ELECTRICAL

SYSTEM

EL

SECTION

When you read wiring diagrams:

o Read Gl section, "HOW TO READ WIRING
DIAGRAMS''.

CONTENTS
STARTINGSYSTEM
STARTINGSYSTEM- Starter- ...
CHARGINGSYSTEM
CHARGINGSYSTEM* AlternatorCOMBINATION
SWITCH ....
HEADLAMP- Without DaytimeLight Systemand Dim-dipLamp System
HEADLAMP- DaytimeLight SystemHEADLAMP- Dim-dipLampSystemHEADLAMP- HeadlampAimingControl
HEADLAMP
EXTERIOR
L A M P. . . . . . . . . . . .
tNTER|OR
1 A M P. . . . . . . . . . . .
M E T E RA N D G A U G E S
WARNINGLAMPS AND BUZZER
WIPERAND WASHER
HORN,CIGARETTELIGHTERAND CLOCK
REARWINDOWDEFOGGER
LOCATIONOF ELECTRICAL
UNITS
H A R N E S SL A Y O U T. . . , . . . . . . . .
( S . M . J . .). . . . . . . . .
S U P E RM U L T I P L E
JUNCTION

EL- 2
EL- 3
EL- 6
EL- 11
EL. 18
EL.20
EL- 28
EL- 30
EL-

EL-

CI

EL- 64
EL.

OO

ELELELEL-

73
80
88
89

I::L-

J Z

EL- 95
EL-101
E L -1 2 9

URING DIAGRAMREFERENCECHART
ENGINEROOM FAN
E.C.C.S.
A/T CONTROL
ANTFLOCKBRAKINGSYSTEM
POWERWINDOU POWEROOOB LOCK, HEATEDSEAT.
SAT BELT. SUN ROOF.OOORMIRROB
HEATERANO AIB CONDITIONER

J/

EL. 39
EL- 40
EL- 42
EL. 44
EL- 49

LC SCTION

EF & EC SECTION
AT SECTION
BR SECTION
BF SECNON
HA SECNON

HARNESSCONNECTOR

Description
HARNESS CONNECTOR
o All harnessconneclorshave been modifiedto preventaccidenlalloosenessor disconneclion.
o The connectorcan be disconnected
by pushingor liftingthe lockingsection.
CAUTION:
Do not pull the harness when disconnecting the connector.
IExample]

PUSH
( Fo. combinrtbn mri..l

EL-2

RELAY
STANDARDIZED
Description
NORMALOPEN,NORMALCLOSEDAND MIXEDTYPE RELAYS
Relayscan mainlybe dividedintothreetypes:normalopen,normalclosedand mixedtyperelays.

s1!r

eatriq,

5M

BATTERY

s r i YI

z
o
3

sEL881t-l

TYPEOF STANDARDIZED
RELAYS
... 1 t\,4ake

1L4

2M
. . . . . . . . . . . . . .2. . t. 4. .a k e
'
1
N
i
l
l Transler
| 18.............1
. .M
. . .a k e1

1T

EL.3

RELAY
STANDARDIZED
Description(Cont'd)
Tvpe

Outa? Yicw

Circuit

Connector iymbol
and connction

Caa colo.

IT

BLACK

IM

BLUE
or
G REEN

2M

8 ROWN

GRAY

IM,IB

EL4

REALY
STANDARDIZED
NOTE

EL.5

POWERSUPPLYROUTING
WiringDiagram
FOB CENTRALEUBOPE
'a'
/:\
-:
: GNi !N
R:LAY-2

ACC:!SORY
FE!i'
I

4'r

LAl+
Nfl*
:)'ts+

s!\

ne

rode

mrJ.

s
Toae

\!:-

:!ceDt

5F2al:

er'.

f--

a:l'

:!c3pa

lalb:l:

e.E

r.A r.ce

..i

:!aep:-12J

-l

t,'t

mode :

e",9:.e

en,e -e

Ll2l

,:;.

;;',ER *a;;*

Si2 !UE

CA16!'lE e.9

e-a.e

ila.i,

n:.JF

!.r: -

n,J.le

riale

R a I O F: ' s - E | ]

P O W E RD O O RL O C K
SYSTEf

L I G r l T I N GS w i I O f l

b
.IDIT:I
-l11

EN

5!

iGNirlOii Sv!ITCH

.|-r,rrTi
-r---

tuL! r

t.ldFF:TTnxTtf
:
_ ao
2
a)

rD

r ri:

.TTI

ast,rage

[T--r--To]
40
ET TT

TOI
IDT} w L

tr
6ln

lil5

-Tre'I

I3\IT:!\:YS-EII

:f;...cl
iAD I AT!'rR
-.i\:;iE,

F_ : : t s _ : L : \ (
A\: ;-:: 3OX

Arr,l

CD

al!i;altr_j:vsTEll

i5A E4
illtr

- f;;;

. r.i

\ot usedO
:!0A E)
Nct

Jsed

t:A ai
zse6
F!Sl BLE
LIN(

a---

-lREtR

Fin-rl.rp

EN:I I.E AfOI:

F ; N 5 Y :i : T

E]
'f

AATTERY
MELTOSB]

EL-6

POWERSUPPLYROUTING
WiringDiagram(Cont'd)

FTl

eQ Eo
BOD\ GR!UND

ACCESSORY
2

:GNII]'N
RELAY'L

'etffi
I R O Ff i l T I - : A F ' R I E A T E R ,
! T ] C R 1 1R
R E A R ' \ l P E R A : . 1 , 1f r ! 5 t s : F

(i;\

-.--

o\-I-t.\to-

8/n-1 1)

r-

lB
w/6@

EE

BR +

f.

