

er

0.3

LT G

RN

8B

-52

HS

A C

/U

Eng

ine

cool

ant

tem

pera

ture

gau

ge

7H

-14

23H

-5

4B

-55

0.5

LT B

LU

0.5

LT B

LU

0.5

LT B

LU

0.5

GR

N/

YE

L

0.5

BLK

EC

M

2E

-90

1E

-90

3

W/S

-C

W/S

-M12

14

13

J/C

-B

J-9

Fra

me

N6A6633E

EC

M

VS

SE

CT

Sen

sor


4HK1-TC Engine (7)

EC

M

0.5

RE

D

0.5

BLU

0.5

BLU

/W

HT

0.5R

ED

0.5W

HT

0.5

WH

T

0.5

RE

D0.

5W

HT

0.5

BLU

/R

ED

0.5

PN

K/

BLK

0.3

BLK

0.5B

LK

0.5

BLK

0.5

BLK

6164

144

1312

4263

310

111

H-4

H-4

6039

4120

J-19

1

B-2

80

AP

Pse

nsor

1si

gnal

AP

Pse

nsor

2si

gnal

Low

ref

eren

ceLo

w r

efer

ence

Shi

eld

grou

ndS

hiel

d gr

ound

5V r

efer

ence

2E

CM

5B

-280

5V r

efer

ence

1

31

AP

PS

enso

r 2

2

64

AP

PS

enso

r 1

N6A6657E

J-19

1

0.5

RE

D0.

5B

RN

0.5

BLU

0.5

BLU

/Y

EL

0.5

RE

D

0.5

PN

K/

BLK

0.5

BLU

/R

ED

0.5

PN

K/

BLK

7066

31 13

Idle

Up

Sen

sor

22

1 3

PT

OT

hrot

tleS

enso

r

2J-

166

B-2

81

H-4

J-16

6B

-281

H-4

PT

Oth

rottl

ese

nsor

sign

al

Idle

up

sens

orsi

gnal

0.5

PN

K/

BLK

BA

RO

Sen

sor

IAT

Sen

sor

BA

RO

Sen

sor

IAT

Sen

sor

0.5

BLK


4HK1-TC Engine (8)

EC

M

0.5R

ED

0.5

BLU

0.5

BLU

/W

HT

0.5

RE

D0.

5W

HT

0.5

WH

T0.

5R

ED

0.5

WH

T

0.5

BLU

/R

ED

0.5

PN

K/B

LK

0.3

BLK

0.5

BLK

0.5

BLK

0.5

BLK

6164

144

1312

4263

310

111

H-4

H-4

15H

-4

6039

4120

J-19

1

B-2

80

AP

Pse

nsor

1si

gnal

AP

Pse

nsor

2si

gnal

Low

ref

eren

ceLo

w r

efer

ence

Shi

eld

grou

ndS

hiel

d gr

ound

5V r

efer

ence

2E

CM

IAT

Sen

sor

2J-

190

1J-

190

5B

-280

71J-

191

0.5

BR

N/

GR

N

0.5

BR

N/

GR

N0.

5R

ED

0.5

BLK

0.5

BLK

0.5

RE

D/

GR

N

72

IAT

sens

orsi

gnal

5V r

efer

ence

BA

RO

sens

orsi

gnal

1B

-422

5V r

efer

ence

1

2B

-422

3

31

AP

PS

enso

r 2

2

64

AP

PS

enso

r 1

N6A6635E

PT

OT

hrot

tleS

enso

rId

le U

PS

enso

r

0.5R

ED

0.5

PN

K/B

LK

PT

OT

hrot

tleS

enso

rId

le U

PS

enso

r

BA

RO

Sen

sor


4HK1-TC Engine (9)

83E

-111

0.5

LT G

RN

/W

HT

FT

Sen

sor

0.5

GR

N/

YE

L

0.5

LT B

LU

0.5

WH

T0.

5R

ED

0.5

BLK

0.5

BLK

0.5

BLK

0.5

BLK

0.5

BLK

Boo

stP

ress

ure

Sen

sor

EC

T G

auge

FT

sens

orsi

gnal

1E

-93

2E

-93

1J-

216

812

H-1

05

2J-

216

3

4H

-105

3

9195

108

EC

M

EC

M

109

E-1

11

0.5

RE

D0.

5W

HT

2E

-90

1E

-90

EC

TS

enso

r

3

84

EC

Tse

nsor

sign

al

Boo

stpr

essu

rese

nsor

sign

al

5V r

efer

ence

5V r

efer

ence

Low

ref

eren

ceS

hiel

d gr

ound

5V r

efer

ence

4

N6A6637E

CK

PS

enso

r0.

5B

LK


4HK1-TC Engine (10)

N6A6636E

EC

M

EC

M

0.5

WH

T0.

5W

HT

0.5

GR

N/

BLU

0.5

BR

N0.

5B

LK

23

E-1

13

1011

E-1

13

E-1

11

E-1

1190

8287

FR

Pse

nsor

sign

al

5V r

efer

ence

5

Low

ref

eren

ce

100

Shi

eld

grou

nd

0.5

WH

T/

OR

N

0.5

GR

N/

BLU

0.5

BLK

/O

RN

0.5

BR

N

0.5

OR

N

EG

R V

alve

Mot

orE

GR

Pos

ition

Sen

sor

31

4E

-94

26

E-9

4

EG

Rva

lve

mot

or lo

wsi

deco

ntro

l(P

WM

)

8611

1

EG

Rva

lve

mot

or h

igh

side

cont

rol

EG

Rva

lve

posi

tion

sens

orsi

gnal

+B

103

105

E-1

11

0.5

WH

T/

RE

D

FR

Pre

gula

tor

high

sid

eco

ntro

l(P

WM

)

0.5

WH

T/

RE

D

0.5

GR

N/

RE

D

FR

Pre

gula

tor

feed

back

0.5

GR

N/

RE

D

0.5

WH

T/

RE

D

1E

-116

2E

-116

E-1

11

113 97

89

0.5

GR

N/

RE

D

FR

PR

egul

ator

+B

CM

PS

enso

r

FR

PS

enso

r


4HK1-TC Engine (11)

E-1

11

EC

M

EC

M

0.5

BLU

/W

HT

0.5

BLU

/B

LK

0.5

BLK

0.5

BLK

0.5

BLK0.

5BLK

E-1

11

2E

-112

100

1E

-112

3

9899

0.5

OR

N

107 2

E-9

8

106

108

CK

Pse

nsor

low

sign

al

1E

-98

0.5

YE

L

CK

Pse

nsor

high

sign

al

12V

ref

eren

ce

CM

Pse

nsor

sign

al

Shi

eld

grou

ndS

hiel

d gr

ound

N6A6634E

0.5

BLK

0.5

BLK

FR

PS

enso

r

Boo

stP

ress

ure

Sen

sor

CM

PS

enso

rC

KP

Sen

sor


4HK1-TC Engine (12)

121 1 1

12

2 WH

T

EC

M

EC

M

116

2 RE

D

2 WH

T

0.75

WH

T

0.75

GR

N

0.75

GR

N/

WH

T

0.75

WH

T

Cyl

inde

r #1

Fue

lIn

ject

or

Cyl

inde

r #4

Fue

lIn

ject

or

Cyl

inde

r #3

Fue

lIn

ject

or

Cyl

inde

r #2

Fue

lIn

ject

or

4 4

21

2 WH

T

0.75

WH

T

0.75

BLK

0.75

WH

T/

YE

L

3 3

1

33

3

2

2 RE

D

0.75

RE

D

0.75

YE

L

0.75

BLK

/B

LU

0.75

RE

D

2 2

H-1

25

H-1

26

2

3E

-138

E-1

41E

-140

E-1

39

1181

E-1

41E

-138

E-1

40E

-139

2 RE

D

0.75

RE

D

0.75

BLU

0.75

BLK

6 6

H-1

26

H-1

25

1207 7

1178 8

1195 5

Cyl

inde

r #1

fuel

inje

ctor

cont

rol

Cyl

inde

r #4

fuel

inje

ctor

cont

rol

Cyl

inde

r #3

fuel

inje

ctor

cont

rol

Cyl

inde

r #2

fuel

inje

ctor

cont

rol

Cha

rge

volta

ge(C

omm

on 1

)C

harg

e vo

ltage

(Com

mon

2)

N6A6638E


4HK1-TC Engine (13)

0.5

PN

K

0.5

GR

N/

OR

N

EC

M

0.85

GR

N/

OR

N

0.5

BLU

/O

RN

0.5

BLU

/O

RN

0.85

GR

N/O

RN

Ref

riger

ator

Com

pres

sor

J-6

0.85

GR

N/

WH

T

0.85

GR

N/

WH

T

The

rmo

A/C

Rel

ay

2H

-5

9H

-105

8H

-41

1J-

7

J-6

2

E-5

1

1

J-19

134

4433

0.75

WH

T/

RE

D

A/C

Pre

ssur

eS

witc

h

A/C

Com

pres

sor

1H

-120 G

low

Plu

g

3 BLK

/Y

EL

3 BLK

/Y

EL

3 BLK

/B

LU

F-9

EN

G. (

IG)

10A

0.5

BLK

/R

ED

0.5

YE

L/B

LK0.

5 Y

EL/

BLK

0.5

YE

L/B

LU

E-3

Igni

tion

Sw

itch

52

4

X-2

0

X-2

03

H-5

18

10

B-8

4

B-8

412

PT

OS

witc

h

A/C

sign

alR

efrig

erat

orsw

itch

sign

alG

low

plu

gre

lay

cont

rolS

BF

-3G

LOW

60A

Fus

e &

Rel

ay B

ox(G

love

Box

)

Fus

e &

Rel

ay B

ox(B

ehin

d th

e C

ab)

Fus

e &

Rel

ay B

ox(B

ehin

d th

e C

ab)

PT

Osw

itch

sign

al

0.5

BLK

1.25

BLK

B-1

Fra

meW

/S-C

+B

N6A6639E

EC

M

Glo

wR

elay


4HK1-TC Engine (14)

F-2

8E

CM

10A

Fus

e &

Rel

ay B

ox(G

love

Box

)

Fus

e &

Rel

ay B

ox(B

ehin

d th

e C

ab)

6 45

H-5

17H

-4

0.5

LT G

RN

/R

ED

0.5

BR

N/

BLK

0.5

LT G

RN

/R

ED

2

102

H-1

05

0.5

LT G

RN

/W

HT

50

Neu

tral

Sw

itch

0.5

LT G

RN

0.5

LT G

RN

0.5

LT G

RN

0.5

LT G

RN

/W

HT

0.85

LT G

RN

0.5

BLK

/B

LU

15J-

191

E-1

11

0.5

BLK

EC

M

Inta

keth

rottl

eso

leno

idva

lve

cont

rol

Exh

aust

brak

eso

leno

idva

lve

cont

rol

Neu

tral

switc

hsi

gnal

Exh

aust

brak

esw

itch

sign

al

F-9

EN

G. (

IG)

10A

0.5

YE

L/B

LU

0.5

BR

N/

YE

LClu

tch

Sw

itch

0.5

BR

N/

YE

L

Igni

tion

Sw

itch

47

Clu

tch

switc

hsi

gnal

12

54

J/C

-2

21J-

40

J-40

21J-

31

J-31

12J-

50

J-50

25B

-69

B-6

9

21B

-89

B-8

9

Inta

keT

hrot

tleS

olen

oid

Val

ve

Exh

aust

Bra

keS

olen

oid

Val

ve

N6A6640E

TC

M0.

5LT

GR

N/

BLU

0.5

BLK

3 BLK

0.5

BLK

1.25

BLK

0.5

LT G

RN

/BLU

0.5

LT G

RN

/BLU

0.5

BR

N/

BLK

0.85

LT G

RN

/R

ED

0.85

LT G

RN

/R

ED

0.5

LT G

RN

/R

ED

0.5

LT G

RN

/B

LU

B-1

Fra

me

B-7

H/L

Bra

cket

F-2

FU

EL

HE

AT

ER

10A

Hea

ter

Rel

ay

F-7

TAIL

LIG

HT

10A

Tail

Rel

ay

5

Eng

ine

War

m u

pS

witc

h

2

63

41

B-3

1

B-3

1

7 51

H-4

Eng

ine

war

m u

psw

itch

sign

al

W/S

-FW

/S-C

4 9

J/C

-D

11 5

J/C

-B

Exh

aust

Bra

keS

witc

h(C

ombi

natio

nS

witc

h)


4HK1-TC Engine (15)

2 1 B-431

7 8 H-8

B-387

Resistor 1

2 1

1

2TCM

3

2

B-427

10

5

H-15

14

9

15

14

J-177

27

26

5 6 H-8

0.5BLU/WHT

0.5BLU

0.5BLU/WHT

0.5BLU

0.5BLU

0.5BLU/WHT

0.5BLU

0.5BLU/WHT

0.5BLU

0.5BLU/WHT

0.5BLU

0.5BLU/WHT

0.5BLU

0.5BLU/WHT

0.5BLU

0.5BLU/WHT

0.5BLU/WHT

0.5 BLU

0.5BLU/WHT

0.5 BLU

0.5BLU/WHT

0.5 BLU

0.5BLU/WHT

0.5 BLU

0.5BLU/WHT

0.5 BLU

0.5BLU/WHT

0.5 BLU

0.5BLU/WHT

0.5 BLU

EHCU

37

18

J-191 CANhigh

CANlow

CANhigh

CANlow

DRM

ECM

Resistor 2

CANhigh

CANlow

3

J/C-F

4

5

6

J/C-F

Without ABS

2

1

3

J/C-R

5

4

6

J/C-R

CANhigh

CANlow

N6A6641E


Connector ListFor 4HE1-TC Engine

No. Connector Face

B-7

X-1

X-8

X-14

X-25

X-20

B-67

B-67

000-012

005-006

005-006

005-001

1

32 4

5

005-006

005-003

1

2 3

54

004-001

1 23 4

004-002

2

4

1

3

B-69

B-69

B-75

B-75

B-89

B-89

B-233

B-234

No. Connector Face

008-001

1

5

2

6

3

7

4

8

008-002

1

5

23

67

4

8

002-022

1 2

002-023

2 1

002-009

1

2

002-010

1

2

022-002

9 8 7

20 19

6 5 4 3 2 1

18 17 16 15 14 1322 21 12 11

10

030-002

9 8 7 6

30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15

5 4 3 2 114 13 12 11 10


B-79

B-51

H-14

H-14

H-13

H-13

E-2

E-3

No. Connector Face

016-005

87654321

161514131211109

014-001

1 2 3 4 5 6 7 8 9 1011121314

016-003

1 2 3 4

5 6 7 8 9

11 12 13 14

15 16

10

016-004

4 3 2 1

9 8 7 6 5

13 12 11 10

16 15

14

012-001

1 2 3 4

5 6 7 8

9 10 11 12

012-002

4

8

12

3

7

11

2

6

10

1

5

9

002-013

1 2

000-009

E-11

E-43

E-74

E-76

J-9

J-23

J-31

J-31

No. Connector Face

002-001

1 2

003-003

1 2 3

001-013

1

003-004

1 2

3

000-001

004-009

1 2 3 4

002-011

1 2

002-012

12


H-5

J-131

J-131

J-145

J-146

J-41

J-40

J-105

J-147

No. Connector Face

002-011

1 2

002-012

12

002-014

1 2

002-015

1 2

002-015

1 2

002-015

1 2

002-016

21

002-017

1 2

P-1

P-4

P-2

P-3

P-5

No. Connector Face

000-004

000-004

000-006

000-006

000-002

1 2 37 8 9

13 14 1519 20 2125 26 2731 32 33 34 35 36 37

4 5 610 11 1216 17 1822 23 2428 29 3038 39 40

6 5 412 11 1018 17 1624 23 2230 29 2840 39 38

3 2 19 8 7

15 14 1321 20 1927 26 2533 32 3134353637

N8A5488E


H-6, H-7, H-8

For 4JH1 Engine

No. Connector Face

B-1

B-7

B-18

X-10

X-11

1 2

1 2

1 2 3 4

5 6 7 8

9 10 11 12 13

14 15 16 17 18

2 1

2 1

4 3 2 1

8 7 6 5

13 12 11 10 9

18 17 16 15 14

H - 6

H - 7

H - 8

N8A5489E

000-001

000-012

004-004

1 2 3 4

005-001

1

32 4

5

005-001

1

32 4

5

X-12

X-14

X-20

X-24

X-26

B-31

B-66

B-339

No. Connector Face

005-001

1

32 4

5

005-001

1

32 4

5

005-003

1

2 3

54

005-006

005-006

006-001

1 2 3

4 5 6

004-010

23 41

004-010

23 41


B-67

B-67

B-69

B-69

B-79

B-89

B-233

B-234

No. Connector Face

004-001

1 23 4

004-002

2

4

1

3

008-001

1

5

2

6

3

7

4

8

008-002

1

5

23

67

4

8

016-005

87654321

161514131211109

002-019

1 2

121-002

121 120119113

105

97

89

112

104

96

88

111

103

95

87

110

102

94

86

109

101

93

85

108

100

92

84

107

99

91

83

106

98

90

82116 115114

118 117

121-001

5 417

55

74

18

56

75

19

57

76

20

58

77

21

59

78

22

60

79

23

61

80

24

62

81

9

47

66

10

48

67

11

49

68

6

44

63

7

45

64

8

46

65

12

50

69

13

51

70

14

52

71

15

53

72

16

36 37 38 39 40 41 42 4328 29 3025 26 27 31 32 33 34 35

54

732 1

3

B-340

B-341

B-342

B-51

B-52

H-14

H-14

H-15

No. Connector Face

002-022

1 2

002-009

1

2

002-009

1

2

014-001

1 2 3 4 5 6 7 8 9 1011121314

012-005

1 2 3 4 5 6 7 8 9 10 11 12

016-003

1 2 3 4

5 6 7 8 9

11 12 13 14

15 16

10

016-004

4 3 2 1

9 8 7 6 5

13 12 11 10

16 15

14

008-023

1 2 3

4 5 6

7 8


H-15

B-80

E-5

E-16

E-110

J-6

J-9

J-31

No. Connector Face

008-024

3 2 1

6 5 4

8 7

003-005

1 2 3

000-009

002-014

1 2

009-003

16

27

34

859

004-011

1

3

2

4

000-001

002-011

1 2

J-31

J-32

J-40

J-50

J-122

J-177

J-182

J-183

No. Connector Face

002-012

12

003-018

1 2 3

002-017

1 2

002-035

001-007

1

034-001

005-004

1 2 3 4 5

003-006

1 2 3


H-5

H-6, H-7, H-8

P-1

P-2

P-4

P-3

P-5

No. Connector Face

000-002

000-002

000-014

000-014

000-007

1 2 37 8 9

13 14 1519 20 2125 26 2731 32 33 34 35 36 37

4 5 610 11 1216 17 1822 23 2428 29 3038 39 40

6 5 412 11 1018 17 1624 23 2230 29 2840 39 38

3 2 19 8 715 14 1321 20 1927 26 2533 32 3134353637

N8A5488E

1 2

1 2

1 2 3 4

5 6 7 8

9 10 11 12 13

14 15 16 17 18

2 1

2 1

4 3 2 1

8 7 6 5

13 12 11 10 9

18 17 16 15 14

H - 6

H - 7

H - 8

N8A5489E


For 4HK1-TC Engine

No. Connector Face

B-1

B-7

B-31

B-51

B-52

B-67

B-67

B-69

000-001

000-012

006-001

1 2 3

4 5 6

020-005

020-005

004-001

1 23 4

004-002

2

4

1

3

008-001

1

5

2

6

3

7

4

8

B-69

B-84

B-89

B-89

B-79

B-280

B-281

B-387

No. Connector Face

008-002

1

5

23

67

4

8

006-001

1 2 3

4 5 6

002-009

1

2

002-010

1

2

016-005

87654321

161514131211109

003-005

1 2 3

003-028

002-038


B-387

B-422

B-427

B-431

B-431

H-4

H-4

H-12

No. Connector Face

002-039

002-027

21

017-001

002-038

002-039

020-002

10111213 14 15

1 2 3 4 5

171819 20

6 7 8 9

16

020-003

9 8 7 6

20191817 16

5

1415

4

13

3

12

2

11

1

10

022-001

1 2 3 4

13 14

5 6 7 8 9 10

15 16 17 18 19 2011 12 21 22

H-12

H-15

H-15

H-105

H-105

H-120

H-120

H-125

No. Connector Face

022-002

9 8 7

20 19

6 5 4 3 2 1

18 17 16 15 14 1322 21 12 11

10

016-003

1 2 3 4

5 6 7 8 9

11 12 13 14

15 16

10

016-004

4 3 2 1

9 8 7 6 5

13 12 11 10

16 15

14

006-026

3 2 1

6 5 4

006-027

1 2 3

4 5 6

001-023

1

001-022

1

008-019

1 2 3 4

5 6 7 8


H-125

H-126

H-126

E-3

E-5

E-90

E-93

E-94

No. Connector Face

008-020

4 3 2 1

8 7 6 5

008-022

1 2 3 4

5 6 7 8

008-021

4 3 2 1

8 7 6 5

000-009

001-021

003-004

1 2

3

002-035

005-007

E-98

E-112

E-113

E-116

E-138

E-139

E-140

E-141

No. Connector Face

002-036

003-026

003-029

002-036

003-031

003-031

003-031

003-031


X-1

X-11

X-18

X-20

X-21

X-26

X-33

J-1

No. Connector Face

005-006

005-001

1

32 4

5

005-003

1

2 3

54

005-003

1

2 3

54

005-003

1

2 3

54

005-006

014-002

1 2 3

7 8 9 10 11

4

12

5

13

6

14

002-003

1 2

J-2

J-6

J-26

J-27

J-31

J-31

J-32

J-40

No. Connector Face

000-001

002-032

1 2

000-002

000-009

002-011

1 2

002-012

12

003-018

1 2 3

002-017

1 2


H-5

J-50

J-166

J-177

J-191

N-6

N-6

P-1

P-4

No. Connector Face

002-035

003-001

1 2 3

034-001

002-022

1 2

002-023

2 1

000-004

000-004

P-2

P-3

P-5

No. Connector Face

000-006

000-006

000-002

1 2 37 8 9

13 14 1519 20 2125 26 2731 32 33 34 35 36 37

4 5 610 11 1216 17 1822 23 2428 29 3038 39 40

6 5 412 11 1018 17 1624 23 2230 29 2840 39 38

3 2 19 8 7

15 14 1321 20 1927 26 2533 32 3134353637

N8A5488E


H-6, H-7, H-8

Engine Stop System

General DescriptionThe circuit consists of starter switch and engine stopmotor.The engine stop mechanism aims at shut-off of fuel sup-ply.Available are motor type and solenoid type dependingon the types of the engine mounted.Motor type is forcible pull the injection pump control rackto the direction of fuel supply reduction by means of en-gine stop motor, thus shutting it off.Solenoid type is to have the starter switch turn from“ON” position to “OFF”, so that the solenoid valve fittedto the injection pump closes to shut off the fuel circuit.

Engine stop system Engine model

Motor type 4HF1, 4HG1,4HE1

Solenoid type 4JB1, 4JG2

1 2

1 2

1 2 3 4

5 6 7 8

9 10 11 12 13

14 15 16 17 18

2 1

2 1

4 3 2 1

8 7 6 5

13 12 11 10 9

18 17 16 15 14

H - 6

H - 7

H - 8

N8A5489E


Parts Location4JB1 / 4JG2 / 4HG1 (N-Spec) Engine

N8A0108E


4HF1 (S-Spec) / 4HG1 / 4HE1 Engine

F-9

, F-1

3

J-34

(NK

R)

J-34

(NP

R/N

QR

)

N8A0450E


Circuit Diagram

N8A0109E


Connector List

No. Connector Face

B-67

B-67

B-68

B-68

J-34

J-34

P-1

P-4

004-001

1 23 4

004-002

2

4

1

3

006-002

1

3 4 5 6

2

006-003

2

6 5 4 3

1

006-004

1 2 3

4 5 6

006-005

3 2 1

6 5 4

000-004

000-004

P-2

P-3

P-5(12 V)

P-5(24 V)

E-15

E-15

H-14

H-14

No. Connector Face

000-006

000-006

000-007

000-002

001-002

1

001-003

1

016-001

1 2 3 4

5 6 7 8

9 10 11 12

13 14 15 16

016-002

4 3 2 1

8 7 6 5

12 11 10 9

16 15 14 13


H-5 H-6, H-7

Function of Engine Stop Motor

1 2 37 8 9

13 14 1519 20 2125 26 2731 32 33 34 35 36 37

4 5 610 11 1216 17 1822 23 2428 29 3038 39 40

6 5 412 11 1018 17 1624 23 2230 29 2840 39 38

3 2 19 8 715 14 1321 20 1927 26 2533 32 3134353637

N8A5488E

1 2

1 2

1 2 3 4

5 6 7 8

9 10 11 12 13

14 15 16 17 18

2 1

2 1

4 3 2 1

8 7 6 5

13 12 11 10 9

18 17 16 15 14

H - 6

H - 7

H - 8

N8A5489E

N8A5127E


Solenoid TypeStarter Switch and Solenoid ValveTurn the starter switch from “ON” position to “OFF”, andthen the solenoid valve fitted to the injection pump clos-es to cut off the fuel circuit.

Key position Solenoid valve

LOCKClose

ACC

ONOpen

START

N8A0112E


Headlight, Fog Light, Rear Fog Light and Cornering LightGeneral DescriptionThe circuit consists of headlight, fog light, cornering light, starter switch, combination switch (Lighting switch, dimmer/ passing switch, cornering light switch), fog light switch, rear fog light switch, rear fog light, high beam indicator lightand relay.When the lighting SW is turned on by setting it at headlight position, the lighting relay is actuated to turn on the head-light. The optical axis of the headlight can be turned up or down by operating the dimmer SW while headlight is on.The passing SW is independent of the lighting SW, and the optical axis of the passing light can be turned up onlywhile the switch lever is pulled up and held in this state.Fog light turns on by switching it to “ON” position to activate relay only while lighting SW is on. Rear fog light turns onby switching it to “ON” position to activate relay only while lighting SW is at headlight position.When the headlight is on, turn the turn-signal switch left or right, and then the cornering switch built in the combinationswitch turns on, followed by the cornering light turning on.Lighting Circuit

Notice:Arrow marks indicate the direction of current.

CORNERING LIGHT HEADLIGHT FOG LIGHT REAR FOG LIGHT

Starter sw.(ON)

Corneringlight relay

Dimmer relay

Corneringlight

Corneringlight sw.

Lighting sw.

Dimmer sw.

Fog lightsw.

Fog light

LO HI

L H

OFF RR FOG

Rearfog light

Rearfog lightrelay

Headlight

Headlight relay

Tail relay

Battery (+)

N8A5573E


Parts Location

FL-

1, F

L-2,

FL-

4 F

US

IBLE

LIN

K

F-6

, F-7

, F-8

, F-1

6,F

-23,

F-2

4, F

-27

B-7

X-4

TA

IL R

ELA

YX

-3 H

EA

DLI

GH

T R

ELA

Y

X-6

DIM

ME

R R

ELA

YX

-9 C

OR

NE

RIN

G L

IGH

T R

ELA

Y

X-2

3 R

EA

R F

OG

LIG

HT

RE

LAY

B-4

HE

AD

LIG

HT

(LH

)

B-7

3 H

EA

DLI

GH

T (

RH

)

N8A0114E


Circuit DiagramFor 12 Volt (Except NKR77 for Taiwan)

HI

B-4

X-9

X-1

4

H-6

B-6

7B

-67

B-1

8

B-1

8

X-6

B-5

5

B-5

2

B-7

3

B-7

3

X-3

H-7

OFF

ON

AC

C

ST

B

B-1

B-7

4B

-5

B-7

0B

-70

B-7

4B

-5

B-7

OFF

H T

HIG

HLO

E2

PA

SS

B-7

0

P-5

P-1

P-2

2

H-7

2

X-3

X-3

X-3

21

45

1

23

X-1

4

X-1

4X

-141

2 45

X-9

X-9

X-9

21

45

B-4

B-4

B-7

3

12

3

21

3

10 10

X-6

X-6

X-6

X-6

21

3

45

11

33

119

LH

RH

B-7

0

B-7

0

B-7

0

Hu

24107

B-7

0

B-7

0

81

B-1

813

2

KE

Y S

W

FL-2

50

A

HE

AD

LA

MP

FL-4

30

A

MA

IN

FL-1

10

0A

3W/B

2W/R

2W/R

8W5W

RELAY; HEAD LIGHT

0.3R D

IOD

ELI

GH

TIN

G S

W

0.3L

/R

0.3R

CO

RN

ER

ING

LIG

HT

SW

ITC

H

COMBINATION SW

0.3L

0.5R/W

0.5P

0.85B0.5P/B

3B

FRA

ME

-LH

(FR

ON

T)

HE

AD

LIG

HT

BR

AC

KE

T (

LH)

0.85B

1.25B

0.3R/L

RE

LAY

; DIM

ME

R

1.25B

0.85

B

0.85B

0.5R/G

0.85

R/G

1.25

R/Y

0.5R

/B

RE

LAY

;C

OR

NE

RIN

G L

IGH

T

0.3G

/O0.

5R/L

0.5B/Y

ST

AR

TE

R S

W

F-16

10

A

ME

TE

R

3W/B

8W/B

RE

LAY

; TA

IL

0.3G

/O

F-24

HE

AD

LIG

HT

(LH

)

F-23

HE

AD

LIG

HT

(RH

)

2R

2R

CORNERING LIGHT(FRT. COMBINATION LIGHT)

(RH)

(LH)

HL

0.85R

0.85R/L

HIGH BEAM INDICATORLIGHT (METER)

2

FRA

ME

RH

LO

HI

HEADLIGHTLH

LO

HEADLIGHT1.

25R

/Y

0.85

R/G

3B/Y

3W/L

5B

F-7

10A

10A

10A

TA

IL L

IGH

T

3W/B

3W/B

4JH1: 3W4HG1-T: 3W4JB1, 4JB1-TC: 3L

4JH

1: 3

W4H

G1-

T: 3

W4J

B1,

4JB

1-T

C: 3

L

B-7

2B

-3

B-7

2

B-8

7B

-87

B-8

7B

-87

23

56

B-3

1 2

1 2

0.85R/G

0.85R/G

0.85LG/R

0.85

LG/R

FRT. COMBINATION LIGHT (LH) (4)

FOG LIGHT SW

FOG LIGHT (LH)

FOG LIGHT (RH)

10A

: 4JB

1,4J

B1-

TC

/ 4J

H1

F-6

10A

: 4H

G1-

TF-

8

FRT

FO

G L

IGH

T,

CO

RN

ER

ING

LA

MP

0.5B

0.85V

0.5B

0.5B

2L

P-3

P-4

4JH

1

N8A0115E


For 24 Volt

HI

B-4

X-9

X-4

H-6

B-6

7B

-67

B-1

8

B-1

8

X-6

B-5

5

B-5

2

B-7

2B

-3

B-7

2

B-8

7B

-73

B-7

3

X-3

H-7

OFF

ON

AC

C

ST

B

B-1

B-7

4B

-5

B-7

0B

-70

B-7

4B

-5

B-7

OFF

H T

HIG

HLO

E2

PA

SS

B-7

0

P-5

P-4

P-3P-1

P-2

2

H-7

2

X-3

X-3

X-3

21

45

1

23

X-4

X-4

X-41

2 45

X-9

X-9

X-9

21

45

B-4

B-4

B-7

3

12

3

21

3B

-87

B-8

7B

-87

32

65

B-3

1 2

1 2

10 10

X-6

X-6

X-6

X-6

21

3

45

11

33

119

LH

RH

B-7

0

B-7

0

B-7

0

Hu

24107

B-7

0

B-7

0

81

B-1

813

2

KE

Y S

W

FL-2

40

A

MA

INFL

-1

100A

or

120A

HE

AD

LA

MP

FL-4

30

A

3W/B

5W/B

2W/R

2W/R

5W

RELAY; HEAD LIGHT

0.3R D

IOD

ELI

GH

TIN

G S

W

0.3L

/R

0.3R

CO

RN

ER

ING

LIG

HT

SW

ITC

H

COMBINATION SW

0.3L

0.5R/W

0.5P

0.85B0.5P/B

3B

FRA

ME

-LH

(FR

ON

T)

HE

AD

LIG

HT

BR

AC

KE

T (

LH)

0.85B

1.25B

0.3R/L

RE

LAY

; DIM

ME

R

0.85B

0.85

B

0.85B

0.5B

0.5B

0.5R/G

0.85R/G

0.85R/G

0.5B

0.5R

/G

0.85

R/Y

0.5R

/B

RE

LAY

;C

OR

NE

RIN

G L

IGH

T

0.3G

/O0.

5R/L

0.5B/Y

ST

AR

TE

R S

W

F-16

10

A

ME

TE

R

3W/B

3W/B

3W/B

RE

LAY

; TA

IL 3W

0.85LG/R

0.85LG/R

F-24

10A

F-23

10A

HE

AD

LIG

HT

(LH

)H

EA

D L

IGH

T(R

H)

F-8

10A

FRT

FO

G L

IGH

T,

CO

RN

ER

ING

LA

MP

F-7

TA

IL L

IGH

TFR

T. C

OM

BIN

AT

ION

LIG

HT

(LH

) (4

)

FOG LIGHT SW

2R

2R/W

CORNERING LIGHT(FRT. COMBINATION LIGHT)

(RH)

(LH)

HL

0.85R

0.85R/L


FOG LIGHT (LH)

FOG LIGHT (RH)

2

FRA

ME

RH

LO

HI

HEADLIGHT

LH

LO

HEADLIGHT

0.85

R/Y

0.5R

/G

3B/Y

3W/L

2B

5B

2L

10A

N8A0386E


With Rear Fog Light

HI

B-4

X-4

H-6

X-6

B-5

5

B-5

2

B-7

2B

-3

B-7

2

B-8

7B

-73

B-7

3

X-3

B-1

B-7

OFF

RR

FO

G

H T

HIG

HLO

E2

PA

SS

P-5

2

X-3

X-3

X-3

21

45

45

X-4

X-4

X-41

2

B-4

B-4

B-7

3

12

3

21

3B

-87

B-8

7B

-87

32

65

B-3

1 2

1 2

10 10

X-6

X-6

X-6

X-6

21

3

45

B-7

0

B-7

0

B-7

0

Hu

4107

B-7

0

B-7

0

81

MA

IN

FL-1

10

0A

HE

AD

LA

MP

FL-4

30

A

8W

2W

5W8W

/B

RELAY; HEAD LIGHT

0.3R

0.3R

LIG

HT

ING

SW

COMBINATION SW

0.5R/W

5BFR

AM

E-L

H (

FRO

NT

)

HE

AD

LIG

HT

BR

AC

KE

T (

LH)

1.25B

0.5R/L

RE

LAY

; DIM

ME

R

1.25B

0.85

B

0.5B

0.5R/G

0.85R/G

0.85R/G

0.3G

/O

RELAY; TAIL

0.85V

4JB

1, 4

JB1-

TC

: 3L

4JH

1: 3

W

F-24

10A

10A

10A

HE

AD

LIG

HT

(LH

)

F-23

HE

AD

LIG

HT

(RH

)FRT. COMBINATIONLIGHT (LH) (4)

LICENSE LIGHT

HEADLIGHT

2R

2R

HL

0.85R

0.85R/L


INDICATORLIGHT (METER)

FOG LIGHT (LH)

FOG LIGHT (RH)

FRA

ME

3B

3B

J-9

FRA

ME

-LH

(C

EN

TE

R)

1.25

B2B

1.25

R/Y 0.

85R

/G

HI

LO

LH

1.25

R/Y

0.85

R/G

HEADLIGHT

LORH

B-7

0 14

F-6

FRT

FO

G L

IGH

T,

CO

RN

ER

ING

LA

MP

F-27

(1

5A)

FOG

LIG

HT

(R

EA

R) 0.5L

G/R

0.85

R/G 2B

H-1

67

1.25

B

F-7

TA

IL L

IGH

T

0.85LG/R

0.85

LG/R

0.85LG/R

0.85LG/W

X-2

3

X-2

3X

-234

1 52

RELAY;RR FOG LIGHT

H-8

X-2

3

5

H-5 5

0.85R/G 0.85R/G

0.5GR/B

H-1

63

H-8

0.5R/G 0.5R

R-1

21

R-1

2 2

RR

FO

GLI

GH

T

0.85

B

0.85

R/G

0.85

LG/R

1.25

B

0.5G

R/B

0.5B

0.5B

P-1

P-2

2W/R

2W/R

2L

P-3

P-4

4JH

1

3W/B

3W/B

B-8

7

B-8

7

FOG LIGHT SWITCH

41

H-7

2

0.5B

4 10

0.5G

/R

10A

N8A0117E


Connector List

No. Connector Face

B-1

J-61

B-3

B-3

B-72

B-72

R-12

R-12

000-001

000-001

002-001

1 2

002-002

12

002-001

1 2

002-002

12

002-001

1 2

002-002

12

B-4

B-73

B-5

B-5

B-74

B-74

B-18

B-7

No. Connector Face

003-007

1

32

003-007

1

32

004-012

1 2

3 4

004-013

12

34

004-012

1 2

3 4

004-013

12

34

004-004

1 2 3 4

000-012


X-3

X-4

X-6

X-9

X-23

B-153

B-154

B-52

No. Connector Face

005-006

005-006

005-006

005-006

005-006

006-007

1 2 34 5 6

000-016

012-005

1 2 3 4 5 6 7 8 9 10 11 12

B-55

B-67

B-67

B-70

B-70

B-87

H-16

H-16

No. Connector Face

012-004

1 2 3 4 5 6 7 8 9 10 11 12

004-001

1 23 4

004-002

2

4

1

3

014-002

1 2 3

7 8 9 10 11

4

12

5

13

6

14

014-003

6 5 4

14131211

3 2 1

9 8 710

006-006

21 3

54 6

008-003

1 2 3 4

5 6 7 8

008-004

4 3 2 1

8 7 6 5


H-6, H-7, H-8

P-1(12 V)

P-2

P-1(24 V)

P-4

P-2(24 V)

P-3

P-5(12 V)

P-5(24 V)

No. Connector Face

000-003

000-004

000-004

000-004

000-006

000-006

000-007

000-002

1 2

1 2

1 2 3 4

5 6 7 8

9 10 11 12 13

14 15 16 17 18

2 1

2 1

4 3 2 1

8 7 6 5

13 12 11 10 9

18 17 16 15 14

H - 6

H - 7

H - 8

N8A5489E


DiagnosisQuick Chart for Check Point1. Headlight

Notice:Figure in parenthesis “( )” indicates the order of inspection.

