ELECTRICAL SYSTEM SECTION E L CONTENTS <1ST REVISION> HARNESS CONNECTORS EL 2 STANDARDIZED RELAYS... EL 3 POWER SUPPLY PROTECTION EL 6 BATTERY, STARTING ‘SYSTEM . 7 STARTING SYSTEM — Starter — CHARGING SYSTEM : CHARGING SYSTEM — ‘Alternator ~ — COMBINATION SWITCH . . HEADLAMP — Without Daytime Light System and Dim-dip Lamp System -. HEADLAMP — Daytime Light System — .... HEADLAMP — Dim-dip Lamp System — HEADLAMP — Headlamp Aiming Control — HEADLAMP EXTERIOR LAMPS — Rear Gombination | Lamps - EXTERIOR LAMPS... : INTERIOR LAMPS... METER AND GAUGES WARNING LAMPS AND BUZZERS WIPERS AND WASHERS nn. HORN, CIGARETTE LIGHTER AND CLOCK REAR WINDOW DEFOGGER AUDIO AND ANTENNA .. LOCATION OF ELECTRICAL “UNITS HARNESS LAYOUT SUPER MULTIPLE JUNCTION (S.M.J.) POWER SUPPLY PROTECTION POWER SUPPLY ROUTING .... ELH13 on EL-A16 ~- EL-120 EL-123 EL-127 EL144 .. EL-1002 . EL-1004COMBINATION SWITCH EL-1010 HEADLAMP econ = . EL-1011 HEADLAMP — Daytime Light System — EL-1012 HEADLAMP — Dim-dip Lamp System — EL10%3 HEADLAMP — Headlamp Aiming Control — EL-1014 EXTERIOR LAMPS. sess EL-1015, INTERIOR LAMPS EL-1025 METER AND GAUGES. - EL-1028 WARNING LAMPS AND BUZZERS EL-1029 WIPERS AND WASHERS EL-1036 HORN, CIGARETTE LIGHTER AND CLOCK EL-1040 LOCATION OF ELECTRICAL UNITS EL-1042 HARNESS LAYOUT .esensen . EL-1044 SUPER MULTIPLE JUCTION (S.M.J.) .. -- EL-1048 WIRING DIAGRAM REFERENCE CHART RADIATOR FAN ——— Le section ENGINE CONTROL SYSTEM, IGNITION SYSTEM EF BEC SECTION LOCK-UP CONTROL SYSTEM AT SECTION ANTI-LOCK BRAKING SYSTEM BR SECTION POWER WINDOW AND POWER DOOA LOCK, SEAT HEATING BF SECTION HEATER AND AIR CONDITIONER, HA SECTION ELECTRICAL SYSTEM SECTION E L When you read wiring diagrams: « Read Gl section, “HOW TO READ WIRING DIAGRAMS”. J CONTENTS POWER SUPPLY PROTECTION POWER SUPPLY ROUTING COMBINATION SWITCH HEADLAMP. HEADLAMP — Daytime Light System — HEADLAMP — Dim-dip Lamp System — HEADLAMP — Headiamp Aiming Control — EXTERIOR LAMPS .... INTERIOR LAMPS METERS AND GAUGES WARNING LAMPS AND BUZZERS WIPERS AND WASHERS... : HORN, CIGARETTE LIGHTER AND CLOCK LOCATION OF ELECTRICAL UNITS HARNESS LAYOUT . EL-1002 EL-1004 EL-1010 ELt011 EL-1012 - EL-1013 EL1014 EL-1015 . EL-1025 EL-1028 €L-1029 EL-1036 soe EL-1040 . EL-1042 . EL-1044 SUPER MULTIPLE JUCTION (S.M.J) . EL-1048 ‘WoRING DIAGRAM REFERENCE CHART RADIATOR FAN es Le SECTION ENGINE CONTROL SYSTEM IGNITION SYSTEM EF REC SECTION LOGK-UP CONTROL SYSTEM AY SECTION ANTI-LOCK BRAKING SYSTEM BR SECTION POWER WINDOW AND POWER GOOR LOCK, SEAT HEATING BF SECTION ESTER AND AIR CONDITIONER Ha SECTION EL-1001POWER SUPPLY PROTECTION lof ‘Blows setssty fe AL qBUBSeSHOCA fel re NeLooo Fuses a. If fuse is blown, be sure to eliminate cause of problem before installing new fuse. b. Use fuse of specified rating. Never use fuse of more than specified rating, ¢. Do not install fuse in oblique direction; always insert it into fuse holder propery. d. Remove fuse for clock if vehicle is not used for a long period of time. e. Use fuse puller provided in fuse box to remove fuses. FUSE LOCATION ‘Power Supply Fuses are located in fuselink box at front of engine compartment. ‘© Component protection fuses are located in main fuse box situated in lower driver-side dash panel FUSE RATINGS RED - 104, BLUE ~ 15A YELLOW ~ 20A EL-1002POWER SUPPLY PROTECTION NOTE: EL-1003POWER SUPPLY ROUTING Wiring L.H.D. MODEL _ With Daytime Running Lamps soz, RR ©: Models aquippad with Seisiock brave system oa os Cd @ : nevi neces i] Ge eB 9 9 A t 'GNITION SWiTOH HL OOOO LUGHTING SwiTcH |_____wa-fionrionsvarew — —— we 5 {omowe-o[ saan] — = er Sere] {Engr 20m ———FLecee] ea | - o +fpomanae] rea i ; | ill? 38 oe] Log ||| Bi cee fea 2 ' EL-1004FUSE BLOCK POWER SUPPLY ROUTING Wiring Diagram (Cont'd) vo sees" EL-1005 Y > ue Remoen suze wung LH.D. MODEL POWER SUPPLY ROUTING Without Daytime Running Lights @ MT models © = NvTmodels © = Models equipped with ‘anisock brake system [RRREREBEREEs es Seance Wiring Diagram (Cont'd) (ain anes ~ fe aL OOO UGHTING SwiTcH VoNrTion sw Bo ena] Ton Sets to erowe-+[snnmania] (€oqine room \ © -+[naaarenravsvorew ] fH g}—aem Ce» 1FUSE BLOCK POWER SUPPLY ROUTING Wiring Diagram (Cont'd) eo cc - US -> REAR DEFORGER EL-1007 ov» getpnnionagar or v > imma nevaseR.H.D. MODEL @ | MT models © NOW models © : Models equippea with ‘anivloce brake system POWER SUPPLY ROUTING Wiring Diagram (Cont'd) f fi H ia Ta IGNITION SWITCH ie (Maio narness) UGHTING SwiTeH ‘gine room harass (crgnea2 $$ 1a] ee] |_B¢ @ Rag rusme EHR. oer sae]POWER SUPPLY ROUTING Wiring Diagram (Cont'd) FUSE BLOCK saute i L__ + ua nemoen euzzen un) EL-1009COMBINATION SWITCH Operational Check WeshivineHEADLAMP_ L.H.D. MODEL Wiring Diagram Without Daytime Running Lamps CcompnasionMerer ri Hl pope ye HEADLAMP FL ae @a3e« sng 2 fre Lf ii id o Oo loo FUSIBLE.NK BOX g = OL 3 @ + Models equipped with aatteny anti-lock brake syetom NeLo9s EL-1011Light HEADLAMP - Di NeL026 @ = h ] ; om E. conn vend 7 ecb cof eof Fi = =o) @ @ oe f at chad we alt iw = rot = ast? ot) Wiring Diagram re i eebeeoSe of ve EL-1012HEADLAMP - Dim-dip Lamy m= Wiring Diagram News EL-1013HEADLAMP - Headlamp Aiming Control - CT EL-1014EXTERIOR LAMPS Clearance, License, Tail and Stop Lamps/Wiring Diagram LH.D. MODEL, we woaieaaens bat SS eee t =] ext estend ‘Without Daytime Running Lamps L Lv ono O] Nevo EL-1015EXTERIOR LAMPS. Clearance, License, Tail and Stop Lamps/Wiring Diagram (Cont'd) (LH.D, MODEL With Daytime Running Lamps ia @ H 3 f EL-1016EXTERIOR LAMPS Clearance, License, Tail and Stop Lamps/Wiring Diagram (Cont'd) R.H.D, MODEL EL-1017EXTERIOR LAMPS Driving Lamp/Wiring Diagram L.H.D. MODEL (tan narness) FaReE TT Dine tame NeLo4e EL-1018R.H.D. MODEL EXTERIOR LAMPS Driving Lamp/Wiring Diagram (Cont'd) EL-1019 NeLo49LLH.D. MODEL, EXTERIOR LAMPS. Rear Fog Lamp/Wiring Diagram LIGHTING SWITCH ; othe 8a 7 f e & EL-1020EXTERIOR LAMPS Rear Fog Lamp/Wiring Diagram (Cont'd) R.H.D. MODEL M/T gp je FUSE UN BOX NeLoss EL-1021EXTERIOR LAMPS Rear Fog Lamp/Wiring Diagram (Cont'd) R.H.D. MODEL N-CVT EAR COMBINATION ‘GHG Sw EL-1022EXTERIOR LAMPS Tum Signal and Hazard Warming Lamps/Wiring Diagram L.H.D. MODEL NevosEXTERIOR LAMPS Tum Signal and Hazard Warning Lamps/Wiring Diagram (Cont'd) R.H.D. MODEL EL-1024LH.D, MODEL, Without Daytime Running Lamps ce (an ness) INTERIOR LAMPS. llumination/Wiring Diagram g “7 # q =o EL-1025INTERIOR LAMPS Mlumination/Wiring Diagram (Cont'd) L.H.D. MODEL With Daytime Running Lamps a. EL-1INTERIOR LAMPS. Mllumination/Wiring Diagram (Cont'd) R.H.D. MODEL NeLost EL-1027METER AND GAUGES Combination Meter NevoseWARNING LAMPS AND BUZZERS Warning Lamps/Schematic “HSS SL Neuo59 —L-1029WARNING LAMPS AND BUZZERS Waring Lamps/Wiring Diagram LL.D. MODEL EL-1030WARNING LAMPS AND BUZZERS Warning Lamps/Wiring Diagram (Cont'd) R.H.D. MODEL.LH.D. MODEL (wT) WARNING LAMPS AND BUZZERS Warning Buzzer/Wiring Diagram 1860" GAOuNo EL-1032 NeLossWARNING LAMPS AND BUZZERS Waring Buzzer/Wiring Diagram (cont'd) R.H.D. MODEL (M/T) oe |, uGHTING switcH use Ln 80x og | NeLosr EL-1033WARNING LAMPS AND BUZZERS Warning Buzzer/Wiring Diagram (Cont'd) L.H.D. MODEL (N-CVT) es goomon NeL050 EL-1034Warning Buzzer/Wiring Diagram (Cont'd) WARNING LAMPS AND BUZZERS R.H.D. MODEL (N-CVT) OHie Ee 3 atatatal Let 7 NeLo59 EL-1035WIPERS AND WASHERS Front Wiper and Washer/Wiring Diagram L.H.D, MODEL, g | EL-1036WIPERS AND WASHERS, Front Wiper and Washer/Wiring Diagram (Cont'd) R.H.D. MODEL, With Intermittent Wipe NewostL.H.D. MODEL WIPERS AND WASHERS Rear Wiper and Washer/Wiring Diagram ‘is raressy rw Ca} H8 ea Waster MOTOR NeLose EL-1038WIPERS AND WASHERS Rear Wiper and Washer/Wiring Diagram (Cont'd) R.H.D. MODEL E1089 EL-1039HORN, CIGARETTE LIGHTER AND CLOCK Wiring Diagram L.H.D. MODEL ros “9 98] aH eo aH = EL-1040HORN, CIGARETTE LIGHTER AND CLOCK Wiring Diagram (Cont'd) R.H.D. MODEL EL-1041LOCATION OF ELECTRICAL UNITS Passenger Compartment L.H.D. MODEL Combination taser nt lan. 9 relay Black. NeLo%s EL-1042LOCATION OF ELECTRICAL UNITS. Passenger Compartment (Cont'd) R.H.D. MODEL. Ne.osr EL-1043HARNESS LAYOUT Main Harness: LH.D. MODELS: EL-1044Main Harness (Cont'd) HARNESS LAYOUT INS J9860}99 1944 rss J9060)00 20944 wun amuos ‘$903 [r- sa re ener pouaes 0313—bveL— fear vovonbuoo sy = tn) uous x wun yonve> 10-14 (g) wos sobs InSNoo 204 1o199uUe9 aysouberg y20qq 9574 ous Jodie wos ‘ous saci 2804, ‘ove Bunun ume BuuBey ‘ays vont ous ue; dois sero. vonwomweg = pum dus 60) 11014 Wis Guawe OusipeoH 7 Hous 3696 CunwoH pis puezey oma) @ on @a ous 1294 009 tue osve> owous (asks Burg ¥poye 204) HW 108095 yuosy hu i, jou sed puns ounssord yo Buuoo}s smog Nevo8s EL-1045HARNESS LAYOUT Main Harness (Cont'd) R.H.D. MODELS. EL-1046Main Harness (Conta) HARNESS LAYOUT un jonveo $993 pees ne ee (= 14-4 — rouse s9860)99 2094 — sume ‘atuson ‘eDues20% =o Goon vows Bunun tun uoussiep ea ees due, 6} 0043 foo) wo 198 |}OHGHHIDOOHOHOHOHOOO GOG888) 9ODHHHIHOOO QO8HGHHAHHHGHOHHGGOHGHIHOOOIA 08 NeLo6o EL-1047SUPER MULTIPLE JUNCTION Terminal Arrangement TAIN HARNESS, TAIN HARNESS (Mi onode ts) GEN onade i A TaBIOCIA yy ELF INE FI) SBI SFI SBE . SFI: poe OS Erg wgbicig US EDT oy, BEL SBE 3} — ET fl 10 5] 4 7| | a cls) 03 fecie<) IasiBcica] O3 EciFa) C32 ES RSBSCS| po ca 2 ie) oA Hci] ©! EifF1 lisiict| °! Ft TBI o1 ELF TBI oi ED abel pe FQ) alco EFF B33, 02 Tasyesie3| 02 FES Baca ps EFa iacipalcd) 3 Esa ICS} ESS ls|esics} ES IAdl Fol [aol Fol in Fy ial FA pe Ee 3) FB hi] 19] 3) 0 0 Tt i il 22] ETF ee Wispisers| OM ELSE SpE OM SEL Hel eis WNISBI SF Bisel O16 Engg Fas Or ae \ ENGINE ROOM HARNESS LH ENSTNE ROOT FARNESS F. # E.G.C.S. CONTROL UNIT manacaups] ere iad dekard © ne eal View from harness side evoeoe EL-1048g = * my 6 88 a i WVAOVIC LINIAID (TTD VUODIW NVSSIN @ @ o— OOD ai =eS ee eep XXX) _O O_o ® 9 GaD200 ~ s aE; | SS CONTENTS When you read Read Gi section, ELECTRICAL SYSTEM SECTION E L ing diagram: OW TO READ WIRING DIAGRAM HORN, CIGARETTE LIGHTER AND CLOCK 0: EL-2002 LOCATION OF ELECTRICAL UNITS EL-2004 HARNESS LAYOUT EL-2006 WIRING DIAGRAM REFERENCE CHART RADIATOR FAN son LC SECTION ENGINE CONTROL SYSTEM, IGNITION SYSTEM EF & EC SECTION LOCK-UP CONTROL SYSTEM ‘AT SECTION ANTI-LOCK BRAKING SYSTEM .cnsscnnnesnieneneenens BR SECTION POWER WINDOW AND POWER DOOR LOCK, SEAT HEATING BF SECTION HEATER AND AIR CONDITIONER . HA SECTION EL-2001HORN, CIGARETTE LIGHTER AND CLOCK NOUYNINATII 42070 ap E 9019 i MUBIG 8S issauiey Wiring Diagram wen ew He HOLIMS NYOH 1ev9 ea! 7 HOLIMS NAOH ae! 07 NOH ne! IH NOH ode SGIHOM SLLUVOI wayets voneuuiniy op = NO28 90¥ HOLINS NOLIN! LHD MODEL EL-2002Wiring Diagram (Cont'd) HORN, CIGARETTE LIGHTER AND CLOCK RHD MODEL annoys 4008 JT @@ a § 6 He HOLIMS NUOH savin: @ j inven Keon [aE nn rohit’ FA ay ey } owmanau | 280 49079 Waid: El oO RH | RE a “ = 1) Geep NaOH Se NERS cerouny wey FEB Cee [NOWNINTT 5 an w f ne — YBIHON ALLGaWOI9 eLsese EL-2003 woieke vores ; I AWTS NAOH fae fal No 39 90y. 3 Fort : BLELOCATION OF ELECTRICAL UNITS Passenger Compartment LHD MODEL EL-2004LOCATION OF ELECTRICAL UNITS Passenger Compartment (Cont'd) RHD MODEL EL-2005LOCATION OF ELECTRICAL UNITS Main Harness — Rear Floor LHD MODELS EL-2006LOCATION OF ELECTRICAL UNITS Main Harness — Rear Floor (cont'd) Rear sensor harness harness sees EL-2007LOCATION OF ELECTRICAL UNITS Main Harness — Rear Floor (Cont'd) RHD