..

frlEg
L-r

- --l

E\Grf= CCTTFC;5.5TEfr

;3ffi

",^-m
. *

^.."
IC;A";l':l',.?EiiJ...oo
I AIL, C.EARAN'E IND
L I CE\CE LAIIP5
T A I L , C L : A R A N C E.,I C E N C E
I L L L | l I N A TI O N L A i P s ,
W A R NN
I G BUZZER,
tsEADLAI'O
AIIJING LONTROL
SIART SI GNAL,
E N G IN E C O N T R O L S Y S T E I ]

I C
Z A R OW A F N N

R/\1+ffi
l! cr

'

Lr']P

R @R/L

rl.
i2

E N C IN E i J O T F A N 5 I 3 --E, I ] , C L O C K ,
A . ] D IO , ' : .
LE!EL I]NI
SYS:Eir
l - - L r N i N A TI O N C O N T R a I L

F u s E8 - 0 c K

ref

|ue

"'.-'-.L--_

: \TER: OR ANO 5POT LAIIP

20A ts,
t0i tE)

R E A R ! \ I N D O WD E F O G ' E t

L,p

REAR ELOW:P

I]ITOII

E A C K C C O RL I C K

r3
fn

MELTOSA

EL.7

POWERSUPPLYROUTING
WiringDiagram(Cont'd)
EXCEPTFOR CENTRALEUROPE

aa

S R 2 O D Ee n g l n e m o d eL s

(6\

G A1 6 D E e n g l n e m o d e l s

(6\

LO20 eng lne riode s

Except

C I R C UT
I
AREAKER

IGNITION
RELAY.2

S R 2 0 O Ee n g i n e m o d el s

E x c e p t G A 1 6 O Ee n g i n e m o d el s

G;\

Except LD20 eng ine models

@
@

Fo.

Nonth

Except

fo.

-JJt
...rT-H
(file)ltrEl

t-t

A C C E-S S O R
R E L A Y3

II

GDr#r
T TI

0118
- t )TH

)i

Euaope fiode s

POWERVYINDOVY
SYSTEI1
SUN ROOFSYSTEI1

Europe models

North

rrr)l

t.ql
l--lJ I

R H . D . m o d el s

\T/
.a-\

f,ceo!
e.g'.c

R J.O Todc
E.o Foocls

5a20DL
s 6 ti
w tr -D20 e^g'.c

a-

e,..pt 6

@,

t n D m o d es w l t h L D 2 o c n g l n e

@,

r o n N o r t h E u r o p e n o d e s v / i t h G A 1 6 D Ee n

@,

r-ooon mooes

@,

5-ooor mooes

@,

engln.
r x c e p t L H . O .m o d e s w l t h S R 2 O O E

g/.1-

, L . H . o . m o d ct s

trFml@

r+n @
"+-

wl
--T-T-l @

./t--

EI]]
lal

Jat-

-gt
]+

r2r3rFE-t

frEl

I G N I T I O N S W IT C I - ]

S T A R II N G S ' S I E r I
I G N IT I O N 5 . jS T E T

F U S IB L E L I N K
AND FUSE BOX

A 6tl
QtD2s2)
6l
l

\i

,jF

*6

4sa @

*6

L 0 0 A@
5oAQ&@
25A ) & q-)
5 o Aq & O
2sA (-l)

rl0

G L O V VS Y S T E I 1

LINK

FIR'!V,?39"cl

C H A R GN
I G 5Y5TEI1

R+l

ABSO

TTE
MEL709B1

EL

POWERSUPPLYROUTING
WiringDiagram(Cont'd)

oR+@
o"re*@
ACCESSORR
Y E L A Y I G N IT I O N
-2
-1
RELAY-I
T-t
r:t
T-t
lan

ll /rn

l/rnll

ftlt

lt-rjl I

D O O RI l I R R O R W I T H I I I R R O RH E A T E R ,
REAR WIPER AND WASIIER

R A D IA T O R F A N R E L A Y ,
REAR HEAIER SYSIEN, REAR A,zC

ilo6fE
S9i'ff;o'.'"'n
TAIL, CLEARANCE
L I, C E N C E A N D
I L L U I l I N A TI O N L A I 1 P S ,
i Y A R NN
I G BUZZER

SIARI SI GNAL,
E N G IN E C O N T R O LS Y S T E I l

G+M
G/B+m

",**ffi
BR+m
I l E T E R A N O G A U G E SW
, ARNIIG LAI1PS,

SIJISTF
iISEI
3}3IEX
HF

E N G I N E R O O t l F A N S Y S T E I l ,C L O C K ,
A U D IO , C I L L E V E L U N IT ,
I L L U I l I N A T I O N C O N T R O LS Y S I E I I

r
airD
'J
FUSE BLOCK

"l P.dP,
t" P.dP,
*L

2 0 AO
L 0 A6
I O A D
L s A@
r0AO&)
L s A@
L 0 A@
lsA @

EL.9

POWERSUPPLYROUTING
Fuse
a. It fuse is blown, be sure to eliminatecause of problem
new fuse.
beforeinstalling
b. Use fuse of specifiedrating.Neveruse fuse of more than
specifiedrating.
c. Do not installfuse in obliquedirection;
alwaysinsertit into
luse holderproperly.
d. Removefuse lor clock if vehicleis not used for a lono
periodof time.

FusibleLink
A meltedfusiblelinkcan be detectedby visualinspection.
lf its
conditionis questionable,
use circuittesteror test lamp.
CAUTION:
a. ll lusible 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 pans.

EL-l0

BATTERY
CAUTION:
a. lf it becomesneoessaryto start the enginewith a booster
batteryand jumpercables,use a 12-voltboosterbattery.
b. Afterconnec-ting
batterycables,ensurethatthey aretightly
clampedto batleryterminalslor good contact.

How to HandleBattery
METHODS OF PREVENTINGOVER-DISCHARGE
The followingprecaulionsmust be taken to preventoverdischarginga battery.
o The batterysurface(particularlyils top) should always be
keptcleanand dry.
lf the top surface of a battery is wet wilh electrolyteor
water, leakagecurrentwill cause the batteryto discharge.
Always keep the batteryclean and dry.
Whenthe vehicleis not goingto be usedovera longperiod
ol time, disconnectthe negativebatteryterminal.(ll the
vehiclehas an extendedstorageswitch,turn it off.)

Check the chargeconditionof the battery.