Check point

FuseFus-ible link Head-

light relay

Light-ing SW

Dim-mer / Pass-

ing SW

Dim-mer relay

Headlight bulb Cable

har-nessF-6

F-8(10 A)

F-23(10 A)

F-24(10 A)

FL-4(30A) LH RH

Trouble mode

1-1. Both Head-lights inopera-tive

(2)

(1)

(4)

(3)

1-2. Headlight on the left (or right) side inop-erative

(1)

((1))

(2)

1-3. Headlight in low-beam inop-erative

(1)

(2)

1-4. Headlight in high-beam inop-erative

(1)

(2)

1-5. Headlight on the left (or right) side in low (or high)-beam inoperative

(1)

((1))

(2)

1-6. Headlight beam does not change

(1)

(2)

(3)

(4)

1-7. Headlights remain on when the lighting switch turned off

(1)

(2)

(3)

1-8. Headlights come on with the lighting SW at the clearance light position

(1)


2. Fog Light


3. Cornering Light

4. Rear Fog Light

Check point

FuseF-6 (10 A): 4JH1,4JB1, 4JB1-

TCF-8 (10 A): 24V, 4HG1-T (12 V)

Tail-light relay

Fog light SW

Fog light bulb Cable

harnessLH RH

Trouble mode

2-1. Both fog lights inopera-tive (while lighting switch is on)

(1)

(2)

(3)

(4)

2-2. Fog light on the left (or right) side inoperative (while lighting switch is on)

(1)

((1))

(2)

2-3. Fog lights remain on

(1)

(2)

(3)

Check point

FuseCornering light SW

Cornering light bulb

Cornering light relay

Cable harness

F-6 : 4JH1,4JB1,4JB1-TC

F-8 : 24V,4HG1-T(12V)

F-16(10 A)

Trouble mode

3-1. Both corner-ing lights inoper-ative

(2)

(1)

(5)

(3)

(4)

3-2. Cornering light on the left (or right) side inoperative

(2)

(1)

(3)

3-3. Cornering light remains on even when steer-ing wheel is in the straight ahead position

(1)

Check point

FuseF-27 (15 A)

Rear fog light SW

Rear fog light relay

Rear fog light bulb

Cable harness

Trouble mode

4-1. Rear fog light inoperative (while headlight is ON)

(2)

(4)

(3)

(1)

(5)


1. Headlight1-1. Both Headlights Inoperative

1-2. Headlight on The Left (or Right) Side Inoperative

N8A0118E

IS FUSE F-24 OR F-23 (10A) NORMAL?

YES NO

REPLACE THE FUSEREPAIR A POOR CONNECTION AT THE CONNECTORSOR AN OPEN CIRCUIT BETWEEN FUSE F-24 (10A) AND 3 B-4 (OR 3 B-148 ) OR FUSE F-23 (10A) AND 3 B-73(OR 3 B-150 )

•

N8A0119E


1-3. Headlight in Low-beam Inoperative

1-4. Headlight in High-beam Inoperative

N8A0120E

• IS THE DIMMER RELAY NORMAL?

• DISCONNECT THE DIMMER / PASSING SWCONNECTOR

• IS THERE ANY CONTINUITY BETWEEN SW SIDECONNECTORS 4 B-70 AND 10 B-70 WHEN THE SW ISAT HIGH-BEAM POSITION?

YES NO

REPLACE THE RELAY

REPAIR A POOR CONNECTION AT THE CONNECTORSOR AN OPEN CIRCUIT BETWEEN 1 X-6 AND 2 B-74

YES NO

REPAIR OR REPLACE THE SW• DISCONNECT THE HEADLIGHT RELAY• IS THERE ANY CONTINUITY BETWEEN CHASSIS SIDE

CONNECTORS 10 B-70 AND 5 X-3 ?

YES NO

REPAIR A POOR CONNECTION AT THECONNECTORS OR AN OPEN CIRCUITBETWEEN 10 B-70 AND 5 X-3

IS FUSE F-6 OR F-8 CONNECTED?

YES NO

REPLACE THE FUSE

•

N8A0121E


1-5. Headlight on The Left (or Right) Side in Low (or High)-beam Inoperative

1-6. Headlight Beam Does Not Change

• IS THE BULB NORMAL?

REPAIR A POOR CONNECTION AT THE CONNECTORSOR AN OPEN CIRCUIT[LOW BEAM]BETWEEN 1 B-4 (OR 1 B-73 ) AND 3 X-6 [HIGH BEAM]BETWEEN 2 B-4 (OR 2 B-73 ) AND 1 X-6

YES NO

REPLACE THE BULB

N8A0122E

N8A0123E


1-7. Headlight Remains On when the Lighting SW is Turned Off

1-8. Headlight Comes On with The Lighting SW at The Clearance Light Position

• IS THE LIGHTING RELAY NORMAL?

• DISCONNECT THE LIGHTING SW CONNECTOR• IS THE CONTINUITY BETWEEN THE SWITCH

CONNECTOR TERMINALS 1 B-70 AND 4 B-70NORMAL?

YES NO

REPLACE THE LIGHTING RELAY

REPAIR A SHORT CIRCUIT BETWEEN 4 X-3 AND 1 B-70

YES NO

REPAIR OR REPLACE THE LIGHTING SW

N8A0124E

• DISCONNECT THE LIGHTING SW CONNECTOR• WITH THE LIGHTING SW AT THE CLEARANCE LIGHT

POSITION, IS THE CONTINUITY BETWEEN 1 B-70AND 4 B-70 NORMAL?(NO CONTINUITY NORMAL)

NO

REPAIR OR REPLACE THE LIGHTING SW

N8A0125E


2. Fog Light2-1. Both Fog Lights Inoperative (While Lighting Switch is On)

• IS FUSE F-6 (10A) OR F-8 (10A) NORMAL?

• IS THE TAIL RELAY NORMAL?

YES NO

REPLACE THE FUSE

• REMOVE THE FOG LIGHT SW• WHEN THE SWITCH IS "ON", IS THERE CONTINUITY

BETWEEN THE SWITCH CONNECTOR TERMINALS 3 B-87 AND 6 B-87 ?

YES NO

REPLACE THE RELAY

• IS THE BATTERY VOLTAGE APPLIED BETWEEN THEHARNESS SIDE CONNECTOR 3 B-87 AND THEGROUND, WHILE THE LIGHTING SW IS ON?(LIGHTING OPERATION IS NORMAL)

YES NO

REPAIR OR REPLACE THE SW

• REPAIR A POOR CONNECTION AT THE CONNECTORSOR AN OPEN CIRCUIT BETWEEN 6 B-87 AND 1 B-3

YES NO

REPAIR A POOR CONNECTION AT THECONNECTORS OR AN OPEN CIRCUIT BETWEEN 8 B-70 AND 5 X-15

N8A0126E


2-2. Fog Light on The Left (or Right) Side Inoperative (While Lighting Switch is On)

Notice:Figures in parenthesis “( )” indicate place of inspection for the fog light on the right.

2-3. Fog Light Remains On

• IS THE BULB NORMAL?

REPAIR A POOR CONNECTION AT THE CONNECTORSOR AN OPEN CIRCUIT BETWEEN 2 B-3 AND B-7 (2 B-72 AND B-7 )

YES NO

REPLACE THE BULB

N8A0127E

• DO THE TAILLIGHTS GO OFF?

REPAIR OR REPLACE THE FOG LIGHT SWITCH

YES NO

REPLACE THE TAIL RELAY

N8A0128E


3. Cornering Light3-1. Both Cornering Lights Inoperative

N8A0129E


3-2. Cornering Light on The Left (or Right) Side Inoperative

Notice:Figures in parenthesis “( )” indicate place of inspection for the cornering light on the right.

3-3. Cornering Light Remains on Even when Steering Wheel is in Straight Ahead Position

N8A5149E

• DOES THE CORNERING LIGHT SWITCH OPERATESMOOTHLY?

NO

REPAIR OR REPLACE THE CORNERING LIGHTSWITCH (COMBINATION SWITCH)

N8A0131E


4. Rear Fog Light4-1. Rear Fog Light Inoperative (while Headlight is On)

• IS THE REAR FOG LIGHT BULB NORMAL?

• IS FUSE FOG LIGHT (REAR) F-27 (15A) NORMAL?

YES NO

REPLACE THE BULB

• IS J-9 GROUNDED SECURELY?

YES NO

REPLACE THE FUSE

• ARE THE REAR FOG LIGHT AND HEAD LIGHT RELAYSNORMAL?

YES NO

GROUND IT SECURELY

YES NO

REPAIR OR REPLACE THE RELAY• DISCONNECT THE REAR FOG LIGHT SWITCHCONNECTOR

• IS THERE ANY CONTINUITY BETWEEN THE SWITCHCONNECTORS 1 B-70 AND 14 B-70 WHEN THESWITCH IS ON?

YES NO

CONTINUED ON THE FOLLOWING PAGE

YES NO

REPAIR A POOR CONNECTION AT THECONNECTORS OR AN OPEN CIRCUIT BETWEEN4 X-3 AND 1 B-70

• RECONNECT THE RELAYS AND REAR FOG LIGHTSWITCH CONNECTOR

• IS THERE A BATTERY VOLTAGE APPLIED BETWEENSWITCH HARNESS SIDE CONNECTOR 1 B-70 ANDGROUND WHEN REAR FOG LIGHT SWITCH IS ON?

REPAIR OR REPLACE THE SWITCH

N8A0132E



High Beam Indicator LightRefer to “METER AND WARNING/INDICATOR LIGHT”in this section.

Headlight Bulb ReplacementRemoval

1. Remove the battery ground cable at the battery.2. Remove the headlight assembly. (Refer to ‘Head-

light Replacement’ below.)3. Remove the headlight bulb.

• Remove the dust cover (3).• Remove the clip (1).• Remove the headlight bulb (2).

Caution:Do not touch the glass portion of the bulb with your fin-gers.

Installation1. Install the headlight bulb.

• Set the headlight bulb (2).• Fix the headlight bulb with clip (1).• Install the dust cover (3).

2. Install the headlight assembly.(Refer to ‘Headlight Replacement’ below.)

3. Connect the battery ground cable at the battery.4. Check if the light lights.

N8A0133E

1 2 3

N8A5468E


Caution:Do not touch the glass portion of the new bulb with yourfingers.

Headlight ReplacementRemovalPreparation: Disconnect the battery ground cable.

1. Remove the battery ground cable at the battery.2. Remove the seal rubber (3).

• Remove the seal rubber from beneath theheadlight.

3. Remove the front combination light (2).• Open the cab door. Insert a screwdriver (1) into

the space between the cab and the cab door.Use the screwdriver to force out the stud pin atthe center of the grommet (the pin securing thefront combination light).

• Remove the fixing screw.• Remove the two catches.

• Remove the front combination light connector.4. Remove the front grille (4).

• Remove the bolt at the center of the front grille.• Remove the four clips securing the front grille.• The grille is secured by 4 clips (2 clips at the in-

side of each headlight). Pull the grille towardyou to remove it.

5. Remove the front corner panel.6. Remove the headlight (1).

• Remove the four bolts securing the headlight(loosen the fixing bolts at the bottom of the frontside panel to create working space).

• Remove the headlight clips.• Remove the headlight connector.

Installation1. Assemble the headlight assembly (1).

• Connect the connector.• Fix it to body panel with four bolts (5).

2. Assemble the front panel side.(Refer to “DOOR” in section 2.)

3. Install the front grille (4).4. Install the front combination assembly (2).

1) Position it by aligning two pawls with the grooveof H/L.

2) Fit the iron PIN in the upper portion by aligningit with the center of corresponding grommet.

Notice:Push it into securely with a force of approx. 250 N (25kgf) until click is heard.

3) Pull the front combination light assembly lightlytoward the front of vehicle to make sure that thePIN and grommet are engaged securely.

4) Tighten one bolt (6) in the lower portion of frontcombination light assembly.

5) Hook the seal rubber (3) on two projections un-der H/L.

1 2 3

N8A5468E

Door side Cab side

1

N8A5471E

1 2

3

4

N8A5472E


5. Connect the battery ground cable.6. Check the operation and lighting of each lamp.

Aiming of HeadlightPreparation: Place the unloaded vehicle on a level sur-face and check to see if the inflation pressure of the tiresis correct, the lenses are clean, and the battery is suffi-ciently charged. Adjust the aim with the headlight tester.When adjusting, follow the procedure of the tester man-ufacturer’s.

Vertical AdjustmentInsert the tip of a screwdriver into the hole beneath theheadlight (the shaft of the screwdriver must be slantedup) until contact is made with the head of the adjustingscrew. Turn the screw to adjust headlight focus up ordown.Two vertical aim screws should be turned in the samedirection at the same time to adjust aiming.

Horizontal AdjustmentInsert the tip of a screwdriver into the hole beneath theheadlight (the shaft of the screwdriver must be slantedup) until contact is made with the head of the adjustingscrew. Turn the screw to adjust headlight focus to theleft or right.

Cornering Light Bulb ReplacementRemoval

1. Remove the battery ground cable at the battery.2. Remove the front combination light.

• Open the cab door. Insert a screwdriver (1) intothe space between the cab and the cab door.Use the screwdriver to force out the stud pin atthe center of the grommet (the pin securing thefront combination light).

1 2

3

4

6

5

N8A0441E

N8A5473E

N8A5474E

N8A5475E


• Remove the fixing screw.• Remove the two catches.• Remove the front combination light (1) connec-

tor.

3. Remove the cornering light bulb.• Turn the cornering / clearance bulb socket (3)

to the left to remove it.• Press the bulb (2) in and turn it to the left to re-

move it from the socket.Installation

1. Install the cornering / clearance bulb.• While pressing the bulb (2), turn it clockwise to

fit.

Notice:Do not let the glass portion dirty with sebum etc.

• Turn the bulb socket (3) clockwise to fit.

2. Installation procedure of front combination light as-sembly• Connect the connector of the front combination

light assembly.• Position it by aligning two pawls with the groove

of H/L.• Fit the iron PIN (1) in the upper portion of the

side by aligning it with the center of correspond-ing grommet.


• Pull the front combination light assembly lightlytoward the front of vehicle to make sure that thePIN and grommet are engaged securely.

• Tighten one bolt in the lower portion of frontcombination light assembly.

3. Hook the seal rubber on two projections under H/L.4. Connect the battery ground cable.5. Check lighting of each light.

Door side Cab side

1

N8A5471E

1

3

2

N8A5477E

1

3

2

N8A0442E


Fog Light BulbRemoval

1. Remove the battery ground cable at the battery.2. Remove the four screws (1) to remove the cover

which holds fog light assembly (2).3. Remove the connector (3).4. Remove the fog light assembly (2).

5. Bulb• Push the clip (1) inward as arrow to remove.• Remove the bulb (2).

Installation1. Install the fog light bulb.

• Set the fog light bulb (2).• Hook the clip (1) to secure fog light bulb.

2. Connect the two locations of connector (4).3. Install the fog light assembly.

• Hold the fog light (2) with right and left covers(1) and secure it with four screws (3).

Notice:Make sure that “TOP” mark on the lens comes upside.

4. Connect the battery ground cable.5. Check lighting.

2

1

3

N8A5478E

12

N8A5479E

1

2

N8A0443E

2

1

4

3 N8A0444E


Fog Light SwitchInspectionCheck the continuity between the connector terminalswhile operating the switch.Replace the switch when the result of inspection isfound abnormal.


1. Meter ClusterRefer to “METER AND WARNING/INDICATORLIGHT” in this section.

2. Fog Light SwitchRelease the lock pushing the switch from the backside of the meter cluster.

InstallationTo install, follow the removal steps in the reverse order.

N8A0435E

N8A0436E


Combination Switch (Lighting Switch, Dimmer, Passing Switch, Cornering Light Switch and RearFog Light Switch)InspectionCheck the continuity between the connector terminals while operating the switch.Replace the switch when the result of inspection is found abnormal.


1. Horn Pad1) Hold the horn pad and pull it upward.

2. Steering Wheel1) Remove the steering shaft nut.2) Remove the steering wheel by using steering

wheel remover.(Refer to Section 3B4 “STEERING COLUMN”for steering wheel removal steps.)

3. Steering CowlRemove the four screws.

4. Combination Switch1) Remove the four screws.2) Disconnect the connector.

1 2 4 5 7 8 9 10 11 12 13 14

REAR FOGSW

OFF

High beam

Passing

Turning left

Neutral

Turningright

Lighting SW

Corneringlight SW

Terminal No.

SW position

N8A0143E


InstallationTo install, follow the removal steps in the reverse order,noting the following point.

1. Tighten the steering shaft nut to the specifiedtorque.

Tighten:Shaft nut to 49 N⋅m (5 kg⋅m / 36 lb⋅ft)

Headlight Leveling

General DescriptionThe circuit consists of starter SW, headlight leveling SWand headlight leveling actuator.When the headlight leveling SW is operated with thestarter SW at ON position, the actuator is operated tochange the angle of the optical axis of the headlight.

Operation of The Circuit


1. When headlight leveling SW is turned to “1” posi-tion

2. When headlight leveling SW is turned to “0” posi-tion

N8A0144E

0 1 2 3

HEADLIGHT LEVELINGACTUATOR - LH

HEADLIGHT LEVELINGACTUATOR - RH

STARTER SW "ON"

HEADLIGHTLEVELING SW

N8A0145E

0 1 2 3

HEADLIGHT LEVELINGACTUATOR - LH

HEADLIGHT LEVELINGACTUATOR - RH

STARTER SW "ON"

HEADLIGHTLEVELING SW

N8A0146E


Parts Location

F-12

B-7

X-1

1 (2

4V)

KE

Y O

N R

ELA

Y

X-1

(24

V)

KE

Y O

N R

ELA

YS

TA

RT

ER

SW

DC

-DC

CO

NV

ER

TE

R (

24V

ON

LY)

RE

LAY

BO

X A

SM

(N

o.1

)

HE

AD

LIG

HT

LE

VE

LIN

G R

ES

IST

OR

N8A0147E


Circuit DiagramFor 12 Volt

P-1

P-2

FL-1

100A

(12V

)M

AIN

B

ST

AC

C

ON

ST

AR

TE

R S

W

B-6

71

H-7

P-5

FRA

ME

FL-2

50A

(12V

)K

EY

SW

3W/L

3W/L

3W/B

23

B-6

7

F-12

10A

H/L

AM

P L

EV

EL

0.5R/W

2L

P-3

P-4

4JH

1

RE

LAY

; KE

Y O

N

3L

0.5B

3B/Y

3B/Y

X-1

X-1

X-1

X-1

AC

G B

2L

FUS

E B

LOC

K

2B

-421

3B

-421

4B

-421

5B

-421

6

0.5O

/G

0.5O

/B

0.5O

/W

0.5O

/L

0.5O

B-4

21

1B

-421

14B

-421

4B

-156

10B

-156

6B

-156

7

3

2

4 0

1B

-156

8B

-156

9B

-156

R5

R6

RESISTOR;H/L LEVELING

R4

R3

R2

R1

0.5R

/W

0.5R

/W

0.5B

1

B-1

55

3

B-1

55

2

0.5B

0.5B

B-1

55

AC

TU

AT

OR

; HLL

(LH

)(D

R S

IDE

HE

AD

LA

MP

)

1

B-1

52

3

B-1

52

2

B-1

52

AC

TU

AT

OR

; HLL

(R

H)

(AS

SID

E H

EA

D L

AM

P)

0.5R/W

0.5R/Y

0.5R

/Y

SW

; H/L

LEV

ELIN

G

1 3

2 5

N8A0148E


For 24 Volt

P-1

P-2

FL-1

100A

or

120A

MA

IN

B

ST

AC

C

ON

ST

AR

TE

R S

W

B-6

71

H-7

FL-2

40A

KE

Y S

W3W

/L

3W/L

3W/B

5W/B

3W/B

23

B-6

7

F-12

10A

H/L

AM

P L

EV

EL

2L

RE

LAY

; KE

Y O

N

3L

0.5B

3B/Y

3B/Y

X-1

1

X-1

1

X-1

1

X-1

1

AC

G B

FUS

E B

LOC

K

P-3

P-4

P-5

FRA

ME

2B

-421

3B

-421

4B

-421

5B

-421

6

0.5O

/G

0.5O

/B

0.5O

/W

0.5O

/L

0.5O

B-4

21

1B

-421

14B

-421

1B

-420

6B

-420

3B

-420

2B

-420

4B

-156

10B

-156

6B

-156

7

3

2

4 0

1B

-156

8B

-156

9B

-156

R5

R6

RESISTOR;H/L LEVELING

R4

R3

R2

R1

0.5R

/W

0.5B

/W1

B-1

55

3

B-1

55

2

B-1

55

AC

TU

AT

OR

; HLL

(LH

)(D

R S

IDE

HE

AD

LA

MP

)

1

B-1

52

3

B-1

52

2

B-1

52

AC

TU

AT

OR

; HLL

(R

H)

(AS

SID

E H

EA

D L

AM

P)

0.5R/W

0.5B/W

0.5R/Y

0.5R

/Y

SW

; H/L

LEV

ELIN

G

CO

NV

ER

TE

R;

DC

-DC

(HLL

)

0.5L

/O

0.5R

/W

0.5B

/W

1 3

2 5

N8A0388E


Connector List

H-7

No. Connector Face

B-7

B-67

B-67

B-152

B-155

B-156

P-1

P-2

000-012

004-001

1 23 4

004-002

2

4

1

3

003-016

3

1 2

003-016

3

1 2

010-002

5

21

6 7 8 9

43

10

000-004

000-003

P-5

B-420(24 V)

B-421

X-1(12V)

X-11(24 V)

No. Connector Face

000-007

006-019

4 5 6

1 2 3

014-002

1 2 3

7 8 9 10 11

4

12

5

13

6

14

005-006

005-001

1

32 4

5

1 2

1 2

1 2 3 4

5 6 7 8

9 10 11 12 13

14 15 16 17 18

2 1

2 1

4 3 2 1

8 7 6 5

13 12 11 10 9

18 17 16 15 14

H - 6

H - 7

H - 8

N8A5489E


DiagnosisQuick Chart for Check Points

1. Both Actuators Inoperative

Check point

FuseF-12 (10 A)

Headlight leveling switch

Headlight leveling actuator

Cable harness

Trouble mode

1. Both actuators inoperative

2. Actuator on the left (right) side inop-erative

3. When leveling SW is turned to a certain position, actuator inoperative

• IS FUSE F-12 (10A) NORMAL?

• IS B-7 GROUNDED SECURELY?

YES NO

REPLACE THE FUSE

• TURN THE STARTER SW TO ON POSITION• IS THE BATTERY VOLTAGE APPLIED BETWEEN THE

FUSE TERMINAL AND THE GROUND?

YES NO

GROUND IT SECURELY

• IS THE CONTINUITY IN THE HEADLIGHT LEVELING SW NORMAL?

YES NO

REPAIR AN OPEN CIRCUIT BETWEEN STARTERSW AND FUSE F-12 (10A)

• IS THERE CONTINUITY BETWEEN 6 B-156 AND THEGROUND?

YES NO


REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN FUSE F-20 AND 1 B-155 (1 B-152 )

YES NO

REPAIR AN OPEN CIRCUIT BETWEEN6 B-156 AND B-7

N8A0149E


2. Actuator on the Left (Right) Side Inoperative

3. When Headlight Leveling SW is Turned to A Certain Position, Actuator Inoperative

• IS THE ACTUATOR ON THE LEFT (RIGHT) SIDENORMAL?

• IS THERE CONTINUITY BETWEEN 6 B-155 (6 B-152 ) AND THE GROUND?

YES NO

REPLACE THE ACTUATOR

REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN F-12 (10A) AND 1 B-155 (1 B-152 )

YES NO

REPAIR A POOR CONNECTION AT THECONNECTORS OR AN OPEN CIRCUITBETWEEN 6 B-155 (6 B-152 ) AND B-7

N8A0150E

• IS THE CONTINUITY IN THE HEADLIGHT LEVELING SW NORMAL?

• IS THE ACTUATOR ON THE LEFT (RIGHT) SIDENORMAL?

YES NO


REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT(REFER TO THE FOLLOWING PAGE)

YES NO

REPLACE THE ACTUATOR

N8A0151E


Inspect and repair the circuit that is corresponding to theheadlight leveling switch position where the actuator be-comes inoperative.Actuator - LH

Actuator - RH

Starter SwitchRefer to “START AND CHARGING” in this manual.

Headlight Leveling SwitchInspectionCheck the continuity between the switch connector ter-minals.Repair or replace the switch when the result of inspec-tion is found abnormal.


1. Switch Bezel2. Headlight Leveling Switch

Disconnect the connector.


Headlight Leveling ActuatorInspectionApply the battery voltage to the connector terminals andcheck its function.This actuator has a mechanism that the angle of head-light leveling varies according to input voltage of SIG-NAL.

1. Make sure that the voltage specified in table is out-put to vehicle harness connector which will be con-nected to actuator.If the power supply is not 12 V, the SIGNAL outputvaries in proportion to its voltage.

2. Connect the connector of actuator and vehicle har-ness connector.Make sure that the reflector of headlight moves tothe position indicated by HEAD LAMP LEVELINGSW.

Headlight leveling SW position Circuit

1 Between 3 and 3

2 Between 2 and 4

3 Between 1 and 5

0 Between 4 and 2

Headlight leveling SW position Circuit

1 Between 3 and 3

2 Between 2 and 4

3 Between 1 and 5

0 Between 4 and 2

B-156 B-155

B-156 B-155

B-156 B-155

B-156 B-155

B-156 B-152

B-156 B-152

B-156 B-152

B-156 B-152

1 2 3 4 6

0

1

2

3

Terminal No.SWposition

B-156

4 3

10 9 8 7

2 1

6 5Switch side

N8A0152E

N8A5175E

B-152 B-155

Actuator side3

1 2

N8A0154E


Caution:1. For vehicles with 12 V and 24 V, this leveling input

voltage is 12 V.2. Input to SIGNAL must be less than 65% of the in-

put voltage to positive terminal.

1 2 3

SIGNAL − +

Input signal voltage ratio for SIGNAL when the volt-age difference between posi-tive and nega-tive is specified as 100%

− +

HEADLAMPPOSITION

Position0

10.0% (1.2 V) 0 V 12 V

Position1

23.4% (2.8 V) 0 V 12 V

Position2

36.7% (4.4 V) 0 V 12 V

Position3

50.0% (6.0 V) 0 V 12 V

Position4

63.4% (7.6 V) 0 V 12 V


Clearance Light, Taillight, License Plate Light and Illumination LightGeneral DescriptionThe circuit consists of the lighting switch, clearance light, taillight, license plate light and the illumination light for eachof switch, meter and ashtray.All these lights come on when the lighting switch is turned on with the switch to either clearance or headlight position.Lighting Circuit

N8A0156E


Parts Location

F-7

B-7

X-4

TA

IL R

ELA

Y

X-2

2

B-3

3 H

EA

TE

RB

EZ

EL

SW

RO

OF

MA

RK

ER

LI

GH

T (

RH

)(F

OR

EC

/ T

UR

KE

Y

N2

CA

TE

GO

RY

ON

LY)

RO

OF

MA

RK

ER

LI

GH

T (

LH)

(FO

R E

C /

TU

RK

EY

N

2 C

AT

EG

OR

Y O

NLY

)

B-4

6 A

SH

TR

AY

F-2

5

B-5

2 M

ET

ER

B-3

1E

NG

INE

WA

RM

UP

SW

N8A0157E



5B

-52

B-5

2

X-4

B-7

0

B-7

0

H T

LOOF

F

PA

SS

HIG

H

EHu

PA

SS

P-1

P-2

1 8 7 10 4

21

45

211 2

8 7

10 9

1 3

HE

AD

LIG

HT

BR

AC

KE

T-L

HFL-

1

MA

IN

RE

LAY

; HE

AD

LIG

HT

(4)

LIG

HT

ING

SW

COMBINATION SW

0.3L

/R

3W

F-7

TA

ILLI

GH

T

2

RELAY; TAIL

RE

LAY

; DIM

ME

R (

4)0.

3R/L

0.5R

/G0.

5R/G

0.5B

0.5B

ASHTRAY

CIGAR LIGHTER

HAZARD WARNING SW

RADIO

DOME LIGHT SW

3B

0.3G

/O

8W8B

100A

0.3R

1 2

HEATER BEZEL

52

FOG LIGHT SW

5METER

B-7

0

B-7

0

B-7

0

H-6

X-4

X-4

X-4

B-8

7

B-8

7

B-8

6

B-8

6

B-2

8

B-2

8

B-3

0

B-3

0

B-4

3

B-4

3

B-3

3

B-3

3

B-4

6

B-4

6

10A

0.5LG/R 0.5B

0.5LG/R 0.5B

0.5LG/R 0.5B

0.5LG/R 0.5B

0.5LG/R 0.3B

0.5LG/R 0.3B

0.5LG/R 0.3B

0.5LG/R 0.85B

ROOF MARKER LIGHT (LH)

ROOF MARKER LIGHT (RH)

NPR / NQR (EC / TURKEY)

1.25B

B-7

B-1

J-9

FR

AM

E-L

H (

FR

ON

T)

FR

AM

E-L

H (

CE

NT

ER

)

B-7

4B

-74

B-7

4

3

CLEARANCE LIGHT-RH

4

B-5

B-5

B-5

3

CLEARANCE LIGHT-LH

4

0.5L

G/R

10

0.85B 2B

3B

1.25B

2B

3B

11

61

TAILLIGHT-LH

R-1

R-1

61

TAILLIGHT-RH

R-6

R-6

11

LICENSE PLATE LIGHT

R-3

0.5G/R

4

H-1

6

0.5G/R

45

H-5

0.5LG/R 0.5LG/RH-1

6

0.85LG/R 0.5LG/R

X-2

2

41

RELAY; MARKER LIGHT

X-2

2

X-2

2X

-22

1.25

W

F-2

5

MA

RK

ER

LIG

HT

15A

0.85

LG/R

0.5LG/R

7H

-16

1.25

B

2B

0.85LG/B J-25

J-24

0.85B

25 1 1

MARKER LIGHT

0.5LG/R

0.85LG/W

0.5B

1.25B

1.25B

0.5B

3W/B

3W/B8W/B

0.5G

/R

R-2

H-5

P-5

FR

AM

E

5W

3W/B

CORNERING LIGHTSW (13)


0.85B

2L

P-3

P-4

4JH

1

N8A0158E


For 24 Volt

J-9

FR

AM

E-L

H (

CE

NT

ER

)1.

25B

2B

H T

LOOF

F

PA

SS

HIG

H

EHu

PA

SS

B-1

8

B-4

3B

-52

B-4

6

H-5

H-6

X-4

B-2

8B

-31

B-8

6B

-87

B-3

3

H-1

6

H-1

6

H-5

R-1

R-2

R-3

B-7

0

H-5

J-63

J-65

J-62

B-7B-1

B-3

0

B-3

0B

-32

B-3

2

B-7

4

R-6

B-5

P-1

P-2

P-3

P-4

P-5

B-7

0

B-7

0

B-7

0

B-7

0

1 8 7 10 4

B-1

8

B-1

8

31

2

X-4

X-4

X-4

21

45

4

5

J-65

J-62

1 6

1 6

1 1

5

5

1

4 11

16

6

B-7

4B

-74

B-5

B-5

4

1

43

3

1

R-1

R-6

B-4

6

B-5

2B

-28

B-3

3

1 2

1 2

10 9

5 10

B-4

3

21

B-8

7B

-86

B-3

1

521 3

2 1

3 1

8 7

FR

AM

E

FL-

1

MA

IN

RE

LAY

; HE

AD

LIG

HT

(4)

LIG

HT

ING

SW

COMBINATION SW

0.5R

0.5L

RE

LAY

; CO

RN

ER

ING

LIG

HT

(4)

0.5L

/R

0.5R

F-7

1

0A

TA

ILLI

GH

T

2

RELAY; TAIL

DIODE

RE

LAY

; DIM

ME

R (

4)0.

5R/L

0.85LG/R

0.85

LG/R

0.5G/R

REAR COMBINATION LIGHT RH (TAIL)

REAR COMBINATION LIGHT LH (TAIL)

0.5LG/R 0.5B

1.25B

1.25B

0.5G/R

0.5G/R

LICENSE PLATE LIGHT

CORNERINGLIGHT SW (9)(COMBINATION SW)


(COMBINATION SW)

CLEARANCE LIGHT (RH)

CLEARANCE LIGHT (LH)

0.5LG/R

2LG/W

0.5LG/R

0.85B

0.85B

0.5B

0.85B1.25LG/B

0.5G/R

0.5G/R

0.5LG/R

0.85B

0.85B

0.5B

TAILLIGHT-RH (REAR COMBINATION LIGHT)

TAILLIGHT-LH(REAR COMBINATION LIGHT)

0.5LG/R

0.5LG/R

0.5LG/R

0.5LG/R

0.5LG/R

ASHTRAY

HEATER BEZEL

RADIO

ILLUMINATION LIGHT (METER)

CIGAR LIGHTER

FOG LIGHT SW

DOME LIGHT SW

ENGINE WARMING UP SW

MIRROR SW

HAZARD WARNING SW

0.85LG/R

0.5LG/R

0.5LG/R

0.5LG/R

0.5R/G

0.3B

0.3B

0.5B

0.85B

0.3B

0.5B

0.5B

0.5B

0.5B

0.5B

3B

0.5G

/O

3W/B

5W

LICENSE PLATE LIGHT

(DU

MP

) J-64

0.5G

/R

0.5L

G/R

100A

or

120A

HE

AD

LIG

HT

BR

AC

KE

T (

LH)

FR

AM

E-L

H (

FR

ON

T)

0.85G/B

H-1

67

(DU

MP

)

2L

0.5L

G/R

0.5L

G/R

0.5B

0.5B

1

12

2

ROOF MARKER LIGHT (LH)

ROOF MARKER LIGHT (RH)

NPR / NQR (EC / TURKEY)

1 2

X-2

2X

-22

X-2

2X

-22

32

51

J-24

J-25

1 1

RELAY; MARKER LIGHT MARKER LIGHT

F-2

5

MA

RK

ER

LIG

HT

15A

0.5B

N8A0538E


Connector List

No. Connector Face

B-5

B-5

B-74

B-74

B-18

X-4

X-22

B-28

004-012

1 2

3 4

004-013

12

34

004-012

1 2

3 4

004-013

12

34

003-024

1 2 3

005-006

005-006

013-001

1 2 3

7 8 9

4 5 6

11 12 1310

B-30

B-31

B-33

B-33

B-46

B-46

B-43

B-43

No. Connector Face

008-005

1 2 3 4

5 6 7 8

006-001

1 2 3

4 5 6

002-022

1 2

002-023

2 1

002-022

1 2

002-023

2 1

002-009

1

2

002-010

1

2


B-52

B-70

B-70

B-86

B-87

H-16

H-16

J-24

No. Connector Face

012-005

1 2 3 4 5 6 7 8 9 10 11 12

014-002

1 2 3

7 8 9 10 11

4

12

5

13

6

14

014-003

6 5 4

14131211

3 2 1

9 8 710

004-001

1 23 4

006-006

21 3

54 6

008-003

1 2 3 4

5 6 7 8

008-004

4 3 2 1

8 7 6 5

000-010

J-24

J-25

J-25

J-62

J-62

J-65

J-65

J-63

No. Connector Face

000-011

000-010

000-011

006-010

1 2 34 5 6

006-015

123

456

006-010

1 2 34 5 6

006-015

123

456

000-010


J-63

J-64

J-64

R-2

R-2

R-3

R-3

P-1(12 V)

No. Connector Face

000-011

000-010

000-011

000-010

000-011

000-010

000-011

000-003

P-2

P-1(24 V)

P-4

P-2(24 V)

P-3

P-5(12 V)

P-5(24 V)

R-1

No. Connector Face

000-004

000-004

000-004

000-006

000-006

000-007

000-002

006-004

1 2 3

4 5 6


H-5

H-6

R-1

R-6

R-6

No. Connector Face

006-005

3 2 1

6 5 4

006-004

1 2 3

4 5 6

006-005

3 2 1

6 5 4

1 2 37 8 9

13 14 1519 20 2125 26 2731 32 33 34 35 36 37

4 5 610 11 1216 17 1822 23 2428 29 3038 39 40

6 5 412 11 1018 17 1624 23 2230 29 2840 39 38

3 2 19 8 715 14 1321 20 1927 26 2533 32 3134353637

N8A5488E

1 2

1 2

1 2 3 4

5 6 7 8

9 10 11 12 13

14 15 16 17 18

2 1

2 1

4 3 2 1

8 7 6 5

13 12 11 10 9

18 17 16 15 14

H - 6

H - 7

H - 8

N8A5489E


DiagnosisQuick Chart for Check Point


Check point

Fuse Light-ing SW

Tail-light bulb

Clear-ance

light bulb

License plate

light bulb

Marker light relay

Cable har-ness

Marker light bulb

F-7(10 A)

F-25(15 A)

Troublemode

1. Both clearance lights inoperative

(1)

(3)

(2)

(4)

2. Clearance light on the left (or right) side inoperative

(1)

(2)

3. Both taillights inoperative

(1)

(2)

(3)

4. Taillight on the left (or right) side inoperative

(1)

(2)

5. License plate light inoperative

(1)

(2)

6. Marker light inoperative

(2)

(3)

(4)

(1)


1. Both Clearance Lights Inoperative

Notice:Figure in parenthesis “( )” indicates place of inspection for clearance light on the right side.

• ARE BOTH TAILLIGHTS OPERATIVE?

• IS B-7 SECURELY GROUNDED?

YES NO

TURN TAILLIGHTS ON (REFER TO TAILLIGHTDIAGNOSIS IN THIS SECTION)

REPAIR A POOR CONNECTION AT THE CONNECTORSOR AN OPEN CIRCUIT BETWEEN CLEARANCE LIGHTCONNECTOR TERMINALS 1 B-5 (1 B-74 ) AND B-7

YES

• TURN THE LIGHTING SWITCH TO OR POSITION• IS THERE BATTERY VOLTAGE APPLIED TO

CLEARANCE LIGHT CONNECTOR 4 B-5 (4 B-74 ) ANDGROUND?