MODELS EL-2008LOCATION OF ELECTRICAL UNITS Main Harness — Rear Floor (Cont'd) antsock brake sytem) Rear sensor harness Rear speaker harness soaeegaeesegeesge EL-2009LOCATION OF ELECTRICAL UNITS Engine Room Harness LHD MODELS EL-2010LOCATION OF ELECTRICAL UNITS Engine Room Harness (Cont'd) MELE EL-2011LOCATION OF ELECTRICAL UNITS Engine Room Harness (Cont'd) RHD MODELS EL-2012LOCATION OF ELECTRICAL UNITS Engine Room Harness (Cont'd) i £ » @ SGssesssseBeeeess i aeegeese MeLeese EL-2013sand Sev HS? Md VAS wos NOT (I) VYOTW NVSSIN WVYOVIC OINIYIM S99420". HOLINS OV m \ 9 wO1sis3y Lid] ef a4 fo 2 | i OE @ s@ yo.STHYaHL ~—-sernenusi0 ie © t a 8 ® 8 (exouzoy tousued*surbes) oTaaNNOD a Lew rag ag Qo e518 Cr ozeuouaes of BRIT LW wosN3s NOSHSS Eel ve GNSS sunivsaaus1 MOS ; Noir is04 Te¥S0 a Stowe? SNioNg | SS¥HHOLIMS ONTLMOTT (esos are {013998 33 ut Jon LROa Agans B08“ T8583, 38078 "38s ® % an Np 0 9; a 0 wor "Rofo estan 30010 HOLINS Nv 9 ee oe @® cy 8 oTSaNNOD osnas_033es SO inaA Slay NOTIWNTaNOS paauive Prof sand a aig BNoe peisns HoLIS NOT a — - 1m Touunoo sav $903 | ee) BS aim OF of @ast ert e 3s 2 sols BE TUR, i woos aa1Bu) 0108 ae ad eNI7b03 is | |NI7b03 @® OEE annoxs yi @8@ + ern |6 HOeEEO BOBO 6 tb | N & ig Uy wots SEF Beh . erin ca [ as @ @ a (eeu oa ee a : voriws 38 vig: aynseits ayaa ax0d§gg 859 on 0} Pina 28 QG8HG8000080 wm & Hy ARE OY 25 R08 onngais wou'lNs” NOT INTsees T |lge ames | fag S z Beas anno8? ay aay SAyAd LIND T0uINOO sev i nddg fiw fa) od 1 ee sil 7 ae @ SI] [peso porerse ———- el? # 1 ette Om] @% oanhiny 5 fi i iss ae ‘ f ; | tt t I Tl bos Bu yBes) ong eg @s oe eady i 8OLOW =I on tae ae) ea 8 SSS i 4 od COR welt) {il “= wots} [Pad) soeoes S88, SAE ‘E, ETB @re8 (@® dowya aim Yoaime J2660s9p voy * GI) @rxwa ee - euj6u9 30199 uaim sjepow x77 «GD SS @Qire%3 @ @le say ui s1epow 1A9-N » @B) a5 s19p08 109.N +) s19p0u Hw @® walle REN senso ES) ae sispou 17 = @) siapou a -G) nae ONIyaIS ATS OYELECTRICAL SYSTEM SECTION E L ‘When you read wiring diagrams: Read GI section, “HOW TO READ WIRING DIA- GRAMS", ~vONTENTS HARNESS CONNECTORS 7 : soesnatenee ELe 2 STANDARDIZED RELAYS : EL 3 POWER SUPPLY PROTECTION EL 6 BATTERY ~ EL+ 16 STARTING SYSTEM . EL. 23 STARTING SYSTEM — Starter — EL. 26 CHARGING SYSTEM EL- 33 CHARGING SYSTEM — Alternator — EL- 35 COMBINATION SWITCH EL- 40 HEADLAMP — Without Daytime Light System and Dim- mai ‘Lamp System EL+ 42 HEADLAMP — Daytime Light Syster\— ... oe BL+ 43 HEADLAMP — Dim-dip Lama System S .. EL: 46 HEADLAMP — Headlamp Aiming Controk— EL. 49 HEADLAMP EL. 55 EXTERIOR LAMPS — Rear Combination Lamps — EL- 59 XTERIOR LAMPS .... : EL- 60 “INTERIOR LAMPS: EL 77 METER AND GAUGES ........ EL a4 WARNING LAMPS AND BUZZE! EL- 92 WIPERS AND WASHERS EL- 99 EL-113 HORN, CIGARETTE LIGHTER AND CLOGK REAR WINDOW DEFOGGER EL-116 AUDIO AND ANTENNA ..... EL-120 LOCATION OF ELECTRICAL EL- 123 HARNESS LAYOUT ....... . EL-127 SUPER MULTIPLE JUNCTION (S.Mu.) snc . EL 144 WIRING DIAGRAM REFERENCE CHART RADIATOR FAN... ENGINE CONTROL SYSTEM IGNITION SYSTEM LOCK-UP CONTROL SYST ANTHLOGK BRAKING SYSTEM ‘POWER WINDOW AND POWER DOOR LOCK, SEAT HEATING HEATER AND AIR CONDITIONERHARNESS CONNECTORS Description HARNESS CONNECTORS «All harness connectors have been designed to prevent accidental looseness or disconnection. «The connector can be disconnected by pushing or lifting the locking section CAUTION: Do not pull the harness when disconnecting the connector. [Example] & | Ss Push ‘se17e00 EL-2STANDARDIZED RELAYS Description NORMAL OPEN, NORMAL CLOSED AND MIXED TYPE RELAYS veer {Nom NORMAL OPEN RELAY NORMAL CLOSED RELAY MIXED TYPE RELAY Relays can mainly be divided into three types: normal open, normal closed and mixed type relays, ‘3h 1 "OFF" TYPE OF STANDARDIZED RELAYS 1 Make 2M 1 Transfer 1M- 1B EL-3 ‘seL001H 2 Make 1 Make 1 Break seuaeontSTANDARDIZED RELAYS Description (Cont'd) (Connector symbol Case Outer View Base style [and connection | colour Application ia GREY Hom Relay CLE] allay Pum UT GREEN | Fuel Pump @|\® | BiG Radiator Fan Relay Rear fog lamp Relay Front fog lamp Relay (where fitted) Driving lamp Relay BLACK | Rear defog Rela y | CVT Relay (where fitted) ar Inhibit Relay (where fitted) ‘Accessory Relay Ignition 1 Relay Ignition 2 Relay |G Idle up Relay BLACK | Rear wiper Relay fitted) Ignition 3 Relay 2 2 | @ l2 | Sif | bh ol@ Tey BROWN | fay nce nea) 2 oN @|\®STANDARDIZED RELAYS. Location Relay key 8. Rear defogger Relay driverside kickplate) 1. Rod Fan Relay 9. Horn Relay” 16.E.GI. Relay 2. Inhibit Relay 10. Acc. Relay 17. Rear Wiper Relay 3. CVT Relay 11. Ign. 1. Relay 18. Rear Fog Relay 4. Air con. Relay 12. Ign. 2. Relay 19. Ign. 3 Relay 5. Horn Relay 13. Spare 20. Rear Fog Relay (model 6. Idle up Relay 14. Cireuit Breaker specific) 7. Front Fog/Driving 15. Fuel Pump Relay (under 21. Rod Fan Relay 2 lamp Relay * (beneath driver side fascia-model specific) LM, mode! Gee aN | EOE | \| } ca \\ iM voy ELSPOWER SUPPLY PROTECTION Fusible Links ‘A meted fusible link can be detected by visual inspection. If its condition is questionable, use circuit tester or test lamp. CAUTION: a. If fusible link should melt, it is possible that critical circuit (power supply or large current carrying circuit) is shorted. In such a case, carefully check and eliminate cause of problem. b, Never wrap periphery of fusible link with vinyl tape. Extreme care should be taken with this link to ensure that it does not come into contact with any other wiring harness or vinyl or rubber parts. LOCATION | © Fusible link box is mounted in front of the battery in the | * engine compartment. To remove cover, lift securing clips and pull off. uevor Power Supply Fuses FUSIBLE-LINK RATINGS CURRENT — | FUSELINK Ratinc —_|coLour _| CIRCUIT PROTECTED ENGINE CONTROL UNIT (E.C.C:S) 258 BROWN | POWER WINDOWS AND DOOR LOCKS RADIATOR COOLING FAN ‘ABS ACTUATOR 30A GREEN | ABS MOTOR IGNITION SWITCH SUPPLY veers 5A BLACK [ALTERNATOR — BATTERY ee EL6POWER SUPPLY PROTECTION ql ver Fuses a. If fuse is blown, be sure to eliminate cause of problem before installing new fuse. b. Use fuse of specified rating. Never use fuse of more than specified rating. ¢. Do not install fuse in oblique direction; always insert it into fuse holder properly. d. Remove fuse for clock if vehicle is not used for a long Period of time, e. Use fuse puller provided in fuse box to remove fuses. FUSE LOCATION «Power Supply Fuses are located in fuselink box at front of ‘engine compartment. «Component protection fuses are located in main fusebox situated in lower driver-side dash panel. FUSE RATINGS, RED - 108 BLUE 158 YELLOW — 208 EL-7POWER SUPPLY PROTECTION Wiring Diagram LH.D. MODEL With Daytime Running Lamps — a JERE oarrne cou goes wr rh ©. wcvr moses gag [FRR Bs f J [ ae AE BE e5tSSbe LEGHTENG swrToH (engine room herness Ltd we. oe BATTERY b=ontnor T0863 |— x08 »WI7 S7e1SN4 i Ay —_e WBisis Nye sole ibe ana] ober a re 007 F TRG |= ve iss entBaWS | ve LSS oNtEAHS |= ema Gn seousoy woos 9u16U3) (300,376) 03, rvs HoL IMs 9NTIKOT7 sanvavaa [44 ~ | TET teow | sorThht | ll Sgr, O00 Bao (eseweu ure (Po BNO onrowo_ 008 G@® an s1epeu 1A9:% eo sipou ii ‘s1y6r Buyuuny awinheg nou 1300W ‘CH (pauog) weaBbeig Burn NOMLOaLOUd ATddNS HIMOdsorman suaivay vas 28134 yotiwiyauo9 ain Tousig Ts) VSG BAA SRE MwA Sa WHOIS WNL ONY OB¥2¥H ONIN GuyZyH HVT god vse a7 sous LINO, JoHINOD_ 199. 2¢ 207 uooe Sogn vido SISA LIND onuNOg 4HOT7 aAtLA¥ axon aviaa able leNt aaiviS ' S ABHSWH OW BSIM GuYTOWEH 0104 waKoe tony —e. wSHSvH) ONY BRGIN UvaY =— > 613 a SUENSYM ONY SHUIK INOYS <— 07 | waiver yout wooo -¥g00050 eva -—en——___] (pauog) wesbeig Buy, recep NOLLOS.LOWd ATddNS HAMOd rae ahs 3008 ZN noith 3078 38hAas a (R POWER SUPPLY PROTECTION iagram (Cont'd) Lo REAR cEFOGGER or/a—e CIGARETTE LIGHTER Le —= FRONT AEPERS ANO WASHERS 6 = REAR WIPER Ano WASHER cre Avot Lae BLONER HoTOR ALR CONDITIONING otanual. ABS*N-CvTD Fuel pure eces ChEARANCE. anes. ILL untwATEON Lanes. CERERRE BATE Sabee RET ERM An EEGaT eon Wrenn 8u) REXSLEABSATSING BontROL UNIT HEADLAMP WIPER AND WASHER AUDLO. ROH LAMP. LUGGAGE ROOM LAMP BERGE NPC ECoR GAPE stop Lane HORN HAZARO WARNING HAZARD ANG TURN SIGNAL LAMPS REVERSE LAr, poner WINDOHS: EGHBENATEON reTERe™ "™*O* vusio7 EL-11POWER SUPPLY PROTECTION Wiring Diagram (Cont'd) FLH.D. MODEL Without Super Multiple Junction Orme gaa [ih it] | eee » ne EEE 9 AFT i IGNITION Swi TGH ig © a at © ® coals | SSoRneso°c'H. > ® Bre Cane unt} oo ews. oe eo gre eatery § FUSTBLE LINK 80% EL-12POWER SUPPLY PROTECTION Wiring Diagram (Cont'd) peo i * = Woe REAR CEFOGIER o2—e CIGARETTE LIGHTER — Loe FRONT WLPERS AND WASHERS Le REAR WIPER AND WASHER LA BLOWER HoTOR oom—e ASS CDLE-UP RELAY) e CY» ECCS. STARTER INHIBITOR RELAY av CVD | nee poge Lane, Auto. LuGtARE ROOM Lane BER RE UF RES Bae E ne ERT oor LL sa pein Ft cree HORN one DRIVING LAMP 2 —e HaZaRo Lames PhEERANCE a canes, CREERSEECATE” Cares: rbCSEfiurion Lanes, Tost AENENDER BuzdeR EL-13POWER SUPPLY PROTECTION Wiring Diagram (Cont'd) R.H.D. MODEL With Super Multiple Junction @: wr novels cxaguny ©: neevr nedeie en @a8 00" GROUND Ln, A Leah [Foner winnows, | | POWER BdOR Sox rein Heenees) AE ; a —— veel IGNETEON SWITCH 5 §@ iH zs] | ca a oe BO & Le RHE @ 7) SemassT ek [Lee noneel STEREO S ster “Bi ——— ies @ ‘eoging noon hanes Crt wn Owe ® Engine no 2 eon = guage | I l 1 * —-[reanes ene | BERPBE are uve Ewe. my sso} on on —e| ant =Loce oats. 3 LEAN SYSTEN | BATTERY FUSTELE LINK 80xPOWER SUPPLY PROTECTION Wiring Diagram (Cont'd) ve Lae REAR DEFOGGER on/a—w CIGARETTE LIGHTER i Lee FRONT WIPERS AND WASHERS == REAR WIPER AND WASHER a Aunt, Lock LA BLOWER MOTOR ane ABS UOLE-UP RELAY. or —» FueL purP [— FP EGCS.A8 5. cxmmuer GAS SENSOR Ge ECCS. STARTER INMEBETOR RELAY @1-6¥T2 coe RODS LATE, AUDIO. LUGGAGE ROOM LARP ERR AEV PYRE RENE aer—e STOP Lane WA REAR FOG LAMP om —e ORTVING LAMP Be HAAR LAMPS: rcttOhtirion Laws come HAZARD AND TURN SIONAL LAMPS pont ere vane EL-15BATTERY METHODS OF PREVENTING OVER-DISCHARGE The following precautions must be taken to prevent over-dis- charging a battery. + The battery surface (particularly its top) should always be kept clean and dry. If the top surface of a battery is wet with electrolyte or water, leakage current will cause the battery to discharge. Always keep the battery clean and dry. ‘© When the vehicle is not going to be used over a long period of time, disconnect the negative battery terminal. © Check the charge condition and electrolyte level of the bat- tery at service intervals. «The electrolyte level should not normally require topping-up during vehicle life; a low electrolyte level may indicate a faulty battery or alternator, check these copmponents for condition and operation and replace defective items. CHECKING ELECTROLYTE LEVEL WARNING: Do not allow battery fluid to come in contact with skin, eyes, fabrics, or painted surfaces. After touching a battery, do not touch or rub your eyes until you have thoroughly washed your hands. If the acid contacts the eyes, skin or clothing, immedi- ately flush with water for 15 minutes and seek medical atten- tion. Normally the battery does not require additional water. However, when the battery is used under severe conditions, adding distilled water may be necessary during the battery life. «Remove cell caps. ‘© Add distilled water up to the MAX level when the battery is in a high state of charge. ‘* Overtopping may lead to electrolyte leakage. EL-16Specie evity — Normal patery Suiphates battery Charging curent yo BATTERY How to Handle Battery (Cont'd) SULPHATION When a battery has been left unattended for a long period of time and has a specific gravity of less than 1.100, it will be completely discharged, resulting in sulphation on the cell plates. Compared with a battery discharged under normal conditions, the current flow in a "sulphated” battery is not as smooth although its voltage is high during the initial stage of charging, as shown in the figure at the left SPECIFIC GRAVITY CHECK 1, Read hydrometer and thermometer indications at eye level. «When electrolyte level is too low, tit battery case to raise it for easy measurement. 