Periodicallycheck the specific gravity of the electrolyte.
Keep a close check on charge conditionto preventoverdischarge.

t
)
,r/

"

s E L1 9 1

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. lf the acid contacts the eyes, skin or clothing, immediately flush with water for 15 minutes and seek medical attention.
Normally the battery does not require additional water.
However,when the battery is used under severe condilions,
addingdistilledwater may be necessaryduringthe batterylife.

EL-11

BATTERY
How to HandleBattery(Cont'd)
No.mal batia.y
____- S{rloharadb.riarv

Chrti't|

volrrt

"_j:=

Ch.rginf

Yolt.g.

Chartingcsr..nr
Ch|rgin' curr.nl

Ogr.rion ol ch.rt

SULPHATION
When a bafteryhas been left unattendedfor a long period of
time and has a specificgravity ot less than 1.100, it will be
completely discharged, resulting in sulphation on the cell
plates.
Comparedwith a batterydischargedunder normalconditions,
the current flow in a "sulphated" battery is not as smooth
althoughits voltageis high duringthe initialstage of charging,
as shown in the figureat the left.

SPECIFIC
GRAV]TYCHECK

Rad top Lvcl

with rcalc

1. Read hydrometerand thermometerindicationsat eye level.

o When electrolytelevel is too low, tilt batterycase to raiseit
for easy measurement.

Th6rmornt6a

2. Convertinto speciticgravityat 20'C (68"F).

Examole:
o When electrolytetemperatureis 35"C (95'F) and specific
gravityof electrolyteis 1.230, convertedspecificgravityat
20'C (68'F) is 1.240.
o When electrolytetemperalureis 0"C (32"F) and specific
gravityof electrolyteis 1.210, convertedspecificgravityat
20'C (68'F) is 1.196.

Hydro.n t.r

e
U
,-a
,rt a

Thsmoniatea

Conwrr.d !p.citic er.vny (S20)

t.$
|.2t
r.2t

t.2a
l.z,
1.20
r.ta
t.ta
t.ta

a t.t2

r.ro
||al

t32t

t50]

tat|

Elactrolvta latnoaratura

tr]
'C

fF,
SEL197P

EL.l2

BATTERY
BatteryTest and ChargingChart

V ISUAL INSPECTION
.Chcct batary cata lor crack! or bat'tdt
. Chack ballary t.rmrnalt tor ctnagc
.|lthcditf.rlnc.b.tw.cnth.maxrndmlh.G|!ct.o|ytc|.*||nct||t'rwnhinl0mm(o-39inl.
r t r sO . K

o.K
R.9l.cr

bfiarY.

C H E C KI N G S P E C I FI C G R A V I T Y
'Sp.cilic Gr.v(y Ch.ck"
Rrl.. ro

SLOWCXARGE
R.l.r to 'Ar slow
Ch.rg.'.

STANOARO CHARGE
R.l.r to "B: St.ndard
.
c,r.rF

CAPACITYTST
R.lcr to "Chart ll

CAPACITY TEST
R.{.. io "Ch..l ll

N.G

o.K.

N,G

Radv
lor ura

CAPACITY TST
'
R.l.r to "Ch.rl ll

O U I C KC H A R G
Ft.l.r lo 'C Ou|ck
Ch..ga".

o.K. N,G.
Rcady tot ura
. Mount batlary .earn
a.id ch.ck loot lar'
mrnalt. Alao, chack
orhar r.latad o.curlt

Ra9l.c.
battary.
C H C KI N G S P C C I FI C G R A V I T Y
R.l.r to "sgacilic GravilY Ch'ck"

RECHARGE
'Cr Ourcl Ch.tg. .
Rclcr to
'dC
-cvt
ri. tt btna.Y |rtFa.aol?t
clr'{'
Alt.v.
t rad F l, rrog dr4i.r..
i. b'lot
in |.|rF?atuna
b.rtaw th-r
8dC fiadFl.

CAPACITYTEST
R.t.r to "Ch.n ll
N.G.
R..dy
tor uat
. 'STAIIDARO

CHABOE" la ..conmandad

R.pl.E.
br(arv

ll th. vahlcla l. In ttot'g"tltr

EL.13

ch"g|ng'

O U I C KC H A R G E
Rrl.. !o "C: Ouicl
Chrrta"
ta6 tri|r.
. tiir tlu-td:

CAPACITYTEST
n.1.. ro "Ch..r ll

o.K
R.-v

N.G,
Rtlact

BATTERY
BatteryTestand ChargingChart(Cont'd)

Chd( b.nary ryp. rnd

cb!.rmina th. F.cilLd
drrnnr urlllo rh. lolbwtnl
tab|.,

F i g .1 O I S C H A R G I N G
CURRENT
(Lo.d re5t6r)
Tatr ul|ng load taata.
cuiienr (A)
28819R
Follow mrnut.crur!r'r
inrtrudion. io chck and
d.t.rmr^Grl ba[ary il

R..dy

tor u..

Go to nlri

Rrrd losd lrrtr. volt46

wh.n .p.citi.d dirch.rging
curr.ni {Fl.l.r ro Fi9. I )
l l o w 3 r h r o u g hb a i t . r y l o r

ittp

EL-14

90

46824A
55D23R

180

80D268

195

95D31R

244

I15D31R

244

BATTERY
BatteryTestand ChargingChart(Cont'd)
A

SLOW CHARGE
F 1 9 .2 l N l T l A L C H A R G I N G C U R R E N T S T T | N G l s t o w c h . r g . ,

\8ATTERY
TYPE
\

coN-\

Dctarmrna Iniiral charcant currant trom

rp.citic arrvily .ct..ring to Fig. 2

VERTEO\
SPEC|FtC \
GRAVITY \

t2 ro l5 voltr

tr

cc

cc

cc

(D

7.0
{A'

8.0
tAt

4.0
tA)

Bdow I .l0O
. C h a . g cb r t . r y .
. C h . c k c h . r g a n 9v o l t . g . 3 0 m r n u r c r a l t c r
rra.tinq tha batla.y chrrgc

c!
t!

5.0
{a)

lo.0
(At

ft

14.O

Chact banary ryp..nd drtrtmin

th. ,p.citht currant uriq th.

tabl sho$rn abov?.