YES NO

NO

GROUND IT SECURELY

REPAIR A POOR CONNECTION AT THECONNECTORS OR AN OPEN CIRCUIT BETWEENFUSE F-7 (10A) AND 4 B-5 (4 B-74 )

N8A0160E


2. Clearance Light on the Left (or Right) Side Inoperative

Notice:Figure in parenthesis “( )” indicates place of inspection for clearance light on the right side.

• IS THE CLEARANCE LIGHT BULB ON THE LEFT (ORRIGHT) SIDE NORMAL?

• IS THERE ANY CONTINUITY BETWEEN THE

YES NO

REPLACE THE BULB

• REPAIR A POOR CONNECTION AT THECONNECTORS OR AN OPEN CIRCUIT BETWEEN 1 B-5 (1 B-74 ) AND B-7

YES NO

REPAIR A POOR CONNECTION AT THECONNECTORS OR AN OPEN CIRCUIT IN THECIRCUIT

HARNESS SIDE CONNECTOR 5 X-15 (12V), 5 X-4 (24VAND NKR77 FOR TAIWAN) AND 4 B-5 (OR 4 B-74 )?

N8A0161E


3. Both Taillights Inoperative


• IS J-9 SECURELY GROUNDED?

YES

REPLACE THE FUSE

• IS THE TAIL RELAY NORMAL?

YES

GROUND IT SECURELY

YES

REPLACE THE RELAY• IS THE LIGHTING SWITCH NORMAL?

• IS THE BATTERY VOLTAGE APPLIED BETWEENLIGHTING SWITCH HARNESS SIDE CONNECTOR 8 B-70 AND THE GROUND?

YES NO

REPAIR OR REPLACE THE LIGHTINGSWITCH

YES NO

NO

NO

NO

• TURN THE LIGHTING SWITCH TO OR POSITION• IS THERE BATTERY VOLTAGE APPLIED TO 4 H-16

AND GROUND?

REPAIR A POOR CONNECTION AT THECONNECTORS OR AN OPEN CIRCUIT BETWEENFUSE F-7 (10A) AND 8 B-70

• REPAIR A POOR CONNECTION AT THE CONNECTORSOR AN OPEN CIRCUIT BETWEEN LIGHTING SWITCHHARNESS SIDE CONNECTORS 7 H-16 AND J-9

YES NO

REPAIR A POOR CONNECTION AT THECONNECTORS OR AN OPEN CIRCUIT BETWEENTAILLIGHT RELAY CONNECTORS 5 X-15 (12V), 5 X-4 (24V AND NKR77 FOR TAIWAN) AND4 H-16

N8A0162E


4. Taillight on the Left (or Right) Side Inoperative

Notice:Figure in parenthesis “( )” indicates place of inspection for taillight on the right side.

5. License Plate Light Inoperative

• IS TAILLIGHT BULB ON THE LEFT (OR RIGHT) SIDENORMAL?

• REPAIR A POOR CONNECTION AT THE CONNECTORSOR AN OPEN CIRCUIT BETWEEN CONNECTORTERMINAL 4 H-16 AND TAILLIGHT CONNECTOR 1 R-1 ( 1 R-6 )

YES NO

REPLACE THE BULB

N8A0163E

• ARE BOTH TAILLIGHTS OPERATIVE?

• IS THE LICENSE PLATE LIGHT BULB NORMAL?

YES NO

TURN THE TAILLIGHTS ON (REFER TOTAILLIGHT DIAGNOSIS IN THIS SECTION)

YES NO

REPLACE THE BULB IS THERE BATTERY VOLTAGE APPLIED BETWEEN 5 H-16 AND THE GROUND WHEN TURNING THELIGHTING SWITCH ON?

• REPAIR A POOR CONNECTION AT THE CONNECTORSOR AN OPEN CIRCUIT BETWEEN 1 R-2 OR 1 R-14AND 7 H-16

YES NO


•

N8A0164E


6. Marker Light Inoperative

Lighting SwitchRefer to “HEADLIGHT, FOG LIGHT AND CORNERINGLIGHT” in this section.

Clearance Light/BulbRemoval



• Remove the fixing screw.



YES NO

REPLACE THE FUSE

• IS MARKER LIGHT RELAY NORMAL?

YES NO

GROUND IT SECURELY

• IS THERE BATTERY VOLTAGE APPLIED TO THEMARKER LIGHT CONNECTOR J-24 WHEN TURNINGTHE LIGHTING SWITCH ON?

YES NO

REPLACE THE MARKER LIGHT RELAY

• REPAIR A POOR CONNECTION AT THE CONNECTORSOR AN OPEN CIRCUIT BETWEEN THE MARKER LIGHTCONNECTORS J-25 - J-9

YES NO

REPAIR A POOR CONNECTION AT THECONNECTORS OR AN OPEN CIRCUIT OF 2 X-22OR BETWEEN 5 X-22 AND J-9

N8A0165E

Door side Cab side

1

N8A5471E


• Remove the two catches.• Remove the front combination light (1) connec-

tor.

3. Remove the clearance light bulb.• Turn the bulb socket (3) to the left to remove it.• Press the bulb (2) in and turn it to the left to re-

move it from the socket.InstallationInstallation procedure of cornering/clearance light bulb

1. Install the cornering/clearance light bulb.• While pressing the bulb (2), turn it clockwise to

fit.



2. Installation procedure of front combination light as-sembly• Connect the connector of the combination light

assembly.

• Position it by aligning two pawls with the grooveof H/L.

• Fit the iron PIN (1) in the upper portion of theside by aligning it with the center of correspond-ing grommet.




3. Hook the seal rubber on two projections under H/L.4. Connect the battery ground cable.5. Check lighting of each light.

Taillight BulbRemoval

1. Lens2. Bulb


1

3

2

N8A5477E

1

3

2

N8A0445E

N8A0167E


License Plate Light BulbRemoval

1. Cover2. Lens3. Bulb


Turn Signal Light, Hazard Warning Light,and Stoplight

General DescriptionThe circuit consists of the starter switch, turn signal light(front and rear), turn signal light switch, hazard warninglight, flasher unit, stoplight and stoplight switch.When turning on the respective switches with the starterswitch on, the turn signal light will operate. When theturn signal light is flashing, the indicator light in the meteralso starts flashing. When the hazard warning switch isturned on, the current flows to the flasher unit throughthe hazard warning switch to cause the hazard warninglight to flash, independent of the position of the starterswitch. At the same time, the indicator lights in the meteralso start flashing.The stoplight switch will turn on and the light comes ononce the brake pedal is depressed, independent of theposition of the starter switch.

N8A0168E


Parts Location

B-7

H5

- H

7

H-2

2S

IDE

TU

RN

SIG

NA

L LI

GH

T (R

H)

(FO

R E

C/T

UR

KE

Y

N2

CA

TE

GO

RY

W/C

AB

ON

LY)

H-2

0S

IDE

TU

RN

SIG

NA

L LI

GH

T (

LH)

(FO

R E

C/T

UR

KE

Y

N2

CA

TE

GO

RY

W/C

AB

ON

LY)

SID

E T

UR

N S

IGN

AL

LIG

HT

(R

H)

(FO

R E

C/T

UR

KE

Y

N2

CA

TE

GO

RY

S/C

AB

ON

LY)

J-62

TU

RN

SIG

NA

L LI

GH

T (

RH

)

J-65

TU

RN

SIG

NA

L LI

GH

T (

LH)

R-1

ST

OP

LIG

HT

(LH

)

SID

E T

UR

N S

IGN

AL

LIG

HT

(LH

)(F

OR

EC

/TU

RK

EY

N2

CA

TE

GO

RY

S/C

AB

12V

ON

LY)

SID

E T

UR

N R

ELA

Y(F

OR

EC

/TU

RK

EY

N2

CA

TE

GO

RY

S/C

AB

ON

LY)

FU

SE

BO

X A

SM

F-4

, F-5

, F-1

1, F

-19,

F-2

0

B-1

6F

LAS

HE

R U

NIT

B-5

3 T

UR

N S

IGN

AL

IND

ICA

TO

R L

IGH

T (

RH

) (M

ET

ER

)T

UR

N S

IGN

AL

IND

ICA

TO

R L

IGH

T (

LH)

(ME

TE

R)

J-9

N8A0536E


Circuit DiagramO

FF

ON

AC

C

ST

B

RH

LH

IGR

HLH

B

TB

FU

B-7

0B

-70

B-7

0

B-1

6

H-6

H-7

B-6

7B

-67

B-5

3

B-5

3

B-7

4

B-7

4

R-6

R-1

R-6

R-1

H-1

6H

-16

H-5

H-5

B-5

B-5

B-5

3

B-5

3

H-2

0

H-2

0

B-3

0

B-3

0

B-3

0

R-1

R-1

H-1

6

R-6

R-6

H-1

6

B-6

6

B-6

6

H-5

J-9

B-7

B-1

P-1

P-2

P-3

P-4

P-5

12

2

3

3

1

2(12

V)

82

6

1

54

37

12

135

17 8

10 12

4 3

211

H-2

2

H-2

24 10

71

1

82 3

2 37

33

66

7

111 2 2 2 6

2 6

(24

V M

OD

EL)

FR

AM

E

MA

IN

ST

AR

TE

R S

WIT

CH

FLA

SH

ER

U

NIT

RELAY; TAIL (5)

3W/L

5W

0.5G

3B/Y 0.5Y/R

0.5B

R

0.5L

G/R

TURN SIGNAL LIGHT SWITCH(COMBINATION SWITCH)

0.5G/B

0.5G/W

0.85

B(2

4V)

0.5G/W

0.5G/B

0.5B

F-19 15A(4JH1, 4JB1, 4JB1-TC)

F-20 15A(24V)

HORN, HAZARD

F-11 10ATURN LIGHT

5W/B

(24V

)8W

/B(1

2V)

F-5 10ASTOPLIGHT

F-4 15AAUDIO

STOPLIGHT SWITCH0.5G0.5G

0.5G 1.25B

2BSTOPLIGHT (RH)

(Exc

ept D

UM

P V

EH

ICLE

)

TURN SIGNALINDICATOR LIGHT (RH) (METER)

0.5G/Y

0.5LG/B

(Except DUMP VEHICLE)

FR

AM

E-L

H(F

RO

NT

)

HE

AD

LIG

HT

B

RA

CK

ET

(LH

)

0.5BR

B-1

6

B-1

6

B-3

0B

-30

B-3

0B

-30

B-3

0H

AZ

AR

D

WA

RN

ING

S

WIT

CH

3W/B

5W

FL-

110

0A o

r 12

0A

KE

Y S

W

FL-

2 40

A(2

4V)

50A

(12V

)

J-65

J-65

J-62

J-62

2 6

2 60.5G 1.25B

2B

5W(2

4V)

8W(1

2V)

TURN SIGNAL LIGHT (FRONT COMBINATION LIGHT-RH)

5(24

V)

0.5B

(NK

R D

UM

P V

EH

ICLE

)

STOPLIGHT (LH)

STOPLIGHT (RH)

STOPLIGHT (LH)

TURN SIGNAL LIGHT(REAR COMBINATION LIGHT-RH)

TURN SIGNAL LIGHT(REAR COMBINATION LIGHT-LH)

TURN SIGNAL LIGHT(FRONT COMBINATION LIGHT-LH)

TURN SIGNAL INDICATOR LIGHT (LH) (METER)

0.5G

/B0.

5G/W

1.25

B(1

2V)

0.5G

0.85B

0.85B

1.25B

1.25B

0.85B

0.85B 3B

FR

AM

E-L

H (

CE

NT

ER

)

2L

P-3

P-4

4JH

1

SIDE TURN SIGNAL LIGHT (RH)(DOOR)

SIDE TURN SIGNAL LIGHT (LH)(DOOR)

(NP

R/N

QR

W/C

AB

EC

ON

LY)

(NP

R/N

QR

W/C

AB

EC

ON

LY)

SIDE TURN SIGNAL LIGHT (LH)(S/CAB)

RELAY; SIDE TURN(S/CAB)

P/SOURCE(SERVICE)

SIDE TURN SIGNAL LIGHT (RH)(S/CAB)

4

25

1

0.5W

3

0.5B

6

0.5L

0.5G/W 0.5B

0.85R

0.85

R0.

5G/W

0.5G

/B

0.5B

0.5B

(S/C

AB

EC

TU

RK

EY

ON

LY)

J-62

J-65

J-62

J-653

3

66

(NK

R D

UM

P V

EH

ICLE

)

TURN SIGNAL LIGHT(REAR COMBINATION LIGHT-RH)

TURN SIGNAL LIGHT(REAR COMBINATION LIGHT-LH)

0.5G/W

0.5G/B

0.5G/B 0.5B

2B

1.25B

N8A0399E


Connector List

No. Connector Face

B-1

J-9

B-5

B-5

B-74

B-74

B-7

B-16(24 V)

000-001

000-001

004-012

1 2

3 4

004-013

12

34

004-012

1 2

3 4

004-013

12

34

000-012

006-010

1 2 34 5 6

B-16(12 V)

B-30

B-53

B-66

B-67

B-67

B-70

B-70

No. Connector Face

003-008

1 3

2

008-005

1 2 3 4

5 6 7 8

012-004

1 2 3 4 5 6 7 8 9 10 11 12

002-024

1 2

004-001

1 23 4

004-002

2

4

1

3

014-002

1 2 3

7 8 9 10 11

4

12

5

13

6

14

014-003

6 5 4

14131211

3 2 1

9 8 710


H-16

H-16

H-20

H-20

H-22

H-22

J-62

J-62

No. Connector Face

008-003

1 2 3 4

5 6 7 8

008-004

4 3 2 1

8 7 6 5

010-003

1098765

4321

010-004

12

5678910

34

010-003

1098765

4321

010-004

12

5678910

34

006-010

1 2 34 5 6

006-015

123

456

J-65

J-65

P-1(12 V)

P-2

P-1(24 V)

P-4

P-2(24 V)

P-3

No. Connector Face

006-010

1 2 34 5 6

006-015

123

456

000-003

000-006

000-006

000-006

000-004

000-004


H-5

H-6, H-7

P-5(12 V)

P-5(24 V)

R-1

R-1

R-6

R-6

No. Connector Face

000-007

000-002

006-004

1 2 3

4 5 6

006-005

3 2 1

6 5 4

006-004

1 2 3

4 5 6

006-005

3 2 1

6 5 4

000-010

000-011

No. Connector Face

000-010

000-011

1 2 37 8 9

13 14 1519 20 2125 26 2731 32 33 34 35 36 37

4 5 610 11 1216 17 1822 23 2428 29 3038 39 40

6 5 412 11 1018 17 1624 23 2230 29 2840 39 38

3 2 19 8 7

15 14 1321 20 1927 26 2533 32 3134353637

N8A5488E

1 2

1 2

1 2 3 4

5 6 7 8

9 10 11 12 13

14 15 16 17 18

2 1

2 1

4 3 2 1

8 7 6 5

13 12 11 10 9

18 17 16 15 14

H - 6

H - 7

H - 8

N8A5489E


DiagnosisQuick Chart for Check Point1. Turn Signal Light, Hazard Warning Light


2. Stoplight


Check point

Fuse Turn signal

light SW

Hazard warning light SW

Flasher unit

Turn signal

light bulb

Cable harnessF-19, F-20

(15 A)F-11

(10 A)

Troublemode

1-1. Turn signal lights inoperative

1-2. Turn signal lights flash too quickly

1-3. Hazard warning lights inoperative

Check point

FuseF-5 (10 A) Stoplight SW Stoplight bulb Cable harness

Troublemode

2-1. Both stoplights inoperative

2-2. Stoplight on the left (or right) side inoperative


1. Turn Signal Light, Hazard Warning Light1-1. Turn Signal Lights Inoperative

N8A0169E


1-2. Turn Signal Lights Flash Too Quickly

• IS THERE ANY CONTINUITY BETWEEN THE HARNESSSIDE CONNECTORS 3 B-16 AND B-7 ?

GROUND IT SECURELY

CONTINUED FROM THE PREVIOUS PAGE CONTINUED FROM THE PREVIOUS PAGE

• DISCONNECT THE COMBINATION SWITCHCONNECTOR

• IS THERE ANY CONTINUITY BETWEEN THE SWITCHCONNECTORS 5 B-70 AND 12 B-70 (WHEN TURNING LEFT), 13 B-70 AND 12 B-70 (WHENTURNING RIGHT) RESPECTIVELY?

YES NO

REPAIR A POOR CONNECTION AT THECONNECTORS OR AN OPEN CIRCUIT BETWEENTHE CIRCUIT

• REPAIR A POOR CONNECTION AT THE CONNECTORSOR AN OPEN CIRCUIT BETWEEN THE HARNESS SIDECONNECTORS 2 B-16 (12V), 5 B-16 (24V) AND 12 B-70

YES NO


N8A0170E

• DOES ANY TURN SIGNAL LIGHT REMAINUNLIGHTED?

YES

DISCONNECT AND REINSTALL THE BULB, ORREPLACE IT, OR REPAIR AN OPEN CIRCUIT INTHE CIRCUIT OF THE INOPERATIVE BULB, ORCHECK THE GROUND

N8A0171E


1-3. Hazard Warning Lights Inoperative

2. Stoplight2-1. Both Stoplights Inoperative

• IS FUSE F-19 , F-20 (15A) NORMAL?

• DOES THE HAZARD WARNING LIGHT SWITCHFUNCTION NORMALLY?

YES NO

REPLACE THE FUSE

• REPAIR A POOR CONNECTION AT THE CONNECTORSOR AN OPEN CIRCUIT BETWEEN FUSE F-19 , F-20 (15A) AND 1 B-30

YES NO

REPLACE THE HAZARD WARNING LIGHTSWITCH

N8A0172E


• IS J-9 GROUNDED SECURELY?

YES NO

REPLACE THE FUSE

• IS BATTERY VOLTAGE APPLIED TO THE 1 B-66 OFTHE STOPLIGHT SW?

YES NO

GROUND IT SECURELY

• IS STOPLIGHT SWITCH NORMAL?

YES NO

REPAIR A POOR CONNECTION AT THECONNECTORS OR AN OPEN CIRCUIT BETWEENTHE FUSE F-5 (10A) AND 1 B-66

YES NO

• DOES THE PUSH ROD OF THE STOPLIGHT SWOPERATE SMOOTHLY?

REPLACE THE STOPLIGHT SW

REPAIR A POOR CONNECTION AT THE CONNECTORSOR AN OPEN CIRCUIT BETWEEN 2 B-66 AND J-9

YES NO

REPLACE THE STOPLIGHT SW

N8A0173E


2-2. Stoplight on the Left (or Right) Side Inoperative

Notice:Figure in parenthesis “( )” indicates the place of inspection for the right side stoplight.


Front Turn Signal Light/BulbRemoval



• Remove the fixing screw.• Remove the two catches.

• Remove the front combination light (1) connec-tor.

3. Remove the front turn signal light bulb.• Turn the bulb socket (2) to the left to remove it.• Press the bulb (3) in and turn it to the left to re-

move it from the socket.Installation

1. Install the front turn signal light bulb.• While pressing the bulb (2), turn it clockwise to

fit.



N8A5206E

Door side Cab side

1

N8A5471E

21

3

N8A5484E


2. Installation procedure of front combination light as-sembly• Connect the connector of the front combination

light assembly.• Position it by aligning two pawls with the groove

of H/L.• Fit the iron PIN (1) in the upper portion of the

side by aligning it with the center of correspond-ing grommet.




3. Hook the seal rubber on two projections under H/L.

4. Connect the battery ground cable.5. Check lighting of each light.

Rear Turn Signal Light/BulbRemovalPreparation:Disconnect the battery ground cable.

1. Lens2. Bulb


Turn Signal Light Switch (Combination Switch)InspectionCheck the continuity between the terminals of the turnsignal light switch.Repair or replace the switch when the result of inspec-tion is found abnormal.

1

3

2

N8A0445E

N8A0176E

2 5 9 11 12 13Terminal No.

SW position

Turningleft

NeutralTurn signallight SW

Turningright

N8A0177E


Removal and InstallationRefer to “HEADLIGHT, FOG LIGHT AND CORNERINGLIGHT” in this section.

Flasher UnitInspectionWhen a 55W bulb is connected to the unit side terminals“L” and “E” while connecting the battery (+) terminal toterminal “B”, and the battery (−) terminal to terminal “E”,does the bulb light on and off?Replace the unit when the result of inspection is foundabnormal.

Stoplight BulbRemoval and InstallationRefer to “CLEARANCE LIGHT, TAILLIGHT, LICENSEPLATE LIGHT AND ILLUMINATION LIGHT” for TAIL-LIGHT BULB removal and installation steps in this sec-tion.

Stoplight SwitchInspection

1. Check to see if the stoplight switch is installed cor-rectly to the specified position. Adjust the positionwhen the result of the inspection is found abnor-mal.

2. Check to see if there is any continuity between theterminals of the stoplight switch.Replace the switch when the result of inspection isfound abnormal.


1. Stoplight Switch1) Disconnect the connector.2) Loosen the lock nut of the switch.3) Remove the switch by turning it.

N8A0178E

1 2

Depress brake pedal (Pushrod out)Release brake pedal (Pushrod in)

Terminal No.SW position

Switch side1 2

B-66

N8A0179E

N8A0180E



1) Check to see if the brake pedal has been re-turned by the return spring to the specified po-sition.

2) Turn the stoplight switch clockwise until the tipof the threaded portion of the switch contactsthe pedal arm.

3) Turn the switch counterclockwise until thespace between the tip of the threaded portionand the pedal arm is 0.5 to 1.0 mm (0.02 —0.04 in.).

Hazard Warning SwitchInspectionCheck the continuity between the terminals of the haz-ard warning switch.Repair or replace the switch when the result of inspec-tion is found abnormal.


1. Meter ClusterRefer to the “METER AND WARNING/INDICA-TOR LIGHT” in this section.

2. Hazard Warning SwitchRelease the lock pushing the switch from the backside of the meter cluster.

InstallationTo install, follow the removal steps in the reverse ordernoting the following point.

1. Push the switch with your fingers until locks se-curely.

N8A0181E

B-30

6 5 1 2 3 4 7 8

ON

OFF

TerminalNo.SW

position

N8A0182E

N8A0436E


Horn, Backup Light and Backup BuzzerGeneral DescriptionThe circuit consists of the starter switch, horn, horn switch, backup light (Rear combination light), backup light switch,back buzzer and the relay.When the horn switch is turned on independent of the position of the starter switch, the relay is activated to sound thehorn. When the backup light switch turns on with the starter switch on, the backup light will operate.Backup Light and Backup Buzzer Circuit

N8A5216E


Parts Location

X-2

J-49

(55

, 69)

F-16

, F-1

9, F

-20

N8A0184E


Circuit DiagramO

N

AC

C

ST

B

J-5

J-4

H-5

X-2

X-2

X-2

X-2

B-6

7B

-67

H-5

J-49

J-49

R-1

R-1

B-7

0

R-6

J-9

H-7

P-1

P-2

P-3

P-4

P-5

1

H-1

67

23

22

1 2

5 6

5 6

3

113

45

12

5W(2

4V)

8W(1

2V)

0.5G

3W/L

3B/Y

0.5G

0.5G

/R

0.5B

/Y

0.5B/Y

0.5R

/L

1.25B

1.25B

0.5G/W1.

25B

2B

MA

IN

ST

AR

TE

R S

W

F-1

915

A :4

JH1,

4JB

1, 4

JB1-

TC

F-2

015

A :2

4V, 4

HG

1-T

(12V

)

HO

RN

, HA

ZA

RD

FR

AM

E

RELAY; HORN HORN (LH)

FR

AM

E-L

H (

CE

NT

ER

)

HORN SW(COMBINATION SW)

F-1

6 1

0AM

ET

ER

ME

TE

R B

-51

(8)

BACKUP LIGHTSW

FL-

110

0A o

r 12

0A(2

4V)

100A

(12V

)

KE

Y S

W

FL-

240

A(2

4V)

50A

(12V

)

(24

V M

OD

EL)

H-6

5W

0.5R/L

HO

RN

CO

NT

AC

T

(EXCEPT DUMP VEHICLE)

2

BACKUP LIGHT(REAR COMBINATION LIGHT-RH)

BACKUP LIGHT(REAR COMBINATION LIGHT-LH)

(EX

CE

PT

DU

MP

VE

HIC

LE)

HORN (RH)

R-6

3W/B

H-1

66

J-65

J-655 6

BACKUP LIGHT(REAR COMBINATION LIGHT-LH)

(DUMP VEHICLE)

0.5B/Y

0.5R

/L

2L

P-3

P-4

4JH

1

N8A0185E


Connector List

No. Connector Face

X-2

B-70

B-70

E-10

E-10

J-49

J-49

H-14

005-006

014-002

1 2 3

7 8 9 10 11

4

12

5

13

6

14

014-003

6 5 4

14131211

3 2 1

9 8 710

002-025

1 2

002-026

2 1

002-025

1 2

002-026

2 1

016-003

1 2 3 4

5 6 7 8 9

11 12 13 14

15 16

10

H-14

H-16

H-16

J-62

J-62

J-65

J-65

J-4

No. Connector Face

016-004

4 3 2 1

9 8 7 6 5

13 12 11 10

16 15

14

008-003

1 2 3 4

5 6 7 8

008-004

4 3 2 1

8 7 6 5

006-010

1 2 34 5 6

006-015

123

456

006-010

1 2 34 5 6

006-015

123

456

001-018

1


H-5

J-5

P-1(12 V)

P-2

P-1(24 V)

P-4

P-2(24 V)

P-3

P-5(12 V)

No. Connector Face

001-018

1

000-003

000-004

000-004

000-004

000-006

000-006

000-007

P-5(24 V)

R-1

R-1

R-6

R-6

No. Connector Face

000-002

006-004

1 2 3

4 5 6

006-005

3 2 1

6 5 4

006-004

1 2 3

4 5 6

006-005

3 2 1

6 5 4

1 2 37 8 9

13 14 1519 20 2125 26 2731 32 33 34 35 36 37

4 5 610 11 1216 17 1822 23 2428 29 3038 39 40

6 5 412 11 1018 17 1624 23 2230 29 2840 39 38

3 2 19 8 7

15 14 1321 20 1927 26 2533 32 3134353637

N8A5488E


H-6

DiagnosisQuick Chart for Check Point1. Horn


2. Backup Light


1 2

1 2

1 2 3 4

5 6 7 8

9 10 11 12 13

14 15 16 17 18

2 1

2 1

4 3 2 1

8 7 6 5

13 12 11 10 9

18 17 16 15 14

H - 6

H - 7

H - 8

N8A5489E

Check point

FuseF-19, F-20

(15 A)Horn Horn SW Horn

relayHorn

contactCable

harness

Troublemode

1-1. Horn does not sound

(1)

(4)

(6)

(2)

(5)

(3)

1-2. Horn does not shut off

(2)

(1)

(3)

Check point

FuseF-16 (10 A)

Backup light SW

(Inhibitor SW)

Backup light bulb

Backup buzzer

Cable harness

Troublemode

2-1. Both backup lights inoperative

(1)

(3)

(2)

2-2. Backup light on the left (or right) side inoperative

(1)

(2)

2-3. Backup light remains on

(1)


1. Horn1-1. Horn Does Not Sound

• IS FUSE F-19 , F-20 (15A) NORMAL?

YES NO

REPLACE THE FUSE• IS THE HORN RELAY NORMAL?

• IS THE HORN NORMALLY GROUNDED?

YES NO

REPLACE THE HORN RELAY

• IS THE HORN CONNECTOR 1 J-4 OR 1 J-5SECURELY CONNECTED?

YES NO

CLEAN UP THE FITTING SURFACE AND THEGROUND FIRMLY

• DISCONNECT THE HORN SWITCH CONNECTOR• IS THERE BATTERY VOLTAGE APPLIED BETWEEN

3 B-70 AND THE GROUND?

YES NO

CONNECT THE CONNECTOR SECURELY

• IS THERE ANY CONTINUITY BETWEEN THE HORNRELAY HARNESS SIDE CONNECTORS 5 X-2 AND 1 J-4 (OR 1 J-5 )?

YES NO

REPAIR A POOR CONNECTION AT THECONNECTORS OR AN OPEN CIRCUIT OR REPAIRA POOR CONNECTION AT THE HORNCONNECTOR

YES NO

DOES THE HORN SOUND WHEN CONNECTING THEBATTERY (+) TERMINAL TO THE HORN CONNECTOR 1 J-4 (1 J-5 ), AND (-) TERMINAL TO THE HORNBRACKET?

NO


PEPLACE THE HORN

N8A0187E


1-2. Horn Does Not Shut Off

2. Backup Light2-1. Backup Lights Inoperative

• IS THE HORN RELAY NORMAL?

• REMOVE THE HORN SW• IS THE MOVABLE PORTION OF THE HORN SW

ALWAYS OUT OF CONTACT WITH THE GROUNDBRACKET?

YES NO

REPLACE THE HORN RELAY

REPAIR A SHORT CIRCUIT BETWEEN HORN RELAYHARNESS SIDE CONNECTORS 4 X-2 AND 3 B-70

YES NO

REPAIR OR REPLACE THE HORN SW

N8A0188E



YES NO

REPLACE THE FUSE

• TURN THE STARTER SW ON• IS THE BATTERY VOLTAGE APPLIED BETWEEN THE

BACKUP LIGHT SWITCH HARNESS SIDE CONNECTOR1 E-10 (OR 1 J-49 )AND THE GROUND?

YES NO

GROUND IT SECURELY

• ENTER THE TRANSMISSION SHIFT LEVER TOREVERSE POSITION

• WHEN REMOVE THE CONNECTOR OF THE BACKUPLIGHT SWITCH, IS THERE ANY CONTINUITY BETWEEN THE SW SIDE CONNECTORS 1 E-10 AND 2 E-10 (OR 1 J-49 AND 2 J-49 )?

YES NO

REPAIR A POOR CONNECTION AT THECONNECTORS OR AN OPEN CIRCUIT BETWEENFUSE F-16 (10A) AND 1 E-10 OR 1 J-49

REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN THE BACKUP LIGHTSWITCH HARNESS SIDE CONNECTORS 2 E-10 (OR 2 J-49 )AND 4 H-16

YES NO

REPAIR OR REPLACE THE BACKUP LIGHTSWITCH OR INHIBITOR SW

N8A0189E


2-2. Backup Light on the Left (or Right) Side Inoperative

2-3. Backup Light Remains on


HornInspectionCheck to see if horn sound when a battery voltage be-tween horn terminal and the fixing bracket. Repair or re-place the horn when the result of inspection is foundabnormal.

N8A5226E

REPAIR OR REPLACE THE BACKUP LIGHT SW OR INHIBITOR SW

N8A0191E

N8A0192E



1. BumperRefer to “BUMPER” in section 2.

2. HornDisconnect the connector (3).


Horn SwitchInspectionWith the contact point of the horn switch pressed to theswitch bracket, check the continuity between the con-nector terminal and the bracket of the switch.Check the contact condition between horn contact of thecombination switch and contact plate of steering wheel.Repair or replace the switch when the result of inspec-tion is found abnormal.


1. Horn Pad1) Hold the horn pad and pull it upward.

2. Steering Wheel1) Remove the steering shaft nut.2) Remove the steering wheel by using steering

wheel remover.(Refer to Section 3B4 “STEERING COLUMN”for steering wheel removal steps.)

3. Horn Switch

InstallationTo install, follow the removal steps in the reverse order,noting the following point.

1. Tighten the steering shaft nut to the specifiedtorque.

Tighten:Shaft nut to 49 N⋅m (5 kg⋅m / 36 lb⋅ft)

1

23

N8A5485E

N8A0194E

N8A0476E


Backup Light BulbRemovalPreparation:Disconnect the battery ground cable.

1. Lens2. Bulb


Backup Light Switch

Inspection1. With the switch installed to the transmission, check

the continuity between the terminals of the switchconnectors.When the continuity is found between the terminalsonly with the switch shifted to the reverse position,the switch is normal.

2. When the result of the above inspection is foundabnormal, remove the switch from the transmis-sion and conduct a test on the switch alone.If the continuity appears between the connectorterminals when the ball of the switch is released,the switch is normal. (When the ball is pushed, thecontinuity disappears.)

3. If there is no continuity with the switch installed tothe transmission, even though the switch is foundto be normal, then adjust the stroke of the switch bychanging the thickness of the switch gasket.


1. Backup Light Switch1) Disconnect the connectors.2) Remove the switch by turning it counterclock-

wise.Installation

1. Backup Light SwitchApply liquid gasket to the screw portion of theswitch to prevent oil leak.

Backup BuzzerInspectionApply battery voltage to the backup buzzer connector tocheck the buzzer sound.Repair or replace the buzzer when the result of inspec-tion is found abnormal.

N8A0195E

N8A0196E

N8A0197E



1. Rear Combination Light Cover2. Backup Buzzer

1) Remove the rear combination light connectorfixing screw.

2) Remove buzzer fixing screw.3) Disconnect the connector.


N8A0198E


Dome Light and Key Remind BuzzerGeneral DescriptionThe circuit consists of the starter switch, dome light, dome light switch, door switch, backup light switch and the keyremind buzzer.The dome light lights up when the left or right side door is opened with the switch set at the door mode. It can be litby operating ON or OFF of the dome light switch.The dome light can be lit by respective switch independent of the position of the starter switch.By operating the dome light switch fitted on the instrument panel, the dome light can be lit independent of the switchposition of dome light.Key remind buzzer sounds to remind the driver of leaving the key in the starter switch when opening the driver’s sidedoor.Lighting Circuit

BATTERY (+)

DOME LIGHT(FOR CREW CAB)

DOME LIGHT

DOMELIGHT SW

DOOR SW(FRT PASSENGERSIDE)

DOOR SW(DRIVER SIDE)

: Lighting circuit by door sw

: Lighting circuit by dome light sw

OFFON

DOOR

NOTE: Arrow marks " " indicate the direction of current

N8A0199E


Parts Location

F-4

, F-1

6

L-3

DIO

DE

(C

RE

W C

AB

)

N8A0200E


Circuit Diagram

B-8

6

L-2

H-1

0

B-8

6

B-6

7B

-67

H-7

OND

OO

RO

FF

B

ST

AC

C

ON

OFF

B-8

6B

-86

B-8

3B

-83

B-8

3

B-6

8

B-6

8

N-2

H-1

2

B-1

7

B-1

7

B-8

3

N-7

L-1

L-1

H-2

0

H-3

L-4

L-3

B-7

L-3

L-4

12

3

3

1

32

1 21

21

21

41

23

3

1

6 5

1 2

1 32

6

4

P-1

P-2 P-3

P-4

P-5

(24

V M

OD

EL)

5W

0.5R

3W/L

3B/Y

0.5R

0.5Y

0.5G

R0.

5Y

0.85

LG/R

RE

LAY

; TA

IL(5

)

DO

ME

LIG

HT

SW

0.5B

DOOR SW (RH)

3BH

EA

DLI

GH

T B

RA

CK

ET

(LH

)

0.5GR/B

DOOR SW (LH)0.5GR/R

0.5G

R/B

KE

Y R

EM

IND

B

UZ

ZE

R

0.5G

R/R

3B

0.5B

0.5P/L

0.5B/Y

KEY CYLINDER SW

F-4

15A

AU

DIO

(B

),D

OO

R L

OC

K

0.5R

F-16

10A

ME

TE

R

ROOM LIGHT (CREW CAB)

ST

AR

TE

R S

W

L-2

H-1

0

H-62 2

H-2

0

L-2

0.5G

R/B

DIODE0.5GR 0.5GRH

-102

0.5GR/R 1.25GR/R

0.5GR/R

1

10.5GR/B

1.25GR/B(CREW CAB)

DIODE

0.5R

0.5B

FRA

ME

DOME LIGHT

(CREW CAB)

2L

P-3

P-4

4JH

15W

/B(2

4V)

8W/B

(12V

)

MA

IN

FL-1

100A

or

120A

(24V

)

KE

Y S

W

FL-2

40A

(24V

)50

A(1

2V)

0.5R

3W/B

N8A0201E


Connector List

No. Connector Face

B-17

B-67

B-67

B-86

B-86

B-68

B-68

B-83

004-004

1 2 3 4

004-001

1 23 4

004-002

2

4

1

3

004-001

1 23 4

004-002

2

4

1

3

006-002

1

3 4 5 6

2

006-003

2

6 5 4 3

1

006-010

1 2 34 5 6

H-3

H-3

H-10

H-10

L-2

L-2

H-12

H-12

No. Connector Face

006-014

1 2 3

4 5 6

006-015

123

456

003-009

1 2 3

003-010

3 2 1

003-009

1 2 3

003-010

3 2 1

014-002

1 2 3

7 8 9 10 11

4

12

5

13

6

14

014-003

6 5 4

14131211

3 2 1

9 8 710


H-20

H-20

L-1

L-3

L-4

L-4

N-2

N-7

No. Connector Face

002-009

1

2

002-010

1

2

002-027

21

002-027

21

002-022

1 2

002-023

2 1

001-009

1

001-009

1

P-1(12 V)

P-2

P-1(24 V)

P-4

P-2(24 V)

P-3

P-5(12 V)

P-5(24 V)

No. Connector Face

000-003

000-004

000-004

000-004

000-006

000-006

000-007

000-002


H-5

H-7


Key Cylinder SwitchRefer to “START AND CHARGING” in this section.

Backup Light SwitchRefer to “HORN, BACKUP LIGHT AND BACKUPBUZZER” in this section.

Dome Light BulbRemovalPreparation:Disconnect the battery ground cable.

1. LensHold the lens and pull it downward.

2. BulbInstallationTo install, follow the removal steps in the reverse order.

Dome Light Bulb (for Crew Cab)RemovalPreparation:Disconnect the battery ground cable.

1. LensHold the lens and pull it down.

2. Bulb


Dome Light SwitchInspectionCheck the continuity between the dome light switch con-nector terminals.Repair or replace the switch when the result of inspec-tion is found abnormal.