2. Convert into specific gravity at 20°C (68°F). Example: «When electrolyte temperature is 35°C (95°F) and specitic gravity of electrolyte is 1.230, converted specific gravity at 20°C (68°F) 1S 1.240 «When electrolyte temperature is 0°C (32°F) and specific gravity of electrolyte is 1.210, converted specific gravity at 20°C (68°F) is 1.196. wh pete ial SS = ms = = Ste pas i fo) fee seLiarP EL-17BATTERY Battery Test and Charging Chart VISUAL INSPECTION = Check battery cay for cracks oF bend = check battery terminals for damage 11 me aiterence between the max. and min, eltetroh - OK yet cals thin 10 men (0.39 in, No. 4 rebate fev Sowei roy Gc oe 1109 1100 320 aoe 1330 peated ‘Stow STANDARD CHARGE Reter to "Char a fore Sse hare’ foxes Rexty Replace r —S CHECKING SPECIFIC GRAVITY Rete 10 "Specie Gravty Check” Reterto charge ‘Aso, check. ox. NG nner rate eeu, ox| NG. CAPACITY TEST “chart a Faaay for use eevee ‘* Mount battery again ‘quick CHARGE "C: Quiek Toe required: 45 mi, RECHARGE ‘CAPACITY TEST orc (10°F) capacity TEST ater to "chart 1" Reedy mepiace ‘+ “STANDARD CHARGE" Ia recommended il the vehicle Is In storage after charging. EL-18 Refer 10 "C, Quik Chars Fer to "Cae (sit bartery temperatura rise bows 60°C (140°), nop charging. Always charge OK NG. Dertery wn it omparetry i below Rexdy Replace foruse battery se.osez‘capaciry Test BATTERY Battery Test and Charging Chart (Cont'd) oO FJ Test vung battery checker Foliow manutacture's instrsevons 0 cheek and Ready Yor use Go next ste Tent using load tester Read load tester voltage when specified dcharging Current (Refer to Fig.) toms through Bate for 1S weonds avove 96v01%8 | | aeiow9.6 vor: OK NG. Reaay to we Go to next step EL-19 1+ Check battery type anc etermine the specified current using the following abe Fig) O'SCHARGING CURRENT (oad tener) Te Curent) 286 19RIL) 30 34819810) 99 4o824R1L) 135 55874R(L) 138 S0023R(L) 150 SSO73R(L) 180 6s026R(L) 195 0026RIL) 195, 76031A(L) 210 95031RIL) 240 11s031R(L) 240 9SEAIRIL) 300 130E41 RIL) 330BATTERY Battery Test and Charging Chart (cont'd) ‘A: SLOW CHARGE 1210 18 volt Below 12 volts or above 1S vate Fig. 2 INITIAL CHARGING CURRENT SETTING (Slow charge! BATTERY | 288 19RIL) B4B 19K SPECIFIC Gravity Below 1.100 fer mating charging, adjustment of charging currant nt necessary Fig 3 ADDITIONAL CHARGE (Siow charge) torte] [oan] [aes | [ionrae ox. [= Paplace battery Continue 10 charge for 12 hours I I L | ‘charge for 5 hours, {stil charging ie tor ¢nours | | Charge for 7 novrs Rieter 19 "Soecite Gravity Cheek CHECKING SPECIFIC GRAVITY | + Conduct additions charge a per Fig 3,11 necessary + Go to “CAPACITY TEST I Goto “CAPACITY TEST E1082 CAUTION: a. Set charging current to value specified. charger is not capable of producing specified current value, set its charg- ing current as close to that value as possible. b. Keep battery away from open flame while it is being charged. c. When connecting charger, connect leads first, then turn on charger. Do not turn on charger first, as this may cause a spark. 4, Ifbattery temperature rises above 60°C (140°F), stop charg- ing, Never charge battery when its temperature is above 60°C (140°F). EL-20BATTERY Battery Test and Charging Chart (Cont'd) RiaTAROARE CHARGE Fig. INITIAL CHARGING CURRENT SETTING (Standard charge BATTERY Tye con. Vented Serene nti charging current from Sreciric tech pwty.relrnng oa 4 Gnaviry ; 100-1130 feoia [50 )[s01ai 0 aileoai| 901 [13.0 | 1390-1160 [ao iaijaoiai|soiaifeormifrom] eo cal [ova [_omeronterto sno 7160-1100 fro wai po ml eoial feo wifeorai] 70. [poral 1.190: 1.220 [201A [20 14) [3.0 1A) ao ca|s.ota)| 5.0 1A) |7.01A) 2aB19RIL) 3aBN9RILI 12084R(L) e0026RIL) ys0a1RiL i é 8 8 © Check battery type and determine the specified current using the table shown above 2 Alter sarting charging, aaiut CHECKING SPECIFIC GRAVITY Rater to "Specie Gravity Check ——__! Prepon \ overcame Tan [Ceeerae | [Crore] [xo rae | [ane Go to "CAPACITY TEST CAUTION: 4. Do not use standard charge method on a battery whose specific gravity is less than 1.100. b. Set charging current to value specified in Fig. 4. If charger is not capable of producing specified current value, set its charging current as close to that value as possible, ¢. Keep battery away from open flame while it is being charged. d. When connecting charger, connect leads first, then turn on charger. Do not tun on charger first, as this may cause a spark. e. If battery temperature rises above 60°C (140°F), stop charging. Never charge battery when its tem- perature is above 60°C (140°F). EL-21BATTERY Battery Test and Charging Chart (contd) CHARGING TIME (Quick emerge) eATTERY 5 3 ree | 22 zzz = Determine sna ehaging current etng an com) | 8S BES 5 charging tome from space paw, aering con. \ nent \| 83 $33 3 ores Verteo ial sreciric Gravity Tow [a | wow [som | ao 1100-1 730 enous + 1930-1160 2onows Coupe batery a 1160-1190 1 Shows 7790. 1220 To nows ‘ ‘Above 1720 078 nous 4S min) oto “CAPACITY TEST ‘= Check batiery type ond determine the specified current using the fable + Atte starting cnarging, adjrtment of charging curent isnot necessary ‘ sevosiz CAUTION: a. Do not use standard charge method on a battery whose specific gravity is less than 1.100, b. Set charging current to value specified in Fig. 6. If charger is not capable of producing specified current value, set its charging current as close to that value as possible. ¢. Keep battery away from open flame while it is being charged. d. When connecting charger, connect leads first, then tum on charger. Do not turn on charger first, as this may cause a spark. e. Be careful of a rise in battery temperature because a large current flow is required during q charge operation. Hf battery temperature rises above 60°C (140°F), stop charging. Never charge battery when its tem- perature is above 60°C (140°F). 1. Donot exceed the charging time specified in Fig. 6, because charging battery over the charging time can cause deterioration of the battery. Service Data and Specifications (S.D.S.) Battery type 46824R (L) Capacity V-AH 12-36 CAUTION: a, Ifit becomes necessary to start the engine with a booster battery and jumper cables, use a 12-volt booster battery. After connecting battery cables, ensure that they are tightly clamped to battery terminals for good contact. EL-22STARTING SYSTEM Wiring Diagram LHD MODEL WT Tex pron SATOHSTARTING SYSTEM Wiring Diagram (Cont'd) LHD MODEL N-CVT TGNETTON wi tor 2qsreitoR AREAS ‘Engine USE 2.00% gore eo ven ‘SOprcr RoUTIAES > t § Sie FUSIBLE LINK BOx g eaTTERY stanrer sia” @E Go Bo0¥ GROUND eu3 RHD MODEL N-CVT Toni Tron Swit ‘gig to eff rt al | ctain nerness? Fuse 9LocK, @® [Lee ae fo i 7 Foencat Be a8 FUSIBLE LINK BOX © 2 ur @§ t@ a 0) ered eee EL-24 veipow puro} 8! Ayeuvouge Aue es) hres ‘81981U09 Yous eoeidoy nw 12849 ave anouSeu 10 feos Jeueys yoins vonuB aapde: 0 uedoy f ieee | ‘voIs01109 pue svona9uL09 Jo; sieUwHe) Ao, 18q puP voRNpU09 Bure49 Jo} MNEq ¥OB4D (amos sun) SW ‘Avesseoau p e0eidouy snug ue "309 ‘Yoessaneu j a2eay 1896 Gun pue Wiring Diagram (Cont'd) E-SHOOTING STARTING SYSTEM 2 UOSUBUP ISNIDY 8 {pins aueuBew a0eydas 20 vedou @ ‘ois 2N00 | Poster on uum yds sue aus & BEN KRSOSSE SINEWIE AO *) oy ON exo u88b {uy pve vowd 0 vonpuce Sunjsow 5) sal eSuget9do sojou Jo wows o1ovBeu 104 A0k UE wae ° —+2_ ©: wo pour ‘9 ws oR doIs WaIEKS 1am) ue waists voruds 2249] ou wn aus642 $900, EL-25 yp warsks Buus sedo1 put 92049 syeuuar Aug 1p vosoiie> pur sv0I20WU09 seday @ ‘Ayaueg 82,081 10 O618uD STARTING SYSTEM TROUBLE ‘su0490uv09 10) 5 ‘von p09 Bubie49 10 Buea ha unt aubua s20g} ‘wim so}ou saue%s $200STARTING SYSTEM — Starter — Construction — BoschSTARTING SYSTEM — Starter — Frxing bots Fang bot N-CVT Transmission Manual Transmission veto Starter Motor There are four basic models of starter motor, dependent on market application, engine size and NeCVT or manual transmis- Starter Type wr eeu revoonw | CsVE - eV 11K | gga Speci - ae aa revoskw CGISDE (Manet Spee) «Ensure correct starter motor is used when replacing. Note that manual and N«CVT starter motors have different front brackets and fixings and cannot be interchanged. REMOVAL AND INSTALLATION Removal — Manual Transmission 1, Remove battery negative cable from battery. 2\ Remove battery cable from starter motor. 3. Disconnect harness connector from starter motor harness. 4. Remove starter motor mounting bolts. 5. Remove starter motor. oO ars imagem oe vuetoas EL-27ot STARTING SYSTEM — Starter Starter Motor (Cont'd) Removal — NeCVT Transmission 1. Remove battery negative cable from battery. 2. Remove air cleaner unit from top of engine. 3. Remove upper starter motor mounting bolt (14 mm). 4. From beneath car remove manifold support bracket. 5. Remove battery cable from starter motor. 6. Disconnect harness connector from starter motor harness. 7. Remove lower starter motor mounting bolt. 8. Remove starter motor. INSTALLATION «Installation procedure is the reverse order of the removal procedure. Solenoid Check » Before starting to check, disconnect battery ground cable. © Disconnect “M” terminal of starter motor. 1. Continuity test (between “M” terminal and switch body). « No continuity ... Replace. 2. Insulation tests (between “B” and “M" terminals, and “B" terminal and solenoid body). Continuity exists ... Replace. 3. Continuity test between “S” terminal and switch body. @ No continuity ... Replace. EL-28STARTING SYSTEM -- Starter Pinion/Clutch Check 1. Remove Starter Motor. 2. Check to see if pinion locks in one direction and rotates ‘smoothly in the opposite direction. «If it does not lock (or locks) in either direction or unusual | resistance is evident... Replace. @._ Inspect condition of pinion and ring gear teeth, replace if teeth are worn or damaged. ue.oad STARTER MOTOR — Disassembly Remove Starter Motor. Remove back cover fixing bolts and end cap fixing screws. Separate field coil yoke from pinion gear. Separate armature and brush gear from starter/armature assembly With starter motor disassembled the following checks can be performed « Assembly is the reverse procedure of disassembly. Fxg bolts BA) pone ‘| Brush Check ™~ 1. With starter motor disassembled check wear of brushes. HSL new tengin Wear limit lengtt Refer to “Service Data and Specifications”, Excessive wear ... Replace by cutting brush connecting leads at their mid-point and soldering the new connectors to them. (If original brushes need cleaning, use a petrol moistened cloth.) 