Aft r rtrrting chrgirE, sdjuttr.nt

ol chrging clJrrrnt ir no!

Salow l2 voltr or sbor

15volr3

Frs 3 ADOITIONAL CHARGE {Slow ch.rg.)

r 150 1 200

Conr'nu. !o cha.o. to.

l2 hou.5
C h s r g ct o , 5 h o u . s

Cha.g? lor 4 hourr

Charg! tor 2 hourt

ar 'nrlr.r charoin9

C H E C K I N GS P E C I FI C G R A V I T Y
R a l c r t o " S o a c r l r cG r a v r t v C h a c t '
Go Io

',CAPACIIY

TEST,'

Conduct addriional charga a! par

Fig 3. il nacaatary

G o t o , , C A P A C I T YT E S T ,

CAUTION:
a. Set charging current to value specified in Fig. 2. lf charger
is not capable of producing specified current value, set its
charging current as close to that value as possible.
b. Keep battery away lrom 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.
d. lf battery temperaturerises above 60"C (140'F),stop charging. Always charge battery when its temperature is below
60"c (140"R.

EL-15

BATTERY
BatteryTest and ChargingChart(Cont'd)
SETTING
F i s . 4 l N t T l A LC H A R G I N GC U R R E N T
lst.nd.rd ch.rerl

A. STANOAROCHARGE

\BATTERY
TYPE
\

coN. \

ihit|.l charging curranl t.om

Oatarhina
rp.citrc gr.vity. rcl.rri.9 lo F19. 4

Cha.g. b.ttrry

VRTEO\
S P E C | F T\C
GRAVITY \

r . 1 m- 1 . 1 3 04 . 0 t A t 5.0 {A) 6.0 {At 7.OtAl

9.O(a)

1 . 1 3 0- 1 . 1 6 0 3.O{At 1.0 tAt 5.0 {Al 6.0 tAt

8.0 (A) l r . o t a l

r . 1 6 0- 1 . 1 $

lor S hou13

2.0 la) 3.0{At 4 . 0( a ) 5.0{At

1 3 . Ot A l

7.0(Al LO {A)

1 . r9 0 - 1 . 2 2 0 2 . 0( A l 2 . 0( a ) 3.0tA) r.0tA, s.0 (al 7 . 0( A t

Ch.ck b.tr.ry
C T I E C KI N G S P E C I F I CG R A V I T Y
R.t.r ro "Spacitrc Gravny Ch.ck"

Coruct
Fq

addrt|onal

charg?.3

typ. 5nd dct.rmrn. rh..rifiad

cu.r.nr rrint

th. i.bl.

Altcr 3iarlrng cha.girE, adiu.tmGnt ol ch.rging cur.ant r. nol n.odta.Y.

Pcr

5, it nccgrary

F r 9 .5 A O D I I I O N A L
Go ro "CAPACITY TEST

CHARGE {Stt^d..d charg.)

'

r 150 I 200

C h a r g ct o r 3 . 5 h o u r s
e l r n r t i a lc h a r g , n g

Chargc lor 2.5 houri

Ch.rgr ro. l Shou.t

er Inrtr.l ch.rtrng

G o I o . , c A P A c I T YT E S T ' '

CAUTION:
a. Do not use standard charge method on a battery whose specific gravity is less than 1.100.
b. Set chargingcurrentto value specifiedin Fig.4. It chargeris not capabteof producingspecified
currentvalue,set its chargingcurrentas closeto that valueas possible.
c. Keep bdtery away from open flame while it is being charged.
d. Whenconnectingcharger,connecileadslirst, then tum on charger.Do not turn on chargerfirst, as
this may causea spark.
e. lf batterytemperaturerises above 6O"C(lril)"D, stop charging.Always chargebattery when its temperatureis below60"C(140"D.

EL.l6

BATTERY
BatteryTest and ChargingChart(Cont'd)
C

OUICK CHAFGE

F r s .6 l N t T l A L C H A R G I N G
C U R R E N T S E T T I NAGN o
CHARGI G TIME lorick chrrg.)
1
\\

O a a r r h i n a r ^ r t . l c h a r g r n gc u r r ! . 1 l a t t r n 9 a n d
c h r r g r n gr r m c l r o m t p . c r f i c g . a v r l y , r l t l r r r n g
ro Frg 6

BATTERY
TYPE

c!

\\-cuR\
\
coN. \ RENr
V E R T E D\ A I
SPECTFTC
\
GRAVITY

1 0t A l

(!

iIC!

_t

cD

oo

3?

15lA)

20 (A)

30 (a)

1 1 0 0- 1 . 1 3 0

2.5 hour3

r .r 3 0. 1 .t 6 0

2.Ohour3

40 (a)

1 . 1 6 0- r . 1 9 0
1 . 1 9 0- 1 . 2 2 0
O.75 houri (45 mi^.)

Above 1.220

G o r o " C A P A C I T YT E S T "

C h . c k b a r t e r y t y p a n d d e t c r m r n ? t h s p e c i l j e dc u r r e n t u t r n g t h e l a b l e
a l r e r r r a r r ' n 9 c h a . g r h 9 ,a d t u r i h ? . t o l c h a r g r n gc u r r ^ l r 3 n o r n a c a r g f v

CAUTION:
a. Oo not use quick charge method on a bdtery whose specific gravity is les.sthan 1.10O.
b. st initial charging curent to valr.p specified in Fig. 6. lf charger is not capable of producing spe
cified current value, set its charging current as close to that value as possible.
c. Keep battery away from open llame while it is being charged.
d. When connecting charger, connect leads tirst, then tum on charger. Do not turn on charger tirst, as
this may caus a spark.

e. 8e carefulof a rise in batterytemperaturebecausea largecurrentflow is requiredduring quickchargeoperation.

lf batterytemperaturcrisesabove6O"C(1.10"D,
stop charging.Alwayschargebatterywhenits temperatureis below6O"C(lrO'D.
f. Do not exceedthe chargin-g
time speciliedin Fig.6, becausechargingbatteryoverthe chargingtime
can causedeteriorationof the battery.