1 2 37 8 9

13 14 1519 20 2125 26 2731 32 33 34 35 36 37

4 5 610 11 1216 17 1822 23 2428 29 3038 39 40

6 5 412 11 1018 17 1624 23 2230 29 2840 39 38

3 2 19 8 715 14 1321 20 1927 26 2533 32 3134353637

N8A5488E

1 2

1 2

1 2 3 4

5 6 7 8

9 10 11 12 13

14 15 16 17 18

2 1

2 1

4 3 2 1

8 7 6 5

13 12 11 10 9

18 17 16 15 14

H - 6

H - 7

H - 8

N8A5489E

N8A5243E

N8A0203E



1. Meter clusterRefer to the “METER AND WARNING/INDICA-TOR LIGHT” in this section.

2. Dome Light SwitchRelease the lock pushing the switch from the backside of the meter cluster.

InstallationTo install, follow the removal steps in the reverse ordernoting the following point.

1. Push the switch with your fingers until locks se-curely.

Door SwitchInspectionCheck to see if there is any continuity between the ter-minals and the body while operating the door switch.Repair or replace the switch, when the result of inspec-tion is found abnormal.


1. Door Switch1) Remove the screw.2) Disconnect the connector of the switch.

B-86

2 4 1 3

ONOFF

TerminalNo.SW

position

N8A0204E

N8A5160E

1 Body

Push

Release

ConnectorNo.

Terminal No.SWoperation

N-2 N-7

N8A0206E



Key Remind BuzzerThe key remind buzzer sounds to remind the driver to remove the starter key from the starter switch when front driverside door is opened (Front driver side door switch is on).

N8A0207E

Key cylinder SW(Starter SW) Key remind buzzer

F-16(10A)

Front door SW

N8A0208E


Inspection of The Buzzer CircuitDisconnect the key remind buzzer connector, measure the continuity and voltage between the harness side connec-tor terminals.

Termi- Item Connect-Wirenal Connected to to be ing Checking conditions StandardcolorNo. checked terminal

2 B Ground Continuity 2-Ground - Continuity

Starter key inserted Approx. batteryvoltage1 P/L Ground Voltage 1-Ground

Starter key removed 0VFront driver·s side door"OPEN" Continuity

3 GR/R Ground Continuity 3-GroundFront driver·s side door"CLOSE" No Continuity

6 B/Y Fuse F-12 (10A) Voltage 6-Ground • Starter SW ONApprox. batteryvoltage

Harness side

1 2 34 5 6

B-83

N8A0209E


Key Cylinder Switch (Starter Switch)InspectionCheck to see if there is any continuity between the connector terminals of the key cylinder switch.Repair or replace the switch when the result of inspection is found abnormal.

B-68

Switch side

5 6

Key removedLOCK

OFFACC Key insertedONSTART

Terminal No.Starter keyposition

N8A0210E


Power Door LockGeneral DescriptionThe circuit consists of the door lock switch, actuator for the front passenger door, rear doors and the door lock con-troller.The door lock controller is always provided with battery voltage. The key or the inside lock knob on the driver’s doorcan activate the lock mechanism of all the doors.When the driver’s door lock switch is turned on, current flows for about one second to the door lock actuator of eachdoor connected in parallel with the controller to activate the actuator to lock and unlock the doors.Operation of Door Lock Controller


When lockingthe door.

Battery(+)

Relay;Door lock

Door lock sw.(Lock position)

To actuator(Actuatoroperateto lock side)

When lockingthe door.

Battery(+)

Relay;Door lock

Door lock sw.(Unlock position)

To actuator(Actuatoroperates tounlockposition)

N8A0211E


Parts Location

F-4

B-7

N8A0212E


Circuit Diagram

2 3

1 2 3

6

5

4

42H-11 H-11

1

B-12 B-12

B-12

B-12

B-12

B-12

D-4

D-4D-4 212112

2

3

1 2 1

D-8 D-8 D-9D-9

H-18

D-10 D-10

H-11

B-7

FL-1 100A or 120A

MAIN AUDIO, DOOR LOCK

5W

RELAY:DOOR LOCK

0.3R

/G

0.3G

/B

0.3R

/G

0.3G

/B

DOOR LOCK SW-LH

0.3B

2B

3BHEADLIGHT BRACKET (LH)

0.85

B

0.85

BR

/R

0.85

BR

/Y

0.85

BR

/R

0.85

BR

/Y

0.85

BR

/R

0.85

BR

/Y

0.85

BR

/R

0.85

BR

/Y

0.5B

R/R

0.5B

R/Y

0.5B

R/R

0.5B

R/Y

DOOR LOCK ACTUATOR-RH

DOOR LOCKACTUATOR-LH(CREW CAB)

(24V MODEL)

P-5

P-3

P-4

P-1

P-2

F-4 15A

H-63W/B

2

H-18 H-19 H-19

H-12 H-12 H-3 H-3

41135

FRAME

0.85

BR

/R

0.85

BR

/R

0.85

BR

/Y

0.85

BR

/Y

UN

LOC

K

LOC

K

UN

LOC

K

UN

LOC

K

UN

LOC

K

LOC

K

LOC

K

LOC

K

4 3H-2 H-2

DOOR LOCKACTUATOR-RH(CREW CAB)

B-1 5BFRAME-LH (FRONT)

0.85

R

2L

P-3

P-4

4JH1

8W/B(12V)

5W/B(24V)

N8A0213E


Connector List

No. Connector Face

B-12

D-4

D-4

D-8

D-8

D-9

D-9

D-10

006-010

1 2 34 5 6

003-003

1 2 3

003-011

3 2 1

002-001

1 2

002-002

12

002-001

1 2

002-002

12

002-001

1 2

D-10

H-18

H-18

H-19

H-19

H-2

H-2

H-11

No. Connector Face

002-002

12

002-001

1 2

002-002

12

002-001

1 2

002-002

12

008-009

1 2 3

84 5 6 7

008-010

123

8 4567

008-009

1 2 3

84 5 6 7


H-6

H-11

H-3

H-3

H-12

H-12

P-1(12 V)

P-2

P-1(24 V)

No. Connector Face

008-010

123

8 4567

006-014

1 2 3

4 5 6

006-015

123

456

014-002

1 2 3

7 8 9 10 11

4

12

5

13

6

14

014-003

6 5 4

14131211

3 2 1

9 8 710

000-003

000-004

000-004

P-4

P-2(24 V)

P-3

P-5(12 V)

P-5(24 V)

No. Connector Face

000-004

000-006

000-006

000-007

000-002

1 2

1 2

1 2 3 4

5 6 7 8

9 10 11 12 13

14 15 16 17 18

2 1

2 1

4 3 2 1

8 7 6 5

13 12 11 10 9

18 17 16 15 14

H - 6

H - 7

H - 8

N8A5489E




Check point

FuseF-4

(15 A)

Door lock controller

Door lock SW (Driver side)

Door lock actuator

Front (Passen-ger side)

Rear(RH)

Rear(LH)

Cable harness

Troublemode

1. All the doors do not lock and unlock

2. All the doors do not get locked (or unlocked)

3. Driver side door does not get locked (or unlocked)

4. Front passenger side door does not get locked (or unlocked)

5. Rear door-RH side does not get locked (or unlocked)

6. Rear door-LH side does not get locked (or unlocked)


All the Doors Do Not Lock and Unlock

All the Doors Do Not Get Locked (or Unlocked)

N8A5256E

N8A5257E


Driver Side Door Does Not Get Locked (or Unlocked)

FRT Passenger Side Door Does Not Get Locked (or Unlocked)RR Door-RH Side Does Not Get Locked (or Unlocked)RR Door-LH Side Does Not Get Locked (or Unlocked)

REPLACE THE DOOR LOCK SWITCH

N8A0216E

REPLACE THE DOOR LOCK ACTUATOR

N8A0217E


Inspection of The Door Lock CircuitCheck the voltage and the continuity between the controller harness side connector terminals.

Termi- Item Connect-Wirenal Connected to to be ing Checking conditions StandardcolorNo. checked terminalUnlock Continuity

1 R/G 1-GroundLock No continuity

Unlock No continuity2 G/B 2-Ground

Lock Continuity

3 B Ground 3-Ground - Continuity

Continuity4 BR/Y Actuator 4-5 - (There is some(Unlock) resistance)

Continuity5 BR/R Actuator 5-4 - (There is some(Lock) resistance)

6 R Fuse F-7 (15A) Voltage 6-Ground - Battery voltage

Conti-nuity

(Resis-tance)

Door lock SW(Unlock)

Door lock SW(Lock)

Driver seat sidedoor

Driver seat sidedoor

Harness side

1 2 34 5 6

B-12

N8A0218E


Door Lock RelayThe door lock controller sends out to each door lock ac-tuator the lock/unlock signals received from door lockswitch of driver seat side.

InspectionRemove the connector of the door lock controller, andcheck the continuity and the voltage between the con-troller side connector terminals.(Connect the (+) terminal of the battery to 6 andthe (−) terminal to 3 .)3 — 5 .................Continuity3 — 4 .................Continuity(Then, ground 2 .)5 ..................Voltage for approx. 1 second(Disconnect the ground of 2 , and ground 1 .)4 ..................Voltage for approx. 1 secondReplace the controller when the result of inspection isfound abnormal.

Door Lock Operation TestAfter confirming that there is continuity between the har-ness side connector terminals 4 and 5 of thedoor lock controller, apply battery voltage to each of theterminals to conduct the operation test.When the door lock will not operate, check the door lockactuator for any trouble.

For 24 Volt

For 12V

N8A0219E

B-12

B-12

B-12 B-12

B-12 B-12

B-12

B-12

B-12 B-12

B-12

B-12

Controller side

3 2 16 5 4

N8A0220E

B-12 B-12

Connecting terminal4 (BR/Y) 5 (BR/R)

Operation

UnlockLock

Harnessside

1 2 34 5 6

B-12

N8A0221E


Door Lock Switch (Driver Seat Side)The door lock switch on the driver’s door is connectedwith the door lock cylinder and the inside lock knob witha rod. The switch sends lock/unlock signals to the doorlock controller.

InspectionCheck to see if there is any continuity between the con-nector terminals of the door lock switch.Replace the switch when the result of inspection isfound abnormal.

Removal and InstallationRefer to Section 2 for “DOOR LOCK ASSEMBLY”.

Door Lock ActuatorReceiving forward or reverse current from the door lockcontroller, the door lock actuator locks or unlocks thedoor with the rod connected to the door lock mecha-nism.

Inspection of The Door Lock ActuatorApply the battery voltage to the connector terminals ofthe door lock actuator to check the operation.When the door lock actuator is checked on the vehicleand there is no continuity, and when the door lock actu-ator itself is checked and no trouble is found, check thecircuit between the door lock actuator and the door lockcontroller for any failure.

N8A0223E

1 2 3

Lock

Unlock

TerminalNo.Operation

Switch side1 2 3

D-4

N8A0224E

N8A0225E


Removal and InstallationRefer to Section 2 for “DOOR LOCK ASSEMBLY”.

Door lock ASM

Actuator

D-8 D-9 D-10

Actuator side Actuator side

RR-LH RR-RH

D-8 D-9 D-10

1 2 1 2 1 2

Lock

Unlock

FRTPassenger

Door

ConnectorNo.

TerminalNo.Operation

N8A0226E


Power WindowGeneral DescriptionThe circuit consists of the starter switch, power window switch for each of the windows and power window motor.When the starter switch is turned on, the battery voltage is applied to each of the power window switches through thecircuit breaker and the power window relay on the circuit.By operating the switches of each window to select “UP” or “DOWN”, the revolving direction of the power windowmotor changes to open or close the window.The driver’s power window switch has a built-in one-touch operating circuit which allows to automatically open thewindow by operating the switch to the AUTO position.When the driver’s power lock switch at the driver side is depressed, the power source to the passenger’s power win-dow switches will be shut off and passenger’s side power window motor will not operate if the switch is operated.Operation of Passenger Side Window

NOTE: Arrow marks " " indicate the direction of current

N8A0227E


Parts Location

F-6,

F-1

6X

-7

FL-1

, FL-

2, F

L-26

FUS

IBLE

LIN

K

B-7

N8A0228E



X-7

B-6

7

H-1

1

H-2

H-2

D-3

H-1

1

D-3

D-3

H-1

1

X-7

X-7

X-7

H-2

H-1

1

D-3

D-7

D-7

D-7

D-7

D-7

D-6

D-6

D-2

D-2

D-3

D-3

B

OFF

ON

AC

C

ST

B-7

B-6

7

FL-1

100

A

MA

IN

ST

AR

TE

R S

W

P-1

P-2

P-5

8W3W

/B

F-16

10A

ME

TE

R

3B/Y

0.5B

/Y

2B/L

2L/B

1.25

L/B

2L/B

2B

0.3B

PO

WE

R W

IND

OW

SW

(LH

)

WIN

DO

W L

OC

K S

W

WINDOW SW-LH

WINDOWSW (RH)

AU

TO

CIR

CU

IT

1.25L/B

1.25L/Y

1.25BR/Y

1.25L

1.25L/W

PO

WE

R W

IND

OW

MO

TO

R(R

H)

UP

DO

WN

UP

DO

WN

UP

DO

WN

FL

DO

WN

UP

DO

WN

POWER WINDOW SW (RH)

1.25G/Y

1.25R/Y

SW

3BH

EA

DLI

GH

T B

RA

CK

ET

(LH

)

12

12

12

35

24

1

3

85

54

1

6 8

1

5 4

1 2

32

85

METER B-51 (8)

B E

0.5B/Y

RE

LAY

; PO

WE

R W

IND

OW

UP

2B

FL-2

50A

(12V

)

KE

Y S

W

5W8W

/BH

-62

H-7

3W/L

3W/B

1

PO

WE

R W

IND

OW

1.25G/Y

1.25R/Y

1.25G/Y

1.25R/Y

2B

FRA

ME

PO

WE

R W

IND

OW

MO

TO

R(L

H)

B-1

FRA

ME

-LH

(FR

ON

T)

5B

2L

FL-2

630

A

P-3

P-4

4JH

1

N8A0229E


For 24 Volt

X-7

B-6

7

H-1

1

H-2

H-2

D-3

H-1

1

D-3

D-3

H-1

1

X-7

X-7

X-7

H-2

H-1

1

D-3

D-7

D-7

D-7

D-7

D-7

D-6

D-6

D-2

D-2

D-3

D-3

B

OFF

ON

AC

C

ST

B-7

B-6

7

ST

AR

TE

R S

W3W/B

F-6

F-16

10A

ME

TE

R

3B/Y

0.5B

/Y

2B/L

2L/B

1.25

L/B

2L/B

2B

0.3B

PO

WE

R W

IND

OW

SW

(LH

)

WIN

DO

W L

OC

K S

W

WINDOW SW-LH

WINDOWSW (RH)

AU

TO

CIR

CU

IT

1.25L/B

1.25L/Y

1.25BR/Y

1.25L

1.25L/W

PO

WE

R W

IND

OW

MO

TO

R(R

H)

UP

DO

WN

UP

DO

WN

UP

DO

WN

FL

DO

WN

UP

DO

WN

POWER WINDOW SW (RH)

1.25G/Y

1.25R/Y

SW

3BH

EA

DLI

GH

T B

RA

CK

ET

(LH

)

12

12

12

35

24

1

3

85

54

1

6 8

1

5 4

1 2

32

85

METER B-51 (8)

B E

0.5B/Y

RE

LAY

; PO

WE

R W

IND

OW

UP

2B

5W/B

H-6

2P

OW

ER

WIN

DO

W

1.25G/Y

1.25R/Y

1.25G/Y

1.25R/Y

2B

PO

WE

R W

IND

OW

MO

TO

R(L

H)

B-1

FRA

ME

-LH

(FR

ON

T)

5B

20A

FL-1

100

A o

r 12

0A

MA

IN

P-1

P-2

5W

FL-2

40A

KE

Y S

W

5W

H-7

3W/L

3W/B

12L

P-3

P-4

P-5

FRA

ME

N8A0390E


Connector List

No. Connector Face

B-1

B-7

X-7

B-67

B-67

D-2

D-2

D-6

000-001

000-012

005-006

004-001

1 23 4

004-002

2

4

1

3

002-028

1 2

002-029

2 1

002-028

1 2

D-6

D-3

D-7

H-2

H-2

H-11

H-11

P-1(12V)

No. Connector Face

002-029

2 1

008-011

1 2 3

4 5 86 7

005-005

1 2 3 4 5

008-009

1 2 3

84 5 6 7

008-010

123

8 4567

008-009

1 2 3

84 5 6 7

008-010

123

8 4567

000-003


H-6, H-7

P-2

P-1(24V)

P-4

P-2(24V)

P-3

P-5(12V)

P-5(24V)

No. Connector Face

000-004

000-006

000-006

000-004

000-004

000-007

000-002

1 2

1 2

1 2 3 4

5 6 7 8

9 10 11 12 13

14 15 16 17 18

2 1

2 1

4 3 2 1

8 7 6 5

13 12 11 10 9

18 17 16 15 14

H - 6

H - 7

H - 8

N8A5489E



Notice: Figure in parenthesis “( )” indicates the order of inspection.

Check point

FuseF-16

(10A)

F-6,FL-26 (20A,30A)

Power win-dow relay

Power window SW

Power window motor Cable

har-nessDriver

side

Pas-senger

side

Driver side

Pas-senger

side

Troublemode

All windows do notoperate

(1)

(2)

(3)

(5)

(4)

Lock SW does notfunction

(1)

Driver side window

Window does notoperate

(1)

(2)

(3)

One-touch opera-tion does not oper-ate

(1)

Window operates inonly one direction

(1)

Front passenger sidewindow

Window does notoperate

(2)

(1)

(3)

(4)

Window does notoperate when oper-ating the driver sideSW

(1)

(2)

Window does notoperate when oper-ating the passen-ger side SW

(1)

(2)

Window operates inonly one directionwhen operating thedriver side SW

(1)

(2)

Window operates inonly one directionwhen operating thepassenger side SW

(2)

(1)


All Windows Do Not Operate


YES NO

REPLACE THE FUSE• IS THE FUSE F-6 or FL-26 NORMAL?

• IS THE POWER WINDOW RELAY NORMAL?

YES NO

REPLACE THE CIRCUIT BREAKER

• IS B-7 SECURELY GROUNDED?

YES NO

REPLACE THE RELAY

• DISCONNECT THE POWER WINDOW SW CONNECTORON THE DRIVER SEAT SIDE

• TURN THE STARTER SW ON• IS THE BATTERY VOLTAGE APPLIED BETWEEN THE

HARNESS SIDE CONNECTOR 6 D-3 AND THEGROUND?

YES NO

GROUND IT SECURELY

• IS THE BATTERY VOLTAGE APPLIED BETWEEN B-7AND THE GROUND?

YES NO

REPLACE THE SWITCH

• IS THE POWER WINDOW SW ON THE DRIVER SIDENORMAL?

YES NO

REPAIR A POOR CONNECTION AT THECONNECTORS OR AN OPEN CIRCUIT BETWEEN 6 D-3 AND 5 X-7

NO

REPAIR A POOR CONNECTION AT THECONNECTORS OR AN OPEN CIRCUIT BETWEEN 8 D-3 AND B-7

N8A0230E


Lock Sw Does Not Function

Window on the Driver Side Does Not Operate

REPAIR OR REPLACE THE POWER WINDOW SWON THE DRIVER SEAT SIDE

N8A0231E

• IS THE POWER WINDOW SWITCH ON THE DRIVERSEAT SIDE NORMAL?

• DISCONNECT THE CONNECTOR OF THE POWERWINDOW MOTOR ON THE DRIVER SEAT SIDE

• WHEN CONNECTING THE MOTOR CONNECTOR 1 D-2 TO THE BATTERY (+) TERMINAL AND 2 D-2TO THE (-) TERMINAL, DOES THE MOTOR ROTATE INTHE "UP" DIRECTION OF THE WINDOW (OR WHENCONNECTING 2 D-2 TO THE (+) TERMINAL AND 1 D-2 TO THE (-) TERMINAL, DOES THE MOTORROTATE IN THE "DOWN" DIRECTION OF THEWINDOW)?

YES NO

REPLACE THE POWER WINDOW SWITCHON THE DRIVER SEAT SIDE

REPAIR A POOR CONNECTION AT THE CONNECTORSOR AN OPEN CIRCUIT BETWEEN HARNESS SIDECONNECTOR TERMINALS 1 D-3 AND POWERWINDOW MOTOR 1 D-2 OR 2 D-3 AND 2 D-2

YES NO

REPAIR OR REPLACE THE POWER WINDOWMOTOR

N8A0232E


Window on the Front Passenger Side Does Not Operate

• IS THE FRONT PASSENGER SIDE POWER WINDOWSW NORMAL?

• IS THE DRIVER´S POWER WINDOW SW NORMAL?

YES NO


• REMOVE THE CONNECTOR OF THE FRONTPASSENGER SIDE POWER WINDOW MOTOR

• WHEN CONNECTING THE MOTOR CONNECTOR 1 D-6 TO THE BATTERY (+) TERMINAL AND 2 D-6TO THE (-) TERMINAL, DOES THE MOTOR ROTATE INTHE "UP" DIRECTION OF THE WINDOW? (OR WHENCONNECTING 2 D-6 TO THE (+) TERMINAL AND 1 D-6 TO THE (-) TERMINAL, DOES THE MOTORROTATE IN THE "DOWN" DIRECTION OF THEWINDOW?)

YES NO


• WITH THE SWITCH AT THE NEUTRAL POSITION, ISTHERE ANY CONTINUITY BETWEEN THE HARNESSSIDE CONNECTORS 1 D-6 AND 2 D-6 ?

YES NO

REPAIR OR REPLACE THE POWER WINDOWMOTOR

REPAIR A POOR CONNECTION AT THE CONNECTORSOR AN OPEN CIRCUIT BETWEEN 5 D-3 AND 2 D-7 (OR 4 D-3 AND 4 D-7 )

YES NO

REPAIR A POOR CONNECTION AT THECONNECTORS OR AN OPEN CIRCUIT BETWEENTHE PASSENGER SIDE POWER WINDOW SWAND THE MOTOR CONNECTOR

N8A0233E


Starter SwitchRefer to “START AND CHARGING” in this section.Power Window Switch-driver SideCircuit InspectionDisconnect the switch connectors to check the voltage and the continuity between the harness side connector termi-nals.

Termi- Item Connect-Wirenal Connected to to be ing Checking conditions StandardcolorNo. checked terminal1 L/W

2 LDriver seat side motor 1-2

4 G/Y 4-5- Continuity

5 R/Y 5-4

6 L/B Power window relay Voltage 6-Ground Starter SW "ON" Battery voltage

8 B GroundContinuity

8-Ground - Continuity(resistance)

Continuity(resistance)Passenger side power

window SW

Harness side

D-3

N8A0234E


InspectionCheck the continuity between the connector terminals of the switch.Repair or replace the switch when the result of inspection is found abnormal.


1. Switch1) Insert the screw driver to the cut off portion to

remove the switch.2) Disconnect the connector.

Driver side Passenger side

6 1 2 8 6 5 4 8UP

OFF

DOWN

UP

OFF

DOWN

LOCK

Window

TerminalNo.

SWposition

D-3

Switch side

N8A0235E

N8A0236E


InstallationTo install, follow the removal steps in the reverse order.Power Window Switch-passenger SideCircuit InspectionDisconnect the switch connectors to check the voltage and the continuity between the harness side connector termi-nals.

InspectionCheck the continuity between the connector terminals ofthe switch.Repair or replace the switch when the result of inspec-tion is found abnormal.

N8A5280E



1. Switch1) Insert the screw driver to the cut off portion to

remove the switch.2) Disconnect the connector.


Driver Seat Side Power Window MotorInspectionBefore checking to see if the motor functions correctly,be sure to check the circuit through the connector of the driver’s power window switch.If the motor does not operate smoothly, either the motoror the circuit between the switch and the motor is defec-tive.

1. Circuit inspection of the driver side window switchDisconnect the switch connector and apply batteryvoltage to the harness side connector terminals tocheck its function.

1 2 4 3 5

UP

OFF

DOWN

TerminalNo.SW position

Switch side

D-7

N8A0238E

N8A0239E

D-3


2. Inspection of the driver seat side motorRemove the motor connector and apply batteryvoltage to the motor side connector terminals tocheck its function.Replace the motor when the result of inspection isfound abnormal.


1. Window Regulator AssemblyRefer to Section 2 for Window Regulator andGlass.

2. Power Window MotorRemove three screws.


Connecting terminal1 (L/W) 2 (L)

Operation

DOWNUP

Harness side

D-3

N8A0240E

D-2M

1 2

DOWNUP

Terminal No.Direction of operation

N8A0241E

N8A0242E


Front Passenger Seat Side Power Window Mo-torInspectionBefore checking to see if the motor functions correctly,be sure to check the circuit through the front passen-ger’s switch connector and the driver’s power win-dow switch connector .If the motor does not operate smoothly, either the motoror the circuit between the switch and the motor is defec-tive.

1. Circuit inspection of the front passenger seat sidewindowDisconnect the switch connector and apply batteryvoltage to the harness side connector terminals tocheck its function.

2. Circuit inspection of the driver seat side switchDisconnect the switch connector and apply batteryvoltage to the harness side connector terminals tocheck its function.

3. Inspection of the front passenger window motorDisconnect the motor connector and apply batteryvoltage to the motor side connector terminals tocheck its function.Repair or replace the motor when the result of in-spection is found abnormal.


1. Window Regulator AssemblyRefer to Section 2 for Window Regulator andGlass.

2. Power Window MotorRemove three screws.


D-7

D-3

D-7

Harness side

Connecting terminal Direction of3 (L/Y) 5 (BR/Y) operation

DOWNUP

N8A0243E

Harness side

D-3

Connecting terminal Direction of4 (G/Y) 5 (R/Y) operation

DOWNUP

++

N8A0244E

D-6

M

1 2

DOWNUP

Terminal No.Direction of operation

N8A0245E

N8A0246E


Windshield Wiper and WasherGeneral DescriptionThe circuit consists of the starter switch, windshield wiper & washer switch, wiper motor, washer motor and the inter-mittent relay.When the wiper & washer switch is turned on with starter switch on, the battery voltage is applied to the wiper motorto activate the wiper.The washer motor squirts glass cleaning fluid while the washer switch is being pushed. The intermittent relay is usedto control motion of the wiper.Operation of Windshield Wiper Motor(When wiper “LO” or “INT” position)


N8A0250E


Parts Location

B-7

X-1

KE

Y O

N R

ELA

Y(1

2V O

NLY

)

X-1

1 K

EY

ON

RE

LAY

(24

V O

NLY

)

RE

LAY

BO

X A

SM

(N

o.1

)

N8A0251E


Circuit Diagram

B-11 B-11

B-11

B-11

B-11

B-69B-69 B-69B-69B-69

B-69

B-9

B-9

B-9

B-9

B-9

B-9

B-8

B-8

B-7

B

ST

ACC

ONB-67

B-67

P-1

P-2

P-3

P-4

P-5

(24V MODEL)

(12V)

23

8

3

6

7

4

2

BPS

I

PM

WE

B

P

4

5

2 3

LO HI

1

3 8 7 4 6

1

POFF I H WL

1

2

HEADLIGHT BRACKET (LH)3B

0.5B

0.5B

(24V

)1.

25B

(12V

)

0.5L/B

0.5BR/Y(24V)0.85BR/Y(12V)

0.5L

(24V

)1.

25L(

12V

)

0.5L

/B

0.5L/O(24V)0.85L/O(12V)

0.5L/R(24V)0.85L/R(12V)

0.5B

R/W

(24V

)0.

85B

R/W

(12V

)

0.5B

R/R

(24V

)1.

25B

R/R

(12V

)

WIPER, WASHER SW(COMBINATION SW)

0.5L(24V)0.85L(12V)

0.5L(24V)1.25L(12V)

0.5L

(24V

)3L

1.25

L(12

V)

3B/Y3W/L

FL-1 60A or 100A(24V)80A(12V)

MAIN

FL-2 40A(24V)50A(12V)

KEY SW

STARTER SW

F-10 15AWIPER, WASHER

WIPER MOTOR

WA

SH

ER

MO

TO

R

0.5B

H-73W/B

1

RE

LAY

; IN

TE

RM

ITT

EN

T

FRAME

2L

P-3

P-4

4JH1

FUSE BLOCK

X-1

X-1

X-1

X-1

RELAYTAIL ON

(24V)

X-11

X-11

X-11

X-11

RELAYTAIL ON

0.5B

3W/L

5 2

3 1

5 2

3 1

N8A0252E


Connector List

No. Connector Face

B-8

B-9

B-11

B-11

B-67

B-67

B-69

B-69

002-009

1

2

008-012

1 2 3 4

5 6 7 8

006-001

1 2 3

4 5 6

006-016

3

6

2

5

1

4

004-001

1 23 4

004-002

2

4

1

3

008-001

1

5

2

6

3

7

4

8

008-002

1

5

23

67

4

8

P-1(12V)

P-2

P-1(24V)

P-4

P-2(24V)

P-3

P-5(12V)

P-5(24V)

No. Connector Face

000-003

000-004

000-004

000-004

000-006

000-006

000-007

000-002


H-7

DiagnosisQuick Chart for Check Point1. Windshield Wiper and Washer


X-1

X-11

No. Connector Face

005-006

005-006

1 2

1 2

1 2 3 4

5 6 7 8

9 10 11 12 13

14 15 16 17 18

2 1

2 1

4 3 2 1

8 7 6 5

13 12 11 10 9

18 17 16 15 14

H - 6

H - 7

H - 8

N8A5489E

Check point

FuseF-10(15A)

Wiper& washer

SW

Intermittent relay

Wiper motor

Washer motor

Cable harness

Trouble mode

1. Windshield wiper does not op-erate at any switch position

(1)

(3)

(4)

(2)

2. Windshield wiper does not op-erate at “INT” position

(1)

(3)

(2)

3. Windshield wiper does not op-erate at “LO” position

(1)

(3)

(2)

4. Windshield wiper does not op-erate at “HI” position

(1)

(2)

(3)

5. Auto-stop function of the windshield wiper motor does not operate

(1)

(4)

(2)

(3)

6. Rotation of the windshield wiper motor does not stop

(1)

(2)

7. Windshield washer motor does not operate

(1)

(3)

(2)


1. Windshield Wiper and Washer1-1. Windshield Wiper Does Not Operate at Any Switch Position


NO

• DISCONNECT THE CONNECTOR OF THE WINDSHIELDWIPER & WASHER SWITCH

• TURN THE STARTER SWITCH ON• IS THE BATTERY VOLTAGE APPLIED BETWEEN THE

SWITCH HARNESS SIDE CONNECTOR 1 B-69 AND THEGROUND?

REPLACE THE FUSE

• DISCONNECT THE CONNECTOR OF THE WINDSHIELDWIPER MOTOR WITH THE MOTOR CONNECTOR 2 B-11CONNECTED TO THE BATTERY (+) TERMINAL, AND THECONNECTOR 1 B-11 TO THE (-) TERMINAL, DOES THEMOTOR ROTATE AT A LOW SPEED?

• AND WITH THE CONNECTOR 3 B-11 CONNECTED TOTHE (+) TERMINAL, DOES THE MOTOR ROTATE AT AHIGH SPEED?

GROUND IT SECURELY

YES NO

• IS CONTINUITY IN THE WINDSHIELD WIPER & WASHERSWITCH NORMAL?


YES NO

• IS B-7 GROUNDED SECURELY? REPAIR OR REPLACE THE SWITCH

YES NO

YES NO

REPAIR A POOR CONNECTION AT THE CONNECTORS ORAN OPEN CIRCUIT BETWEEN 1 B-11 AND B-7

REPAIR OR REPLACE THE WINDSHIELD WIPERMOTOR

YES

N8A0254E


1-2. Windshield Wiper Does Not Operate at “INT” Position

1-3. Windshield Wiper Does Not Operate at “LO” Position

NO

• DISCONNECT THE CONNECTOR OF THEINTERMITTENT RELAY

• IS THERE CONTINUITY BETWEEN THE RELAY ANDTHE WINDSHIELD WIPER & WASHER SWITCHHARNESS SIDE CONNECTOR 6 B-9 AND 8 B-69 ,OR 3 B-9 AND 3 B-69 RESPECTIVELY?

REPAIR OR REPLACE WINDSHIELD WIPER &WASHER SWITCH

YES NO

REPLACE THE INTERMITTENT RELAY REPAIR A POOR CONNECTION OR AN OPENCIRCUIT BETWEEN THE CIRCUITS

YES

• IS CONTINUITY IN THE WINDSHIELD WIPER &WASHER SWITCH NORMAL?

N8A0255E

NO

• DISCONNECT THE WINDSHIELD WIPER MOTORCONNECTOR

• CONNECT THE BATTERY (+) TERMINAL TO THEWINDSHIELD WIPER MOTOR CONNECTOR 2 B-11 ANDTHE (-) TERMINAL TO 1 B-11

• DOES THE MOTOR ROTATE AT A LOW SPEED?

REPAIR OR REPLACE THE WINDSHIELD WIPER &WASHER SWITCH

YES NO

REPAIR A POOR CONNECTION AT THE CONNECTORS ORAN OPEN CIRCUIT BETWEEN THE CONNECTORS 7 B-69AND 2 B-11


YES


N8A0256E


1-4. Windshield Wiper Does Not Operate at “HI” Position

NO

• DISCONNECT THE WINDSHIELD WIPER MOTORCONNECTOR

• CONNECT THE BATTERY (+) TERMINAL TO THEWINDSHIELD WIPER MOTOR CONNECTOR 3 B-11 ANDTHE (-) TERMINAL TO 1 B-11

• DOES THE MOTOR ROTATE AT A HIGH SPEED?


YES NO


YES


REPAIR A POOR CONNECTION AT THE CONNECTORSOR AN OPEN CIRCUIT BETWEEN 4 B-69 AND 3 B-11

N8A0257E


1-5. Auto-stop Function of the Windshield Wiper Motor Does Not Operate

NO

• DISCONNECT THE CONNECTOR OF THE WINDSHIELDWIPER MOTOR

• CONNECT THE MOTOR CONNECTOR 2 B-11 TO THEBATTERY (+) TERMINAL, AND 1 B-11 TO THE BATTERY(-) TERMINAL, AND THEN CHANGE THE CONNECTIONOF THE BATTERY (+) TERMINAL TO THE CONNECTOR 4 B-11 WHILE ROTATING THE MOTOR AT A LOW SPEED

• WHEN CONNECTING THE CONNECTOR TERMINALS 2 B-11 AND 5 B-11 IN THIS CONDITION, DOES THEMOTOR STOP AT AUTO-STOP POSITION?


NOYES

YES NO

NOYES

• TURN THE STARTER SWITCH ON• IS THERE BATTERY VOLTAGE APPLIED BETWEEN THE

WINDSHIELD WIPER MOTOR HARNESS SIDECONNECTOR TERMINAL 4 B-11 AND GROUND?

• DISCONNECT THE CONNECTOR OF THE WINDSHIELDINTERMITTENT RELAY

• IS THERE CONTINUITY BETWEEN THE RELAY HARNESSSIDE CONNECTOR 7 B-9 AND THE WINDSHIELD WIPERMOTOR HARNESS SIDE CONNECTOR 5 B-11 ?


REPLACE THE WINDSHIELD INTERMITTENT RELAY REPAIR A POOR CONNECTION AT THECONNECTORS OR AN OPEN CIRCUIT BETWEENTHE CIRCUITS


YES


N8A0258E


1-6. Rotation of the Windshield Wiper Motor Does Not Stop

NO

• THE MOMENT THE WINDSHIELD WIPER COMES TOAUTO-STOP POSITION, TURN THE STARTER SWITCHOFF(ALTERNATIVELY, CONNECT THE BATTERY (+)TERMINAL TO THE WINDSHIELD WIPER MOTORCONNECTOR 2 B-11 AND THE (-) TERMINAL TO 1 B-11 , AND THEN MOVE THE WINDSHIELD WIPERMOTOR TO AUTO-STOP POSITION AND STOP IT)


YES

CONFIRM CONTINUITY BETWEEN THE WINDSHIELDWIPER MOTOR SIDE CONNECTOR TERMINALS 4 B-11AND 5 B-11 , AND REPAIR OR REPLACE THE MOTOR

YES


N8A0259E


1-7. Windshield Washer Motor Does Not Operate

NO

NO

NO

NO

NO

• TURN THE STARTER SWITCH ON• IS THE BATTERY VOLTAGE APPLIED BETWEEN THE

WINDSHIELD WIPER & WASHER SWITCH HARNESSSIDE CONNECTOR TERMINAL 1 B-69 AND THEGROUND?

• DISCONNECT THE CONNECTOR OF THE WINDSHIELDWASHER MOTOR

• TURN THE STARTER SWITCH ON• WITH THE WASHER BUTTON OF THE WINDSHIELD

WIPER & WASHER SWITCH DEPRESSED, IS THEBATTERY VOLTAGE APPLIED BETWEEN THE WASHERMOTOR HARNESS SIDE CONNECTOR TERMINAL 1 B-8AND THE GROUND?


• CONNECT THE MOTOR SIDE CONNECTOR 1 B-8 OFTHE WINDSHIELD WASHER MOTOR TO THE BATTERY(+) TERMINAL, AND THE CONNECTOR 2 B-8 TO THE (-)TERMINAL

• DOES THE MOTOR ROTATE?

REPAIR A POOR CONNECTION AT THE CONNECTORS ORAN OPEN CIRCUIT BETWEEN 2 B-8 AND B-7



REPAIR A POOR CONNECTION AT THECONNECTORS OR AN OPEN CIRCUIT BETWEEN 1 B-8 AND 6 B-69

GROUND IT SECURELY

REPAIR OR REPLACE THE WINDSHIELD WASHERMOTOR

YES

YES

YES

YES

YES


N8A0260E



Windshield Wiper & Washer SwitchWith the starter switch on, the windshield wiper andwasher switch controls the start and stop operation aswell as the change of operating speeds.Both the windshield washer motor and the wipermotor jointly operate while the washer button ispushed.

InspectionCheck the continuity between the connector terminals of the switch.Repair or replace the switch when the result of inspection is found abnormal.

Removal and InspectionRefer to “HEADLIGHT, FOG LIGHT AND CORNERINGLIGHT” in this section.

N8A0261E

Terminal No.Washer SW Wiper SW

3 7 1 4 8 6

OFF

OFFINT

LO

HI

ONMIST,OFF

INT,LO,HI

B-69

Switch side1

5

2

6

3

7

4

8

N8A0262E


Windshield Wiper Motor

Inspection1. Operation in low speed

With the motor connector terminal 2 connect-ed to the battery (+) terminal and the connector 1

to the (−) terminal, check to see if the motorrotates in low speed.