2. Check brush spings and ensure brushes move backwards and forwards freely in their holders. minimum leoghn . uex09} Brush Holder 1. Perform insulation test between brush holder (positive side) iS 2 and its base (negative side). + Continuity exists ... Replace 2. Check brush to see if it moves smoothly. «If brush holder is bent, replace it; if sli clean it 1g surface is dirty, Field Coil Check 1. Continuity test (between field coil positive terminal and pos- itive brushes). «No continuity ... Replace yoke assembly. 2. Insulation test (between field coil positive terminal and yoke) + Continuity exists ... Replace yoke assembly. ‘Set io2e| EL-29STARTING SYSTEM — Starter — 1 Yoke Assembly Check Check magnet for cracks and replace malfunctioning parts as an assembly. Armature Check Test continuity between adjoining segments. No continuity .., Replace. Insulation test (between each commutator bar and shaft) Continuity exists ... Replace. Check commutator surface. Check the armature and commutator for wear or damage. A dirty or burned surface may be cleaned with fine grade emery paper. Check diameter of commutator. Commutator minimum diameter: Refer to “Service Data and Specifications”. Less than specified value ... Replace. EL-30STARTING SYSTEM — Starter — ran ban aren @oF20) sevz07e| Pon wore busy oot Press mew bus ins fluan wien casein From Brace se.z0er| se.200P| pion thrust gap cr039 ‘Armature Check (Contd) 5. Check depth of insulating mica from commutator surface. © Less than 0.3 mm (0.012 in) ... Replace. Bearing Check Renew bearing bushes if there is: * evidence of armature fouling magnets. * perceptible side play between bush and shaft. Press wom out bushes from the Front and Intermediate brackets using lever/hand operated press and suitable mandrels. ‘Soak new bushes in engine oil for 30 minutes before press fiting into position using a suitable press and man- drel 1 Pinion Shaft Trust Gap Check Check movement ":” of pinion when it is pushed forward until it touches front bracket stopper. Movement ‘:": Refer to S.DS. It movement “r" is not within specified range Adjust gap. EL-31STARTING SYSTEM — Starter — Starter Motor — Assembly — Assembly is the reverse process to disassembly. © Apply high-temperature grease to lubricate the bearing, gears and pinion shaft when assembling the starter. Service Data and Specifications (8.0.S.) STARTER Rating KW] 09) 14 ‘System voltage v 12 2 No-load voltage v 15) 1" (Cureent (maximum) Al 50 75: Revolution "pm 4900 2700 . od Ey) Eee Minimum length of brushes mm (in) 502) 502) Brush spring tension | Niko. )| 149-252 (1.46- 257, 822-567) | 149-252 (146-257, 3.22 5.62) Clearance "1" between pinion front 0-045 MT 0-045 MT ‘edge and pinion stopper mm 0-06 NeCVT 0-06 NcVT EL-32CHARGING SYSTEM Wiring Diagram LHD MODEL Fuse s.0p% ‘orminavion reTER git even SEER ROUTINES» cnarce uw t TEMETION, SwI Tox ‘On ors Paar ‘Reenee°C°R > a oe Ewe. HOS me » =e ee Ee FORE. —S ee FUSTaLE LINK BOX c pony GROUND earrery ews RHD MODEL fuse sroce cher ve ceOHER COMBINATION METER ‘SOBELY ROUTING” > ‘CHARGE @ w t sme ete fo FSS5ut°p9¢¢.) isin parneaes ‘| L_1] peics.ra%8 > Hogug! tcansonte roent Sper "PS: Pipte Junction Oe Sa 1 poset eng tyT ip @ oneal SiGAT SEBS AUPE TST ERE, pepe OXRHED __swre oe em een tos en bi jal bis “367 — S ey = — $ poor GROUND aarteny EL-33CHARGING SYSTEM Trouble-shooting Before conducting an alternator test, make sure that the battery is fully charged. A 30-volt voltmeter and suitable test probes are necessary for the test. The alternator can be checked easily by referring to the Inspection Table. Before starting trouble-shooting, inspect the fusible link. ‘WITH IC REGULATOR: 7 ce GRO) Sica Tore) ~ ~----------- [eet Henman) owen} [ieee [Bomseo cS. — foomoneaa ce Toy) —[Bumager ORG. sonch Cam OFF) tome weed L(G non 1550) — [Rima Uidensne® OK sorter | Ges 41). Use tity charged battery 2) Light: Chrage warning light A.C.G. : Alternator parts except IC regulator IGG: ICregulator ©.K. = IC-alternator is in good condition 3) When reaching "Damaged A.C.G.", remove alternator from vehicle and disassemble, inspect and correct or replace faulty parts. Connector veuist 4). Terminal "8" is marked on rear cover of alternator. EL-34CHARGING SYSTEM — Alternator — ConstructionCHARGING SYSTEM — Alternator — ciarkahat er Pray Alternator — Removal (for cars fitted with Power __ Puiey___Nas 5 conpresr] Steering and/or Air Conditioning) ° Paley | 1, Remove battery negative lead from battery 2. From beneath car remove front and RHS splash guards. 3. Loosen idler pulley nut (17 mm) ———_ 4. Slacken belt by tuming adjusting bolt clockwise (access from topside of engine - 12 mm) Remove power supply cable. Disconnect hamess connector. Remove lower altemator mounting bolts (2 x 14 mm). Remove upper altemator mounting bolt (14 mm) and remove alternator. Austing ett iter puey exon lorarksnan —{ JPurey Alternator —- Refitting Refit alternator using the reverse procedure to removal. Tighten fixing bolts to the torque specified. «Tighten drive belt by turning adjusting bolt in anti-clockwise direction (Refer to MA section for full details of belt tension- ing) + When belt is correctly tensioned tighten idler pulley bolt to torque specified EL-36CHARGING SYSTEM — Alternator ‘Adjusting Prate _Lpper Fixing “ONSITE \ eo terme Aternator Adjust Bott Lower xing Aerator Securing bot batt BD x73-5 ees) & Fy s73-s008-51) Bem trem | Alternator — Removal (for vehicles without power steering and/or air conditioning). Remove battery negative lead from battery. Remove lower alternator fixing bolt Remove power supply cable. Disconnect harness connector. Slacken alternator securing bolt Slacken drive belt by slackening alternator adjusting bolt (anti-clockwise) and moving alternator. Remove alternator upper securing bolt and remove alterna- tor. Alternator — Refitting ‘+ Installation ot the alternator is the reverse of the removal procedure. + Tighten bolts to the torque figures specified. «Refer to MA section for full details of belt tensioning spec- ifications. ‘Aternator ———sensiniog __ Atemator | Pulley Ccrankshat Pulley Pr pens ] Alternator — Disassembly ay ee Remove alternator from vehicle as described previously. Remove bolts (3) from back cover. Pull out wing clips (3) and remove back cover To remove brushes, remove two screws holding connector! brush assembly to body. The brushes and power transistor are soldered to the con- nector p.c.b., replace complete unit if brush holder, power transistor of connector is found to be faulty. PONo EL-37CHARGING SYSTEM — Alternator —- StatorDrede Pack | 1A = Normal brush length 8 = Mnemum Brush length eros Stator, regulator Alternator — Disassembly (Cont'd) 5. Remove screws holding stator assembly to front cover (4) and separate stator from rotor. «The stator field coils are soldered to the regulator/diode pack and should not be separated. Replace stator, regula- tor and diode pack as a complete assembly if found defec- tive. 6. Bearings can be removed using suitable bearing pullers. Rotor Slip Ring Check 1. With Rotor/Front Cover and Stator separated, check conti- nuity of rotor slip rings. « No continuity ... Replace rotor. 2. Insulator test «. Continuity exists ... Replace rotor. 3. Check slip ring for wear Slip ring jum outer diameter: Refer to “Service Data and Specifications”. BRUSH CHECK 1. Check brush length for wear. «Replace brush if it is worn down to 10 mm (0.39 in) or below. 2. Check brush spring pressure. Measure brush spring pressure with brush pressed to moul- ding Spring pressure: Refer to “Service Data and Specifications”. «Not within the specified values ... Replace. STATOR AND DIODE CHECK The stator and diode assembly cannot be separated. If the alternator output voltage is less than specified in “Service Data and Specifications", the stator/diode assembly should be replaced as a unit Alternator — Assembly The alternator should be assembled using the reverse process to disassembly. EL-38CHARGING SYSTEM — Alternator — Alternator — Disassembly (Cont'd) Service Data and Specifications (S.D.S.) ALTERNATOR Manufacturer Bosch Nominal rating val 12-65 a ‘Ground polarity Negative Minimum revolution under no-load 1050 max (ovhen 14-volts is applied) rpm 4000 Hot output current Aim 65/5000 Regulated output voltage v 144-147, “Minimum length of brush mm (in) 300.39) Brush spring pressure N(@. o2), 1.9 (194, 6.84) Slip fing outer diameter em (in.) 15.3 (0,602) EL-39COMBINATION SWITCH Operational CheckCOMBINATION SWITCH LUghiting switch eae Wiper and vetoe7 Replacement «Each switch can be removed from the switch base while stil in place on the steering column. 1. Remove 4 screws from underside of steering column cover and remove cover. 2, Remove switches by pinching top and bottom fixing wings and pulling switch out from switch base. 3. Remove connectors from switch assembly. To remove combination switch base Remove switches as described above, Remove steering wheel (refer to ST section). Undo attaching screw and pull switch base off of steering column. ELHEADLAMP — Without Daytime Light System and Dim-dip Lamp System — Wiring Diagram LigeTinG swore —— corpinarion HETER OH BEAT ody cRounn a (3 = “| cee | Gz f : ; eas ‘= HEADLANE LH @p® j@ * wo0r GROUND ayy EL-~42HEADLAMP — Daytime Light System Operation After starting the engine with the lighting switch in the “OFF” position, the headlamp low beam and clearance, tail, ficense and instrument illumination lamps automatically turn on. Light- ing switch operations other than the above are the same as conventional light systems. Erone Ti enare spond Tih ogre ng om [ist | ao | oF | ist a0 Ling sch a[e[efaTspelals[eolalelela]ele}alefe am [grea [xx fopx}xtolo}xtolxfxpo]x{xfofo]xfo estan 4 0 tonbeam {xx x]x}x [x] x}o]xfoToroy x(x] x] «fox Cerne aa rp x[x[xjofetotefelofafofofolololefolo senso ansinewomenrtumnss TTT o]o/ofololofolojololololololo a 1 it rao SR tens Schematic [pS TTT Tess EL-~43 pace | | ieee “Oise Pees veoHEADLAMP — Daytime Light System — Wiring Diagram | @3@y eo mm LrouTtng sutton FUSEBLE LINK Box m1 'g cal if | I vue EL-44HEADLAMP — Daytime Light System — "| Location Canto Unit a The Daytime Light Control Unit is fitted to a mounting bracket located beneath the dash panel to the left of the steering column, The unit is sealed, with no serviceable parts; in the event of failure replace unit, EL-45,HEADLAMP — Dim-dip Lamp System — Operation When ignition switch is in the “ON" position with the lighting ‘switch in the 1ST” position, the headlamp low beam comes on dimly to function as a clearance lamp. Lighting switch opera- tions other than the above are the same as conventional light systems. Ignition switch OFF or ACC oN ‘OFF 1st 2ND OFF 41st 2ND Lighting switen a : ale, elals|clalelciale[clalelclalslc High beam |x| x]O[x|x]o]o|xlolx x[o[o|x | Headamp eo boam [x Tx [x [x [xx] xfo[x [x] x o[x Pind (low Vx rxtx lt xf x] x] xix] x] x} x x] x beam) | Clearance and tail lamp x[x[x[ofolojolo[o|x|x ofo een cision urine: TT x [9 ofejofofo|x|x ale Stang OW X Lamp “OFF Aida onetons Schematic — Lionring swtrox Sarton, outer Peta OATES PAT a eich atch OUM-DIP LAMP CONTROL UNCT vets EL-46FF HEADLAMP — Dim-dip Lamp System — Wiring Diagram MT Model (without Super Multiple