ServiceDataand Specifications(S.D.S.)
Destination

ForNorthEurope

Exceplfor North Europe

Engine

SR2ODE

GA16DE

LD20tl

Type

46824R

28819R

1245

12-30

95D31R
'12-80

CapacityV-AH

EL.17

SR2ODE

GA16DE

LD20rl

80D26R
't245

55D23R

11 5 D 3 R
1

12-60

12-aO

SYSTEM
STARTING
WiringDiagram

clreor
e'..pt

fi)

e n g i n e m o c J es
@

I
@;
615)o

(cl0)[r

n
[-r]

/:;,\
!.&_r ! tr

1l
Ll

@
.:^r

ii
ad)

6i

{pT

.)-li

!@.,
UNJ

F.]:I BLT LiNK

FUSE EOX

_]

5TAFI:Ii

|]c r0R

AND/.i \,
!::]-/

EL-18

STARTINGSYSTEM
Trouble-shooting
lf any abnormality is found, immediately disconnect battery negativeterminal.
-

s3
lo

!
h

96

6
E
E

q
I

g>

6 3+
-E
a 39

9:

ih

::

H:
F

d b;

o(Ig

;r;
b

q-_

;-9:

qi"

:;

55;

Ee

io

Eis.E:
E5 s =3 s

Coo.

eB
EO

L'l;ct

!
>E

69

. EEE

6
9

1 e =F

;9

9
I

!.

iq

=2

.p6.

e!;9.

;> ;i

i;
Oo

O9

E
99dgP

E
2

E
qF;

9;

6
E
o

-9

E
I
q

cr
d

O 5(!
-9

o
2

og
o-

EL-l9

STARTINGSYSTEM- StarterConstruction(Mitsubishimake)
M1T6681(SR2oDEengine)

O
O
O
O
@
@
O

Rear cover
Metal rear cover
Brushspring
Brush
Brushholder
Fieldcoil
Armature

O
@
@
@
@
@

Pack
Magneticswitch
Shittlever
Gearcase
Stopperprnion
Pinionshalt

EL-20

@ Gear
'rt Hrnron
@ Bearing
@ Housing
(} Startermotorassembly
(t Gear case metal

STARTINGSYSTEM- StaderConstruction(Cont'd)(BOSCHmake)
9q)0.3.31424 (LlI2Ollengine)

w$
FF.-,

wk
I@----.

@ /K:b@;-"
O
O
O
O
@
O

Bearing
Gearcass
Bushing
Pinionassmbty
wheelcrown
Plate

O
@
@
@
O
@

Armatureassembly
Armaturelrame
Solenoid
shitt tever
Pinionshatt
Brush

EL.21

@
@
@
@
O

Dust cap
Rear cover
Fieldcoil
Brushspring
Brushspring guide

STARTINGSYSTEM_ StArtEr_
Bemovaland Installation
SR2ODEENGINE

ENGINE
GA16DE

N m 1 r s - mh . r u 1 y(

LD2OIIENGINE

Dismantling(SR20DE,
GA16DE)
REMOVINGTHE MAGNETIC SWITCH
the feed wire irom the solenoidterminalaf .
o Disconnect
Removethe screws if , securingthe switchto the end hous.
ing O
o Liftthe frontend of the solenoidto disengagethe plunger
from the engagemenllever.Removethe solenoid.

BEMOVING THE REAR COVER

o Take out the throughbolts.
the rearcoverQ and the
o Removethe screws@, securing
bruchplatei! ,respecitvely.
o Removethe rear platetakingcare lhat the brushplatedoes
not move f rom its place.

EL-22

STARTINGSYSTEM_ Starter_
Dismantling(SR20DE,
GA16DE)(Cont'd)
REMOVE THE BRUSH PLATE
o By meansof a pliers,move the end @ of the brushsprings
Irom the rearlo the left side of the brush.This is to release
the brushesfrom pressure.
Repeatthe same operationfor the rest of brushes.
o Take out the brush plate assembly.

REMOVING
THEFIELDCOILANDTHEARMATURE
o

Withdrawboth the field coil and the armatureat the same

time.

(SMODE engine)
Take care not to lose the ball located inside the planeting
assembly.This ball is for bearingthe armatureend.

SR20DEengine

Dismantlinggearcase

EL-23

STARTINGSYSTEM_ Starter_
MagneticSwitchCheck
Beforestartingto check,disconneclbatterygroundcable.
Disconnect"M" terminalof startermotor.
Continuitvtest.

Continuilybetween

Continurty

Action

"S" lerminaland switch

DOOy

Yes

o.K.

No

Replace

"S" terminaland "l\,t"

terminal

Yes

o.K.

No

Replace

Pinion/Clutch
Check
1. Inspectpinionteeth.
o Replacepinion if teeth are worn or damaged.(Also check
conditionof ring gear teeth.)
2. Check to see if pinion locks in one directionand rotates
smoothlyin the oppositedirection.
o lf it locksor rotalesin both directions,or unusualresistance
is evident.... Reolace.

REDUCTIONGEAR TYPE
3. Inspectreductiongear teeth.
o Replacereductiongear it teeth are worn or damaged.(Also
check conditionof armalureshaft gear teeth.)

EL.24

STARTINGSYSTEM_ Starter_
BrushCheck
BRUSH
Checkwearof brush.
Wearlimit length:
Referto S.D.S.
wear...Replace.
o Excessive

BRUSHSPRINGPRESSURE
Checkbrushspringpressurewithbrushspringdetachedfrom
brush.
Springpressure(with new brush):
Referto S.D.S.
o Notwithinthespecified
values...Replace.
S r u s hs p r i n g

BRUSHHOLDER
1. Performinsulation
testbetweenbrushholder(positive
side)

and its base (negativeside).

Continuity
exists.... Replace.
2 . Check brush to see if il moves smoothlv.
lf brush holderis bent. replaceit: if slidingsurfaceis dirty.
ctean.

ilv betweenbrush holderand....

Negative
brush
rsolat
Positivebrush

ArmatureCheck
1. Continuitytest (betweentwo segmentsside by side).
o No continuiw...Reolace.