2. Operation in high speedWith the motor connector terminal 3 connect-ed to the battery (+) terminal and the connector 1

to the (−) terminal, check to see if the motorrotates in low speed.

3. Stop operationAfter stopping the windshield wiper in the positionon the way by confirming the operation at the lowspeed in item No. 1.When the connectors 2 and 5 are con-nected, while connecting the motor connector ter-minal 4 to the battery (+) terminal, check tosee, if the motor rotates at low speed and stops atthe auto-stop position.Repair or replace the motor when the results of theabove inspections are found abnormal.


1. Glove BoxRefer to “INSTRUMENT PANEL” of section 2.

2. Windshield Wiper Motor1) Disconnect the connector.2) Remove four screws.3) Remove the ball joint between crank arm and

wiper link.


• Windshield Wiper MotorWhen the crank arm is removed from the wind-shield wiper motor, tighten the motor shaft nut withthe specified torque.

Tighten:Shaft nut to 17 N⋅m (170 kg⋅cm/147 lb⋅in)

• Temporarily fit the motor by using one of the fourwiper motor fixing screws.

• Put the crank arm ball joint in the wiper link holeand fix them together while pulling the wiper link.

N8A0263E

B-11

B-11

B-11

B-11

B-11 B-11

B-11

N8A0264E


Windshield Washer MotorInspectionWith the battery (+) terminal connected to the washermotor connector terminal 1 and the (−) terminal tothe connector 2 , check to see if the cleaning fluidpushes out.Replace the tank/motor when the result of inspection isfound abnormal.


1. Instrument Panel Under CoverRefer to “INSTRUMENT PANEL” of section 2.

2. Washer Tank1) Disconnect the washer motor connector.2) Disconnect the washer hose.3) Remove three fixing screws.

3. Clip Band4. Windshield Washer Motor

Hold the motor and pull it out from the washer tank.


B-8

B-8

1 2

B-8

N8A0265E

3

42

1

N8A0266E


Intermittent RelayCircuit Diagram


1. Glove BoxOpen the lid and remove the four screws.

2. Intermittent Relay1) Press A position with your finger and pry up B

position with the tip of a screw-driver.2) When the relay moves up by about 2/3 of its

size, tilt and take off the relay to avoid interfer-ence with the instrument panel.

3) Disconnect the connector.

N8A0267E



Windshield Wiper Arm & BladeRemoval

1. Cover2. Wiper Arm Nut3. Wiper Arm & Blade


1. Before installing the wiper arm & blade to the shaft,confirm that the motor stops at the auto-stop posi-tion.

2. Set the wiper arm & blade so that the tips of bothblades are positioned as shown in the illustration.

3. Tighten the wiper arm nut to the specified torque.

Tighten:Wiper arm nut to 17 N⋅m (170 kg⋅cm/147 lb⋅in)

Instrumental panel

Instrumentpanel rein-forcement

1

2

2

A

S

B

View S

N8A0268E

321

N8A0269E

Approx. 45mm(STD Cab)Approx. 70mm(Wide Cab)

N8A0270E


Windshield Wiper LinkageLocation of Rod and Pivot


1. Wiper Arm & BladeRemove the cover, nut and wiper arm & blade.

2. Pivot NutRemove the rubber seal, nut and retaining rubber.

Pivot (Wiper: LH)

Rod Rod

Pivot (Wiper: RH)

Wiper motor

N8A0271E

1NutCover

N8A0272E

Rubber seal

2 Retaining rubber

N8A0273E


3. Instrument Panel AssemblyRefer to “INSTRUMENT PANEL” of section 2.

4. Wiper Motor1) Remove the four screws.2) Disconnect the ball joint between the crank arm

and the wiper link.

5. Instrument Panel ReinforcementRefer to “INSTRUMENT PANEL” of section 2.

6. Wiper Link AssemblyRemove two retaining nuts from left hand side ofpivot.

3

N8A0274E

N8A0275E

N8A0276E

6

Pivot (Wiper: LH)

N8A0277E


Remove two retaining nuts from right hand side ofpivot.


• Temporarily fit the wiper motor by using one of thefour wiper motor fixing screws.

• Put the crank arm ball joint in the wiper link holeand fix them together while pulling the wiper link.

• Fit the motor with four screws.• Tighten the pivot nut with the specified torque.

Tighten:Pivot nut to 8 N⋅m (80 kg⋅cm/70 lb⋅in)

• Tighten the wiper arm nut with the specified torque.

Tighten:Wiper arm nut to 17 N⋅m (170 kg⋅cm/147 lb⋅in)

Wiper Blade RubberRemoval

1. Wiper BladePush the wiper blade lock while pulling the wiperblade in the arrow direction.

Notice:When the wiper blade has been removed, wrap the tipof the wiper arm with cloth, to avoid damaging the glass.

2. Wiper Blade Rubber1) Pull the end of rubber and remove the projec-

tion from the click of the blade stay.2) Pull the rubber out in the same direction.

6

Pivot (Wiper: RH)

N8A0278E

N8A0477E

N8A0280E


Installation1. Wiper Blade Rubber

Install the click of the blade stay in the groove of thenew rubber and slide it in. Complete installation bypushing the click.

Finally, check that the click of the stay has caughtin the hole of the rubber.

2. Wiper BladePush the lock of wiper blade (1) into the retentiveportion on the tip of wiper arm (2).

Audio and Cigar Lighter

General DescriptionThe circuit consists of the starter switch, radio, cigarlighter and the relay.The audio circuit is designed for the current to flowthrough the receiver circuit when the radio switch isturned on with the starter switch in “ACC” or “ON”. Cur-rent runs through the memory circuit of the audio regard-less of the position of the starter switch.When the cigar lighter is pushed in with the starterswitch at either “ACC” or “ON” position, a circuit isformed in the cigar lighter case to heat the lighter coil.The cigar lighter is spring back to its original position af-ter the lighter coil is heated.

N8A0281E

N8A0282E

1

2N8A0486E


Parts Location

X-4

TA

IL R

ELA

Y

F-4,

F-7

, F-1

5

N8A0283E


Circuit Diagram

2

D-5

1

D-5

H-71

5

10 11 4

6135129

6767

12

1

B-28

B-28B-28B-28

B-67

B-45

H-11H-2H-2

B-28B-28B-28B-28

4

H-11

B-44

B-43

2

2 1

2

B-7

X-4

X-4

X-4

X-4

H-6

B-67B

ST

ACC

ON

OFF

STARTER SWITCH

FL-1 100A or 120A

KEY SW

FL-2 40A(24V)50A(12V)

AUDIO(B),DOOR LOCK

F-4 15AF-15 15A

1

RELAY; TAIL

LIG

HT

ING

SW

ITC

H(8

)(C

OM

BIN

AIT

ION

SW

ITC

H)

(24V MODEL)


CLE

AR

AN

CE

LIG

HT

(LH

)

3W/B

5W3W

/B

3W/B

0.85

LG/R

3W

0.3G

/O

0.5B

3B 2B

5W/B

(24

V)

8W/B

(12

V)

3R/Y

0.

5R/Y

0.5R

2B

0.3B0.

5G/R

0.5G

/R

0.5G

0.5G

0.5O

0.5O

0.5B

0.5B

0.5LG/R

SPEAKER (LH) SPEAKER (RH)

RADIO & CLOCK

CIG

AR

LIG

HT

ER

P-1

P-2

P-3

P-4

P-5

MAIN

3W/L

5W

AUDIO(IG)CIGAR LIGHTER

1

B-43

2

D-1

1

D-1

0.5LG/R

FRAME

(12V

)8W

0.85LG/R

0.5B

(24

V)

1.25

B (

12V

)

2L

0.5R

/Y

0.5R

/YTAILLIGHT

F-7 10A

0.85

G/B

N8A0284E


Connector List

No. Connector Face

B-1

B-7

X-4

B-28

B-43

B-43

D-5

D-5

000-001

000-012

005-006

013-001

1 2 3

7 8 9

4 5 6

11 12 1310

002-009

1

2

002-010

1

2

002-009

1

2

002-010

1

2

D-1

D-1

B-44

B-45

B-67

B-67

H-2

H-2

No. Connector Face

002-009

1

2

002-010

1

2

001-011

1

001-009

1

004-001

1 23 4

004-002

2

4

1

3

008-009

1 2 3

84 5 6 7

008-010

123

8 4567


H-6, H-7

H-11

H-11

P-1(12V)

P-2

P-1(24V)

P-4

P-2(24V)

P-3

No. Connector Face

008-009

1 2 3

84 5 6 7

008-010

123

8 4567

000-003

000-004

000-004

000-004

000-006

000-006

P-5(12V)

P-5(24V)

No. Connector Face

000-007

000-002

1 2

1 2

1 2 3 4

5 6 7 8

9 10 11 12 13

14 15 16 17 18

2 1

2 1

4 3 2 1

8 7 6 5

13 12 11 10 9

18 17 16 15 14

H - 6

H - 7

H - 8

N8A5489E


Diagnosis1. Cigar Lighter Does Not Heat Sufficiently


NO

• REMOVE THE CIGAR LIGHTER• SET THE STARTER SWITCH TO EITHER "ACC" OR "ON"

POSITION• IS THE BATTERY VOLTAGE APPLIED BETWEEN THE

BIMETAL AT THE CENTER OF THE CASE AND OUTEROF THE CASE?

REPLACE THE FUSE

YES


YES NO

GROUND IT SECURELY

YES

NO


• SET THE STARTER SWITCH TO EITHER "ACC" OR "ON"• IS THE BATTERY VOLTAGE APPLIED BETWEEN B-7

AND GROUND?

REPLACE THE CIGAR LIGHTER ASSEMBLY

YES

REPAIR A POOR CONNECTION AT THECONNECTORS OR AN OPEN CIRCUIT BETWEEN 1 B-45 AND B-7

NO

N8A0285E


2. The Cigar Lighter Does Not Spring Out After Being Heated


RadioRemovalPreparation:Disconnect the battery ground cable.

1. Center Cluster1) Pull it to remove. Pry off three clips by the tip of

screwdriver.2) Remove the cigar lighter power source and its

illumination connector.

Notice:To remove the center cluster, do not force to pry offthree clips at upper portion of the center cluster.

2. Radio1) Remove the two radio fixing screws.2) Disconnect the connector and feeder plug.


AntennaInspectionThe metal A is connected to the pole D at the top of theantenna through the core of the feeder.The metal B is fitted in the feeder shielding the core, andgrounded at the screw C to avoid the core hampered bynoise.Defective grounding would cause noise.

• IS THE FORM OF CIGAR LIGHTER NORMAL?

NO

REPLACE THE CIGAR LIGHTER ASSEMBLY(INCLUDE OUTER CASE)

REPLACE THE CIGAR LIGHTER

YES

N8A0286E

Legend1. Center Cluster

N8A0392E

Legend1. Radio

1

N8A0393E


In checking, measure the following three points with thecircuit tester in the range of “resistance x 1 (Ω).”Between A and BNo continuity (No reading at the indicator) →NormalContinuity (A bite in the feeder. The core grounded) →Lower receptionBetween B and CContinuity (Indicator reading: 0Ω) → NormalNo continuity (Shielded core disconnected or defectivegrounding at the screw → Hampered by noise)Between A and DContinuity or no continuityThere are some antenna feeders and relay feeders witha condenser built in their connections.Measuring resistance between the two points does notresult in correct judgment. Connect temporarily anothernormal antenna to the radio and check to see if its re-ception is audible. Most antenna now available are slidetype. Rust at the screw C and the cab panel wheregrounded would lead no continuity, followed by lower re-ception.Keep this portion clean to avoid rust.RemovalPreparation:Disconnect the battery ground cable.

1. Antenna1) Disconnect the joint connector.2) Remove the upper and lower side antenna

bracket.3) Pull out the antenna feeder.

Notice:For easier fitting, tie the lead wire to the end of the an-tenna feeder in advance.


SpeakerInspection

1. With the circuit tester set to the range of × 1 (Ω),connect the circuit tester probes (red and black) tothe (+) and (−) terminals of the speaker.

2. When the speaker is normal, a low buzzing soundis heard.

3. When the speaker is defective, no sound is heard.However, the distortion or chattering of the soundcannot be identified.When the speaker is installed to the vehicle, dis-connect the connectors before checking.

N8A0289E

Legend1. Antenna2. Antenna Bracket3. Feeder4. Joint Connection5. Feeder6. Clip7. Radio

1

2

3

4

5

67

N8A0394E


When no sound is heard, the following are consid-ered as the cause.

• The speaker wiring is disconnected at the speakerterminals.

• The speaker body is defective.• There is an open circuit somewhere in the speaker

harness on the vehicle side.• The speaker harness on the vehicle side is ground-

ed or caught up.RemovalPreparation:Disconnect the battery ground cable.

1. Door PadRefer to “FRONT DOOR TRIM PAD” of section 2.

2. Speaker PanelDisconnect the speaker connector.

3. Speaker4. Waterproof Sheet


Cigar LighterRemovalPreparation:Disconnect the battery ground cable.

1. Center ClusterRefer to “RADIO” in this section.

2. Cigar Lighter AssemblyRemove the nut, then remove cigar lighter assem-bly, bezel and outer case.


Meter and Warning/indicator Light

General DescriptionThe circuit consists of the starter switch, meter assem-bly, vacuum tank switch, seat belt switch, oil pressureswitch, fuel sedimenter switch, brake fluid switch, park-ing brake switch, vehicle speed sensor, fuel tank unit,thermo unit and engine speed sensor.The meter assembly contains the speedometer, ta-chometer, fuel meter, thermometer and the warning/in-dicator light.The meter warning/indicator lights and their bulb sock-ets are a unit, they are installed from the back of thespeedometer assembly.

Legend1. Trim Panel2. Speaker Panel3. Speaker4. Waterproof Sheet

N8A5341E

Legend1. Bezel2. Cigar Lighter Assembly3. Center Cluster4. Outer Case5. Nut

2

14

5

3

N8A0395E



AFR

AM

EH

AR

NE

SS

E-1

4O

IL P

RE

SS

UR

ES

WIT

CH

E-7

TH

ER

MO

UN

IT

H-1

4

H-1

4

E-2

TA

CH

OS

EN

SO

R H

-14

E-7

TH

ER

MO

UN

IT

<4J

B1>

<4J

H1>

<4J

H1>

FU

SE

BO

X A

SM

F-4

,F-7

,F-1

6

B-5

5 M

ET

ER

B-3

34, B

-335

TA

CH

OG

RA

PH

(IN

ME

TE

R)

B-3

38T

AC

HO

GR

AP

H(I

N IN

ST

)

H-5

~H

-7

B-1

B-6

7

B-3

37P

LUS

CO

NV

ER

TE

RB

-7

H-1

2

J-9

B-7

1 V

AC

UU

MT

AN

K S

WB

-85

BR

AK

EO

IL L

EV

EL

SW

ST

AR

TE

R

J-8

OIL

PR

ES

SU

RE

SW

(Exc

ept 4

JH1)

J-12

8H

BB

LE

VE

L S

W

FL-

1,F

L-2

FU

SIB

LE L

INK

RE

LAY

BO

XA

SM

P-1P-2

P-5

BA

TT

ER

Y

J-32

VE

HIC

LES

PE

ED

SE

NS

OR

J-28

F

UE

L T

AN

K U

NIT

N-6

P

AR

KIN

G B

RA

KE

SW

J-53

,J-5

4 F

UE

L S

ED

IME

NT

ER

ST

AT

ER

SW

B-5

2 M

ET

ER

B-5

1 M

ET

ER

B-3

36 M

ET

ER

(4JH

1)

A

N-5

P-5

P-1 (1

2V)

P-2

P-4

P-3

<4J

H1>

B-2

36

AIR

PR

ES

SU

RE

SW

ITC

H

X-5

AB

SIN

DIC

AT

OR

RE

LAY

B-1

8 D

IOD

EX

-33

DIO

DE

X-1

3 B

UZ

ZE

RC

AN

CE

L R

ELA

Y

N8A0534E


For 24 Volt

<4H

E1,

4H

F1,

4H

G1,

4H

K1>

J-28

FU

EL

TA

NK

UN

IT

N-6

PA

RK

ING

BR

AK

E S

W

J-32

VE

HIC

LE S

PE

ED

SE

NS

OR

E-2

TA

CH

O S

EN

SO

R

H-1

4

P-5

P-1

P-2

P-3

P-4

RE

LAY

BO

X A

SM

FL-

1, F

L-2

FU

SIB

LE L

INK

J-9

H-1

2

B-6

7

B-7

B-1

H-5

, H -

7, H

-8

ST

AR

TE

R

J-8

OIL

PR

ES

SU

RE

SW

B-7

1 V

AC

UU

M T

AN

K S

WB

-85

BR

AK

E F

LUID

LE

VE

L S

W

BA

TT

ER

Y

H-1

4

ST

AR

TE

R S

W

B-5

2 M

ET

ER

B-5

1 M

ET

ER

B-5

5 M

ET

ER

FU

SE

BO

X A

SM

F-4

, F-7

, F-1

6

E-7

6 T

HE

RM

O

SE

NS

OR

(UN

IT)

J-12

8H

BB

LE

VE

L S

W

X-1

3 B

UZ

ZE

RC

AN

CE

L R

ELA

Y

B-1

8D

IOD

E

B-2

36

AIR

PR

ES

SU

RE

SW

ITC

H

X-3

3 D

IOD

E

X-5

AB

S

IND

ICA

TO

R R

ELA

Y

J-53

, J-5

4F

UE

L S

ED

IME

NT

ER

N-5

SE

AT

BE

LT S

W

N8A0535E


Circuit DiagramExcept 4JH1 / 4HK1 Engine

B-5

1B

-52

0.3BR/Y

0.3BR

B-5

2 3 0.5W/L

RELAY; CHARGE (5)

B-8

5

B-8

5

B-5

1 14 2 10.3W/B

0.5B

0.5B

/Y

0.3W

/B

0.3W

/B

0.3W

/B

0.3W

/B

0.3B

SHORT CONNECTOR (WITH HBB)

RELAY;BUZZER CANCEL

BRAKE FLUID SWITCH

3B

11

3 5

X-1

3

X-1

3

X-1

3

X-1

32 4 1

HBB LEVELSW

J-12

8

J-12

82

J-12

8

J-12

8412

TACHOMETER

SPEEDOMETER

CHARGE

SEAT BELT (SAUDI ARABIA)

GLOW

COOLANT TEMPERATURE GAUGE

TURN - RH

BOOST

TURN - LH

HIGH BEAM

EXHAUST BRAKE

SP

EE

D W

AR

NIN

G(S

AU

DI A

RA

BIA

)

VACUUM

BRAKE FLUID LEVEL

ILLUMINATION (X5)

WATERSEDIMENTER

OIL PRESSURE

BUZZER

REAR FOG

H-1

4H

-14

E-2

E-2H-5

H-5

B-5

2B

-52

3938

109

12

ENGINE SPEEDSENSOR

0.3L/O

0.5B/L

98

H-5

H-1

4

E-7

B-5

5

4 23

6 1

0.3Y/B

FUEL GAUGE

FUEL LEVEL

J-28

J-28 3

B-5

5B

-51

H-5

H-5

105

1421

21

J-280.3BR/R

0.3Y/R

B-5

5

H-5

J-32

J-32

B-5

5

H-5

B-5

2

H-5

B-5

5

J-32

72

31

1931

25

21

3

0.85B

0.3Y/G

0.3B/Y

0.5B

WATER SEDIMENTER SW

SEAT BELT SW

N-5

N-5

H-1

2

3B

B-5

1

H-1

2

2 10 3

43

15

1

0.5B0.3W/G 0.3W/G

J-53

J-54

B-5

1

H-5

12 30 1 1

0.3BR/W 0.5BR/W

B-5

1

6

0.3O/L

0.5W2B0.5B

0.3W/V

0.5B/Y

QOS-III CONTROL UNIT (13)

ABS

B-5

1

7

0.5L/O

0.5B/L

0.5L/O

0.5B/L

0.5Y/B 0.5Y/B

THERMO UNIT

0.5BR/R

0.5Y/R

FUEL TANK UNIT

0.5Y/G

0.5B/Y

0.5B

SIG

+

OIL PRESSURE SW (55, 69, 66)

J-8

B-5

2

H-5

1 20 1

0.3SB 0.5SB

QOS-II CONTROL UNIT (7)

9

TIMER

B-5

212

B-5

5B

-55

B-5

5B

-51EXHAUST BRAKE SW

B-69 (2)

B-5

18

B-5

25

HEAD LIGHT (LH)

TURN SIGNAL LIGHT SW B-70 (5)

TURN SIGNAL LIGHT SW B-70 (13)

RELAY:RR FOG LIGHT(5)

FUSE NO. 9

RELAY; TAIL (5)

H-7

B-6

7B

-67

B

ST

AC

C

ON

OF

F

2

P-1

P-2

P-3

P-4

P-5

21

3

FR

AM

E

FL-

1

3B/Y

ST

AR

TE

R S

W

(24V

MO

DE

L)

F-1

6 1

0A

ME

TE

R

H-6

3W/L

MA

IN

FL-

2

100A

or

120A

40A

(24V

)50

A(1

2V)

KE

Y S

W

8W

0.5B/Y

F-4

15A

AU

DIO

(B),

DO

OR

LO

CK

0.5LG/R

(24V)

0.5LG/L

118

101

0.5R/G

0.5G/B

0.5G/W

0.5R/B

B-5

52

0.3W

0.5R0.85R

5W/B

(24

V)

8W/B

(12

V)

B-7

J-9

HE

AD

LIG

HT

BR

AC

KE

T (

LH)

FR

AM

E-L

H(C

EN

TE

R)

B-1

FR

AM

E-L

H(F

RO

NT

)

0.5B

VEHICLE SPEED SENSOR

DSW

QOS-III CONTROL UNIT (9)

2B

SENSORPOWER SOURCE

CIRCUIT

B-5

2

4

EHCU ; ABS

ABS INDICATOR RELAY

X-5

X-5

X-5

X-5

SHORT CONNECTOR (W/O HBB)

1 5 4 3 10 6 2

0.3W/B

PARKING BRAKESW

0.3W/B3 1

H-1

2

H-5

N-6

0.3W

/L

0.3B

R

9 3

78

X-3

3

X-33

X-33

DIO

DE

0.3

W/R

0.3W

/B

H-5

H-50.5BR

0.5W/B

13

980.5W

/R

23

4

B-18

B-18

VACUUM TANKSW

1

DIO

DE

AIR PRESSURESW

B-23

6

B-23

62 10.3BR0.3BR

0.3BR0.3

BR

/Y

B-7

1

B-18

N8A0527E


For 4JH1 Engine

B-5

1B

-52

0.3BR/Y0.3W/B

0.3BR

B-5

2 3 0.5W/L

RELAY; CHARGE (5)

B-8

5

B-8

5

B-5

1 14 2 10.3W/B

0.5B

0.5B

/Y

0.3W

/B

0.3W

/B

0.3W

/B

0.3W

/BPARKING BRAKESW


RELAY;BUZZER CANCEL

BRAKE FLUID SWITCH

3B

11

3 5

X-1

3

X-1

3

X-1

3

X-1

3

0.3W/B3 1

H-1

2

N-6

2 4 1

HBB LEVELSW

B-5

2B

-52

B-5

1B

-55

B-5

5B

-55

H-6

H-5

J-28

B-5

5B

-52

B-5

2

J-28

E-7

H-1

4

B-5

1

H-5

H-5

B-5

5

J-32

J-32

B-5

5

H-5

B-5

2

J-28

H-5

B-5

5

H-5

B-5

5

J-32

B

ST

AC

C

ON

B-6

7B

-67

8

B-5

2

H-5

E-1

4

J-9

B-7

B-1

B-5

1

70dB

J-53

J-54

H-5

B-5

1

BUZZER

P-1

P-2

P-5

H-7

21

3

2

B-5

1

61

12

20 1

30 1 1

310

15

3119

25

12

3

7

21 1

104

98

1423 6 1

2

3

1

B-5

2410

811

FR

AM

E

FL-

1

100A

3W/L

ST

AR

TE

R S

WIT

CH

F-1

6

ME

TE

R10

A

0.5B

/Y

3B/Y

EXHAUST BRAKE SWITCH B-69 (2)

(COMBINATION SWITCH)

HEADLIGHT (LO)

RELAY; RR FOG LIGHT (5)

TURN SIGNAL LIGHT SWITCH (LH) B-70 (5)


TURN SIGNAL LIGHT SWITCH (RH) B-70 (13)


0.5LG/L

0.5R/G

0.5R/G

0.5G/B

0.5G/W

B-33

6312

5

0.3W/R

0.5LG/R

5W8W

/B

0.5R 0.5R

FR

AM

E-L

H(F

RO

NT

)

HE

AD

LIG

HT

BR

AC

KE

T (

LH)

FR

AM

E-L

H(C

EN

TE

R)

0.85

B

3B2B 0.5B

0.3O/LECM (43)

OIL PRESSURE SWITCH

0.3LB

0.3LG/W 0.5LG/W 0.5B

WATER SEDIMENTER SWITCH

0.3B/Y 0.5B/Y

0.3Y/R 0.5Y/R

0.85B 0.5B

0.85B

0.5B0.3BR/R 0.5BR/R

0.3Y/B 0.5Y/B 0.5Y/B

0.3B

0.5LG

THERMO UNIT

FUEL TANK UNIT

VE

HIC

LE S

PE

ED

SE

NS

OR

0.3Y/G 0.5Y/G

8WM

AIN

2L

FL-

2

50A

KE

Y S

W

TACHOMETER

COOLANTTEMPERATURE GAUGE

FUEL LEVEL

FUEL GAUGE

SPEEDOMETER

ILLUMINATION(X5)

TURN (RH)

TURN (LH)

HIGH BEAM

EXHAUST BRAKE

REAR FOG

CHARGE

BRAKE FLUIDLEVEL

WATER SEDIMENTER

OIL PRESSURE

VACUUM

GLOW

SENSORPOWER SOURCE

CIRCUIT

ECM (27)

CHECK ENGINE

B-5

1 4

0.5G/YECM (43)

B-5

1 2

0.5G/R

EC

M (

60)

0.5LB H-1

4

1.25LB

B-5

1 7ABS

X-54

X-5

3

15

X-5

X-5

ABS INDICATORRELAY

0.5W

0.5B/Y

2B0.5B

0.3W/VEHCU ; ABS

0.3B

B-33

7B-

3374

1 PLU

SC

ON

VE

RT

ER

B-33

7B-

337 6

5

B-33

8B-

3384

3

TA

CH

OG

RA

PH

(IN

INS

T)

B-33

8B-

338 2

6

B-33

85

B-33

81

B-33

5B-

334

B-33

5 13

2

TA

CH

OG

RA

PH

(IN

ME

TE

R)

7B-

335

6B-

335

5B-

335

F-7

1

0A

TA

IL L

IGH

T

0.5R

0.5L

G/R

0.5B0.

3W/B

0.5B

0.5B/Y

0.5B/Y

0.5LG/R

0.5R

BOOSTER

0.85

LG/R

F-4

1

5A

AU

DIO

(B),

DO

OR

LO

CK

TA

IL R

ELA

Y

0.5B

/Y

4

P-3

P-4

FOR EC ONLY


1 5 4 3 10 6 2

AIR PRESSURESW

B-23

6

B-23

6

23

4

2 1

B-18

B-18

VACUUM TANKSW

1

DIO

DE

0.3

BR

B-7

1

0.3B

R

0.3

BR

0.5BR

0.5W/B

2 1

412 3

98

0.3W

/L

0.3B

R

9 3

78

X-3

3

X-33

X-33

DIO

DE

0.3

W/R

0.5W

/R0.

5W/B

0.3

BR

/YJ-

128

J-12

8

J-12

8

J-12

8

H-5

H-5

H-5

H-5

B-18

N8A0528E


For 4HK1 Engine

B-5

5

H-5

J-32

H-7

B-6

7

J-32

B-6

7

B-5

5

H-5

B-5

2

H-5

B-5

5

J-32

2

B-5

5B

-55

B-5

5B

-51

B-1

5

J-28

J-28

H-5

H-1

4

3

E-7

6

E-2

E-2

B-5

5B

-51

H-5

H-5

B-5

2B

-52

B-5

5

B-5

2

P-1

P-2

P-3

P-4

P-5

21

B-5

2

118

101

104

12

23 7 3

57

1421

21

103

1

1931

25

21

3

FR

AM

E

FL-

1 1

00A

or

120A

B

ST

AC

C

ON

OF

F

ST

AR

TE

R S

WIT

CH

5WH

-6

EXHAUST BRAKE SWITCH B-69 (2)(COMBINATION SWITCH)

HEADLIGHT (LO)

TURN SIGNAL LIGHT SWITCH (LH) B-70 (5)(COMBINATION SWITCH)

TURN SIGNAL LIGHT SWITCH (RH) B-70 (13)(COMBINATION SWITCH)

0.5R0.5R

F-4

1

5A

AU

DIO

(B),

DO

OR

LO

CK

J-28

ENGINE SPEED SENSOR

THERMO UNIT

0.3B/L

0.3LG

0.3Y/B

0.3BR/R

0.3Y/R

0.5B

FUEL TANK UNIT

0.85B

0.85B

VE

HIC

LE S

PE

ED

SE

NS

OR

0.3Y/G

0.3B/Y

0.5B/Y

0.5Y/G

0.5B

FR

AM

E-L

H(F

RO

NT

)

3W/L

MA

IN

2L

FL-

2 4

0A

KE

Y S

W

TACHOMETER

89

THERMO METER

FUEL LEVEL

FUEL METER

SPEEDOMETER

ILLUMINATION(X5)

TURN(RH)

TURN(LH)

HIGHBEAM

EXHAUSTBRAKE

0.5G/W

12

0.5G/B

0.5R/G

0.5LG/R

SENSORPOWER SOURCE

CIRCUIT

3

F-1

6 1

0A

ME

TE

R

B-5

24

RR FOG RELAY X-23 (5) RR FOG0.5R/G

H-8

H-8

1615

H-8

13

H-1

4H

-14

1213

H-1

413

0.3V

0.3LG0.3LG

0.3V

0.3LG

0.3V

(

)(

)

F-7

1

0A

TA

ILLI

GH

TT

AIL

RE

LAY

5W/B

0.5LG/R

BUZZER

B-5

1

90dB

B-5

1

67

ECM (3)0.3O/L

2B

GLOW

ABS

J-8

B-5

2

H-5

B-5

18

1 20

1

OIL PRESSURE SWITCH

0.3LB

0.5B

/Y 0.5LBOIL PRESSURE

CHARGE

BOOSTER

VACUUM

BRAKE FLUIDLEVEL

ABS INDICATOR RELAY

0.5W

0.5B/Y

0.5B

EHCU ; ABS0.3W/V

4 1

3 5

X-5

X-5

X-5

X-5

J-9

B-7

3BH

EA

DLI

GH

TB

RA

CK

ET

(LH

)

FR

AM

E-L

H(C

EN

TE

R)

0.5B

B-5

1B

-52

0.3BR/Y

0.3BR

B-5

2 3 0.5W/L

RELAY; CHARGE (5)

B-8

5

B-8

5

B-5

1 14 2 10.3W/B

0.5B

0.5BR

0.5W/B

0.5B

/Y

0.3W

/B

0.3

W/B

0.3

W/R 0.

5W/R

0.5W

/B

0.3W

/B

0.3W

/B

0.3W

/B

0.3B

PARKING BRAKESW

AIR PRESSURESW


RELAY;BUZZER CANCEL

BRAKE FLUID SWITCH

3B

11

3 5

X-1

3

B-23

6

X-1

3

X-1

3

X-1

3

B-23

60.3W/B3 1

H-1

29

78

X-3

3

N-6

2 4 1

23

4

2 1


HBB LEVELSW

B-18

B-18

X-33

X-33

2 1

12 4 3

98

VACUUM TANKSW

1

DIO

DE

DIO

DE

0.3B

R

0.3B

R

0.3B

R

1 5 4 3 10 6 2

0.3

BR

0.3

BR

B-7

1H

-5H

-5

J-12

8

J-12

8

J-12

8

J-12

8

0.3

BR

H-5

H-5

B-18

N8A0529E


Connector ListExcept 4JH1 / 4HK1 Engine

No. Connector Face

B-1

B-7

B-18

B-52

B-51

B-55

N-6

N-6

000-001

000-001

004-004

1 2 3 4

012-005

1 2 3 4 5 6 7 8 9 10 11 12

014-001

1 2 3 4 5 6 7 8 9 1011121314

012-004

1 2 3 4 5 6 7 8 9 10 11 12

001-002

1

001-011

1

B-67

B-67

B-71

B-71

J-8

J-8

B-85

B-85

No. Connector Face

004-001

1 23 4

004-002

2

4

1

3

001-013

1

001-014

1

001-013

1

001-014

1

002-009

1

2

002-010

1

2


B-236

N-5

N-5

E-2(66)

E-2(66)

E-2(55,69)

E-2(55,69)

E-7

No. Connector Face

002-022

1 2

003-020

2 3

1

003-021

1

3 2

002-001

1 2

002-002

12

002-011

1 2

002-012

12

001-018

1

H-12

H-12

H-14

H-14

J-9

J-53

J-53

J-54

No. Connector Face

014-002

1 2 3

7 8 9 10 11

4

12

5

13

6

14

014-003

6 5 4

14131211

3 2 1

9 8 710

016-003

1 2 3 4

5 6 7 8 9

11 12 13 14

15 16

10

016-004

4 3 2 1

9 8 7 6 5

13 12 11 10

16 15

14

000-001

000-010

000-011

000-010


J-54

J-128

J-28

J-28

J-32

P-1(12V)

P-1

P-4

No. Connector Face

000-011

004-018

003-016

3

1 2

003-017

3

2 1

003-018

1 2 3

000-003

000-004

000-004

P-2

P-3

P-5(12V)

P-5

H-14

H-14

J-8(FOR

4J type ENGIN

E)

X-5

No. Connector Face

000-006

000-006

000-007

000-002

016-001

1 2 3 4

5 6 7 8

9 10 11 12

13 14 15 16

016-002

4 3 2 1

8 7 6 5

12 11 10 9

16 15 14 13

001-019

1

005-006


H-5

H-6, H-7

For 4JH1 Engine

X-13

X-33

No. Connector Face

005-006

014-002

1 2 3

7 8 9 10 11

4

12

5

13

6

14

1 2 37 8 9

13 14 1519 20 2125 26 2731 32 33 34 35 36 37

4 5 610 11 1216 17 1822 23 2428 29 3038 39 40

6 5 412 11 1018 17 1624 23 2230 29 2840 39 38

3 2 19 8 715 14 1321 20 1927 26 2533 32 3134353637

N8A5488E

1 2

1 2

1 2 3 4

5 6 7 8

9 10 11 12 13

14 15 16 17 18

2 1

2 1

4 3 2 1

8 7 6 5

13 12 11 10 9

18 17 16 15 14

H - 6

H - 7

H - 8

N8A5489E

No. Connector Face

B-1

B-7

B-18

B-52

B-51

B-55

B-67

B-67

000-001

000-017

004-004

1 2 3 4

012-005

1 2 3 4 5 6 7 8 9 10 11 12

014-001

1 2 3 4 5 6 7 8 9 1011121314

012-004

1 2 3 4 5 6 7 8 9 10 11 12

004-001

1 23 4

004-002

2

4

1

3


B-71

B-71

E-14

E-14

B-85

B-85

N-6

B236

No. Connector Face

001-013

1

001-014

1

001-013

1

001-014

1

002-009

1

2

002-010

1

2

002-023

2 1

002-022

1 2

B-334

B-335

B-336

B-337

B-338

E-7

H-12

H-12

No. Connector Face

004-014

2

1

4

3

008-014

234

1678

5

006-018

1 2 3 4 5 6

008-013

8 7 6 51 2 3 4

006-003

2

6 5 4 3

1

001-009

1

014-002

1 2 3

7 8 9 10 11

4

12

5

13

6

14

014-003

6 5 4

14131211

3 2 1

9 8 710


H-14

H-14

J-9

J-53

J-53

J-54

J-54

J-28

No. Connector Face

016-003

1 2 3 4

5 6 7 8 9

11 12 13 14

15 16

10

016-004

4 3 2 1

9 8 7 6 5

13 12 11 10

16 15

14

000-001

000-010

000-011

000-010

000-011

003-016

3

1 2

J-28

J-32

J-128

P-5

P-1

P-2

P-3

P-4

No. Connector Face

003-017

3

2 1

003-018

1 2 3

004-018

000-007

000-002

000-002

000-014

000-014


H-5

H-6, H-7

For 4HK1 Engine

X-5

X-13

X-33

No. Connector Face

005-001

1

32 4

5

005-006

014-002

1 2 3

7 8 9 10 11

4

12

5

13

6

14

1 2 37 8 9

13 14 1519 20 2125 26 2731 32 33 34 35 36 37

4 5 610 11 1216 17 1822 23 2428 29 3038 39 40

6 5 412 11 1018 17 1624 23 2230 29 2840 39 38

3 2 19 8 715 14 1321 20 1927 26 2533 32 3134353637

N8A5488E

No. Connector Face

B-1

B-7

J-9

B-18

X-5

1 2

1 2

1 2 3 4

5 6 7 8

9 10 11 12 13

14 15 16 17 18

2 1

2 1

4 3 2 1

8 7 6 5

13 12 11 10 9

18 17 16 15 14

H - 6

H - 7

H - 8

N8A5489E

000-001

000-001

000-001

004-004

1 2 3 4

005-006


X-13

X-33

B-52

B-51

B-55

B-67

B-67

B-71

No. Connector Face

005-006

014-002

1 2 3

7 8 9 10 11

4

12

5

13

6

14

012-005

1 2 3 4 5 6 7 8 9 10 11 12

014-001

1 2 3 4 5 6 7 8 9 1011121314

012-004

1 2 3 4 5 6 7 8 9 10 11 12

004-001

1 23 4

004-002

2

4

1

3

001-013

1

B-71

J-8

J-8

B-85

B-85

B-236

N-6

E-2

No. Connector Face

001-014

1

001-013

1

001-014

1

002-009

1

2

002-010

1

2

002-022

1 2

002-023

2 1

002-013

1 2


E-76

H-12

H-12

H-14

H-14

J-28

J-28

J-32

No. Connector Face

003-004

1 2

3

014-002

1 2 3

7 8 9 10 11

4

12

5

13

6

14

014-003

6 5 4

14131211

3 2 1

9 8 710

016-003

1 2 3 4

5 6 7 8 9

11 12 13 14

15 16

10

016-004

4 3 2 1

9 8 7 6 5

13 12 11 10

16 15

14

003-016

3

1 2

003-017

3

2 1

003-018

1 2 3

J-128

P-1

P-4

P-2

P-3

P-5

No. Connector Face

004-018

000-004

000-004

000-006

000-006

000-002


H-5

H-6, H-7, H-8

1 2 37 8 9

13 14 1519 20 2125 26 2731 32 33 34 35 36 37

4 5 610 11 1216 17 1822 23 2428 29 3038 39 40

6 5 412 11 1018 17 1624 23 2230 29 2840 39 38

3 2 19 8 715 14 1321 20 1927 26 2533 32 3134353637

N8A5488E

1 2

1 2

1 2 3 4

5 6 7 8

9 10 11 12 13

14 15 16 17 18

2 1

2 1

4 3 2 1

8 7 6 5

13 12 11 10 9

18 17 16 15 14

H - 6

H - 7

H - 8

N8A5489E


DiagnosisQuick Chart for Check Point1. Speedometer


2. Tachometer


3. Coolant Temperature Gauge


Check point

Speedometer Vehicle speed sensor Cable harness

Troublemode

1-1. Speedometer and odometer do not func-tion

(3)

(1)

(2)

1-2. Speedometer does not function(odometer is normal)

(1)

1-3. Odometer does not function(Speedometer is normal)

(1)

1-4. Speedometer needle fluctuates(May be wide fluctuation)

(3)

(1)

(2)

1-5. Speedometer needle jumps erratically

(3)

(1)

(2)

Check point

Tachometer Engine speed sensor Cable harness

Troublemode

2-1. Tachometer does not function

(3)

(1)

(2)

2-2. Tachometer needle fluctuates(May be wide fluctuation)

(3)

(1)

(2)

2-3. Tachometer needle jumps erratically

(3)

(1)

(2)

Check point

Meter ASM

Thermo meter

Thermo unit

Thermo seat

Cable harness

Troublemode

3-1. Coolant temperature gauge nee-dle does not move

(3)

(4)

(2)

(1)

3-2. Coolant temperature gauge read-ing is too low (or high)

(4)

(5)

(3)

(1)

(2)

3-3. Needle overshoots (or goes up tothe “H” range)

(3)

(4)

(1)

(2)


4. Fuel Gauge


5. Warning/indicator Light

Check point

Meter ASM Fuel gauge Fuel tank unit

Cable harness

Troublemode

4-1. Fuel gauge needle does not move

(3)

(4)

(2)

(1)

4-2. Even when the tank is filled up with fuel,the needle does not reach “F”

(3)

(4)

(2)

(1)

4-3. When the tank is not full of fuel, the nee-dle overshoots (or goes to “F”)

(3)

(4)

(2)

(1)

Check point

Light bulb

Parking brake SW

Brake fluid SW

Oil pressure

SW

Fuel tank unit

Vacuum SW

4WD SW

Sedimenter SW

Seat belt SW

Cable harness

Troublemode

5-1. When the parkingbrake lever is pulled, theindicator light does notlight up

(2)

(1)

(3)

5-2. Even when the park-ing brake lever isreleased, the indicatorlight does not go off

(1)

(2)

5-3. While the engineoperating, the oil pressurewarning light does not gooff

(2)

(1)

5-4. Even when the tank isfull with fuel, the fuel warn-ing light lights up

(1)

(2)

5-5. Even when the tank isempty, the low fuel warn-ing light does not light up

(1)

(2)

(3)

5-6. Even when the float inthe water sedimenter goesup above the drain warn-ing level, the indicator lightdoes not light up

(2)

(1)

(3)

5-7. Even when the brakefluid is lower than speci-fied level, the level warn-ing light does not light up

(1)

(2)

(3)

5-8. Even when the vac-uum tank is empty vac-uum warning buzzer doesnot sound

(1)

(2)



1. Speedometer1-1. Speedometer and Odometer Do Not Function

1-2. Speedometer Does Not Function (Odometer Is Normal)

• DOES THE VEHICLE SPEED SENSOR OUTPUT INNORMALLY?