Junction) FUStBLE Lin Box parrery EL-47HEADLAMP — Dim-dip Lamy Wiring Diagram 'N-CVT Model and M/T Model (with Super Multiple Junction) Ltauring swtron Heapeane stem — vetiasHEADLAMP — Headlamp Aiming Controt Description ‘The vertical direction of the headlamp projection can be adjusted from inside the vehicle to prevent the headiamp beam axis from facing upward due to a change in the number of ocoupants and load conditions in the vehicle. No continuity {wire portion) sensor | {Rotating portion) No continuity (Winte portion sensor! Rotting 1 ------) SELBSEF EL~49HEADLAMP Headlamy ing Control Description (Cont'd) I DOWN con MoToR S£.060F| vp con ZN DOWN con MoToR se.2sie| SeL220° CIRCUIT OPERATION [Example] Aiming switch « When the aiming switch is set to “0”, the motor will not start because the power terminals are positioned at the noncon- uctive section of the sensor's rotary unit Aiming switch “0” — “1 © When the aiming switch is moved from “0” to “1”, power is applied to the motor through the sensor's conductive sec tion. The headlamps will then move in the "DOWN" direc- tion, The motor continues to rotate while the rotary unit of the sensor moves from point A to point B. «The power terminals will then be positioned at the noncon- ductive section, disconnecting the power to the motor. Then motor stops. Aiming switch “1” — “0” «When the aiming switch is moved from “1” to “0”, power is applied to the motor through the conductive section of the sensor. The motor will rotate to move the headlamps in the “UP” direction. + When the rotary unit of the sensor moves from point B to point A, the motor will stop. HEADLAMP AIMING — Adjust 1. Horizontal aiming of the headlamp is achieved by adjusting the top adjusting screw as detailed for non-headlamp aim version. 2. Vertical aiming of the headlamp is achieved in the same way as for non headlamp-aim versions, except that the aim adjusting screw is situated on the back of the headlamp aim motor. EL-50Hi IEADLAMP — Headlamp Aiming Control HEADLAMP SWITCH — Removal To remove Headlamp aiming switch for replacement or testing purposes, press in plastic wing clips before removal. sevzase| EL-51HEADLAMP — Headlamp Aiming Control — Schematic GnHEADLAMP — Headlamp Aiming Control — Wiring Diagram veti2aHEADLAMP — Headlamp Aiming Control aay Trouble-diagnosis & SYMPTOM: Headlamp ing does not operate. CHECK (For aiming switch) *| (Reler to “POWER SUPPLY Check it 12 volts exist between ROUTING.") EEX || POWER SUPPLY cincuT NS. f Cneck 1A ise att Boe terminals @ and © Voltmeter terminals] Oo sezare|] — @ Voltage (V1 [Approx 12 OK a t AIMING SWITCH CHECK NG. Replace aiming switch Check continuity between termi- Tem] ral | |] nals at each switch positon. | switen — |®|® || position 0 se.222P| 1 2 x cS ames 2" GROUND CIRCUIT CHECK NG. || Repair hamess between aiming [a] FOR AIMING MOTOR [*| motor and body ground Check continuity between ernie | (——_"_] nals @® and body ground. Continuity exists ... O.K. K P sevz2a9| POWER SUPPLY ciRcUT [NG [ Check harness between aiming CHECK switch and aiming motor unit (For aiming motor unit) Check it 12 volts exist between terminals ®, @, @, @ and ® i Vor Lughting smten meter Aiming termi- | Voltage [V}Jowitch post nals tion ei sevzz]|' 5) (Renton 12] =o" a | erat ~| © approx 78 2 o [Approx 72 2 0 [Except [ex Replace aiming motor unit, EL-54HEADLAMP. Fixing ! 44-65) Flr gm, ty ‘Fig Grommet oo Removal 1. Remove battery negative earth cable from battery. 2. Remove headlamp wiper arm (where fitted) 3. Remove body front grille by releasing square-head fixing studs (2 off) and prising grille from body fasteners (see BF section for details). Remove lower fixing screw. Flemove lower and upper retaining nuts. Remove upper fixing screw. Remove electrical connectors from back of headlamp, Remove headlamp. Installation 1. Align headlamp with mountings and locate fixing grommet to position. 2. Installation is the reverse process to removal, ensure fixing screws and nuts are fitted in the reverse order to removal and tightened to the specified torque figures. 3. Check headlamp aiming is within specifications and adjust if necessary (see headiamp aiming procedure). eNOS ¢ Ensure all bulb sockets and wiring are fully secured to the lamp housing and all connectors are securely locked into position. ¢ Donot pull on harness wire to move lamp. « Donot use organic solvents on the lamp hous EL-55clearance: bulb removal ‘sg & “Turn gaat bulb removal e195 ~e) Rubber cap HEADLAMP_ Bulb Replacement The headlamp is a semi-sealed beam type which uses a repla- cable halogen bulb for the main and dipped beam. The headlamp unit also contains the clearance lamp and front turn signal indicator bulbs. Main Beam/Dipped Beam 12.V 6055 W (Ha) 12V5W [12 V 21 W (yellow) Clearance Lamp Front tur signal lamp All headlamp bulbs can be replaced from the engine compart- ment side without removing the headlamp body from the vehi- cle. Main/Dipped Beam (H4) Grasp only the base when handling the bulb. Never touch the glass envelope. 1. Disconnect the battery cable. 2. Disconnect the harness connector from the rear side of the bulb. 3. Pull off the rubber cap. 4. Release bulb retaining spring by squeezing spring sides and pulling backwards. 5. Remove headlamp bulb carefully. Do not shake or rotate the bulb when removing it 6. Install in the reverse order to removal Clearance Lamp Disconnect the battery cable. Disconnect the H4 Bulb Harness Connector. Pull off the rubber cap. Twist clearance bulbholder assembly (anti-clockwise) and withdraw from headlamp unit. Remove bulb from holder. Install in the reverse order to removal. Pepe on Front Turn Signal Lamp 1. Disconnect the battery cable. 2. Disconnect the tur signal/clearance lamp hamess connec- tor from rear of headlamp. 3. Twist bulb holder anti-clockwise using moulded wings for leverage, 4. Remove bulb from bulbholder. 5. Install in the reverse order to removal EL-56HEADLAMP_ Bulb Replacement (Cont'd) ‘nn Baar CAUTION: Doped beng] Ten srl (-¥4) Ee on vie «Do not leave the bulbs out of the headlamp reflectors for ong periods of time; particles of dust, moisture, smoke etc, may enter the headlamp enclosure and affect the perf mance of the lamps. In particular, the H4 main/dipped beam bulb should not be removed from the headlamp reflector Until just before a replacement bulb is to be installed. DISASSEMBLY The headlamp can be disassembled for lens/reflector replace- ment. i ‘i (| i | To remove headlamp lens release lens retaining clips. iS Pr ( EL-57HEADLAMP Top acjster screw lor norzontal aiming ef” WB) ~ ACCEPTABLE RANGE s ( I Vee ee baci a a crest sevzs Aiming Adjustment Vertical aiming of the headiamp reflector is achieved by adjust- ing the bottom adjuster screw. Horizontal aiming of the headlamp reflector is achieved by adjusting the top adjuster screw. ‘When performing headlamp aiming adjustment, use an aiming machine, aiming wall screen or headlamp tester. For operating instructions of any aimer, it should be in good repair, calibrated and used according to respective operation manuals supplied with the unit. Hf aiming equipment is unavailable, aiming adjustment can be performed as follows: Low Beam 1, Tum headlamp low beam on. 2. Use Top and Bottom adjusting screws to achieve horizon- tal and vertical aiming respectively. «Main optical axis of headlamp beam can be adjusted by +/- 2° horizontally and +2°/-4° vertically. + First tighten the adjusting screw all the way and then make adjustment by loosening the screw. Vehicle Conditions: 1) Vehicle should be correctly loaded i.e. coolant and engine oil filled up to the correct fevel, a full fuel tank and no other load other than the driver or an equivalent weight (75 kg) placed in the driver's position. 2) Keep all tires inflated to correct pressure. 3) Place vehicle and tester on same flat surface. «Check specific regulations relating to country for intended use. Adjustment Procedure 1. Adjust headlamps so that main axis of light is parallel to center line of body and is aligned with point P shown in illustration 2. Figure to the left shows headlamp aiming pattern for driv- ing on right side of road; for driving on left side of road, aiming patter is reversed. 3. Dashed lines in illustration show center of headlamp. “H": Horizontal centre line of headlamps. “W,": Distance between each headlamp center. “LU: 5 m (16 ft.5 in.) “C": 65 mm (2.56 in.) EL-58EXTERIOR LAMPS — Rear Combination Lamps Reverse lamp (RHO) Bub removal A mee eat fog tam (LHO) Fixing wings: \ bute otaer UE.0s¢ PNK Face as \= Ao)s (Fer ate ae Bt eros Rear Combination Lamp — Bulb Replacement LHD and RHD versions have the following variations: Sip ad Tal Gav BV] Top Boh See | Too Bo Ses Tu Sal Lane 12v- 2 New tof@pbam [Rex op bah Foglaro (eu) (iaV- wo] Boon ur ac | Batam Ar ade Reverse Lamp (av 21W)| Bottom RH side | Bottom LH side 1. To Replace Bulbs, pull back luggage compartment trim; pinch bulb holder fixing tabs and remove bulb holder. 2. Replace Defective Bulb. 3. Replace bulb holder ensuring it is locked into position. Rear Combination Lamp — Removal Remove battery negative cable from battery. Remove bulb holder as described above. Remove nuts from fixing studs. Heat mastic from luggage compartment side until it is pli able enough to allow lens unit to be pulled away from mounting sope Rear Combination Lamp — Installation 1. Remove all traces of mastic prior to applying new sealant. 2. Apply suitable bead of hot butyl around lens mounting, «Hot Butyl should be applied without excess or gaps and must not protrude outside periphery of lens edges «Bead joint should be at the bottom of lamp in mounting position. 3. Fit lamp in position, 4, Tighten retaining nuts on fixing studs to the specified torques in the following order @), @. @ 5. Replace bulb holder ensuring it is locked securely in posi- tion. «Take care not to damage surface of lens, rim and coat- ing of vehicle body panel when mounting. « Do not use organic solvents to clean exterior of the lamp. EL-59Fixing nut EXTERIOR LAMPS HIGH MOUNTED STOP LAMP — Bulb replacement Remove battery negative cable from battery. Open Back Door to access lamp. Remove screws in lamp rear cover and remove cover. Unciip reflector. Twist out defective bulb and replace Bulb: 12V 21W gaan HIGH MOUNTED STOP LAMP — Removal and Installation 1. Remove battery negative cable from battery. 2. Remove screws in lamp rear cover (2 off) and remove cover. 3. Remove fixing nuts and remove assembly. © Refit in reverse order. LICENSE PLATE LAMP — Bulb removal 4. Remove battery negative cable from battery. 2. Unscrew lens fixing screws (2 off), pull off lens cover (screws remain captive). 3. Pull out defective bulb and replace. Bulb: 12V 5W EL-60EXTERIOR LAMPS: Clearance, License, Tail and Stop Lamps/Wiring Diagram — — LH.0. MODEL Without Daytime Running LampsEXTERIOR LAMPS Clearance, License, Tail and Stop Lamps/Wiring Diagram (Cont'd) L.H.D. MODEL With Daytime Running Lamps ecoiz 2's +8 aariery 5 EL-62EXTERIOR LAMPS Clearance, License, Tail and Stop Lamps/Wiring Diagram (Cont’d) R.H.D. MODEL REAR COMBINATION LAMP RH Liciring swt To Baby GROUND vetia8 EL-63EXTERIOR LAMPS: Back-up Lamp/Wiring Diagram LH.D. MODEL 3G 8 | 2 t=, == EL-64EXTERIOR LAMPS Back-up Lamp/Wiring Diagram (Cont'd) R.H.D, MODEL ‘ooY GROUND IRAIBETOR SWETOH a| 2 || — gz e653) veti28 ‘EL-65Connector YF” Fisher Twist and PULL Back cover | vueties veL164 EXTERIOR LAMPS Driving/Fog Lamp — Bulb Replacement ~ 1. Remove battery negative cable from battery. 