EL-25

STARTINGSYSTEM_ StaTteT_

ArmatureCheck(Cont'd)
2. Insulatrontest (betweeneach commutatorbar and shafl).
exrsts.... Replace.
o Continuity

3. Check commutatorsurface.
o Rough... Sand lightlywith No.500 - 600 sandpaper.

Check diameterol commutator.

Commutatorminimum diameter:
Refer to S.D.S.
Lessthan specifiedvalue... Replace.
Vnniar ctlipar

5. Check depth of insulatingmold irom commutatorsuriace.

o Lessthan 0.2 mm (0.008in) ... Undercutto 0.5 to 0.8 mm
(0.020to 0.031in)

Undercutprocedures

Round
-->-

O.
IO.O2O.
^/

r{\\ilrr,
\\\\r'////
Correc!

Sr

F ,t e

rF:=

E1.26

STARTINGSYSTEM- StarterAssembly
greaseto lubricatethe bearing,gears
Apply h igh-temperature
and frictionalsurfacewhen assemblingthe starter.
Care{ullyobservethe followinginslructions.
Assemblyat next order:
Gear case
.
Pinionassemblyand shiftlever,musl be mountedtogether.
Ringand pinionshaft.
.
(sR20DE)Put the ball in its hole.
.
o Fieldcoil and armatureframe,must be mountedtogether.
Don'tlockthe holesof screws.
o Armaturef rame.
o Brushholder.
Checkthe correctalignmentof holesof screws.
o Rear cover.
Magneticswitch.
.

(S.D.S.)
ServiceDataand Specifications
M TSUBISHI

Type

t\.rf
1T6 058 I

SR20DE

Engineapplied
Systemvoltage

BOSCH

M002T25481 9000.3
31424
GA16DE

LD20rl

12

No load
Terrnrnavoltage

t1

115

Current

[ra.x 88

50

[,,lorelhan 150

tulorethan
3 000

5.600

Less than
4,500

Minimumdiameterof comrnulamm (rn)

lor

288

28 8 (1 134)

2 8 . 9( 1 . 1 3 8 )

Mrnimumlenglhof brush mm (in)

12.0

1 20 ( 4 . 4 7 2 )

7 (0 028)

Bevolubon

Brushspringtenson

EL.27

rpm

N (kg, lb)

13.7 25.5
(1.4 26
3 . 1- 5 7 )

137
( 1. 4 - 2 . 6
3.1

16.5 32.0
( 1 . 7- 3 . 3
3.7- 7.3)

CHARGING
SYSTEM
WiringDiagram
ffi

dd
'HEE

.<

-Fr
Fl-1

Etr

t44

E
o

t-.t-.]
-H
t-f1

t-t-1
H

t:]-

c
rr,

F;

ll

(E/

8sF

r?r r
_llD

,"

@+
A.r\sl'-Y

,,!

9t I

taA.

r-.

"Ll z
f_

^l

t9E[!J0

v)Z

o
tr
o

.6\F

tsF r.g?

.
cD

f)

fsl

EF+

ai_

!!
9!

3 6;
;;p

@#
SoS *@
ra$d@
|r
*- :
At-- -------r
lln 6

frt6
-l

-:?

-l

il' a

lEt

'l

-=:'

EL.28

.9
!F

;; '; ;: : v : l P
6 i, ofo)to6

F 9
n

HHI'::IP:
ooo(,
0a<ox
v1 0
)u

it:

urr!

@@@@@@ec

CHARGING
SYSTEM
Troubleshooting
Beforeconductingan alternatortest, make sure that the batteryis fullycharged.A 3o-voltvoltmeterand
suitabletest probesare necessaryfor the test. The alternatorcan be checkedeasilyby relerringto the
InsoectionTable.
Betore starting troubleshooting, inspec,t the fusible link.
WITH IC REGULATOR
l/Vrrh.lt.rn.to. iid. L r.rm;nel
g r o u n d a d , I n t c r n a l 3 h o 7 to c c u r i
whln + diod. ri 3hoit-crrcurtod.

|;;;;-l
I burb Repl.ceI
Proceed I

I end
- -l'."r-"
' S G e4 l l o r g r o u n d i n g F t e r m r n e l .

\--6;;"*;l
,/

( H I T A C HI

lRepleco.

I
I

) F"-"r"""c;:l

E."*;;I

- -lo, a.c.c

- F;"d"-l
_-l

--F*
-@

D-|;;;d'cnc'l
/

Morethan 15.5V

I
__l
---l;*
lR6elacs.

1 3r o l 5 V

1 ) Ur lully dr.n d brtr.ty.

2l Light : Cbrgt wrming light
A.C.G. : Alt.nrator p.rtr ax6pt lC lrguhtot
IC.RG : lC r.!ul or
: lC-rhrrtt.tor it in good @ndhbn.
O.K.
3) Wbn r.aafiing "O.nrqad A.C.G.", rar|oy!
allarnatc tron r.lrida ||td ditaaxmbla, intpasr
|rrd corrrct or aapLc. fasltY prn!.
4) 'Mrthod of ero{Ddirt F t.rmin.l {HITACHI mrkc
onlyl

Make suro connodor

(S, L) is connocted

EL-29

CHARGING
SYSTEM_ Alternator_
Removaland lnstallation
SR2ODEENGINE

pl

ro :r t.6-p1 12 i,,i

."-"'-E

Z|o! as. so
( 4 . 6, 6 . 1
33 - 44)

fq:

r?)

N m { K om . t l - l b )

GA16DEENGINE
--'-.!

t)

N m r r . t j ma , b )

r e - z r t 16

f)

EL-30

21 1p,i5t

//

rz so(38 s r 27 37r

EEL0]3

SYSTEM_ Alternator_
CHARGING
Removaland Installation(Cont'd)

EL-31

CHARGING
SYSTEM- AlternatorConstruction
SF2ODEENGINE _ LR.19O-719
GA16DE ENGINE_ LR-18G735

*>d0

(n
.eu'r6

,"d

@shM*
(v\
. \
" .\ Y

.'

.i,

,9

LII20[ ENGINE- 9120.335.000

O
O
(D
@

pump
Vacuum
Rotor
Frontcover
Fan

.9 Pulley
O stator
O Diodeplateassy.