• ARE THE CIRCUITS BETWEEN THE VEHICLE SPEEDSENSOR AND THE METER, AND THE FUSE ( F-16 10A)AND THE GROUND NORMAL?

REPLACE THE VEHICLE SPEED SENSOR

YES NO

YES NO

REPAIR A POOR CONNECTION AT THECONNECTORS OR AN OPEN CIRCUIT INTHE CIRCUIT

REPLACE THE SPEEDOMETER

N8A0299E

REPLACE THE SPEEDOMETER ASSEMBLY

N8A0300E


1-3. Odometer Does Not Function (Speedometer Is Normal)

1-4. Speedometer Needle Fluctuates (May Be Wide Fluctuation)

REPLACE THE SPEEDOMETER ASSEMBLY

N8A0300E

N8A5366E


1-5. Speedometer Needle Jumps Erratically

N8A5366E

Inspection of waveform by oscilloscope1. Connect a resistance of 1.3 to 5k ohm (1.4W or more) between the harness side connectors 8 B-51

and 1 B-55 of the meter.

2. Install a speedometer tester.

3. Turn on the starter SW.

4. Check the waveform at the time when the vehicle speed is at 60 Km (37 mph).

Normal waveform

Approximate battery voltage

23.6 m sec.

0V

2V or less

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

B-51 B-55

N8A0304E


2. Tachometer2-1. Tachometer Does Not Function

2-2. Tachometer Needle Fluctuates (May Be Wide Fluctuation)

N8A5368E

N8A5368E


2-3 Tachometer Needle Jumps Erratically

• IS THE PULSE INPUT NORMAL?

YES NO

REPAIR A POOR CONNECTION AT THECONNECTORS IN THE CIRCUIT OR A FAILURE INTHE HARNESS, OR REPLACE ENGINE SPEEDSENSOR

REPLACE THE TACHOMETER

N8A0307E


3. Coolant Temperature Gauge3-1. Coolant Temperature Gauge Needle Does Not Move

• IS THE CONNECTOR OF THE THERMO UNITCONNECTED SECURELY?

• DISCONNECT THE CONNECTOR OF THE THERMOUNIT

• CONNECT A 3.4W BULB BETWEEN THE HARNESSSIDE CONNECTOR 1 E-7 AND THE GROUND OF THETHERMO UNIT

• WHEN THE STARTER SW IS TURNED ON, DOES THETEMPERATURE GAUGE NEEDLE MOVE ABOUT 10SECONDS AFTER THAT?

• IS THE THERMO UNIT NORMAL?

YES NO

REPAIR A POORCONNECTION AT THECONNECTOR

REPLACE THETHERMO UNIT

YES

YES NO

YES

• IS THERE A BROKENWIRE IN THE PRINTEDCIRCUIT OF THEMETER ASSEMBLY?

YES NO

REPLACE THE PRINTEDCIRCUIT BOARD

CHECK THE COOLANTTEMPERATURE GAUGEAND REPLACE IT WITH ACORRECT ONE IFNECESSARY

• REPAIR A POORCONNECTION AT THECONNECTORS OR ANOPEN CIRCUIT IN THECIRCUIT

NO

• IS THE CIRCUIT BETWEEN THE TEMPERATUREGAUGE AND THE THERMO UNIT NORMAL?

NO


N8A0308E


3-2. Coolant Temperature Gauge Reading Is Too Low (or High)

• DOES THE THERMOSTAT OPERATE NORMALLY?

• TURN THE STARTER SWITCH ON• WHEN INSERTING AND PULLING OUT THE

THERMOSTAT CONNECTOR 1 E-7 SEVERALTIMES, DOES THE INDICATION OF THE COOLANTTEMPERATURE GAUGE VARY?

• IS THE THERMO UNIT NORMAL? REPAIR A POOR CONNECTION AT THE CONNECTOROF THE THERMO UNIT

• IS THERE AN OPEN CIRCUIT IN THE METERASSEMBLY PRINTED CIRCUIT BOARD?

REPLACE THE THERMO UNIT

YES

YES NO

YES NO

YES NO

REPLACE THE PRINTED CIRCUIT BOARD

CHECK THE COOLANT TEMPERATURE GAUGE ANDREPLACE IT IF FOUND DEFECTIVE

NO

REPLACE THE THERMOSTAT

N8A0309E


3-3. Needle Overshoots (or Goes Up to the “H” Range)

• DISCONNECT THE CONNECTOR OF THE THERMOUNIT

• WHEN THE STARTER SW IS TURNED ON, DOESTHE POINTER REACH TO THE "H" RANGE?

• IS THERE A SHORT CIRCUIT BETWEEN THETHERMO UNIT AND THE COOLANTTEMPERATURE GAUGE?

REPLACE THE THERMO UNIT

• IS THE PRINTED CIRCUIT OF THE METERASSEMBLY GROUNDED SECURELY?

REPAIR A SHORT CIRCUIT

YES

YES

NO

YES

NO

NO

REPAIR OR REPLACE THE PRINTED CIRCUIT BOARD

CHECK THE COOLANT TEMPERATURE GAUGE ANDREPLACE IT IF FOUND ABNORMAL

N8A0310E


4. Fuel Gauge4-1. Fuel Gauge Needle Does Not Move

• IS THE CONNECTOR OF THE FUEL TANK UNIT J-28CONNECTED SECURELY?

• DISCONNECT THE CONNECTOR OF THE FUELTANK UNIT

• CONNECT A 3.4W BULB BETWEEN THE HARNESSSIDE CONNECTOR 1 J-28 AND THE GROUND OFTHE FUEL TANK UNIT

• WHEN THE STARTER SW IS TURNED ON, DOES THEFUEL GAUGE NEEDLE FLUCTUATE AFTER ABOUT 90SECONDS?

• IS THERE CONTINUITY BETWEEN THE FUELTANK UNIT CONNECTOR TERMINALS 1 J-28AND 3 J-28 ?

YES NO

REPLACE THE FUELTANK UNIT

REPAIR A POORCONNECTION AT THECONNECTORS OR ANOPEN CIRCUITBETWEEN THE FUELTANK UNIT AND THEMETER

YES

YES NO

YES

• IS THERE A BROKENWIRE IN THE PRINTEDCIRCUIT OF THEMETER ASSEMBLY?

YES NO

CHECK THE FUELMETER, AND REPLACE ITIF NECESSARY


REPAIR A POORCONNECTION AT THECONNECTORS OR ANOPEN CIRCUIT IN THECIRCUIT

NO

• IS THE CIRCUIT BETWEEN THE FUEL GAUGE ANDTHE FUEL TANK UNIT NORMAL?

NO


N8A0311E


4-2. Even when the Tank Is Filled Up with Fuel, the Needle Does Not Reach “F”

• WHEN INSERTING AND PULLING OUT THECONNECTOR J-28 OF THE FUEL TANK UNITSEVERAL TIMES, DOES THE POINTER OF THE FUELGAUGE STAY AT THE SAME POSITION?

• DISCONNECT THE CONNECTOR OF THE FUEL TANKUNIT

• CONNECT THE FUEL TANK UNIT HARNESS SIDECONNECTOR 1 J-28 AND 3 J-28 WITH A LEADWIRE

• WHEN THE STARTER SW IS TURNED ON, DOES THENEEDLE OVERSHOOT TO "F" AFTER ABOUT 5MINUTES?

• IS THERE A BROKEN CIRCUIT IN THE PRINTEDCIRCUIT OF THE METER ASSEMBLY?

YES NO


CHECK THE FUELGAUGE AND REPLACEIT IF FOUNDABNORMAL

YES

YES NO

YES

• IS THE RESISTANCEVALUE OF THE FUELTANK UNIT NORMAL?

NO

REPLACE THE FUELTANK UNIT

• REMOVE THE FUEL TANK UNIT• DOES THE FLOAT ARM OPERATE SMOOTHLY?

NO

REPAIR A POOR CONNECTION AT THE CONNECTOROF THE FUEL TANK UNIT

N8A0312E


4-3. When the Tank Is Not Full of Fuel, the Needle Overshoots (or Goes Up To “F”)

• DISCONNECT THE CONNECTOR OF THE FUEL TANKUNIT

• WHEN THE STARTER SW IS TURNED ON, DOES THENEEDLE STILL POINT TO "F"?

• IS THE CIRCUIT BETWEEN THE FUEL TANK UNITAND THE FUEL METER NORMAL?

YES NONO

REPAIR A SHORTCIRCUIT IN THECIRCUIT

REPAIR OR REPLACETHE PRINTED CIRCUITBOARD

CHECK THE FUELGAUGE, AND REPLACEIT IF NECESSARY

• IS THE PRINTEDCIRCUIT OF THEMETER ASSEMBLYGROUNDEDSECURELY?

• ARE THE RESISTANCE VALUES OF THEFUEL TANK UNIT AT "E" AND "F" POINTSNORMAL?

YES

YES YESNO

REPLACE THE FUEL TANK UNIT

NO

• REMOVE THE FUEL TANK UNIT• DOES THE FLOAT ARM OPERATE SMOOTHLY?

N8A0313E


5. Warning/indicator Light5-1. When the Parking Brake Lever Is Pulled, the Indicator Light Does Not Light Up

5-2. Even when the Parking Brake Lever Is Released, the Indicator Light Does Not Go Off

N8A5377E

N8A5378E


5-3. While the Engine Is Operating, the Oil Pressure Warning Light Does Not Go Off

5-4. Even when the Fuel Tank Is Full with Fuel, the Fuel Warning Light Lights Up

• IS THE ENGINE OIL PRESSURE NORMAL?

• WITH THE OIL PRESSURE SWITCH CONNECTOR J-8DISCONNECTED, DOES THE WARNING LIGHT GOOFF?

• WHILE THE ENGINE IS OPERATING, IS THERECONTINUITY BETWEEN THE OIL PRESSURE SWITCHCONNECTOR J-8 AND THE BODY GROUND?

YES

YES

NO

NO

NO

REFER TO THE "ENGINE" SECTION

REPAIR A SHORT CIRCUIT BETWEEN 1 J-8 AND 1 B-52 (METER)

REPLACE THE OIL PRESSURE SWITCH

N8A0316E

• WHEN THE FUEL TANK UNIT CONNECTOR J-28 ISDISCONNECTED, DOES THE WARNING LIGHT GOOFF?

• IS THE FUEL TANK UNIT NORMAL?

YES NO

NO

REPAIR A SHORT CIRCUIT BETWEEN THE FUELTANK UNIT HARNESS SIDE CONNECTORS 2 J-28AND 10 B-51 (METER)


N8A0317E


5-5. Even when the Fuel Tank Is Empty, the Low Fuel Warning Light Does Not Light Up

• DOES THE WARNING LIGHT HAVE A BURNED OUTBULB, OR IS THE SOCKET POORLY CONNECTED?

• IS THE FUEL TANK UNIT NORMAL?

YES

YES

NO

NO

REPLACE THE BULB, OR REPAIR A POORCONNECTION AT THE SOCKET


REPAIR A POOR CONNECTION AT THE CONNECTOROR AN OPEN CIRCUIT BETWEEN THE HARNESSSIDE CONNECTORS 2 J-28 AND 10 B-51 (METER)OR 3 J-28 AND J-9

N8A0318E


5-6. Even when the Float in the Water Sedimenter Goes Up above the Drain Warning Level, the Indicator LightDoes Not Light Up

NO

REPLACE THE BULB, OR REPAIR A POORCONNECTION AT THE SOCKET

YES

• DOES THE INDICATOR LIGHT HAVE A BURNED-OUTBULB OR IS THE SOCKET POORLY CONNECTED?

YES

• IS THE WATER SEDIMENTER SWITCH NORMAL?

NO

REPLACE THE WATER SEDIMENTER SWITCH

REPAIR A POOR CONNECTION AT THECONNECTORS OR AN OPEN CIRCUIT IN THECIRCUIT BETWEEN THE WATER SEDIMENTERSWITCH HARNESS SIDE CONNECTOR 1 J-53AND 12 B-51 (METER), OR 1 J-54 AND J-9

N8A0319E


5-7. Even when the Brake Fluid Is Lower than Specified Level, the Level Warning Light Does Not Light Up

5-8. Vacuum Warning Buzzer Does Not Sound


Turn Signal Light SwitchRefer to “TURN SIGNAL LIGHT, HAZARD WARNINGLIGHT AND STOPLIGHT” in this section.

Exhaust Brake SwitchRefer to “EXHAUST BRAKE” in this section.

N8A5384E

N8A0321E


Meter AssemblyLayout for Gauges, Warning, Indicator and Illumination LightsExcept 4HK1-TC

Notice:The calibration and the red zone of tachometer are various depending on the models fitted.

1

0

2

x1000 r/min

3

4

PUSHSET

MH

km/hTRIPODO

AB

E F

HC

Speedometer

Fuel gauge Coolant temperature gauge

Tachometer &digital clock

Warning lens

N8A0479E


For 4HK1-TC

Without Smoother Smoother

Fuel gauge Coolant temperature gauge

Speedometer TachometerWarning lens Warning lens

1STSTART

N8A0480E


Bulb Location for Warning LensExcept 4HK1-TC

N8A0481E


For 4HK1-TC

*1 : Smoother

*2 : Without Smoother

1STSTART

N8A0482E


Table for Meter Connector Terminal ConnectionsExcept 4HK1-TC

B-336

B-51

B-55

ECT - Engine Coolant Temperature

B-55

B-52

B-51

B-336

N8A0483E


1 IGN (+)

2 —

3 Speed pulse input

4 —

5 Ground

6 Illumination (+)


1 Exh. Brake

2 Exh. Brake / Seat belt (GCC)

3 —

4 Check engine

5 PTO

6 Glow

7 ABS

8 IGN (+)

9 4WD

10 Fuel low

11 Vacuum / Booster

12 Sedimenter

13 Low coolant

14 Brake


1 Speed pulse input

2 —

3 Power output (sensor)

4 ECT unit (GAUGE)

5 Fuel tank unit (GAUGE)

6 —

7 Ground

8 Turn signal (LH)

9 —

10 Beam (+)

11 Turn signal (RH)

12 —


B-52

For 4HK1-TC


1 Oil pressure

2 Vacuum SW

3 Charge

4 Parking / Rear fog

5 Illumination (+)

6 —

7 Illumination (−)

8 Signal (tacho)

9 Ground (tacho)

10 Ground

11 —

12 +B

N8A0484E


B-53 (With Smoother)

B-51

*1: With Smoother*2: Without Smoother

B-52


1 TCM

2 —

3 —

4 —

5 —

6 1st Start

7 ECONO

8 Smoother

9 —

10 —

11 —

12 —


1 Turn LH

2 Beam

3 —

4 Brake (*1) / — (*2)

5 Check Engine (*1) / Brake (*2)

6 Exhaust Brake

7 —

8 —

9 Brake Booster

10 Charge

11 Oil Pressure

12 ABS

13 — (*1) / Check Engine (*2)

14 —

15 Ground

16 Vehicle Speed Signal Output

17 Illumination +

18 Ignition

19 Rear Fog

20 ASR


1 4WD

2 —

3 Turn RH

4 —

5 Thermal

6 Fuel

7 TAM Pulse (−)

8 TAM Pulse (+)

9 —

10 Sedimenter

11 Front Fog

12 —

13 —

14 —

15 Glow

16 Battery

17 Vehicle Speed Sensor

18 —

19 —

20 Ground


1 Battery

2 —

3 Ground



1. Meter Cluster

2. Meter AssemblyRemove the five screws.

Disconnect the meter connectors.


SpeedometerThe speedometer is made up of the cross coil type am-meter (movement) that displays indications, the steppermotor that drives and adds up the odometer and tripmeter, and the driving circuit (printed circuit board) thatmakes exchanges between the pulse signals and thecurrent.

N8A0325E

N8A0326E

N8A0327E

TRIPODO

AB

km/h

0

20

4060

80 100120

140

160

N8A0328E


On-vehicle ServiceCheck the meter display accuracy and the operation ofthe odometer with the speedometer tester.

Notice:Inappropriate tire inflation may affect the accuracy of theodometer.(To conduct this test, refer to the tester manufacturer'sinstruction manual.)Since the meter display permissible levels above arespecifications solely for the meter, they are to be usedas reference values when conducting on-vehicle ser-vice.

Except 4HK1-TC

For 4HK1-TC (General Export)

For 4HK1-TC (Europe)

Individual InspectionRemove the speedometer from the meter assembly andmeasure the resistance and the current consumptionbetween each terminals.Replace the speedometer when the result of inspectionis found abnormal.


Tester display speed Meter display permissible level

20 km/h 17.5 — 22.5 km/h

40 37.5 — 42.5

60 57.5 — 62.5

80 77.5 — 82.5

100 97.6 — 103.4

120 117.6 — 123.4

140 137.6 — 143.4


20 MPH 18.3 — 21.7 MPH

40 38.3 — 41.7

60 58.3 — 61.7

80 77.8 — 82.8

TRIPODO

AB

MPH

0

10

20

3040 50 60

7080

90

100

N8A0330E


40 km/h 37 — 41 km/h

60 58 — 62

80 77.5 — 82.5

100 97.5 — 103

120 117 — 122.5

140 137.5 — 143


20 km/h 20 — 22.5 km/h

40 40 — 42.5

60 60 — 63.2

80 79.7 — 83.4

Terminal symbol Resistance value

IGN — GND 58±20 kΩ

SEN — GND 70±20 kΩ

4P — GND ∞

IGN

GND

SENSOR B4 Pulse output

N8A0332E


• Except 4HK1-TC1. Meter Assembly

Refer to “METER ASSEMBLY” in this section.2. Meter Glass

Remove it by pushing the catches with your finger.3. Speedometer

Remove four screws securing the meter at theback side.

• For 4HK1-TC1. Remove the meter assembly/speedometer (1).

Notice:Speedometer cannot be removed as a single unit sinceit is integrated into the meter assembly.

• Refer to “Meter Assembly” in this section.2. Remove the meter plate (2) and meter glass (3).

• Remove the two installing screws on the metersurface.

• Remove the meter plate by pushing the catch-es with your finger.


TachometerThe tachometer is made up of the cross coil type amme-ter (movement) that displays indications, and the drivecircuit (printed board) that makes exchange betweenthe pulse signals and the current.

On-vehicle Service Inspection1. Set up the tune-up tester to the engine.2. Start the engine and compare the readings dis-

played by the tachometer and the tester.When the difference between these two readingsdiffers largely from the specified value, replace itwith a correct one.

Notice:Since the meter display permissible levels above arespecifications solely for the meter, they are to be usedas reference values when conducting on-vehicle inspec-tion.

N8A0333E

N8A0485E

N8A0334E


Except 4HK1-TC

For 4HK1-TC

Individual InspectionRemove the tachometer from the meter assembly andmeasure the resistance value and the current consump-tion between each terminals.Replace the tachometer when the result of inspection isfound abnormal.

1. Resistance valueUse the analog type circuit tester. (Range: 1K)For 12 Volt tachometer

For 24 Volt tachometer

2. Current valueUse the analog type circuit tester.Since the current consumption fluctuates as the powervoltage varies, check to be sure that the voltage appliedis 12±1 V or 24±1 V.




Remove it by pushing the catches with your finger.3. Tachometer

Remove three screws securing the meter at theback side.


500 400 — 500

1000 800 — 1050

2000 1800 — 2050

3000 2800 — 3050

4000 3800 — 4050


750 700 — 800

2000 1900 — 2150

3000 2950 — 3200

4000 3950 — 4200

N8A0336E

Terminalsymbol

Tester terminal

Red (+)

Black (−)

Black (−)

Red (+)

IGN — GNDIGN GND IGN GND

∞ 30±5 kΩ

PIN — GNDPIN GND PIN GND

33±5 kΩ 500 — 1000 kΩ

Terminalsymbol

Tester terminal

Red (+)

Black (−)

Black (−)

Red (+)

IGN — GNDIGN GND IGN GND

∞ 30±5 kΩ

PIN — GNDPIN GND PIN GND

33±5 kΩ 500 — 1000 kΩ

Voltage Connecting terminal

Current consumption Remarks

12Volt

IGN — GND

12±1 V(when 12±1 V

applied)

No signal input

24Volt 24±1 V

(when 24±1 V applied)

No signal input


• For 4HK1-TC1. Remove the meter assembly/tachometer (1).

Notice:Tachometer cannot be removed as a single unit since itis integrated into the meter assembly.

• Refer to “Meter Assembly” in this section.

2. Remove the meter plate (2) and meter glass (3).• Remove the two installing screws on the meter

surface.• Remove the meter plate by pushing the catch-

es with your finger.


Coolant Temperature GaugeCircuit Diagram

InspectionRemove the coolant temperature gauge from the meterassembly, and measure the resistance value betweeneach terminal.Replace the coolant temperature gauge when the resultof inspection is found abnormal.

N8A0337E

N8A0485E

+

IGN

GND

UNIT

Thermo unit

Engine coolant temperature gauge

-

N8A0338E





Remove it by pushing the catches with your finger.3. Coolant Temperature Gauge

Remove six screws securing the meter at the backside.

• For 4HK1-TC1. Remove the meter assembly (1).

Notice:Coolant temperature gauge and fuel gauge cannot beremoved as a single unit since they are integrated intothe meter assembly.

• Refer to “Meter Assembly” in this section.2. Remove the meter plate (2) and meter glass (3).

• Remove the two installing screws on the metersurface.

• Remove the meter plate by pushing the catch-es with your finger.



IG — U 169 Ω±10%

U — E 333 Ω±10%

IG — E 242 Ω±10%

N8A0339E

N8A0340E

N8A0485E


Fuel GaugeCircuit Diagram

InspectionRemove the fuel gauge from the meter assembly, andmeasure the resistance value between each terminal.Replace the meter when the result of inspection is foundabnormal.

Removal and InstallationRefer to the “COOLANT TEMPERATURE GAUGE” inthis section.

Warning LensRemovalPreparation:Disconnect the battery ground cable.

1. Meter AssemblyRefer to “METER ASSEMBLY” in this section.

2. Meter GlassRemove it by pushing the catches with your finger.

3. Meter PlateRemove it by pushing the catches with your finger.

4. Warning Lens

N8A0341E


IG — U 108.1 Ω±10%

U — E 103 Ω±10%

IG — E 211.1 Ω±10%

N8A0342E

3

2

1

4

N8A5404E



Warning Light Bulb, Indicator Light Bulb and Il-lumination Light BulbRemovalPreparation:Disconnect the battery ground cable.


2. Socket and BulbHold the bulb socket by hand and rotate it counter-clockwise to remove them from the meter body.

3. BulbPull out the bulb from the socket.


Vehicle Speed SensorThe vehicle speed sensor is installed on the rear portionof the transmission or transfer case.The number of pulses generated is four pulses per onerotation of the pinion shaft.

Inspection1. Connect a resistance of 390 Ω±5%, 2W between

connector terminal 1 and battery (+) terminaland connect the connector terminal 2 to thebattery (−) terminal.

Caution:Be extremely careful not to connect the battery (+) ter-minal to the connector 3 .

This may damage the vehicle speed sensor.

2. Rotate the shaft of the vehicle speed sensor slowlyand measure the voltage between 3 and 2

with a digital tester.The voltage, with one rotation of shaft, fluctuates fourtimes in the following range: 10 to 14V ↔ 24 or less.Replace the sensor when the result of inspection isfound abnormal.

Legend1. Meter Assembly2. Meter Glass3. Meter Plate4. Warning Lens

N8A0344E

N8A0345E

J-32

J-32

J-32

J-32

J-32



1. Vehicle Speed SensorDisconnect the connector.

Installation1. Tighten the vehicle speed sensor to the specified

torque.

Tighten:Vehicle speed sensor to 25 N⋅m (2.5 kg⋅m/18 lb⋅ft)

Caution:Tightening must be made at the hexagonal part of thesensor.

To tighten the connector itself would cause damage.

Thermo UnitInspectionThe thermo unit is thermistor type and must be inspect-ed under the conditions as shown below.

1. Put the deviation of the galvanometer to 0 by usingthe variable resistor, switch the thermo unit off andthen measure the resistance of the resistor throughthe bridge.Confirm that the resistance is continuously variablein any other points than those shown below.

2. Dip the thermo unit into 80 — 90°C (176 — 194°F)water and confirm that there is no bubble continu-ously coming out of inside of the unit.Replace the unit when the result of inspection isfound abnormal.

N8A0346E

Parkingbrake drum

Connector

1

N8A0347E

Check conditionTemperature

50°C(112°F)

115°C(239°F)

7 V 55 Ω Gauge Resis-

tance value(Ω)

+33.6−33.6226.0

+1.71−2.2126.4

7 V 25 Ω Gauge —

+2.68−3.6824.3

N8A0348E


Oil Pressure SwitchInspectionCheck the continuity between the switch terminal andthe body ground with the starter switch is OFF position.Replace the switch when the result of inspection isfound abnormal.

Circuit Inspection1. Start the engine.2. When disconnecting the oil pressure switch con-

nector then connecting the harness side connectorto the ground, check to see if the oil pressure warn-ing light lights up. When the light will not light up,check the circuit between the meter and the oilpressure switch, and repair an open circuit if nec-essary.

Fuel Tank UnitThe tank unit varies the internal resistance according tothe float position (fluid level) to operate the fuel meterneedle. Also available is the build-in switch type to warnthe driver of low fuel level (about 5 liters left in the tank)by illuminating the fuel warning light.

Inspection(Level Switch type of warn low fuel level)

1. Check the resistance between the connector termi-nals 1 and 3 while shifting the floatfrom “E” to “F” point.

2. Check if the low fuel warning switch turns on andoff at the specified positions. If found defective, re-place the fuel tank unit.

N8A5410E

N8A5411E

N8A5412E

J-28 J-28


(Float type of warn low fuel level)1. Check the resistance between the connector termi-

nals 1 and 3 while shifting the floatfrom “E” to “F” point.

2. Check if the low fuel warning light turns on whenthe float is at “E” position. If found defective replacethe fuel tank unit.

N8A0352E

Float position Resistance value (Ω)

F 3±2.1

1/2 32.5±4.8

E 110±7.7

N8A0331E

J-28 J-28



1. Fuel Tank Unit1) Disconnect the connector.

2) Remove five screws.


Engine Speed SensorInspectionMeasure the resistance value between the enginespeed sensor connector terminals.Replace the engine speed sensor when the result ofinspection is found abnormal.4J Series engine = 1.36 — 1.86 KΩ4H Series engine = 0.57 — 0.86 KΩ

N8A0353E

Float position Resistance value (Ω)

F 3±2.1

1/2 32.5±4.8

E 110±7.7

N8A0331E

N8A0354E



1. Engine Speed Sensor1) Disconnect the connector.2) Remove the engine speed sensor.


Vacuum SwitchInspectionWhen the pressure value is below 250±30 mm Hg(33.3±4.0 kPa), check to see if there is continuity be-tween the terminal and the ground. If no continuity, re-place the switch with a normal one.


1. Vacuum Switch1) Disconnect the connector.2) Remove the vacuum switch.

InstallationApply liquid gasket to the screw portion of the switch toprevent vacuum leak.

Vacuum Warning BuzzerInspectionApply battery voltage to the buzzer connector terminalsto check the buzzer sound.Replace the buzzer when the result of inspection isfound abnormal.RemovalPreparation:Disconnect the battery ground cable.


2. Vacuum Warning Buzzer1) Disconnect the connector.2) Remove the buzzer fixing screw.

N8A0355E

N8A0356E

N8A0357E



Water Sedimenter SwitchInspection

1. When the float in the water sedimenter is above thedrain warning level, confirm if there is continuity be-tween the switch connector terminals.

2. Turn the starter switch on, disconnect the watersedimenter connector and connect the harnessside connector terminals. Then confirm that thesedimenter warning light turns on.If found defective, replace the switch or repair apoor connection or an open circuit between theconnector terminals.

Brake Fluid SwitchInspection

1. Confirm there is continuity between the switch con-nector terminals when the brake fluid in the tank isbetween 60 — 75 cc level.

2. Turn the switch on, disconnect the brake fluidswitch connector and connect the harness sideconnector terminals. Then confirm that brakewarning light turns on.If found defective, replace the tank, or repair a poorconnection or an open circuit between the connec-tor terminals.


1. Instrument Panel AssemblyRefer to “INSTRUMENT PANEL” of section 2.

2. Brake Fluid Tank (Brake Fluid Switch)1) Disconnect the switch connector.2) Remove four fixing nuts.3) Drain brake fluid in the tank.4) Disconnect the tubes.

Caution:Be very careful not to allow the brake fluid to come incontact with painted surfaces or resin parts surfaces.

Legend1. Meter Assembly2. Vacuum Warning Buzzer

1

2

N8A0358E

N8A0359E

N8A0360E



1. Bleed the air from brake and clutch fluid pipe line.2. Check to see if the brake fluid level in the tank with-

in specified level.3. Check to see if brake warning light comes on when

starter switch is turned on and then warning lightgoes off after the engine running.

Parking Brake Indicator LightThe parking brake indicator light is connected in serieswith the parking brake switch installed to the parkingbrake lever bracket.The light comes on when the parking brake lever ispulled, and goes out when the parking brake lever is ful-ly released.

Notice:The parking brake indicator light illuminates to warn thedriver that the parking brake is on. This light does not in-dicate the condition of the operability of the parkingbrake.Circuit Inspection

1. Disconnect the parking brake switch connector.2. Connect the harness side connector terminal to the

ground.3. Check to see if the indicator light comes on with the

starter switch “ON”.Check the bulb or the harness when the result ofinspection is found abnormal.

Parking Brake SwitchInspection

1. Disconnect the parking brake switch connector.2. Check to see if there is any continuity between the

switch terminal and the body ground with the circuittester connected between them.

Repair the parking brake switch or replace it when theresult of inspection is found abnormal.


1. Parking Brake Switch1) Disconnect the connector.2) Remove the fixing screw.

N8A0361E

When parking brake applied Continuity

When parking brake released No continuity

N8A0362E

N8A0363E



Heater and Air ConditioningGeneral DescriptionThe air conditioning consists of compressor, evaporator,condenser, A/C switch, fan switch, etc. When the engineis rotating, the A/C starts to work with both the A/C andfan switches “ON”, followed by the engagement of themagnetic clutch. It stops to work when either the fanswitch or the A/C switch turns “OFF”. In addition to theswitches, the A/C has the function of temporary stop ofits operation by the sensing system in the A/C cycle,such as:

• sensing abnormal rise of the refrigerant pressureby means of the pressure switch.

• sensing temperature of the blowing-off air bymeans of the thermo switch preventing the evapo-rator from freezing.

• sensing the coolant temperature by the thermoswitch (available for limited models only).

N8A0364E



X-1

0

X-1

2<

4JB

1, 4

JH1,

4JG

2>

FL-

1, F

L-25

FU

SIB

LE L

INK

X-2

4 A

/C C

OM

PR

ES

SO

R R

ELA

YX

-26

A/C

SIG

NA

L R

ELA

Y

<4H

G1>

(55)

H-5

, H-6

,H

-8

B-3

39 A

/C O

NS

IGN

AL

RE

SIS

TO

R

RE

LAY

BO

X A

SM

(N

o.2)

B-2

34 E

CM

N8A0532E


For 24 Volt

X-1

0

X-1

2

<4H

F1

/ 4H

G1

/ 4H

E1

/ 4H

K1>

J-19

1 E

CM

H-1

4, H

-105

(4H

K1)

FU

SE

BO

X A

SM

F-1

F-2

6 F

US

EF

L-1

FU

SIB

LE L

INK

J-23

DIO

DE

X-2

7 C

ON

DE

NS

ER

FA

NR

ELA

Y

N8A0533E


Circuit DiagramFor 12 Volt - Except 4JH1

X-1

2

X-1

2

X-1

2

X-1

2

B-1

4

B-1

4

B-3

9B

-39

B-3

9

B-1

7

B-1

7

B-1

5B

-15

X-1

0

X-1

0

X-1

0

X-1

0

J-6

J-6

H-5

B-4

2

B-1

3

B-1

3

B-1

3

B-4

2

B-4

2

B-4

2

B-4

2

H-6

B-1

5

J-57

J-58

B-1

B-7

J-9

221

5 4

15

24

2

4 3

12

3

31 2

3 6 5 4

2

4

B-1

31 2 3

2 1

1 1

1

30B

/R8B

2L8W

0.5W

/R

3L0.

5BR

0.5B

2L/B

0.5BR

1.25LG/B

0.5L

G

1.25

L

0.85

G/W

0.85

G/W

0.85

G/O

0.85

G/O

0.5G/O

0.5G/Y0.

5G/Y

2L/B

2L/B 1.

25L/

O

0.85

L/Y

0.5L

/W

B-4

21

0.5P/G

2L

0.5B

2B

2B

3B3B

5B

1.25B

8W/B

3W/B

P-1

P-2

P-5

FR

AM

E

FL-

1 1

00A

RE

LAY

;H

EA

TE

R &

A/C

RE

LAY

; CH

AR

GE

(5)

FL-

2530

A

F-1

10

A

BLO

WE

RM

OT

OR

DIO

DE

PR

ES

SU

RE

SW

ITC

H

4 1

3 2

OF

F

FA

N S

WIT

CH

BLO

WE

R R

ES

IST

OR

ELECTRONIC THERMOSTAT

A/C

SW

ITC

HM

AG

NE

TIC

CLU

TC

H(C

OM

PR

ES

SO

R)

RE

LAY

;A

/C T

HE

RM

O

HE

AD

LIG

HT

BR

AC

KE

T (

LH)

FR

AM

E-L

H (

FR

ON

T)M

AIN

AIR

CO

N

HE

AT

ER

FR

AM

E-L

H (

CE

NT

ER

)

E-5

10.85G/O

VSV FICD

2

4JB1 / 4HG1 ENGINE ONLY

N8A0518E


For 12 Volt - 4JH1 Engine

X-1

2

X-1

2

X-1

2

X-1

2

B-1

4

B-1

4

B-3

9B

-39

B-3

9

B-1

7

B-1

7

B-1

5B

-15

X-1

0

X-1

0

X-1

0

X-1

0

B-4

2

B-1

3

B-1

3

B-1

3

B-4

2

B-4

2

B-4

2

B-4

2

H-6

B-1

5

B-1

B-7

J-9

2

215 4

15

24

2 1

12

3

31 2

3 6 5 4

2

4

B-1

31 2 3

2 1

30B

/R8B

2L8W

/B

0.5W

/R

3L0.