2. Remove Driving/Fog Lamp finisher by unscrewing captive screw. 3. Unscrew lamp from bumper. Twist lamp out of bumper. Twist and pull out sealing cap from back of unit. Release bulb securing clip Disconnect defective bulb and replace. Do not touch bulb directly. When re-fitting sealing cap on back of lamp, ensure it is in correct orientation to prevent water ingress. Bulb: H4 12V 55W ee Nome Driving/Fog Lamp — Replacement 1, Remove battery negative cable from battery. 2. Remove Driving/Fog Lamp finisher by unscrewing captive screw. Unscrew amp from bumper. Twist lamp out of bumper. Remove connector from bumper stud. Disconnect lamp from harness and remove. esse Refit new unit in reverse order to the above. Do not stick items onto lens. : ‘+ Donat allow plastic areas of lamp to come into contact with chemicals, Driving/Fog Lamp — Aiming 1. Remove Driving/Fog Lamp finisher by unscrewing captive screw. 2. Adjust vertical aim by turning the top aiming screw. 3. Adjust horizontal aim by turning both the top and bottom aiming screws in the same direction © When aiming the tamp do not cover any part of the lens. EL-66LH.D. MODEL EXTERIOR LAMPS Driving Lamp/Wiring Diagram ortving Lane Ce Lo) a4 o® SorecasEXTERIOR LAMPS Driving Lamp/Wiring Diagram (Cont'd) xis @ega Camm ea Tos fy elo) {8 [jen ols "fit [eeccueee i i LnaomaedEXTERIOR LAMPS Front Fog Lamp/Wiring Diagram 5 Tol ga age | HiPlas: qT | TAT ~ | -— fee ja HO H® [estes ©) : THO) t © joo 3 | ee we §@2@ coy GROUND RonT FOC CaaS RE ve, EL-69EXTERIOR LAMPS Rear Fog Lamp/Wiring Diagram LH.D. MODEL ae® 8 ces a ‘FUSEOLE LINK BOX a a i o=0 EL-70Rear Fog Lamp/Wiring Diagram EXTERIOR LAMPS R.H.D. MODEL WT connoys 1008 @Qe@ enti 208i) L sont +t : SS — Boge OT / I 7 | 5 | FS (lp! + : yh 8 gaa ot) = | ne (fi) : veti93 EL-71R.H.D, MODEL N-CVT EXTERIOR LAMPS. Rear Fog LampiWiring Diagram (Cont'd) soni i iEXTERIOR LAMPS Turn Signal and Hazard Warning Lamps/Wiring Diagram LH.D. MODEL EL-73EXTERIOR LAMPS Turn Signal and Hazard Warning Lamps/Wiring Diagram (Cont'd) R.H.D. MODEL wazeea SHER $ 3 FRONT Tum EL-74Car vooy apenure Lamanoiser ana bake ~~ ) Ww vue.s67 EXTERIOR LAMPS Side Turn Signal Lamp — Bulb Replacement Remove battery negative cable from battery. Push down on side turn lamp holder to dislodge it from body aperture. Twist off lens cap Pull out defective bulb and replace. Bulb: 12 SW Push fit side turn lamp holder into body aperture to refit. Be Re Combination Flasher Unit + The flasher unit is non-serviceable and can only be replaced as a complete unit. Location «The flasher contro! unit is located on the steering column cross member. Flasher Unit Check * Before checking ensure that standard bulbs are fitted. Connect a battery and test lamp to the combination flasher unit as shown. Combination flasher unit is properly func- tioning if it blinks when power is supplied to the circuit EL-75EXTERIOR LAMPS Bulb Specifications Headlamp High/Low Driving lamp Wattage (12 volt) 60185 55 Front fog lamp Front turn signal lamp Front clearance lamp ‘Sige wrn signal lamp Rear Combination lamp Tum signat Stopital Reverse Rear fog ‘License plate lamp Interior room lamp Luggage Compartment lamp High Mounted Stop lamp EL-76 55 at 5 pe a 2115 2h Ez 2h 5 10 5 21ELs69} INTERIOR LAMPS Defogger/Hazard/Rear Fog Switch — Bulb Replacement Remove battery negative cable from battery. Remove screws securing front fascia to centre console. (Refer to BF Section.) Displace front fascia forwards for access to switch bodies. Remove connector from back of switch. Pinch fixing wings of switch and push through aperture in front fascia. po oeeo Unscrew defective bulb and replace bulb and lamp holder. To replace switch, use the same procedure as above. Headlamp Aim Switch/Driving Lamp/Front Fog Lampilliumination Control Switch — Replacement The Headlamp aim switch bulbs are not replaceable, replace the switch complete. 1.” Remove battery negative cable trom battery. 2. Remove screws from instrument pack cowl. (Refer to “Instrument Pack — Removal”) 3. Displace Instrument pack cowl. 4. Remove connector from back of switch. 5. Pinch fixing wings of switch and push through aperture in instrument cowl. 6. Replace switch. NeCVT Selector — Bulb Replacement 1, Remove battery negative cable from battery. 2. Prise off top cover of selector lever trim, 3. Twist and pull out bulb holder. 4, Pull bulb out of holder and replace bulb and filter cap. EL-77INTERIOR LAMPS Cigarette Lighter Illumination The cigarette lighter illumination bulb is not replaceable. EL-78INTERIOR LAMPS lluminationWiring Diagram LH.D. MODEL Without Daytime Running Lamps EL-79 vue.INTERIOR LAMPS. MuminationWiring Diagram (Cont'd) 1LH.0, MODEL With Daytime Running LampsINTERIOR LAMPS MluminationWiring Diagram (Contd) R.H.D. MODEL EL-81Luggage room Lamp bute yeu Connector Lampholder: veut INTERIOR LAMPS Room Lamp — Bulb Replacement Remove battery negative cable from battery. Prise off lens from lamp. Unclip defective bulb from lamp holder. Insert new bulb by pushing in end nearest switch first, then clip other end into place. Insert lens into end furthest from switch first, then clip other end into place. Bulb: 12V 10W festoon Pops Room Lamp — Replacement Remove battery negative cable from battery. Prise off lens from lamp. Remove screws (2 off) securing lamp holder. Pull lamp holder from trim Disconnect connector. Replace unit in reverse order to the above. Insert lens into end furthest from switch first, then clip other end into place. Switch: 3 posit * ogsens (Door switched/ON/OFF). Luggage Room Lamp — Bulb Replacement 1. Remove battery negative cable from battery. 2. Remove screws (2 off) securing lamp to trim. 3. Remove lens cover. 4. Prise out defective bulb and replace Bulb: 12V 5 Luggage Room Lamp — Replacement Remove battery negative cable from battery. Remove screws (2 off) securing lamp to trim. Pull lamp holder away from trim Disconnect connector from back of lamp holder. Replace unit in reverse order to the above. oseona EL-82INTERIOR LAMPS Interior and Luggage Room Lamps/Wiring Diagram ec ewMETER AND GAUGES Combination MeterMETER AND GAUGES Tachometer, Temp., Oil and Fuel Gauges/Wiring Diagram cus eee ‘SUPBLY ROUTING". > Penue! trensexte models QD CBD: w ov" modes COVSINATION METER ffonne vy ee 22 8+ Od TacHoveTER $—s2010(8)8 - 3 TBEROIB # EL-85METER AND GAUGES instrument Pack Cow ( onto! Fixing Screws (2) Instrument Pack Instrument Pack — Removal 1. Remove battery negative cable from battery. Instument | 2 Adjust tilt steering column (where fitted) to lowest position Numination for access to instrument pack cowl fixing screws. 3. Remove fixing screws from base of instrument pack cowl (2 off) and pull cow! forward to release cow!'s rear fixing clips from dash panel. 4, Remove instrument illumination rheostat connector (and accessory switch connectors where fitted) from back of cowl 5. Remove cowl 6. Remove instrument pack fixing screws (3 off) to release instrument pack from mounting brackets, 7. Remove connectors (3 off) from rear of instrument pack by pressing side release buttons and pulling connector from back of pack. 8. Remove speedometer cable from rear of instrument pack by pressing release lever and pulling cable connector away from pack. 9. Remove instrument pack. JS f Back of AZ | ateament | Pace Foiease lever ELo6s Installation Installation of the instrument pack is the reverse of the removal procedure. EL-86METER AND GAUGES Oe Specdomtr Tachome Upper Housing tp tings Lower Housing uel & Temperature J] Front cover f Gauges evoes | pecdomeer Instrument Pack — Disassembly Component parts of the instrument pack which can be replaced are as follows: 1. Lower Housing, Upper Housing. Front Cover Fuel Gauge Coolant Temperature Gauge Tachometer Speedometer Warning symbol lenses Bulbs 0. Flexible Printed Circuit Board. Gauges, rigid pcbs, digital clock and pcb components are not serviceable and must be replaced as a complete unit To disassemble: 1. Unclip and remove front cover and upper housing. 2. Remove nuts from rear of meter to remove fuel, tempera ture and tachometer gauges. 3. Remove 4 screws from raised area of rear of instrument pack to remove speedometer. «Take care not to scratch faces of gauges or bend pointers. Do not place gauges face down. 4, Warning tenses can be removed by unclipping from back of upper housing; take care not to damage lens surface when refitting. FuctTemperature __‘Tachometer/Temperature leauge Securing Nuts Saupe Secunng ut * s0ovomEoN Installation Component parts can be fitted using the inverse procedure to removal. « Inst'ument pack disassembly and repair should be per- formed in a clean dust-free environment to prevent damage to the moving gauges. EL-87METER AND GAUGES Warning Lamps — Replacement Instrument warning bulbs can be replaced without disassem- bling the instrument pack. Twist bulbholder anti-clockwise to remove. Ensure correct wattage bulb is used when refitting ‘3W [Fuel iow, Battery Charge Warning Lamps. 2W [instrument ilumination NeGV7, Main Beam, RH Turn, LH Tum, Brake, Oil and ABS Warning Lamps Flexible Printed Circuit Board — Replacement 1. Remove aii warning lamps from rear of instrument pack. 2. Remove 2 screws securing flexible printed circuit board (fp.c.b,) to raised area of lower housing, 3. Carefully peel f.p.c.b. from rear ot iower housing retaining lugs. Replace components in reverse order, taking care not to dam- age {.p.c.b. and inserting warming lamps of the correct wattage into the appropriate aperture. «Instrument Pack repair should be performed in a clean dust-free environment. ue.o70 EL-88METER AND GAUGES Inspection — Fuel Gauge/Water Temperature _Gauge INSPECTION START CHECK POWER SOURCE 1) Turn ignition switch "ON" 2) Check voltage between terminal () and ground, Battery voltage should exist. (Check the following items: 1) Harness continuity between battery termi- ral and combination meter 2) Ignition relay 1 3) Fusible link (65) and fuse (104). 4) Ignition switch opera- tion and connections. uetosg|| CHECK GAUGE OPERATION [NG] Repair orrenace gauge: ] S| 1) Tum ignition switch “ON” 2) Connect terminal (@) and © to ground with wire through 3.4W test bub. (Test points are raised soldered ter rrinals on 1p.c.,) 3) Check operation of gauge. Gauge should move smoothly to fat scale. Ox a Damme I nowt onperhre ong | Check harness continuity between com- N.C Repair or replace. ponent and combination meter (©) and © Lf = _—— —— eee (CHECK COMPONENT N.G.| Repair or replace. Check gauge units and namess. | | Refer to FE section, (Fuel Refer "Fuel Tank Gauge Unit Check" | | tank gauge unt) and “Thermal Transmitier Check’. ae) eer Reinstall any part removed. INSPECTION END EL-89METER AND GAUGES Fuel Tank Gauge Unit Check «For removal of Fuel Tank Sender Unit, refer to FE section. Check the resistance between terminals 1 and 2. ‘Ohmmoter Float position ri) Resistance valve (0) 3 Ful | ea ‘Appion 4-6 1 2 [2 | | 2a 2m 1 Empty | 200 20-89 e.or4 Fuel Warning Lamp Sensor Check 1. Place a 12V - 3.4W test lamp from the battery positive ter- minal to terminal 3, with the Fuel Tank Sender Unit removed (refer to FE section), and a connecting wire from terminal 2 to battery — ve. The test lamp should light after a short delay. 