EL.32

@ Rearcover
O Voltageregulator
f,Q Brush

CHARGING
SYSTEM- AlternatorDisassembly
BEAR COVER REMOVAL
CAUTION:
Rear cover may be hard to remove because a ring is used to
lock outer race of rear bearing. To facilitate removal of rear
cover, heat iust bearing box section with a 2oGwatt soldering
iron.
Do not use a heat gun, as it can damage diode assembly.

S o l d e r i n ga r o n
{200W capacirv,

RotorSlip RingCheck
1. Continuity
test
o No continuity...Replacerotor.

Ohmmeter

Erushwoar limiting line

2 mm (0.O8in)

2. Insulatortest
exists... Replacerotor.
. Continuity
3. Checkslip ringfor wear.
Slip ring minimum outer diameter:
Referto S.D.S.

BrushCheck

'L Check smoothmovement

of brush.
. Not smooth... Checkbrushholderand clean.
2. Checkbrushfor wear.
o Replacebrushif it is worndown to the limitline.

3. Check brush lead wire for damage.

o Damaged...Replace.
4. Check brush spring pressure.
Measure brush spring pressure with brush projected
approximately
2 mm (0.08in) from brushholder.
Spring pressure:
Refer to S.D.S.
o Not withinthe specifiedvalues... Replace.

EL.33

CHARGING
SYSTEM- AlternatorStatorCheck
To test the stator or diode, separatethem by unsolderingthe
connectingwires.
CAUTION:
Useonly as much heatas requiredto melt solder.Otherwise,
diodeswill be damagedby excessiveheat.

1. Continuity
test
o No continuity...
Replace
stator.

2. Groundtest
o Continuity
exists...Replace
stator.

MAINDIODES
r
o

Use an ohmmeterto checkconditionof diodesas indicated

in chart below.
lf any of the test resultsis not satisfactory,replacediode
assembly.
probes
Ohmmeter
PositiveO
Positivediode plale

NegativeO
Diodeterminals

Continuity

Yes

Diodelerminals

Positivediode plate

No

Negalivediode plate

Oiodeterminals

No

Oiodeterminals

Negativediode plate

Yes

EL-34

- AltematorCHARGING
SYSTEM
StatorCheck(Gont'd)
SUB-DIODES
o
o

Attach ohmmeter's orobe to ach end of diode to check for

continuity.
Continuityis N.G. ... Replacediode assembly.

Assembly
Carefullyobservethe followinginstructions.
eachstatorcoilleadwireto diodeassemo Whensoldering
bly terminal,carryoul lhe operationas fastas possible.

Crolin

REARCOVERINSTALLATION

.nia|| ,Dod.l

Brurh litt rvira

1. Beforeinstalling
frontcoverwithpulleyand rotorwith rear
cover,push brush up with lingersand retainbrush by
insertingbrushliftwireintobrushlift holelrom outside.
pull out
2. After installingfront and rear sidesof alternator,
brushlift wire.

EL5

SYSTEM- AlternatorCHARGING
(S.D.S.)
ServiceDataand Specifications
ALTERNATOR
LR190-719

Type

1 R 1 8 0 - 7 3 5 I 120.335.000

HITACHI

Engine
Nomina rating

V-A

SR2ODE

GAl6DE

LD20rl

12-90

12- 80

12-90

Groundpolarity

Negalrve

l\,4inimum
revolutionunderno-load
(When13 5 voltsis applred) rpm

Hotoutputcurrent
Regulatedoulpulvollage

A./rpm

Brushspringpressure N (9,oz)

E1.36

10500
234300
63/2500
87/5000

Minimumlengthot brush mm (in)

Slip nng minimumouter

orameler

BOSCH

mm (1n)

2311300
63/2500
77l5000

16.5/1300
68.5/2500
B3/5000

1 4 . 1 14.7

6 0 (0 236)

t 010.276)

1.0003.432 1.8633.040
(102 350,
( 1 S 0- 3 1 0 ,
3 . 6 0- 1 2 . 3 4 ) 6 7 0 - 1 0 . 9 3 )
26.0
( 10 2 4 )

306 (1.20s)

1 00 { 0 . 3 9 )
1 . 9( 1 9 4 ,
6 84)
1 s . 3( 0 6 0 2 )

COMBINATION
SWITCH
CombinationSwitch/Check
REARWIPER
AND WASHER
-wrpEa

o"fr

TURN
a; --r

WASH& WIPE
OFF

Lf

INT

1ST

in,A
tl {

t\

-r-\

OFF
LIGHT

;*-a

\\1t

\-:=///
o

ll
F

LO

Ht

a-Lj

F N O N TW I P E R
AND WASHEF

a]
tq-Tfll

til

.td
Iii ,6iGT,

l-l

l , L 6 l eL , r tIr
L r g h t r n ga n d
rurn srgnal

FRONTWIPERAND
WASHERSWITCH

REARWIPERAND
WASHERSWITCH

PER
\ OFF I NT

WIPE O F F WIPE

I]I GH

LIGHTING SWITCH

HORN SWITCH
TURN
SIGNAL

swtTcH

NmNn
llo

ol

f2TdTm
ETT r0l

l-1
tGt

INTERMITTENT
wlPEF VOLUME

EL-37

COMBINATION
SWTCH
Replacement
o

Each switch can be replacedwithout removingcombination

switch base.

To removecombinationswitchbase,removebase anaching screwand turnafterpushingon rt.