85B

R

0.5B

2L/B

0.85BR

1.25LG/B

0.5L

G

1.25

L

0.85

G/W 0.5G/Y

0.5G

/Y

2L/B

2L/B 1.

25L/

O

0.85

L/Y

0.5L

/W

B-4

21

0.5P/G

2L2B

0.85

B0.

5B

2B

5B3B

2B

8W/B

3W/B

P-1

P-2

P-5

FR

AM

E

FL-

1 1

00A

RE

LAY

;H

EA

TE

R &

A/C

RE

LAY

; CH

AR

GE

(5)

FL-

2530

A

F-1

10

A

BLO

WE

RM

OT

OR

DIO

DE

4 1

3 2

OF

F

FA

N S

WIT

CH

BLO

WE

R R

ES

IST

OR


A/C

SW

ITC

H

RE

LAY

;A

/C T

HE

RM

O

HE

AD

LIG

HT

BR

AC

KE

T (

LH)

FR

AM

E-L

H (

FR

ON

T)

MA

INA

IR C

ON

HE

AT

ER

FR

AM

E-L

H (

CE

NT

ER

)

J-6

J-6

H-1

4

E-5

H-5

2

1 1

12

0.85

G/W

0.85

G/O

0.85

G/Y

0.5W

/G 0.5G

/Y

PR

ES

SU

RE

SW

ITC

H

A/C

ON

SIG

NA

L R

ES

IST

OR

MA

GN

ET

ICC

LUT

CH

(CO

MP

RE

SS

OR

)EC

M

0.85G/Y

0.5G/O

0.5L/R

0.5W/G

0.5G/Y

0.5G/Y

0.5B

B-3

391

2B

-339

X-2

6

X-2

6

X-2

6

X-2

6

12

53

X-2

4

X-2

4

X-2

4

X-2

4

12

53

B-2

34B

-23433

41

H-8

H-816

15

RE

LAY

;G

LOW

(4)

RE

LAY

;A

/C S

IGN

AL

RE

LAY

;A

/C C

OM

PR

ES

SO

R

P-3

P-4

N8A0514E


For 12 Volt - 4JH1 Engine For Taiwan

X-1

2

X-1

2

X-1

2

X-1

2

B-1

4

B-1

4

B-3

9B

-39

B-3

9

B-1

7

B-1

7

B-1

5B

-15

X-1

0

X-1

0

X-1

0

X-1

0

J-6

J-6

H-1

4

E-5

H-5

B-1

3

B-1

3B

-42

B-1

3

B-1

3

B-1

3

B-4

2

B-4

2

B-4

2

B-4

2

H-6

B-1

5

B-1

B-7

J-9

21 2

5 4

15

24

2

2 1

12

3

31 2

3 6 5 4

2 1

3 6 4 1

22 1

1 1

12

30B

/R

8B

2L

8W/B

0.85

W/R

3L0.

85B

R

0.5B

2L/B

0.85BR

1.25LG/B

0.5L

G

1.25

L

0.85

G/W

0.85

G/W

0.85

G/O

0.85

G/Y

2B

0.5G/Y

0.5G

/Y

2L/R

1.25

L/O

0.85

L/Y

0.5L

/W

0.5P/G

2L

2B 2B

0.85

B0.

5B

5B3B

2B

5W3W

FL-

1 1

00A

RE

LAY

;H

EA

TE

R &

A/C

RE

LAY

; CH

AR

GE

(5)

F-2

5 3

0A

F-1

10

A

BLO

WE

RM

OT

OR

DIO

DE

PR

ES

SU

RE

SW

ITC

H

4 1

3 2

OF

F

FA

N S

WIT

CH

A/C

ON

SIG

NA

L R

ES

IST

OR

BLO

WE

R R

ES

IST

OR


A/C

SW

ITC

HM

AG

NE

TIC

CLU

TC

H(C

OM

PR

ES

SO

R)

EC

M

RE

LAY

;A

/C T

HE

RM

O

HE

AD

LIG

HT

BR

AC

KE

T (

LH)

FR

AM

E-L

H (

FR

ON

T)

MA

INA

IR C

ON

HE

AT

ER

FR

AM

E-L

H (

CE

NT

ER

)

0.85G/Y

0.5W/G

0.5G/O

0.5W/G

0.5G/Y0.5G/Y

0.5G/Y

0.5B

B-4

2

B-3

391

2B

-339

X-2

6

X-2

6

X-2

6

X-2

6

12

53

X-2

4

X-2

4

X-2

4

X-2

4

12

53

B-2

34B

-23433

41

H-8

H-816

15

RE

LAY

;G

LOW

(4)

RE

LAY

;A

/C S

IGN

AL

RE

LAY

;A

/C C

OM

PR

ES

SO

R

P-1

P-2

P-5

FR

AM

E

P-3

P-4

N8A0517E


For 24 Volt - Except 4HK1 Engine

J-6

J-6

B-1

3

B-1

3

B-1

3

B-4

2

B-4

2

B-4

2

B-4

2

B-4

2

B-7

B-1

J-9

B-3

9B

-39

B-3

9

B-1

5B

-15

B-1

5

X-1

0

X-1

0

X-1

0

X-1

0

H-5

B-1

7

B-1

7

H-6

B-1

4

B-1

4

B-1

3

OF

F

X-1

2

X-1

2

X-1

2

X-1

2

J-41

J-41

E-5

P-5

P-4

P-3

P-2

P-1

2

1 2

5 4

1 21

2

3

34

1 2

5 4

1 4 2 3

3 6 5 4

2

31 2

21

2

9

H-1

4

J-23

2

3

J-23

J-23

4

1 2

1

30B

/R8B

8W/B

2L

8W/B 3W/B5W/B 0.5W/R

3L

0.85L

0.85

BR

0.85BR

0.85L/B

0.5B 0.85B

2BB

-42

1

0.5G

/Y

0.5G/Y 0.5G/Y

0.5LG

0.5L

G

0.5P/G0.85

G/W

0.85

G/W

0.85

G/O

0.5G

/O

0.85G/O

0.85

BR

3B

5B

FR

AM

E

FL-

1 1

00A

or

120A

F-1

15

A

RE

LAY

; A

/C T

HE

RM

O

VS

VF

ICD

MA

GN

ET

IC

CLU

TC

H

ELE

CT

RO

NIC

TH

ER

MO

ST

AT

4

3 2

1

FA

N S

WIT

CH

BLO

WE

R R

ES

IST

OR

A/C

SW

ITC

H

RE

LAY

;H

EA

TE

R &

A/C

RE

LAY

; CH

AR

GE

(5)

FR

AM

E-L

H (

FR

ON

T)

HE

AD

LIG

HT

BR

AC

KE

T (

LH)

PR

ES

SU

RE

SW

ITC

H

0.5LG/B

MA

INA

IR C

ON

, HE

AT

ER BLOWER MOTOR

DIODE

FR

AM

E-L

H (

CE

NT

ER

)

0.85G/O

0.5B

2B

0.85

L/B

0.5L

/O

0.5L

/Y

0.5L

/W

0.85

B

DIODE

ECM

(WITHOUT 4HE1 ENGINE)

(4HE1 ENGINE ONLY)

N8A0515E


For 24 Volt - 4HK1 Engine

J-6

J-6

J-6

J-6

B-1

3

B-1

3

B-1

3

B-4

2

B-4

2

B-4

2

B-4

2

B-4

2

B-7

B-1

J-9

B-3

9B

-39

B-3

9

B-1

5B

-15

B-1

5

X-1

0

X-1

0

X-1

0

X-1

0

H-5

B-1

7

B-1

7

H-6

B-1

4

B-1

4

B-1

3

OF

F

X-1

2

X-1

2

X-1

2

X-1

2

E-5

P-5

P-4

P-3

P-2

P-1

2

1 2

5 4

1 21

2

3

34

1 2

5 44

3

1 4 2 3

3 6 5 4

2

31 2

21

J-19

134

2

9

H-1

05 1

30B

/R8B

8W/B

2L

5W/B 3W/B5W/B 0.5W/R

3L

0.85L

0.85

BR

0.85BR

0.85L/B

0.5B 0.85B

2BB

-42

1

0.5G

/Y

0.5G/Y 0.5G/Y

0.5LG

0.5L

G

0.5P/G

0.85B

2B

0.85

G/W

0.85

G/W

0.85

L

0.5B

2B/L

0.85

G/O

0.5G

/O

0.75G/O

0.85

BR

3B

5B

FR

AM

E

FL-

1 1

00A

or

120A

F-1

15

A

RE

LAY

; A

/C T

HE

RM

O

MA

GN

ET

IC

CLU

TC

H

ELE

CT

RO

NIC

TH

ER

MO

ST

AT

4

3 2

1

FA

N S

WIT

CH

BLO

WE

R R

ES

IST

OR

A/C

SW

ITC

H

RE

LAY

;H

EA

TE

R &

A/C

RE

LAY

; CH

AR

GE

(5)

FR

AM

E-L

H (

FR

ON

T)

HE

AD

LIG

HT

BR

AC

KE

T (

LH)

PR

ES

SU

RE

SW

ITC

H

RE

LAY

;C

ON

DE

NS

ER

FA

N

RE

LAY

;G

LOW

(3)

CO

ND

EN

SE

RF

AN

EC

M

0.5LG/B

MA

INA

IR C

ON

, HE

AT

ER BLOWER MOTOR

DIODEF

RA

ME

-LH

(C

EN

TE

R)

0.85G/O

0.5G/Y 0.85L/Y

2B

0.85

L/B

0.5L

/O

0.5L

/Y

0.5L

/W

0.85

B

X-2

7

X-2

7

X-2

7

X-2

75

1

23

21

F-2

6 1

5AC

ON

D. F

AN

N8A0519E


Connector ListFor 12 Volt

No. Connector Face

B-1

B-7

B-13

B-13 (For Tai-wan)

B-14

B-17

B-234

B-339

000-001

000-012

004-010

23 41

006-010

1 2 34 5 6

002-009

1

2

004-004

1 2 3 4

121-001

5 417

55

74

18

56

75

19

57

76

20

58

77

21

59

78

22

60

79

23

61

80

24

62

81

9

47

66

10

48

67

11

49

68

6

44

63

7

45

64

8

46

65

12

50

69

13

51

70

14

52

71

15

53

72

16

36 37 38 39 40 41 42 4328 29 3025 26 27 31 32 33 34 35

54

732 1

3

004-010

23 41

B-15

X-12

X-10

X-24

X-26

B-39

B-42

E-5

No. Connector Face

003-009

1 2 3

005-001

1

32 4

5

005-001

1

32 4

5

005-006

005-006

003-019

2 3

1

006-001

1 2 3

4 5 6

001-013

1


H-5

E-5

J-6

J-9

J-57

J-58

P-1

P-2

P-4

No. Connector Face

001-014

1

004-011

1

3

2

4

000-001

001-009

1

001-009

1

000-003

000-004

000-004

P-3

P-5

H-14

H-14

No. Connector Face

000-006

000-007

016-001

1 2 3 4

5 6 7 8

9 10 11 12

13 14 15 16

016-002

4 3 2 1

8 7 6 5

12 11 10 9

16 15 14 13

1 2 37 8 9

13 14 1519 20 2125 26 2731 32 33 34 35 36 37

4 5 610 11 1216 17 1822 23 2428 29 3038 39 40

6 5 412 11 1018 17 1624 23 2230 29 2840 39 38

3 2 19 8 7

15 14 1321 20 1927 26 2533 32 3134353637

N8A5488E


H-6

For 24 Volt

No. Connector Face

B-1

B-7

B-13

B-14

B-17

1 2

1 2

1 2 3 4

5 6 7 8

9 10 11 12 13

14 15 16 17 18

2 1

2 1

4 3 2 1

8 7 6 5

13 12 11 10 9

18 17 16 15 14

H - 6

H - 7

H - 8

N8A5489E

000-001

000-012

004-010

23 41

002-009

1

2

004-004

1 2 3 4

J-23

J-191

B-15

X-12

X-10

X-27

B-39

B-42

No. Connector Face

004-004

1 2 3 4

003-009

1 2 3

005-001

1

32 4

5

005-001

1

32 4

5

005-006

003-019

2 3

1

006-001

1 2 3

4 5 6


E-5

E-5

H-14

H-14

H-105

H-105

J-6

J-9

No. Connector Face

001-013

1

001-014

1

016-003

1 2 3 4

5 6 7 8 9

11 12 13 14

15 16

10

016-004

4 3 2 1

9 8 7 6 5

13 12 11 10

16 15

14

012-001

1 2 3 4

5 6 7 8

9 10 11 12

012-002

4

8

12

3

7

11

2

6

10

1

5

9

004-011

1

3

2

4

000-001

J-41

P-1

P-4

P-2

P-3

P-5

J-23

No. Connector Face

002-015

1 2

000-004

000-004

000-006

000-006

000-002

001-009

1


H-5

H-6

Fuel Heater and Rear Heater

General DescriptionThe circuit consists of fuel heater, rear heater, rear heat-er switch and the exhaust brake relay.The fuel heater circuit is always in “ON” position whenthe generator is charging and its temperature is auto-matically controlled by the circuit breaker built in the fuelheater.

1 2 37 8 9

13 14 1519 20 2125 26 2731 32 33 34 35 36 37

4 5 610 11 1216 17 1822 23 2428 29 3038 39 40

6 5 412 11 1018 17 1624 23 2230 29 2840 39 38

3 2 19 8 715 14 1321 20 1927 26 2533 32 3134353637

N8A5488E

1 2

1 2

1 2 3 4

5 6 7 8

9 10 11 12 13

14 15 16 17 18

2 1

2 1

4 3 2 1

8 7 6 5

13 12 11 10 9

18 17 16 15 14

H - 6

H - 7

H - 8

N8A5489E


Parts Location

F-2,

F-3

X-1

3 H

EA

TE

R R

ELA

Y (

12V

, 4JH

1)R

ELA

Y B

OX

AS

M (

No

.1)

X-8

EX

HA

US

T B

RA

KE

RE

LAY

(4JB

1 / 4

HF1

/ 4H

G1

4HE

1 E

NG

INE

)

N8A0369E


Circuit DiagramExcept 4JH1 Engine

2L

B-7

H-25

H-3

B-59

B-59

N-8

N-8

1J-52

B-1

J-9

H-6 X-8H-5

P-1

P-2

P-5

2

X-8

1

2 X-8

X-8

4

5 6

J-522

N-8

H-25

32

H-3

52

B-59

41

2

FRAME

30B

/R8B

FL-1 100A

MAIN8W 5W 8W/B 3W/B

RE

LAY

; CH

AR

GE

(5)

0.85W/R

RELAY; EXHAUSTBRAKE

3B/R

F-2 15AEXH. BRAKE,FUEL HEATER

F-3 15AREAR HEATER

0.5B/R

0.5B

/R

0.5B

FUEL HEATER

0.5B

/RREAR HEATER

0.5B

0.85

L/R

0.5L

/R

0.5L

/W0.

85L/

W

H ILO

OFF

REAR HEATER SW

3B

5B

0.5B

2B

0.85

L/R

0.85

L/W

0.85

B/R

12

3

0.5W/R

H-25

H-3

0.5B

/R

1

6

2B

3B


FRAME-LH(FRONT)

FRAME-LH (CENTER)

N8A0370E


4JH1 Engine

2L

B-7

H-25

H-3

B-59

B-59

N-8

N-8

1J-52

B-1

J-9

H-6 X-13H-5

P-1

P-2

P-5

2

X-13

1

2 X-13

X-13

4

5 6

J-522

N-8

H-25

32

H-3

52

B-59

41

2

FRAME

30B

/R8B

FL-1 100AMAIN

8W 5W 8W/B 3W/B

RE

LAY

; CH

AR

GE

(5)

0.85W/R

RELAY; HEATER

2B/R

F-2 15AFUEL HEATER

F-3 15AREAR HEATER

0.5B/R

0.5B

/R

0.3B FUEL HEATER

0.5B

/R

REAR HEATER

0.5B

0.85

L/R

0.5L

/R

0.5L

/W0.

85L/

W

H ILO

OFF

REAR HEATER SW

3B

5B

0.5B

2B

0.85

L/R

0.85

L/W

0.85

B/R

12

3

0.5W/R

H-25

H-3

0.5B

/R

1

6

2B

3B

P-3

P-4


FRAME-LH(FRONT)

FRAME-LH (CENTER)

N8A0396E


Connector List

No. Connector Face

X-8

X-13

B-59

H-3

H-3

H-25

H-25

J-52

005-006

005-006

004-015

1 2

3 4

006-014

1 2 3

4 5 6

006-015

123

456

003-020

2 3

1

003-021

1

3 2

002-033

1 2

J-52

N-8

N-8

P-1(12 V)

P-2

P-1(24 V)

P-4

P-2(24 V)

No. Connector Face

002-034

2 1

003-022

1 2 3

003-023

23 1

000-003

000-004

000-004

000-004

000-006


H-5

H-6

Fuel Heater

P-3

P-5(12 V)

P-5(24 V)

No. Connector Face

000-006

000-007

000-002

1 2 37 8 9

13 14 1519 20 2125 26 2731 32 33 34 35 36 37

4 5 610 11 1216 17 1822 23 2428 29 3038 39 40

6 5 412 11 1018 17 1624 23 2230 29 2840 39 38

3 2 19 8 715 14 1321 20 1927 26 2533 32 3134353637

N8A5488E

1 2

1 2

1 2 3 4

5 6 7 8

9 10 11 12 13

14 15 16 17 18

2 1

2 1

4 3 2 1

8 7 6 5

13 12 11 10 9

18 17 16 15 14

H - 6

H - 7

H - 8

N8A5489E

N8A0371E


Characteristic of fuel heater

Rear Heater SwitchInspectionCheck the continuity between the connector terminalswhile operating the switch.Replace the switch when the result of inspection isfound abnormal.

Rear Heater MotorInspectionDisconnect the rear heater connector.Connect the battery positive terminal to the NO.3 termi-nal of the rear heater motor side connector and negativeto the NO.2. Check to see if rear heater motor operateslow-speed correctly.Connect the battery positive terminal to the NO.3 termi-nal of the rear heater motor side connector and negativeto the NO.1. Check to see if rear heater motor operateshigh-speed correctly.Replace the rear heater motor when the result of inspec-tion is found abnormal.

4WD Transfer (Vacuum Control)

General DescriptionThe circuit consists of the starter switch, 4WD switch,4WD detect switch, 4L switch, vacuum switching valve,4WD indicator light, neutral switch and the relay.When the 4WD switch is turned on to drive in the 4WDmode, the vacuum switching valve for the transfer con-trol is activated through the 4WD relay, and the transfershift rod connected to the vacuum actuator is shifted tothe 4WD side to turn on the 4WD detect switch. At thesame time, the indicator light in the meter lights on to tellthat the mode is transferred to 4WD mode.However, when running in the normal mode (2WD), the4WD switch is not operated. Accordingly, no currentflows through the 4WD vacuum switching valve for thetransfer control, with the 4WD detect switch left in the“OFF” condition (2WD mode).

N8A5440E

N8A5438E

N8A5439E


Parts Location

H-5

~H

-8FU

SE

BO

X A

SM

F-1

6

ST

AR

TE

R S

W

J-9

RE

LAY

BO

X A

SM

X-2

4 4W

D R

ELA

YF

L-1,

FL-

2 F

US

IBLE

LIN

K

RE

LAY

BO

X A

SM

(N

o.2)

RE

LAY

BO

X A

SM

(N

o.1) B-7

B-6

7

B-5

1

B-9

3 4W

D S

WJ-42

J-43

, J-4

4 4W

D D

ET

EC

T S

W

ST

AR

TE

R

N8A0398E


Circuit Diagram

X-24

X-24

J-44

J-43

H-8

J-42

J-42

B-93

B-93

B-93

J-42

J-42

B-93

B-93

X-24

X-24

H-8H-8

OFF

ON

ACC

ST

B

B-67B-67

B-7

J-9

P-1

P-2

P-3

P-4

P-5

23

5 8

6 7 3

9

1

15

2

3 4

1

1

4 5

2

10

2WD

4WD

FRAME

FL-1 100AMAIN2L

FL-2 40A

STARTER SWITCH

3W/B 3W/L

3B/Y

KEY SW

FUSE BLOCK

F-16 10AMETER

RELAY; TAIL (5)

0.5L

G/R

0.5B

/Y

0.5B/Y

0.5B

/Y

0.5B

/Y

4WD SWITCH

0.5G

R/B

0.5GR/R

0.3G

R/G

4WD

IND

ICA

TO

R L

IGH

T(M

ET

ER

)

0.5G

R/G

0.5B

/Y

RE

LAY

; 4W

D

0.5B/R

0.85

B/R

0.5G

R/R

0.85

B

VS

V:1

TR

AN

SF

ER

C

ON

TR

OL

(2W

D)

VS

V:2

TR

AN

SF

ER

CO

NT

RO

L (4

WD

)

4WD

DE

TE

CT

IVE

SW

ITC

H 2

WD

=O

N 4

WD

=O

FF

(

)

0.85

B

2B2B2B

3B3B

0.5B

0.3B


FRAME-LH (CENTER)

H-71

B-51

B-51

8

22

9

0.5G

R/B

H-5

3

N8A0427E


Connector List

No. Connector Face

B-51

B-67

B-67

B-93

X-24

J-42

J-42

J-43

014-001

1 2 3 4 5 6 7 8 9 1011121314

004-001

1 23 4

004-002

2

4

1

3

008-005

1 2 3 4

5 6 7 8

005-006

004-012

1 2

3 4

004-013

12

34

001-002

1

J-43

J-44

J-44

P-1

P-4

P-2

P-3

P-5

No. Connector Face

001-003

1

001-002

1

001-003

1

000-004

000-004

000-006

000-006

000-002


H-5

H-7


Neutral SwitchRefer to “START AND CHARGING” in this section.

4WD Indicator LightRefer to “METER AND WARNING/INDICATOR LIGHT”in this section.

4WD SwitchInspectionCheck the continuity between the connector terminalswhile operating the switch.Replace the switch when the result of inspection isfound abnormal.

Vacuum Switching Valve: Transfer Control (for2WD)InspectionConnect the vacuum switching valve connector terminalNo. 1 to the battery (+) terminal and terminal No. 3 to the(−) terminal and then check the continuity among eachport.

1 2 37 8 9

13 14 1519 20 2125 26 2731 32 33 34 35 36 37

4 5 610 11 1216 17 1822 23 2428 29 3038 39 40

6 5 412 11 1018 17 1624 23 2230 29 2840 39 38

3 2 19 8 715 14 1321 20 1927 26 2533 32 3134353637

N8A5488E

1 2

1 2

1 2 3 4

5 6 7 8

9 10 11 12 13

14 15 16 17 18

2 1

2 1

4 3 2 1

8 7 6 5

13 12 11 10 9

18 17 16 15 14

H - 6

H - 7

H - 8

N8A5489E

N8A5444E

N8A5445E


Vacuum Switching Valve: Transfer Control (for4WD)InspectionConnect the vacuum switching valve connector terminalNo. 2 to the battery (+) terminal and terminal No. 4 to the(−) terminal and then check the continuity among eachport.

4WD Detective SwitchInspection of the 4WD Warning Light Circuit

1. Disconnect the 4WD switch connectors.2. Connect the harness side connector terminals.3. Check to see if the indicator light comes on with the

starter switch “ON”.Check the bulb or harness when the result of in-spection is found abnormal.

Inspection1. Shift the transfer lever to the 4H (4L) position.2. Check to see if there is continuity between the

4WD switch connectors.Replace the switch when the result of the inspec-tion is found abnormal.

N8A5446E

N8A5447E

N8A5448E


ABS (Anti-lock Brake System, Without ASR)Parts Location

H-1

6

J-74

F/R

H S

EN

SO

R

B-6

6 S

TOP

LIG

HT

SW

(BR

AK

E S

W)

B-1

EA

RT

H ;

FR

AM

E (

FR

)

B-6

7 IG

NIT

ION

SW

"A

"

B-2

33,B

-234

EC

M

FU

SE

BO

X A

SM

F-2

,F-5

,F-1

6 S

TA

RT

ER

SW

J-14

8 R

/RH

SE

NS

OR

(24

V)

J-17

7A

BS

EH

CU

B-5

2 E

XH

. BR

AK

EIN

D. L

AM

P (

ME

TE

R)

B-5

1A

BS

AR

NIN

G L

IGH

T(M

ET

ER

)

J-75

F/L

H S

EN

SO

R

B-7

9 D

AT

A L

INK

CO

NN

EC

TO

R

J-9

EA

RT

H ;

FR

AM

E

(12V

)

(24V

)

X-5

AB

S IN

DIC

AT

OR

RE

LAY

X-8

EX

HA

US

T B

RA

KE

RE

LAY

(24

V)

RE

LAY

BO

X A

SM

(N

o.1)

X-2

5 E

XH

AU

ST

BR

AK

E C

ON

TR

OL

RE

LAY

X-2

8 E

XH

AU

ST

BR

AK

E C

UT

RE

LAY

J-23

DIO

DE

FL-

1,F

L-2,

FL-

9 F

US

IBLE

LIN

K

J-31

EX

H. B

RA

KE

MA

GN

ET

IC V

ALV

E

B-7

5A

CC

EL

SW

H-1

3

P-5

P-1

~P

-4B

AT

TE

RY

H-1

7

H-1

4

H-1

5

J-14

9 R

/LH

SE

NS

OR

(24

V)

R-6

ST

OP

LIG

HT

(R

H)

R-1

ST

OP

LIG

HT

(LH

)

SE

NS

OR

(12

V)

J-78

R/R

H,R

/LH

B-7

EA

RT

H ;

HE

AD

LIG

HT

B/T

B-6

9E

XH

. BR

AK

E S

W

B-8

9 C

LUT

CH

SW

H-5

~H

-8

N8A0537E


Circuit DiagramFor 12 Volt (4JH1 Engine)

ABS60A

P-5

P-2BATTERY

P-1

B-1

B-7

0.85B

H-62

B-517

B-518

FL-9

MAIN100A

FL-1

KEY SW50A

FL-2

METER10A

F-16

8B 8W/B

3R

8W/B 3W/B

3W/B 0.5G/Y 0.5GSW ; STOP LIGHT

B

OFF

ACC

ON

ST

B-672

B-673

KEY SW

3W/L

0.5B2B3B

0.5B

/Y

0.5B/Y

0.5B/Y

STOP LIGHT10A

F-5

B-664

B-661

0.5B/Y

0.5W

X-5

4

X-5

5

X-5

1

X-5

3

3B/Y

METER

ABS

RELAY ;ABS IND.

3W/L

H-7

1

3B

3B

2B

0.3W

/V

22

H-5

J-9

P-4

P-3

FRAME-LH (CENTER)

FRAME LH (FRONT)


C

D

E

F

A

B

G

H

N8A5590E


J-784

J-783

0.5R

0.5W

0.3W/G

0.3W/B

0.3W/G

0.3W/B

0.3W/B

0.5B

0.5B

SPEEDSENSOR(RR,RH)

J-741

J-742

0.5P

0.5L

SPEEDSENSOR(FRT,RH)

J-751

J-752

0.5V

0.5R/B

0.5P

0.5L

0.5V

0.5R/B

SPEEDSENSOR(FRT,LH)

0.85B

J-17722J-177

16STOP LAMP

EHCU ; ABS

ECMB-234 (62)

RL 12V

34

J-782

J-781

24MOTOR +B

RL SIG

32

2VALVE +B

FL SIG

33

23MOTOR GND

FL GRD

10

1VALVE GND

FR SIG

11

8 EXH.B/CUTOUT

FR GRD

21

7 EXH.B/CUTIN

RR 12V

12

6IND.

RR SIG

29

IG

MODE1

MODE2

MODE3

J1850

4FRASH

VEHICLE TYPE CONNECTOR

NKR77-3 (FLAT LOW)

EXCEPT NKR77-3(EXCEPT FLAT LOW)

2B

3R

3R

3B

3B

0.5B/Y

0.3W/V 0.3W/V 0.3W/V

0.5B/Y

0.5B

/Y

0.5B

/G

0.5B

/R

0.5B

/W

1.25

B

0.5G

0.5G 0.5G0.5G

0.5G

H-511 2

(30)

ECM

H-162

STOPLIGHT(RH)

STOPLIGHT(LH)

0.5G

1.25B

1.25

B

0.5L

0.5Y

SPEEDSENSOR(RR,LH)

16 15 14 13 12 11 10 9

8 7 6 5 4 3 2 1

H-535

H-536

H-540

H-1410

H-1411

H-1412

DATA LINKCONNECTOR

B-79

0.3W

/G

H-527

H-526

3R

0.5G

0.5LG/B

0.5LG/W

0.5LG/B

0.5LG0.5LG/W

0.5LG/B

3B

3B

ECMB-234 (32)

B-234

J-177

J-177

J-177

J-177

J-177

J-177

J-177

J-177

J-177

J-177

J-177

J-177

J-177

J-177

J-177

J-177

H-14

H-1415

H-1416

H-151

H-152

H-155

H-156

H-154

H-153

H-157

H-158

3J-177

17J-177

14J-177

15J-177

H-149

H-1

74

H-1

73

H-1

71

H-1

72

H-1

7

H-1

7

H-1

7

H-1

7

H-1

7

H-1

7

H-1

7

H-1

7

R-1

2

6

R-1

7H-16

7

H-14

R-6

2

6

R-6

C

D

A

B

E

F

G

H

0.5Y

0.5LECM

35

45

B-234

B-234

N8A5591E


For 24 Volt

ABS40A

P-4

P-5

BATTERYP-3

P-2BATTERY

P-1

FRAME-LH (CENTER)

3B

2B2B2B

2B

3B

B-7HEADLIGHT BRACKET (LH) 3B

B-1FRAME-LH (FRONT) 0.85B

RELAY ;EXH.BRAKE

X-81

X-85

X-82

H-62

X-83

B-517

B-518

FL-9

MAIN100A

or120A

FL-1

EXH.BRAKE10A

F-2

KEY SW40A

FL-2

METER10A

F-16

8B 8W/B

3R

5W/B 3W/B

0.5W/R

0.5B

3W/B 0.5G/Y 0.5G

0.5LG

SW ; STOP LIGHT

B

OFF

ACC

ON

ST

B-672

B-673

KEY SW

3W/L

3W/L

3B/R 0.5LG/W

0.5L

G/W

0.5B

0.5B

0.5B

0.5B

/Y

0.5L

G/B

0.5P

0.5B

0.5B

/G

0.5L

G/R

0.5B

0.5B

0.5B 0.5B

2B

0.5L

G/B

0.5LG/B 0.5LG/R

0.5B

/Y

0.5L

G/B

RELAY;CHARGE

X-28

4

X-28

2

X-28

5

X-28

1

H-8

8

H-7

1

X-28

3

STOP LIGHT10A

F-5

B-662

B-661

SW ; NEUTRAL(Neutral=ON)

RELAY ;EXH. BRAKECONTROL

SW ; EXH.BRAKE

0.5LG/B

0.5B/Y

0.5B/Y

0.5W

X-5

4

X-5

5

X-5

1

X-5

3

E-11

2

H-145

E-11

1

X-25

3

X-25

5

H-14

10

H-5

22

3B/Y

METER

ABS

5

H-8

10

B-692

X-25

4

X-25

1

H-8

17

SW ; CLUTCH

B-892

B-891

B-5210

B-511

IND. LAMP ;EXH. BRAKE

0.5LG/R0.5LG/R

H-5

38

0.5G/O

RELAY ;ABS IND.

A/CCOMPRESSOR

0.5B/Y

0.5B/Y

RELAY ;EXH. B/CUT(ABS)

0.5B

0.5B

1.25B

0.85

B

0.3W

/V

0.5L

G/R

B-69

J-9

D

E

F

G

H

IJ

A

B

C

KLM

N8A5592E


1.25

B1.

25B

7H-16

7

H-14

SPEEDSENSOR(RR,RH)

SPEEDSENSOR(FRT,RH)

SPEEDSENSOR(FRT,LH)

SPEEDSENSOR(RR,LH)

STOPLIGHT(LH)

STOPLIGHT(RH)

0.5G

1.25B

R-1

2

6

R-1

R-6

2

6

R-6

2B

J-1481

J-1482

0.5R

0.5W

0.3Y

0.3W/G

0.3W

/G

0.3W/B

0.3W/G

0.3W/B

0.3W/B0.3L

0.5B

0.5B

J-741

J-742

0.5P

0.5L

J-751

J-752

1

2

0.5V

0.5R/B

0.5V

0.5R/B

3B

0.5B

0.5B

0.5B

1.25B

0.5LG/W

J-17722J-177

16STOP LAMP

EHCU ; ABS

RL 12V

34

J-1491

J-1492

24MOTOR +B

RL SIG

32

2VALVE +B

FL SIG

33

23MOTOR GND

FL GRD

10

1VALVE GND

FR SIG

11

8 EXH.B/CUTOUT

FR GRD

21

7 EXH.B/CUTIN

RR 12V

12

6IND.

RR SIG

29

3IG

J1850

4

15MODE1

FRASH

14MODE2

17H-5

30

H-524

3

4

MODE3

0.5L

/G0.

5L/G 0.

5LG

0.5B

0.5LG

J-23

2

H-13

2

VEHICLE TYPE CONNECTORFOR TURKEY / GCC(4-WHEEL DRUM BRAKE MODEL)

FOR OTHER COUNTRIES

SW ; ACCEL

B-751

B-752 B-234

14

B-23321

QWS

ECM

CHECKER

B-23429

B-23314

EXH.BRAKE

DIAGB-23415

H-537

FICD

0.5B/G(NQR)

3R

3R

0.5B/Y

0.3W/V 0.3W/V

0.5LG

0.5LG/B

0.5B/R(NQR)

0.5B/W(NQR)

NQR

0.5LG 0.5LG

0.5L/W

0.5L/W

0.5G

3B

0.5GH-5

11H-16

2

0.5L

0.5Y

16 15 14 13 12 11 10 9

8 7 6 5 4 3 2 1

H-13

12

J-41

2

J-41

4

J-233

J-231

DIODE ; FICD

J-31

2

J-31

1

MAG.VALVE ;EXH.BRAKE

VSV ;FICD

J-40

2

J-40

1

VSV ; INT.THROTTLE

H-13

6

H-5

32

DATA LINKCONNECTOR

B-79

0.5G

0.5LG

3R

0.5LG/B

1.25B

3B

0.5B

J-177

J-177

J-177

J-177

J-177

J-177

J-177

J-177

J-177

J-177

J-177

J-177

J-177

J-177

J-177

J-177

J-177

J-177

J-177

J-177

10H-14

2H-14

12H-14

11H-14

9H-14

15H-14

16H-14

7H-15

8H-15

H-56

H-1

7

2

H-1

7

1

H-1

7

3

H-1

7

4

H-1

7

H-1

7

H-1

7

H-1

7

H-1

7

H-1

7

H-1

7

H-1

7

H-15

H-15

H-15

H-15

5

6

0.5P

0.5L

H-15

H-15

D

E

F

G

H

IJ

A

B

C

KLM

N8A5593E


Connector List

No. Connector Face

B-1

B-7

X-5

X-8

X-25

X-28

B-51

B-52

000-001

000-012

005-006

005-006

005-006

005-006

014-001

1 2 3 4 5 6 7 8 9 1011121314

012-005

1 2 3 4 5 6 7 8 9 10 11 12

B-66

B-67

B-67

B-69

B-69

B-75

B-75

B-79

No. Connector Face

004-010

23 41

004-001

1 23 4

004-002

2

4

1

3

008-001

1

5

2

6

3

7

4

8

008-002

1

5

23

67

4

8

002-022

1 2

002-023

2 1

016-005

87654321

161514131211109


B-89

B-89

B-233(24 V)

B-234(24 V)

B-234(12 V)

E-11

E-11

H-13

No. Connector Face

002-009

1

2

002-010

1

2

022-002

9 8 7

20 19

6 5 4 3 2 1

18 17 16 15 14 1322 21 12 11

10

030-002

9 8 7 6

30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15

5 4 3 2 114 13 12 11 10

121-001

5 417

55

74

18

56

75

19

57

76

20

58

77

21

59

78

22

60

79

23

61

80

24

62

81

9

47

66

10

48

67

11

49

68

6

44

63

7

45

64

8

46

65

12

50

69

13

51

70

14

52

71

15

53

72

16

36 37 38 39 40 41 42 4328 29 3025 26 27 31 32 33 34 35

54

732 1

3

002-001

1 2

002-002

12

012-001

1 2 3 4

5 6 7 8

9 10 11 12

H-13

H-14(12 V)

H-14(12 V)

H-14(24 V)

H-14(24 V)

H-15(12 V)

H-15(12 V)

H-15(24 V)

No. Connector Face

012-002

4

8

12

3

7

11

2

6

10

1

5

9

014-004

1 2 3 4

5 6 7 8

9 10 11 12

13 14

014-005

4 3 2 1

8 7 6 5

12 11 10 9

14 13

016-003

1 2 3 4

5 6 7 8 9

11 12 13 14

15 16

10

016-004

4 3 2 1

9 8 7 6 5

13 12 11 10

16 15

14

008-023

1 2 3

4 5 6

7 8

008-024

3 2 1

6 5 4

8 7

016-003

1 2 3 4

5 6 7 8 9

11 12 13 14

15 16

10


H-15(24 V)

H-16

H-16

H-17

J-9

J-23

J-31

J-31

No. Connector Face

016-004

4 3 2 1

9 8 7 6 5

13 12 11 10

16 15

14

008-003

1 2 3 4

5 6 7 8

008-004

4 3 2 1

8 7 6 5

004-011

1

3

2

4

000-001

004-009

1 2 3 4

002-011

1 2

002-012

12

J-40

J-41

J-74

J-74

J-75

J-75

J-148

J-148

No. Connector Face

002-015

1 2

002-015

1 2

002-011

1 2

002-012

12

002-011

1 2

002-012

12

002-011

1 2

002-012

12


J-149(24 V)

J-149(24 V)

J-78(12 V)

J-78(12 V)

J-177

P-1(12 V)

P-2

P-1(24 V)

No. Connector Face

002-011

1 2

002-012

12

004-011

1

3

2

4

004-018

034-001

000-003

000-004

000-004

P-4

P-2(24 V)

P-3

P-5(12 V)

P-5(24 V)

R-1

R-1

R-6

No. Connector Face

000-004

000-006

000-006

000-007

000-002

006-004

1 2 3

4 5 6

006-005

3 2 1

6 5 4

006-004

1 2 3

4 5 6


H-5

H-6, H-7, H-8

ABS/ASR System

General DescriptionABS (Anti-lock Brake System) and ASR (Anti-Slip Reg-ulator) are the system to prevent the wheels from lock-ing and wheel spin, and to assure stability and steeringability of the vehicle.When a malfunction occurs in the system, fail-safe de-activate the ABS and ASR, and the warning lamp comeson. Also, the self-diagnosis function is equipped to im-prove serviceability.