2. Immerse the fuel tank sender unit so that the fuel low sen- sor is covered. The test lamp should be extinguished. svors EL-90onmmeter [a] METER AND GAUGES. Thermal Transmitter Check Check the resistance between the terminals of the thermal transmitter and body ground with the transmitter in situation. «For a more accurate test, remove thermal transmitter and immerse in a vessel of water. «Heat water, and test transmitter resistance at suitable tem- peratures to determine if transmitter resistance is changing correctly in accordance with temperature variaton, temperature (°C) Resistance (0) 52.5 LC _ 2100 65 1975 - 1420 a 470 - 570 113 210 - 235 © Apply sealant to screw threads when refitting, Maximum installation torque — 14.51 N-m (1.48 kg fm) Oil Pressure Switch Check the continuity between the terminals of oil pressure switch and body ground. ll pressure Resistance value kPa (bar, kglem*, psi) esistane PusH TO CONNECT PRESS TO DISCONNECT sei24F| More than 49-265 oman (0.089 - 0.248, 0.7 - 3.6) ° Less than 49 - 24.5 (0.049 - 0.245, 0.05 - 0.25, 0.7 - 36) Engine stop ‘© Apply sealant to screw threads when refitting, + Maximum installation torque — 12.28 - 17.16 Nem (125 - 175 kg.cm) Speedometer Cable Removal and Installation Aiter disconnecting speedometer cable ond from transaxle, push speedometer cable so that combination meter is pushed into passenger compartment. Disconnect speedometer cabie end from combination meter as shown in the figure at left. Speed Sensor Signal Check © A-speed sensor is built into the speedometer. 1. Turn speedometer slowly using a small screwdriver. 2. Check continuity of speed sensor circuit. Continuity exists two times for each turn ... O.K. EL-91s1spou peddines 149-N » CON) s12pou peddinbs uorede Surweua ¥o0!-12u¥ SSD ao rons anno ae yous wguims SH rows Seyr agelMS “Givtlg gina sie) aa 3 18 vised «= Sve wonynwauay Warning Lamps/Schematic iG ANTE Lock, WARNING LAMPS AND BUZZERS. FUEL Ws, 22 1, vol hg WotR EL-92WARNING LAMPS AND BUZZERS Warning LampsiWiring Diagram LHD, MODEL saon@z sons soon Qi __conptnarton nereR @®, ann 1 on eriauNe @k §@ " vais EL-93WARNING LAMPS AND BUZZERS Warning Lamps/Wiring Diagram (Cont'd) R.H.D. MODEL nit 00% —o—nWARNING LAMPS AND BUZZERS Warning Buzzer — Location The “Lights ON” and “NeCVT" Warming Buzzers are attached to the back of the instrument console parcel shelf, below the steering column. ‘The Buzzer contains no serviceable parts, replace as a complete unit Warning Buzzer — Replacement 1 2. onse Disconnect battery negative cable from battery. Remove screws (2 off) from driver side parcel shelf. (Refer to BF section) Pull shelf forward. Remove buzzer from bracket at rear of shelf. Disconnect connector. Refit new buzzer in reverse sequence to removal. EL-95WARNING LAMPS AND BUZZERS Warning Buzzer/Wiring Diagram LH.D. MODEL (WT) TENTION SWITEH on CIGHTING SwiTCH OFF TT ra FE BORE ig ae ar | Gain 5 l aa { a4 goge fe] ci id 5 ied | [=] 2 ewr orono [. 4 - © verlsiat eure J R.H.D. MODEL (M/T) lea BEER BATTERY| ToRETEON, SuLTCH DRT oe SPAR ‘Dao ow g2y® ©: vectea wy SREGIBR AER s @®: RUT BET over Sato BREN Saf EL-96 & euzzerLHD. MODEL (NeCVT) WARNING LAMPS AND BUZZERS Warning Guzzer/Wiring Diagram (Cont'd) LIGHTING suttonR.H.D. MODEL (NeCVT) WARNING LAMPS AND BUZZERS Warning Buzzer/Wiring Diagram (Cont'd) N-OVT CONTROL UNITWIPERS AND WASHERS Front Wiper and Washer/Wiring Diagram LHD. MODEL, wWiPER noroRWIPERS AND WASHERS Front Wiper and Washer/Wiring Diagram (Cont'd) Without Intermittent Wipe R.H.D. MODEL S08 Seeu' TAN GSD. sR SHesGSS enee « Ca alae , eg OD [eiieteitie}} ft yen conv Bali o33a8"e vueLis0 EL-100WIPERS AND WASHERS Front Wiper and Washer/Wiring Diagram (Cont'd) R.H.D. MODEL. With Intermittent Wipe EL-101WIPERS AND WASHERS. Rear Wiper and Washer/Wiring Diagram LH.O. MODEL 8, B88tno veLiseWIPERS AND WASHERS Rear Wiper and Washer/Wiring Diagram (Cont'd) R.H.D. MODEL ie (Dre ma eLisa EL-103WIPERS AND WASHERS \ctearance | Cow tpg ena Bim ese, Unit Nem (kgs) exon — ‘S > | fae Seal Fixings Seal x te 78 | Wiper ar nut ‘securing nuts 51 (039-082, 28-28) wiper inka ueto7e FRONT WIPERS — Removal The above illustration shows an exploded view of the front windscreen wiper assembly for LHD vehicles; RHD vehicles have components fitted with the opposite orientation «Before removing wiper arms, ensure the wiper blades are in the park position 1, Lift plastic nut covers on wiper arms, 2. Remove wiper arm securing nuts and prise otf wiper arms. Installation 1, Before replacing wiper arms, clean up the pivot splines with a stiff brush to reduce the possibility of wiper arm loose- ness. 2. Prior to wiper arm installation, turn on wiper switch to oper: ate wiper motor and then turn it “OFF” (Auto Stop) 3._ Lift the blade up and then set it down onto surface of wind: screen to set the blade center to clearance “A” immediately before tightening nut to torque figure indicated in illustra- tion. 4. Eject washer (uid. Turn on wiper switch to operate wiper motor and then turn it “OFF”: 5. Ensure that wiper blades stop within clearance “A” © Clearance “A”: 17.5 - 32.5 mm (0.7 - 1.3 in). 6. Ensure that the wiper operates smoothly at all speeds and without judder o “screeching” when the screen is wet, and that all fluid is removed from the screen in one sweep of the wiper. EL-104Jeo (Gace Y WIPERS AND WASHERS Fring Engine Bay vetoes Bal joint Com top Seal wo be feoe from , distoren eros Front Wiper Motor and Linkage — Removal ‘Switch wipers on and off to “park” wiper blades. Remove battery negative cable from battery. Remove wiper arms as described in previous procedure. Remove cowl top cover from borinet (see exploded view of wiper system) by removing fixing screws and pulling cow! upwards off of fixing lugs. sono 5. Disconnect Ball and Socket at Linkage/Motor Interface. «Take care to apply separation force as close to socket on linkage as possible 6. Disconnect harness connector from wiper motor. 7. Remove bolts (4) holding wiper motor assembly and remove wiper motor. 8. Remove linkage fixing bolts (6) and pull linkage out of link- age channel Wiper Motor and Linkage Assembly Assembly is the reverse procedure to removal. 1. Check that there is sufficient grease on ball and socket joint; apply grease if required. 2. Fit motor and linkage fixing bolts to torque figures specified. EL-105WIPERS AND WASHERS ‘evowe Wiper Motor and Linkage Assembly (Cont'd) ‘After mounting motet and linkage, operate wipers and stop in auto-stop position, then fit wiper arm as described in “Wiper arm replacement". Operate wipers and ensure that wipers retu to correct park position and that assembly operates normally at all wiper switch positions without judder. Front Wiper Motor Amplifier Location The Front Wiper motor amplifier is located in the engine bay, bolted to the vehicle body close to the wiper motor. Wiper Amplifier Check 1. Connect amplifier as shown. 2. If test lamp comes on when connected to terminal (6) and battery ground, wiper amplifier is normal. «If wiper amplifier is faulty, replace unit; the module is non- serviceable EL-106WIPERS AND WASHERS Wiper motor ‘xing bot ‘38-81 DD) Ne gem, ty Wiper Am | postion Demster i element uexoad Wiper arm Wiper arm 15-1013 18) vevo29 Rear Wiper Arm — Removal 1. Ensure the wiper arm is in the park position by switching wiper on and off Remove battery negative cable trom battery. Lift wiper arm nut cover and remove wiper arm nut. Prise wiper arm off drive pivot splines. Clean drive pivet splines with a stiff brush to reduce possi- bility of wiper arm looseness. onen Rear Wiper Arm — Installation 1. Prior to installation, ensure the wiper arm pivot is in the pack Position by switching wiper on and off 2, Remove battery negative cable from battery. 3. Ensure drive pivot splines are clean 4. Lift the blade up and set it down onto glass to set the blade enter to position before tightening the wiper arm nut. 5. Eject washer fluid and turn on wiper switch to operate wiper motor. * Ensure that wiper blade stops in location identified by the demister element. «Ensure wiper operates smoothly at all speeds. «Ensure wiper does not contact screen finisher. Ensure all fluid is removed from the screen in one sweep of the wiper. EL-107Wiper moror vue.o9d WIPERS AND WASHERS Rear Wiper Motor — Removal 1. Before removing ensure motor is in the park position by switching wipers on and off. 2. Remove battery negative cable from battery 3. Lift wiper-arm nut cover and Temove nut 4. Prise off wiper arm from drive pivot spline. 5. Remove nuts holding motor to back door. 6. Disconnect connector and remove motor. «Replace wiper motor complete. Rear Wiper Motor — Installation Wiper motor installation is basically the inverse process of removal, but utilising the following salient points: 1. Fit motor to back door so that the drive shaft protrudes through wiper aperture, and fix but do not tighten bolt 2. Fit and tighten bolts (@ and @) to the torque indicated, fol lowed by bolt @) 3. Fit wiper arm as directed in previous procedure, ensuring all operational checks are satisfactory. REAR WIPER AMPLIFIER Location The Rear Wiper amplifier is located behind the front dash panel 40 the \eft of the steering column on LHD vehicles, and to the right of the steering column on RHD vehicles. Rear Wiper Amplifier Check 1. Connect as shown in test circuit 2. Iftest lamp comes on when connected to terminal @ and battery ground, wiper ampiiier is normal. EL-108WIPERS AND WASHERS eat Seton ruin HOM tang cips ay os wy / ) 5 lresenoi pS } Headamp ceservol. vetoes iinet ~~ —|- Washer Nozzle — Adjustment | | Adjust front and rear washer nozzles with a suitable tool. ew Each nozzle has two jets which should be set to provide water at the specified aiming points LA Front Washer nozzles output volume — 250 cm*/sec. S Rear Washer nozzle output volume — 150 cm*/sec. Nozzle Jets ear Front washers washers Washer Nozzle — Replacement Nozze 1. To remove washer nozzle pull tubing off of check valve, | pinch fixing lugs and push nozzle through bonnet aperture. | 2. Push fit new nozzle, taking care not to damage surround | ing point. we | 3. Adjust nozzle to give correct spray pattern. Fang Tu 9s te ame Washer Nozzie Check Valve - © Accheck valve is provided in the washer fluid line. Be care- . ful not to connect check valve in the wrong direction. CHECK Valve eI eee Tor% Resevoir EL-109WIPERS AND WASHERS = Rear Washer Nozzle — Replacement . Speuring Nut 1. Open Back Door. pie 2. Remove Washer Tubing. 