R-6

No. Connector Face

006-005

3 2 1

6 5 4

1 2 37 8 9

13 14 1519 20 2125 26 2731 32 33 34 35 36 37

4 5 610 11 1216 17 1822 23 2428 29 3038 39 40

6 5 412 11 1018 17 1624 23 2230 29 2840 39 38

3 2 19 8 715 14 1321 20 1927 26 2533 32 3134353637

N8A5488E

1 2

1 2

1 2 3 4

5 6 7 8

9 10 11 12 13

14 15 16 17 18

2 1

2 1

4 3 2 1

8 7 6 5

13 12 11 10 9

18 17 16 15 14

H - 6

H - 7

H - 8

N8A5489E


Parts Location

J-74

F/R

H S

EN

SO

R

H-4

, H-5

H-6

, H-7

, H-8

B-6

6 S

TO

PLI

GH

T S

W(B

RA

KE

SW

)

B-1

EA

RT

H ;

FR

AM

E (

FR

)

B-6

7 IG

NIT

ION

SW

"A

"

B-7

EA

RT

H ;

HE

AD

LIG

HT

B/T

FU

SE

BO

X A

SM

F-5

, F-7

, F-1

6, F

-21

ST

AR

TE

R S

W

B-1

25 A

SR

OF

F S

W

B-4

31 R

ES

IST

OR

1

B-3

87 R

ES

IST

OR

2J-

148

R/R

H

P-5

SE

NS

OR

J-14

9 R

/LH

SE

NS

OR J-

177

AB

S E

HC

U

P1~

P4

BA

TT

ER

Y

H-1

4, H

-15

B-5

1 A

BS

WA

RN

ING

LIG

HT

(M

ET

ER

)

AS

R W

AR

NIN

G L

IGH

T (

ME

TE

R)

J-75

F/L

H S

EN

SO

R

B-7

9 D

AT

A L

INK

CO

NN

EC

TO

R

J-19

1 E

CM

J-9

EA

RT

H ;

FR

AM

E

FL-

1, F

L-2,

FL-

9 F

US

IBLE

LIN

K

N5A2075E


Circuit Diagram

8B

8W/B

5W/B

3R3R

ACG(B)

5W/B

3B/Y

0.5B

/Y

0.3W

/V

0.3W

/L

0.5G

3W/L

100A/120A

34

2ABS (IG)

TAILLIGHT

H-8

12

H-15

15

H-15

16

J-191

37

J-191

18

J-191

38

J-191

52

H-4

20

H-4

9

B-79

B-1

12

B-79

5

0.3W

/G

H-8

13

H-15

11

H-15

6

B-79

2

B-79

1

B-79

4

B-79

7

0.3W

/B

3B 3B

0.3W

/G

0.3W

/B

3B 3B

0.3W

/B

0.3W

/G

0.5B

0.5Y

0.5B

H-8

8

B-431

1

0.5L

H-8

7

B-431

2

0.5L

/W

0.5L

0.5L

/W

RESISTOR 1

H-8

6

B-387

1

0.5L

H-8

5

B-387

2

0.5L

/W

0.5L

0.5L

/W

RESISTOR 2

DATA LINK CONNECTOR

1.25

B

FRAME-LH (FRONT)

B-7

3B


J-9

FRAME-LH (CENTER)

0.5L

0.5L/W0.5SB

0.5SB

3B

0.5Y

CANL

CANH

CC-KW2000

IS-DIAG

ECM

N5A2073E


Connector List

No. Connector Face

B-1

B-7

B-51

B-66

B-67

B-67

B-79

B-125

000-001

000-012

020-004

002-031

1 2

004-002

2

4

1

3

004-001

1 23 4

016-005

87654321

161514131211109

008-001

1

5

2

6

3

7

4

8

B-387

B-387

B-431

B-431

H-4

H-4

H-14

H-14

No. Connector Face

002-038

002-039

002-038

002-039

020-002

10111213 14 15

1 2 3 4 5

171819 20

6 7 8 9

16

020-003

9 8 7 6

20191817 16

5

1415

4

13

3

12

2

11

1

10

016-004

4 3 2 1

9 8 7 6 5

13 12 11 10

16 15

14

016-003

1 2 3 4

5 6 7 8 9

11 12 13 14

15 16

10


H-15

H-15

J-9

J-74

J-74

J-75

J-75

J-148

No. Connector Face

016-003

1 2 3 4

5 6 7 8 9

11 12 13 14

15 16

10

016-004

4 3 2 1

9 8 7 6 5

13 12 11 10

16 15

14

000-001

002-012

12

002-011

1 2

002-012

12

002-011

1 2

002-012

12

J-148

J-149

J-149

J-177

J-177

J-191

P-1

P-2

No. Connector Face

002-011

1 2

002-012

12

002-011

1 2

034-001

034-002

000-004

000-006


H-5

H-6, H-7, H-8

Transmission Control System (Smoother)

General Description“Smoother” is the name of a new-generation drive trainthat provides benefits in terms of both life cycle costs(low initial cost and maintenance cost, lower fuel con-sumption, etc.) and easy driving. Smoother is a systemthat adds an automatic transmission to the existingSmoother, for even better fuel consumption and easierdriving. This is accomplished by installing a solenoidsystem shift control box on the Smoother, which com-bines a manual transmission with fluid coupling, so allshifting is performed automatically in accordance withsignals from the transmission control module (TCM).When starting moving the vehicle, depressing the brakepedal and operating the change lever as on an automat-ic vehicle causes a change lever position signal to bedetected by the TCM. This actuates the shift control boxsolenoid and shifts the gear into the starting position orthe reverse position, and then engages the shift changeclutch (wet multi-disc clutch). (After the shift clutch en-gages, creep force is generated the same as on an ATvehicle.) Releasing the foot from the brake pedal andpressing the accelerator pedal starts the vehicle movingforward. If there is an up-shift or down-shift while run-ning, the control unit determines the vehicle statusbased on vehicle speed, accelerator opening angle, andother factors, and shifts to the optimal gear automatical-ly. If the driver moves the change lever in the “+” or “-”direction, a gear change is indicated, so sequential man-ual shifting is also possible. (Even during sequentialmanual shifting, the transmission shifts to the startingposition when the vehicle is stopped.)

P-3

P-4

P-5

X-4

No. Connector Face

000-006

000-004

000-002

005-006

N5A2011E

1 2

1 2

1 2 3 4

5 6 7 8

9 10 11 12 13

14 15 16 17 18

2 1

2 1

4 3 2 1

8 7 6 5

13 12 11 10 9

18 17 16 15 14

H - 6

H - 7

H - 8

N8A5489E


Parts Location

RELAY BOX ASM (No. 2)

FUSE BOX ASMF-5,F-13,F-16, F-17,F-22

B-431RESISTOR 2

B-387RESISTOR 1

B-79DATA LINK CONNECTOR

B-66STOPLIGHT SW

B-51, B-53 METER

B-67 STARTER SW

B-1

B-7

H-15

P-5

P-1

P-2

BATTERY

P-3P-4

F-28 FUSESBF1, SBF2, SBF5, SBF7, SBF8 FUSIBLE LINKX-18 ECM MAIN RELAYX-19 GEAR SHIFTER RELAYX-21 STARTER RELAYX-26 STARTER CUT RELAY

RELAY BOX ASM

H-10

H-12H-17

H-4, H-5, H-6,H-7, H-8

RELAY BOX ASM (No. 1)

N-7 DOOR SW (RH)

N-19 SELECT SW

N-17 EMERGENCY SW

N-18 EMERGENCY SHIFT SW

B-417 PTO SWITCH

STARTERSW

L-2 DOME LIGHT

X-14 SMOOTHEREMERGENCY RELAY

H-3

X-5 SMOOTHER MAIN RELAYX-32 DIODE

B-105 RESET SW

J-9

B-106 ADJUST SW

B-86DOME LIGHT SW

B-425, B-426,B-427, B-428TCM

H-118N-2DOOR SW (LH) H-119

H-118

H-119

J-177 EHCU

J-191 ECM

J-237SOLENOID & ATF TEMPERATURE SENSOR

J-50NEUTRAL SW

J-223SELECT STROKE SENSOR

J-234SELECT SOLENOID

J-232TURBINE SPEED SENSOR

J-236SHIFT SOLENOID 2, 4, R

J-235SHIFT SOLENOID 1, 3, 5J-139

INPUT SPEED SENSOR

J-142SHIFT STROKE SENSOR

N7A2053E


Circuit Diagram8W

HT

/BLK

8BLK

2L J-26

B

SB

F-8

60A

SB

F-4

40A

Bat

teryP-1

P-2

P-3

P-4

P-5

STA

RT

ER

Sta

rter

HE

AD

LAM

P

SB

F-5

EC

M40

A

Fus

e &

Rel

ay B

ox(B

ehin

d th

e C

ab)

SB

F-3

60A

GLO

WS

BF

-2

40A

KE

Y S

WS

BF

-9

40A

AB

SS

BF

-7

60A

NE

ES

SB

F-6

60A

CE

RA

MIC

HE

AT

ER

SB

F-1

MA

IN10

0A o

r12

0A

3 WH

T/

BLU

F-2

1

10A

F-9

3 BLK

/Y

EL

3BLK

/YE

L

F-1

6

10A

F-1

7N

EE

S (

IG)

10A

F-1

8

10A

Fus

e &

Rel

ay B

ox(G

love

Box

)E

NG

. (IG

)10

AA

BS

(IG

)M

ET

ER

SR

SF

-22

10A

STA

RT

ER

3 WH

T/

BLU

5 WH

T/

BLK

5 WH

T/

BLK

8 WH

T/

BLK

1.25

RE

D

0.5B

LU/B

LK

0.5

BLK

3 WH

T/

BLK

J-9

Fra

me

3 WH

T/

GR

N

2 RE

D

Mai

nR

elay

42

53

X-1

8

X-1

8

F-2

8E

CM

10A

Fus

e &

Rel

ay B

ox(C

ab S

ide)

EC

M

EC

M

Fus

e &

Rel

ay B

ox(B

ehin

d th

e C

ab)

Fus

e &

Rel

ay B

ox(G

love

Box

)

F-4

15A

AU

DIO

(B)

DO

OR

LO

CK

F-1

3N

EE

S (

B)

10A

F-5

F-6

10A

PO

WE

RW

IND

OW

10A

ST

OP

LIG

HT

W/S

-I/-

J

W/S

-H

W/S

-H3B

LK/Y

EL

ON

Rel

ay

H-6

1Ig

nitio

nS

witc

h

2

ST

ON

AC

CO

FF

B-6

7

34

B-6

7

US

W J

OIN

T3

0.5B

LK

N7A2131E


EC

MT

CM

30 B

LK/R

ED

8 B

LK8

BLK

8 B

LK

3 B

LK/Y

EL

P-1

P-2

P-3

P-4

Bat

tery

P-5

3 BLK

/W

HT

3 WH

T/

BLK

0.5

RE

D/W

HT

0.5

RE

D/W

HT

0.5

RE

D

0.5

WH

T/

BLU

0.3

BLK

/WH

T

3 WH

T/

BLU

3 WH

T/

BLU

2L

SB

F-8

STA

RT

ER

60A

SB

F-2

KE

Y40

A

F-2

2S

TAR

TE

R10

A

14H

-8

0.5

RE

D/

WH

T

0.5

WH

T/

BLU

0.5

WH

T/

BLU

J-9

Fra

me

4

B-6

7

US

WJO

INT

32 B

LK

0.5

BLK

14J-

191

B-4

2546

Sta

rt c

utre

lay

cont

rol

Sta

rtsw

itch

sign

al

38H

-5

16

Sta

rter

cut

rela

yco

ntro

l

Fus

e &

Rel

ay B

ox(G

love

Box

)

F-2

8E

CM

10A

Fus

e &

Rel

ay B

ox(B

ehin

d th

e C

ab)

Fus

e &

Rel

ay B

ox(B

ehin

d th

e C

ab) Fus

e &

Rel

ay B

ox(B

ehin

d th

e C

ab)

2 3J/C

-2

0.85

LT G

RN

0.5

LT G

RN

EC

MM

ain

Rel

ay

52

X-2

1Sta

rter

Rel

ay

43

X-2

1 51

X-2

6Sta

rter

Cut

Rel

ay

34

X-2

6

ST

ON

AC

CO

FF

Igni

tion

Sw

itch

Sta

rter

B C 1J-

27

1J-

26

F-1

6

10A

ME

TE

R

0.5

BLK

/Y

EL

0.5

BLK

/Y

EL

0.5

BLK

/Y

EL

14H

-12 E

mer

genc

yS

witc

h

51N

-17

N-1

7

W/S

-M

0.3

BLU

/R

ED

0.3

BLU

/R

ED

0.3

BLK

0.3

BLKW

/S-E

0.3

BLK

B-7

Hea

dlig

htB

rack

et

Sm

ooth

erE

mer

genc

yR

elay

1X

-14

3

Rel

ay B

ox(I

nstr

umen

t Pan

el)

0.3B

LU/R

ED

4B

-428

14

4H

-12

Em

erge

ncy

switc

hsi

gnal

1H

-7

2B

-67

25

X-1

4

N7A2144E


N7A2132E

0.5

WH

T/

VIO

0.5

GR

N/

WH

T

1.25

GR

N/

WH

T

1.25

GR

N/

WH

T

TC

M

Fus

e &

Rel

ay B

ox(G

love

Box

)

15B

-425

F-1

3N

EE

S(B

)10

A

1.25

WH

T/

OR

N

3

Sm

ooth

erM

ain

Rel

ay

15

2

X-5X-5

3

Mai

nre

lay

cont

rol

Bat

tery

vol

tage

Rel

ay B

ox(I

nstr

umen

t Pan

el)

0.5

BLK

/O

RN

0.5

BLK

/O

RN

0.5

BLK

/O

RN

2B

-426

1

Igni

tion

volta

ge

F-1

7N

EE

S(I

G)

10A


TC

M

4B

-426

0.5

BLK

2 BLK

12

0.5

BLK

17

1.25

BLK

8

212

113 D

iagn

ostic

requ

est

(SR

S)

Dia

gnos

ticre

ques

t(E

CM

)

Dia

gnos

ticre

ques

t(E

HC

U)

Cla

ss 2

Ser

ial

Com

mun

icat

ion

Gro

und

Gro

und

5B

-79

4

18B

-428

11

Dia

gnos

ticre

ques

tsw

itch

Dia

gnos

ticre

ques

t

1.25

BLK

1.25

BLK

0.3

BLK

/W

HT

0.5

BLK

0.5

BLK

0.3

WH

T/

BLK

0.3

WH

T/

GR

N

0.5

YE

L0.

5G

RY

0.5L

T B

LU

DLC

9B

-426

7

Key

wor

d 20

00

Key

wor

d se

rial

com

mun

icat

ion

0.3

LT B

LU

0.5

LT B

LU

EH

CU

(A

BS

Mod

ule)

EH

CU

(A

BS

Mod

ule)

EC

M

SR

S C

/U

EC

M

B-1

Fra

me

W/S

-D

1821

22

J/C

-B

W/S

-C

Sig

nal g

roun

dS

igna

l gro

und

Pow

er g

roun

dP

ower

gro

und

N7A2133E


0.5

YE

L/B

LK

0.5

1(LH

D)

3(R

HD

)3(

LHD

)5(

RH

D)

RE

D/

YE

L

0.5

YE

L/B

LK

0.5

RE

D/

YE

L

0.5

YE

L/B

LK

0.5

RE

D/

YE

L

0.5

YE

L/R

ED

0.5

BLU

/W

HT

0.5

BLU

/W

HT

0.5

YE

L/R

ED

0.5

BLU

/W

HT

0.5

YE

L/R

ED

3029

6

12B

-427

B-4

25

31

2

4J-

237

J-23

7

TC

M

Oil

Pum

p A

SM

Tran

smis

sion

fluid

tem

pera

ture

sens

or

Lock

up

clut

chso

leno

id v

alve

Gea

rshi

ft cl

utch

sole

noid

val

ve

5

6H

-4

H-1

7

6

14H

-119

H-1

187

3

Low

ref

eren

ceT

CM

H-4

B-4

27

TF

Tse

nsor

sign

al

5V r

efer

ence

Gea

rshi

ft cl

utch

sole

noid

val

veco

ntro

l

+B

Lock

up

clut

chso

leno

id v

alve

cont

rol

+B

N7A2134E


0.5

YE

L/W

HT

TC

M

33H

-5

1110

B-4

2610

4B

-427

2923

H-5

0.5

YE

L/W

HT

11H

-119

0.5

YE

L/W

HT

0.5

YE

L/B

LK

32

0.5

YE

L/B

LK

7

0.5

YE

L/B

LK

Low

ref

eren

ce

0.5

WH

T

10H

-8

1918

0.5

WH

T

3H

-119

0.5

WH

T

0.5

RE

D

0.5

WH

T/

BLU

0.5

OR

N/

BLU

0.5

WH

T/

BLU

0.5

OR

N/

BLU

812

H-1

190.

5W

HT

/B

LU

0.5

OR

N/

BLU

9

0.5

RE

D

2

0.5

RE

D

Turb

ine

Spe

edS

enso

r

Low

ref

eren

ce

5V r

efer

ence

Inpu

t sha

ftsp

eed

sens

orsi

gnal

TC

M

13B

-426

0.5

YE

L/R

ED

15H

-119

0.5

YE

L/R

ED

27H

-5

0.5

YE

L/R

ED

20

H-8

0.5

BLK

6

0.5

BLK

11

0.5

BLK

12

J-23

2

5V r

efer

ence

Turb

ine

spee

d se

nsor

sign

al

5V r

efer

ence

Gea

r se

lect

posi

tion

sens

orsi

gnal

5V r

efer

ence

Gea

r se

lect

posi

tion

sens

orsi

gnal

115

2620

H-5

0.5

YE

L0.

5B

RN

0.5

YE

L0.

5B

RN

0.5

YE

L0.

5B

RN

52

H-1

18

Inpu

tS

haft

Spe

edS

enso

r

12

J-13

9

21

J-22

3

3J-

223

Gea

r S

elec

tP

ositi

onS

enso

r

Gea

r S

hift

Pos

ition

Sen

sor

21

J-14

2

3J-

142

Low

ref

eren

ceLo

w r

efer

ence

N7A2135E

F
-5

10A

F-1

7N

EE

S (

IG)

10A

F-1

6

10A

F-1

8

10A

0.5

BLK

/O

RN

0.5

BLK

/O

RN

0.5

BLK

/O

RN

0.3

GR

Y/

BLU

0.3

GR

Y/

RE

D

0.3

GR

Y/

BLK

0.5

GR

N

0.5

GR

N

0.5

GR

N/

YE

L 0.5G

RN

Sto

p Li

ght

11H-5

3B

-428

29

17

Fus

e &

Rel

ay B

ox(G

love

Box

)S

TO

P L

IGH

TM

ET

ER

SR

S

TC

M

J/C

-2

Bra

keP

edal

Sw

itch

21B

-66

B-6

6

Neu

tral

Sw

itch

12J-

50

J-50

F-2

8E

CM

10A

0.5

LT G

RN

0.5

LT G

RN

EC

M

Exh

aust

B

rake

S

olen

oid

Val

ve

0.5

BLK

/B

LU

0.5

BLK

/B

LU

37H

-5

10

0.5B

/L

2

64

1

Neu

tral

switc

hsi

gnal

Res

etsw

itch

sign

al

Slo

wsw

itch

sign

al

Fas

tsw

itch

sign

al

Bra

kepe

dal

switc

h

Res

etS

witc

h

64B

-105

B-1

05

Hal

f-cl

utch

Adj

ustm

ent

Sw

itch

3B

-106

12

B-1

06

J/C

-G

5

46

TC

M

0.3

2 BLK

0.5

BLK

3 BLK

1.25

BLK

B-7

Hea

dlig

htB

rack

et

Tai

lLi

ght

BLU

/W

HT

2 BLK

2 BLK

0.5G

RY

/RE

D

1.25

GR

Y/

BLK

0.5

GR

Y/

RE

D

0.5

GR

Y/

RE

D

12 5

7 1

1

6H

-12

19B

-428

3H

-3

B-1

Fra

me

Roo

m L

amp

TC

M

PT

Osw

itch

sign

al

Doo

rsw

itch

sign

al

Igni

tion

volta

ge

W/S

-B

J/C

-D

J/C

-H

W/S

-D

W/S

-C

2 3

Doo

r S

witc

h(L

eft)

1N

-7

Doo

r S

witc

h(R

ight

)

1N

-2

PT

OS

witc

h

12

3

B-4

17

B-4

174Ig

nitio

nvo

ltage

N7A2136E


20 3 1

0.5

RE

D

0.5

RE

D

R

TC

M

6 13 2

0.5

WH

T

0.5

WH

T

N

14 9 3

B-4

28

H-1

2

N-1

8

5N

-18

0.5

GR

N

0.5

GR

N

1

13 8 2

B-4

27

0.5

RE

D/

BLK 0.5

RE

D/

BLK

R

Em

erge

ncy

Shi

ft S

witc

h

21

202

67

B-4

28B

-427

0.5

WH

T/

BLK 0.5

WH

T/

BLK

N

Sel

ecto

rLe

ver

14

0.5

OR

N

0.5

OR

N

D

12 1015

0.5

BLU

/B

LK 0.5

BLU

/B

LK

+

1 87

0.5

PN

K/

BLK 0.5

PN

K/

BLK

-

11 48

0.5

GR

N/

BLK 0.5

GR

N/

BLK

A

1.25

BLK

B-1

Fra

me

0.5B

LK0.

5BLK

N-1

99

15

IPC

Leve

r Asw

itch

sign

al

Igni

tion

volta

ge

Leve

r -

switc

hsi

gnal

Igni

tion

volta

ge

Eco

nom

ym

ode

switc

hsi

gnal

Igni

tion

volta

ge

1st g

ear

star

tsw

itch

sign

al

Igni

tion

volta

ge

Leve

r +

switc

hsi

gnal

Igni

tion

volta

ge

Leve

r D

switc

hsi

gnal

Igni

tion

volta

ge

Leve

r N

switc

hsi

gnal

Igni

tion

volta

ge

Leve

r R

switc

hsi

gnal

Igni

tion

volta

ge

Em

erge

ncy

shift

1st

switc

hsi

gnal

Igni

tion

volta

ge

Em

erge

ncy

shift

Nsw

itch

sign

al

Igni

tion

volta

ge

Em

erge

ncy

shift

Rsw

itch

sign

al

Igni

tion

volta

ge

1B

-427

0.5

YE

L/R

ED 0.5Y

EL/

RE

D

13

10 5

B-4

28

H-1

2

EC

ON

OM

ode

Sw

itch

1st

Gea

rS

tart

Sw

itch

0.5

BLU

0.5

BLU

21 3N

-19

0.5

YE

L/R

ED

IPC

0.5

BLK

0.5

BLK

N-2

0

N-2

0

64

31

N7A2137E


12

J-23

5

J-23

5 1-3-

5S

hift

Sol

enoi

d

0.5

VIO

/W

HT

3 PN

K3 P

NK

0.5

VIO

/W

HT

2 RE

D3 R

ED

3 RE

D

TC

M

12

B-4

25

1.25

BLK

1.25

BLK

Fus

e &

Rel

ay B

ox(B

ehin

d th

e C

ab)

18

Gea

r sh

iftco

ntro

l box

rela

y co

ntro

l

19H

-17

8H

-118

14H

-17

1H

-118

7H

-17

SB

F-7

NE

ES

60A

1

715

B-4

28B

-425

1.25

BLK

2 BLK

1.25

BLK

1.25

BLK

1.25

BLK

8H

-17

67

1.25

BLK

1.25

BLK6

H-1

7

J-9

Fra

me

45

2131

B-4

25B

-426

1.25

PN

K

1.25

BLK

/R

ED

1.25

PN

K

1.25

BLK

/R

ED

56

89

B-4

25

1.25

PN

K

1.25

BLK

/B

LU

1.25

BLK

/R

ED

2 BLK

2 GR

N

1.25

BLK

/R

ED

4H

-119

12H

-17

1H

-119

2 BLK

2 BLU

1.25

BLU

16H

-119

10H

-17

13H

-119

2 BLK

2 BLK

1.25

BLK

1.25

BLK

/B

LU

1.25

PN

K

1.25

BLK

/B

LU

18

1622

B-4

28

1.25

PN

K

1.25

WH

T/

BLK

1.25

WH

T/

BLK

1.25

PN

K

1.25

WH

T/

BLK

TC

M

Gro

und

Gro

und

Gro

und

2 BLK

1-3-

5 sh

iftso

leno

id v

alve

cont

rol

2-4-

6-R

shi

ftso

leno

id v

alve

cont

rol

Sel

ect

sole

noid

val

veco

ntro

l

12

J-23

6

J-23

6 2-4-

6-R

Shi

ftS

olen

oid

12

J-23

4

J-23

4 Sel

ect

Sol

enoi

d

1.25

BLK

1.25

BLK

1.25

BLK

1.25

BLK

W/S

-Q US

WJO

INT

2

US

WJO

INT

1

Gea

r S

hift

Con

trol

Box

Rel

ay

25

3

X-1

9

X-1

94

N7A2138E


0.5

VIO

/W

HT

3 PN

K3 P

NK

0.5

VIO

/W

HT

2 RE

D3 R

ED

3 RE

D

Fus

e &

Rel

ay B

ox(B

ehin

d th

e C

ab)

18

Gea

r sh

iftco

ntro

l box

rela

y co

ntro

l

19H

-17

8H

-118

14H

-17

SB

F-7

NE

ES

60A

1

B-4

25

45

2131

B-4

25B

-426

1.25

PN

K

1.25

BLK

/R

ED

1.25

PN

K

1.25

BLK

/R

ED

56

89

B-4

25

1.25

PN

K

1.25

BLK

/B

LU

1.25

BLK

/R

ED

2 GR

N

1.25

BLK

/R

ED

4H

-119

12H

-17

2 BLU

1.25

BLU

16H

-119

10H

-17

151

8

2 BLK

1.25

BLK

1.25

BLK

/B

LU

1.25

PN

K

1.25

BLK

/B

LU

18

1622

B-4

28

1.25

PN

K

1.25

WH

T/

BLK

1.25

WH

T/

BLK

1.25

PN

K

1.25

PN

K1.

25P

NK

1.25

PN

K

1.25

WH

T/

BLK

TC

M1-

3-5

shift

sole

noid

val

veco

ntro

l

2-4-

6-R

shi

ftso

leno

id v

alve

cont

rol

Sel

ect

sole

noid

val

veco

ntro

l

US

WJO

INT

4G

ear

Shi

ftC

ontr

ol B

oxR

elay

25

3

X-1

9

X-1

94

12

J-23

5

J-23

5 1-3-

5S

hift

Sol

enoi

d

TC

M

12

B-4

25

1.25

BLK

1.25

BLK

1H

-118

19H

-17

715

B-4

28

1.25

BLK

2 BLK

1.25

BLK

1.25

BLK

1.25

BLK

17H

-17

67

1.25

BLK

1.25

BLK

21H

-17

J-9

Fra

me

2 BLK

1H

-119

2 BLK

13H

-119

2 BLK

Gro

und

Gro

und

Gro

und

2 BLK

12

J-23

6

J-23

6 2-4-

6-R

Shi

ftS

olen

oid

12

J-23

4

J-23

4 Sel

ect

Sol

enoi

d

1.25

BLK

1.25

BLK

1.25

BLK

1.25

BLK

US

WJO

INT

2

US

WJO

INT

1

N7A2139E


1112

B-4

25

TC

M

0.5

BLK

/Y

EL

0.5

BLK

/Y

EL

0.5

YE

L

0.3

YE

L/G

RN

0.5

YE

L/R

ED

Sel

ecto

r Le

ver

0.3

GR

N/

OR

N

818

IPC

B-5

1

Fus

e &

Rel

ay B

ox(G

love

Box

)

F-1

6M

ET

ER

10A Tr

ansm

issi

onw

arni

ngla

mp

7

EC

ON

Ola

mp

61

1st

STA

RT

lam

p

B-5

3

14

Gea

rP

ositi

onIn

dica

tor

Gea

r po

sitio

ndi

spla

y co

ntro

l

0.5B

LKS

moo

ther

Em

erge

ncy

Sw

itch

EC

ON

Ola

mp

cont

rol

Tran

smis

sion

war

ning

lam

pco

ntro

l

W/S

-M

Dio

deB

-1

21X

-32

X-3

2

0.3

PN

K

N7A2141E


2 1 B-431

7 8 H-8

B-387

Resistor 1

2 1

1

2TCM

3

2

B-427

10

5

H-15

14

9

15

14

J-177

27

26

5 6 H-8

0.5BLU/WHT

0.5BLU

0.5BLU/WHT

0.5BLU

0.5BLU

0.5BLU/WHT

0.5BLU

0.5BLU/WHT

0.5BLU

0.5BLU/WHT

0.5BLU

0.5BLU/WHT

0.5BLU

0.5BLU/WHT

0.5BLU

0.5BLU/WHT

0.5BLU/WHT

0.5 BLU

0.5BLU/WHT

0.5 BLU

0.5BLU/WHT

0.5 BLU

0.5BLU/WHT

0.5 BLU

0.5BLU/WHT

0.5 BLU

0.5BLU/WHT

0.5 BLU

0.5BLU/WHT

0.5 BLU

EHCU

37

18

J-191 CANhigh

CANlow

CANhigh

CANlow

DRM

ECM

Resistor 2

CANhigh

CANlow

3

J/C-F

4

5

6

J/C-F

Without ABS

2

1

3

J/C-R

5

4

6

J/C-R

CANhigh

CANlow

N6A6641E


Connector list

No. Connector Face

B-1

l

B-7

B-51

B-53

B-66

B-67

B-67

B-79

000-001

000-018

020-004

012-009

002-031

1 2

004-002

2

4

1

3

004-001

1 23 4

016-005

87654321

161514131211109

B-86

B-86

B-105

B-106

B-387

B-387

B-417

B-425

No. Connector Face

004-001

1 23 4

004-002

2

4

1

3

006-021

003-014

1

2

3

002-038

002-039

004-001

1 23 4

031-001


B-426

B-427

B-428

B-431

B-431

H-3

H-3

H-4

No. Connector Face

024-001

017-001

022-006

002-038

002-039

006-014

1 2 3

4 5 6

006-015

123

456

020-003

9 8 7 6

20191817 16

5

1415

4

13

3

12

2

11

1

10

H-4

H-10

H-10

H-12

H-12

H-15

H-15

H-17

No. Connector Face

020-002

10111213 14 15

1 2 3 4 5

171819 20

6 7 8 9

16

003-009

1 2 3

003-010

3 2 1

022-002

9 8 7

20 19

6 5 4 3 2 1

18 17 16 15 14 1322 21 12 11

10

022-001

1 2 3 4

13 14

5 6 7 8 9 10

15 16 17 18 19 2011 12 21 22

016-003

1 2 3 4

5 6 7 8 9

11 12 13 14

15 16

10

016-004

4 3 2 1

9 8 7 6 5

13 12 11 10

16 15

14

008-007

1 2 3 4

5 6 7 8


H-17

H-118

H-118

H-119

H-119

H-xx

J-9

J-26

No. Connector Face

008-008

1234

5678

008-003

1 2 3 4

5 6 7 8

008-018

016-001

1 2 3 4

5 6 7 8

9 10 11 12

13 14 15 16

016-002

4 3 2 1

8 7 6 5

12 11 10 9

16 15 14 13

001-002

1

000-001

000-002

J-27

J-50

J-139

J-142

J-177

J-191

J-223

J-232

No. Connector Face

000-009

002-035

002-040

003-005

1 2 3

034-001

003-005

1 2 3

002-040


J-234

J-235

J-236

J-237

L-2

L-2

P-1

P-2

No. Connector Face

002-003

1 2

002-003

1 2

002-042

004-020

003-009

1 2 3

003-010

3 2 1

000-004

000-006

P-3

P-4

P-5

P-6

X-5, 14, 18,

26

X-19, 21

X-32

X-33

No. Connector Face

000-006

000-004

000-002

000-002

005-006

005-003

1

2 3

54

004-004

1 2 3 4

014-002

1 2 3

7 8 9 10 11

4

12

5

13

6

14


H-5

H-6, H-7, H-8

Electronic Control Type PTO

General DescriptionThis circuit consists of starter switch, PTO switch (fordump vehicle, it shares with dump control switch), relay,diodes, solenoid and control unit.Electronic control type PTO is installed on the left side oftransmission. PTO's gears are engaged at any time. There is a sleeveinstalled on the output shift, and the sleeve is shifted bythe solenoid through the shift rods(s) and shift arm(s).This causes turning the power on or off.

N-2

N-7

N-17

N-18

N-19

No. Connector Face

001-020

001-020

008-005

1 2 3 4

5 6 7 8

006-007

1 2 34 5 6

010-003

1098765

4321

1 2 37 8 9

13 14 1519 20 2125 26 2731 32 33 34 35 36 37

4 5 610 11 1216 17 1822 23 2428 29 3038 39 40

6 5 412 11 1018 17 1624 23 2230 29 2840 39 38

3 2 19 8 715 14 1321 20 1927 26 2533 32 3134353637

N8A5488E

1 2

1 2

1 2 3 4

5 6 7 8

9 10 11 12 13

14 15 16 17 18

2 1

2 1

4 3 2 1

8 7 6 5

13 12 11 10 9

18 17 16 15 14

H - 6

H - 7

H - 8

N8A5489E


Parts Location

B-6

7 S

TA

RT

ER

SWB

-84

PT

O S

W

P-1

J-12

3, J

-124

PT

O C

ON

TR

OL

UN

IT

J-12

5 P

TO

SO

LEN

OID

J-12

6 P

TO

SO

LEN

OID

SW

P-2

P-3

P-4

J-9

B-5

1P

TO

IND

ICA

TO

R L

AM

P (

ME

TE

R)

RE

LAY

BO

X A

SM

FL-

1, F

L-2

FU

SIB

LE L

INK

BA

TT

ER

Y

P-5

RE

LAY

BO

X A

SM

(N

o.1)

X-1

2 H

EA

TE

R &

A/C

RE

LAY

X-3

2, X

-34

DIO

DE

FU

SE

BO

X A

SM

F-1

6 F

US

E

RE

LAY

BO

X A

SM

(N

o.2)

F-2

9~F

-31

FU

SE

X-1

4 P

TO

MA

IN R

ELA

YX

-15

PT

O S

OLE

NO

ID R

ELA

YX

-16

PT

O C

UT

RE

LAY B-7

B-2

74H

6~H

8 B-8

9 C

LUT

CH

SW

N8A0526E


Circuit Diagram

40AKEY

P-1

P-2

P-3

P-4

P-5FRAME

H-71

B-672

2

FL-2

10A

PTO

F-31

100A/120AMAIN

CHARGERELAY

HEATER& A/CRELAY

FL-1

B

ST

ACC

ON

STARTER SW

DIODE

PTO CUTRELAY

CLUTCHSWITCH

DIODE

PTO SOLM/T RELAY

PTOSWITCH

B-67

B-67

3

4

X-34

1

X-16

3

X-34

2

X-16

5

3.0W/L

3.0L

3.0W/B

3.0B/Y

3.0B/Y

0.5B/Y

0.5W/B 3.0B/Y

0.5B/W

0.5L/R

0.5R/Y

0.3W

0.3W

0.3B

0.5Y

0.5Y0.5Y

0.3B

0.85P

0.85Y

0.85B

0.85W/G

0.85B

0.5B

0.5V/W

0.5R/Y

1.25W/L

0.85G/O

0.5L

10APTO

F-30

10AMETER

F-16

20APTO

F-29

X-16

1

X-16

2

X-16

4

X-12

1

X-12

2

X-12

5

X-12

4

X-15

5

X-15

2

X-15

3

X-15

1

B-89

1

B-89

4

H-8

2

B-51

5

J-126

1

J-126

2

B-51

8

H-6

2X-14

0.85L

3.0B/Y

2X-32

1X-32

X-34

3

3X-14

DIODE

PTO MAINRELAY

PTO SOL.SWITCH

METERPTO

3X-32

4X-32

B-84

4

B-84

B-7

1

J-9 B-274

H-81

J-1232

J-1245

1X-14

5X-14

J-1231

J-1253

J-1252

J-1244

J-1243

J-1251

FRAME FRAME H/L BRACKET

PTO SOL.

CONT UNITPTO

2.0L

0.5B

N8A0516E


Connector List

No. Connector Face

B-7

B-51

B-67

B-67

B-84

B-89

B-274

J-9

000-018

014-001

1 2 3 4 5 6 7 8 9 1011121314

004-002

2

4

1

3

004-001

1 23 4

006-001

1 2 3

4 5 6

004-001

1 23 4

000-001

000-001

J-123

J-123

J-126

J-126

X-12

X-14

X-15

X-16

No. Connector Face

002-012

12

002-011

1 2

002-012

12

002-011

1 2

005-001

1

32 4

5

005-006

005-006

005-006


H-6, H-7, H-8

X-32

X-34

No. Connector Face

004-004

1 2 3 4

004-004

1 2 3 4

1 2

1 2

1 2 3 4

5 6 7 8

9 10 11 12 13

14 15 16 17 18

2 1

2 1

4 3 2 1

8 7 6 5

13 12 11 10 9

18 17 16 15 14

H - 6

H - 7

H - 8

N8A5489E

CAB AND CHASSIS ELECTRICAL

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Transcript of CAB AND CHASSIS ELECTRICAL