3. Undo and remove nozzle securing nut. 4. Remove nozzle. Refit using reverse procedure to removal Adjust aiming to attain correct spray pattern VY | = Front Washer Spray Pattern Sa | Ensure that washers operate correctly and that spray jets ! | hit the screen within the specified areas so that washer fluid * ; is contained within the wiper swept area 2A 80 (mmm) 2c 80 (mmm) OB omm | oD 0 (mm) 7a [—163¢mm [5 Siem 2 19 (rm) 6 178 (mm) 3 zoe tmm) | 7 | SPA mm) 4 367 (am) 3 238 (a) Rear Washer Spray Pattern a + Ensure that washer operates correctly and that spray jets _Mowntea, Eage hit the screen in the specified areas when the vohiclo io | __Stationary } aA 60 (mm) \ | So \ 50 (mm) 1 50 (mm) 2 ~30 (mmm) veLs04 3 EL-110WIPERS AND WASHERS Head lamp = Mounting Bracket PS2kEs sa wiper arm _ ve.io4 Headlamp Wipers Two motors are fitted, one under each headlamp, A wash noz- zie is included on each arm supplied via tubing from a 2.0ires- ervoir located in the engine bay. Wiper Arm — Removal 1. Ensure wiper arm is in the park position by switching head lamp wiper switch on and off 2. Remove battery negative cable from the battery. 3. Lift wiper arm nut cover and remove nut. 4. Remove wiper arm Wiper Arm — Installation ‘+ Installation is the reverse procedure to removal, «Ensure the motor is in park position before refitting wiper ‘arm, by switching headlamp wiper switch on and off. ‘When fitting the wiper arm/blade, tighten up the securing nut with the blade under the lower stop and then replace arm in the correct park position. Wiper Motor — Removal Remove wiper arm as described above. Remove the Headlamp as described in “Headlamp sec- Remove bolts from mounting bracket Disconnect harness connector. Remove wiper motor oso woe Wiper Motor — Installation © Wiper motor installation is the reverse procedure to removal «Fit wiper arm using procedure described above. ‘+ Take care not to damage finish of vehicle bumper, grille or fender during removal and installation. ‘+ Check that wiper action operates normally without judder. EL-111WIPERS AND WASHERS Headlamp Wiper and Washer/Wiring Diagram 5)HORN, CIGARETTE LIGHTER AND CLOCK Horn — Replacement 1. Remove fixing bolt (13 mm). 2. Disconnect connector from horn. 3. Refit new horn in reverse order to removal procedure and test operation. ‘* For vehicies containing two horns (high note and low note) ensure correct horn is replaced. Pitch can be changed Using adjusting bolt (5.5 mm) in back of horn Horn Switch — Replacement 1, Pull horn pad from steering wheel. 2. Disconnect connectors from switch at back of horn pad. 3, Replace horn pad by press fitting to steering wheel and test ‘operation, Cigarette Lighter — Replacement Pines 1. Remove instrument centre console front fascia (Refer to BF Section). Rewinngang —=«d’«s«~--~Pise defective case from fascia. 3. Push fit replacement lighter assembly into instrument yrossessseny |" panel, the case is cetained in place by plastic clipe of ring kop | 4. Test operation. | | replaced as seperate items. e.7 The lighter illumination bulb is not replaceable, unit must be : changed. Clock + The clock is an integral part of the tachometer or coolant emperature gauge refer to “Meter and Gauges” section for details of replacement EL-113HORN, CIGARETTE LIGHTER AND CLOCK Wiring Diagram LH.D. MODEL Soo! rect) esousoy ure WoL ies aes are Per NMBt Batt eo a aauiva] eLi8s EL-114HORN, CIGARETTE LIGHTER AND CLOCK Wiring Diagram (Cont'd) R.H.D. MODEL ueLise EL-115REAR WINDOW DEFOGGER Wiring Diagram LHD. MODEL With Timer NOLEN ILI Bot bAs Lai te EFOGGER swt pitas wstbg88 [ L Oa enoneag0S50 vues?REAR WINDOW DEFOGGER Wiring Diagram (Cont'd) R.H.D. MODEL and LLH.D. MODEL Without Timer Le am 13950730 ae sispou any -@® syepou an @ ownous ot ike fe — - OP; @eeuse4 2 ON AOD jaewey Ue — Tis 32 wot eso ueLise EL-117REAR WINDOW DEFOGGER ge ERG ZA g Filament Check 1. Attach probe circuit tester (in volt range) to middle portion of each filament. 2. Ifa filament is burned out, circuit tester registers 0 or 12 volts. 3. To locate burned out point, move probe to left and right along filament to determine point where tester needic swings abruptly. EL-118REAR WINDOW DEFOGGER Drawing pen Una: men dy 2549 Pome eee pot at 9 se.o%20| Filament Repair REPAIR EQUIPMENT 1. Conductive silver composition (Dupont No. 4817 or equiva- lent) Ruler 30 om (11.8 in) long Drawing pen Heat gun Alcohol Cloth onsen REPAIRING PROCEDURE 1. Wipe broken heat wire and its surrounding area clean with a cloth dampened in alcohol. 2. Apply a small amount of conductive silver composition to tip of drawing pen. Shake silver composition container before use. 3. Place ruler on glass along broken line. Deposit conductive silver composition on break with drawing pen. Slightly over- lap existing heat wire on both sides [preferably 5 mm (0.20 in)] of the break. 4. After repair has been completed, check repaired wire for continuity. This check should be conducted 10 minutes after silver composition is deposited. Do not touch repaired area while test is being conducted. 5. Apply a constant stream of hot air directly to the repaired area for approximately 20 minutes with a heat gun. A min- imum distance of 3 cm (1.2 in) should be kept between repaired area and hot air oullet. If a heat gun is not available, let the repaired area dry for 24 hours. EL-119> AUDIO AND ANTENNA Audio/Wiring Diagram B] REAR SPEAKER B] SEAR speaKeR warn Glare o ore veLiseAUDIO AND ANTENNA od Antenna HO-moaels Fod Antenna LHO-medele veLs08 Radio ANTL-THEFT SYSTEM By using a personal 4-digit code known only to the vehicle owner, the possibility of the audio unit being stolen is effectively reduced, because without the code the unit can not be acti- vated. When in normal use, the unit is unlocked and accessi- ble in the usual way. If however, someone attempts to remove the unit or the ground cable is disconnected {rom the battery, the Anti-theft system activates and the unit “locks”. The only way it can be unlocked is by entering a personal code number known only by the owner. «With the ignition switch off, a flashing LED indicates thatthe anti-theft system is activated. «For details of setting up the radio activation and tuning, refer to the audio unit manufacturer's operation booklet and the owner's manual. EL-121AUDIO AND ANTENNA | Mounts Fixing Tabs brackets Bash Pane! Front Fascia Fixing screw Bracket Fring Screw Fang Tabs eLo0 Radio — Removal Remove negative battery cable from battery. Remove fixing screws from front dashboard fascia. Press in fascia fixing wings and remove panel. Remove four fixing screws from radio mounting bracket Disconnect antenna and power/speaker connectors from rear of radio. Remove radio. 2 ghone Radio — Installation «Installation is the reverse procedure of removal. EL-122LOCATION OF ELECTRICAL UNITS Engine Compartment {UNO moe kK A (no, med Som) (Woe motor es _\ == (AHO mode) we SS f a SI XO OO be A. 288 Y ( S : [tt =x /) Rear defogger relay (black) (LH.0,) Roar fog relay (Btack) \ Front fog rolay (Black) Ho) (HD) ‘Spare relay (RHO) Front FogDrving lame Spare relay (LHD) relay (Black) (LH.D) | \ Radiator fan relay ee up clay (Back) \ (tacky RHO) (RHO) \ ‘Aroon vey (Brown) \, MOVT ray aay N (LHD) . \ \ Innit rola (Blac) ieee (HD) \\\ Spare relay (RHO. Hom cy (Gro) cee \ (Ho. EG. relay (Green) \ ‘ \ on \ \\33 Fue tie = Fuse and fusible tk NeLo0t EL-123LH.D. MODEL LOCATION OF ELECTRICAL UNITS Passenger Compartmernt ‘Ace. relay (Black) | 1 gn. 2 relay (Black) — | Jk ln. 9 relay Black) EL-124 NeLoo2LOCATION OF ELECTRICAL UNITS. R.H.D. MODEL Passenger Compartmernt (Cont'd) “| 7 et pure cae ‘Stop lamp switct | | j | es te a 4 war [IL Zl | omen || | TER, | sewn | Les \ Combination flasher unit ———— g J par ontan ay i EL-125 NELo0aLOCATION OF ELECTRICAL UNITS Luggage Compartment "REAR WIPER RELAY (@LACK) Fear wipes relay (Back) NetoHARNESS LAYOUT Outline LH.D. MODELS: ews20e | e19008 EL-127L.H.D. MODELS. HARNESS LAYOUT Engine Room Harness EL-128Engine Room Harness (Cont'd) HARNESS LAYOUT ounce fae] as row 253) 90 (ras) @ a: G oora oF unos Kp08 (ue) Bone yuma He awe Bag (ue, 60) wun) H7 cue Bop 104 H7 won HY woH 2oi0w ve} s25u2pUe) He duepeon weave EL-129HARNESS LAYOUT Engine Room Harness (cont'd) — RD. MODELS MeLoree —~ EL-130Engine Room Harness (Cont'd) HARNESS LAYOUT @~a (ashe Supe 9201 104) Hy 198095 1014 yons oxnssoid yo 6 EL-131HARNESS LAYOUT Main Harness LH.D. MODELS EL-132Main Harness (Cont'd) HARNESS LAYOUT [ene 12060} 2804) 4 [: uli) Res J9680}9p 10945 dorow voreaques tun oauos gate is 29-961 — ane suse 91s bet — far uoapven iy su yonvos son Se — ts puezeH (Pow LAD-N) WOH po oie unser yo vue sajous woneuques evoote EL-133HARNESS LAYOUT Main Harness (Cont’d) RLH.D. MODELS wetscae EL-134Main Harness (Cont'd) HARNESS LAYOUT (iap0u Ano) we wetoes6 EL-135,HARNESS LAYOUT Door Hamess (LH. side) FRONT DOOR HARNESS GH) wn0. woe GiDRHD. modes @® -To @ wo mode) @® = boek knoe swith (LH. mode @ -To @ WH. moat @® To @ ino. mae @ Door speaker (LHD. mode) @ To @ (RHO. mode) GB] Power window reguistor (LHD. mode!) @ - dow speaker (RMD. model) © - door miror detogger GD «Power window reguater (A.D, model) GZ = Main ewten (LO. model) GD: Sub-switch (AHO. model @® Main switch (CHO. modo) @ : Door setuator (RH. mode) REAR DOOR HARNESS } ‘Sr 8 A iL evoroe EL-136HARNESS LAYOUT ne Door Harness (R.H. side) FRONT DOOR HARNESS yy Dene ae lL feo on Duro moan GB) Ho moa To @ (HO mode) a @® : To @ (AHO. moos, @® -To @ (AHO. moat @ : Door speaker (Ri @ 20) = Power window regulator (RH, mode) G * Door spasker (LHD, model) @® = Man swten (RH, model) G2 Power window regulator (LHD. model) GB Main switen (RHLD. modal) @ Door mieror defogger @ = Lock knob switeh (RHO. modal G] : sub-owten (LHD. mode ® To GW (WHO. mae ©) door actustor (LHD. model) REAR DOOR HARNESS @r® @ : Door actuate EL-137HARNESS LAYOUT Back Door /\ EL-138 SO mat names Ho. 2 @® #10 Gwen ser wise) @® 10 @ wou ver wioen 8888890890 Body ground @: @ ro Beck door hammess r@ 6 ® Lgpge room lamp wich fer wer motor faba stop are Ucene pate tame Body gran tek window deogoer Beek wow donor eat Body ground” Body pound }GG88G898 © r@® Back door harness r@ To CB) (Win ese woe Lsgoape room tmp sich Pear wiper motor conse lt lamp 809) ground ack wow defogger 0 G5) (winout rear woen fac window dogger eh 803 grouna eLoosaQr@ @) | Interior amp. HARNESS LAYOUT Room Lamp Meera EL-139HARNESS LAYOUT E.F.l. Harness LH.D. MODELS: weis250 EL-140Harness (Cont'd) HARNESS LAYOUT jomea $953 fre — nn) MeLoase soyssven saMog EL-141 ouo® LAN unos aut Lesvos oe6 iene, ee o> vowuby sowssuen semeg 9 J0Sues UE HUD { veou uns { some va {E.F.1. Harness (Cont'd) HARNESS LAYOUT RH.D. MODELS EL-142T Harness (Cont'd) lui HARNESS LAYOUT 09 vob ¥ jones s093 Ew} ssowey oubua, 2) EL-143 Puno LA3-N sosues #96 tena o> wonu6| seyssueN sowed 9 1 anea plouses OTs ¥ NeSUPER MULTIPLE JUNCTION (S. ) ‘SM. (Main name Terminal Arrangement INSTALLATION To install S.M.J., tighten to specified torque as required. ): 3-5.Nm (0.3 - 0.5 kg-m, 22 - 3.6 fib) CAUTION: Do not overtighten bolts, otherwise they may be damaged. EL-144 \)SUPER MULTIPLE JUNCTION (S.M.J : Terminal Arrangement (Contd) ALN HARNESS NAIN HARNESS nol node ts) GeNoMmods is) CS Aaa IESE rg BIER pis EOF SESS Erg hse fr} Iapiactd O15 ii ca US Eid BIEL OIG ISBT pie 21211 WI2B 2b i i py Wg isl Fa Ea ig ASBSIES iagaica) 0 ISESEST po ES, aleelc2}—EaF flfetict] ©! (Evry IBID TF] RIBIICT TF | Baa eo hopata tere : a3pB3ics|_ 02 lasipsics| 02 |e3 i apalccl ps dra ppcied) 03 Ga : Seske: Fa . lsess}— ESF) Il Fa ia 7 Ez! ° =a ES EE Talal [Sle] = ia Wier} Ee SBI} WAISBISEC3 Ty ing} IALSBie] AISBIS IAISBISK 5} I 8 picid 08 Frid , wa — 4 ENGINE FOOW FARVESS Lv ENGINE ROOW HARNESS : j €C.C.S. CONTROL UNIT st Tene ro mide alot eae uae View from harness side EL-145