SEL39OL

EL.38

HEADLAMP- Without DaytimeLight Systemand Dim-dipLamp SystemWiringDiagram

ttf

ffi

T.-l

m
G

ffii
ff-l

E
L

t=
t-:J!.ll=

rT_-

m q4+
L

[-/
z

o
ztx

/-, lEl z
aolr,?
a

.o11'A

@E
I /-:\
qtrLdl

al

q+

tP

1+

6i rA r-l 6\
!-rtrr""

rf
" --1-tf-

9(
t.A.r
)
;\
\-r-{-/
3 v

+
rJl
'
g(--.1-t+.
;\

fI Ii f f

EL.39

ur

\ll,
'\-,--l

,/

- DaytimeLight SystemHEADLAMP
Operation
After startingthe engine with lhe lightingswitch in the "OFF"
position,the headlamplow beam and clearance,tail, license
and instrumenlillumination
lampsautomatically
turn on. Lighting switch operationsother than the above are the same as
conventionallight systems.
Engine

Wjth enginestopped
OFF

Lightingswitch

Wrthenginerunning

2ND

1ST

c
o

High beam

LOWDeam

Clearanceand tail lamp

x
o

o
o

Licenseand instrument
illumination
lamp

Headlamp

OFF

c
o

o
o

1ST

o
o

c
o
o
o

2ND

c
o

O: Lamp"ON"
X: Lamp"OFF"
El: Added functions

Schematic
] GNI TI ON SWI ICIl
ON o. START

JGN] T] ON SW] ICI

SIART

BATTERY

L]GNTING SW]TCH

tt

)?

3
OAYIIIlE L] GII
C O NI R O L U N ] T

HEAO.

H] GH AEAM
] NDI CAIOR

Rf.

ALIERNAIOR

LO20 ensine

mode s

Exccpt

eng ine

LDz0

node

MEL675A

EL4O

- DaytimeLightSystemHEADLAMP
WiringDiagram

t
4c)
iY
i

Y
-u \Y/

ea^an. e

amF+

-..

ir F
ril trTT
FE rq
!4
ffi

tTt

r-

ffi

To.

ffi
q

l-.l

z
o

ffi
zu
-n

-.- qr
E,i )
Z

t,t -F

H{

B!0!]

trTl
A

?
--J
;

FF ffi
H fl
-T-t F?r
Tt l
!:l:l
E
:
-l-

o-"

.a .a

ttr
fT_
-T-

G ra , -

6lr6

-----1

c
o

5
al E
t, til
- /:\

3- rR."i
t

---D

/:\

=l

L/

rldadd

n o

;;

dd

F:u

;
.4

trT-l

.G+

h:i
!:r
/

L=

/-L I

DLi
/a a.n

2
rEl

5
6),

Frl

t-,

reJc
eml

+so

=
zu
I

. .r c- je-T"
t I
.tr'
,i'j
,-D', [r_]

A
."

ffi'
fl

qF,3l

eH

-n

rtr

-i

,--]---.:
t-*,-'

t!.4E16744

EL.41

HEADLAMP- Dimdip lamp SystemOperation

When ignitionswitch is in the "ON" positionwith the lighting
switchin the "1ST" oosition.the headlamolow beam comeson
dimly to functionas a clearancelamp. Lightingswitch operations other than the above are the same as conventionalfioht
svstems.
lgnitionswitch

ON

OFF or ACC
OFF

Lighting switch

1ST

2ND

High beam

c
o

Low beam

Dimp-dip
(Low bam)

Clearanceand tail lamo

Licenseand instrument
illumination
lamp

Headlamp

c
o

2ND

1ST

OFF

(.

o
o

O: Lamo "ON"
X: Lamo "OFF"
Cl Added functions

Schematic
I G N JI ] O N S W JI C H
0N o. START

AAITERY

L ] G I l T ] N G S W JT C H

To c a.ance,
ta i I
I iccnse
amps

O]I1'O]P LJGHT
C O NI R O L U N I I

9
?

it
]?
HI GH 8EAI1
JN O ]C A I O R

MEL6/78

EL42

HEADLAMP- Dimdip lamp SystemWiring Diagram

(J :

6,3
r_re'jt =

Tr]
Tr"l

rn

ffi

\y

T5-1

!'t-

-T-.1-.1|

E
LG,S_

F. s -Gll

H +fm
:J^-r

LZ
OO

:}<

|] tl

|l

euJJ'g@
tq
);)))d)d;,i

6d

p6
,', i'
u or----f-t-l-t-t-

'i

/l

tvr l

a66l

ol :l:9dc9{,!
i - -

-L _-

-;:+H++++H+a

-----6-d-:',P

r r 4 - - - t

^l
/ax\ I
Lti19

bl tr<<:ir"li(7
dc rrrrrlrrri

co

f$a
t?T

/'\
\9
EEE tffi-

mJ r+Ft
ffi llE
L::

c
E

6\cc

6t,'F

I!r

@ll,:

OE

9a

(9

;)j

t_i.Iri

;;

(t tt

lm aj

tu..r,!
ta i

6t,

tcn
|i

; Til

t.frh
6\

U'

co

ttl_\

,/

tcD
l|

: t.rl

t.trh
6\

U-,l ,/

II

MEL676A

- Headlamp
HEADLAMP
AimingControlDescription
The verticaldirectionof the headlampprolection
can be adjustedlrom insidethe vehicleto prevent
lhe headlightbeam axis from facingupwarddue to a changein the numberof occupantsand load
conditionsin the vehicle.

Battot^y

R c v cn a I n 9
t cIlv

Fon /ard
.e lay
No cont Inu lty
(Whltc po.t I or,

ContInu lty

Almlno
gw I tc6

S E N S O R( R o t E t I n a
por-t I od

Thoi. trto.
AI I1ING I1OTORUNI T (R. I-t )

Rcve.aIno
rc l!y

No cont Inu lty

( W hl t 6 p o . t l o r ,

Contlnu lty

SENS0R (Rotat Ino

po.t I od
Jhcnn I ator
AI MI NG I'IOTORUNI T (L. I{ )

EL-44

EnI a.ocd
gont l6n A

- Headlamp
HEADLAMP
AimingControlDescription(Cont'd)
l J p a n d d o w n a d j u s t r n gs c r e w

A r m r n gm o t o r u n t t

CIRCUIT
OPERATION
IExample]
Aimingswitch"0"
o

0
l
2
3

Whenthe aimingswitchrs set to "0", the motorwillnot start

becausethe powerterminalsare positioned
at the nonconductivesectionol lhe sensor'srotarvunit.

Aiming switch "O" -- "1"

o When the aimingswitchismovedfrom "0" to "1", poweris
appliedto the motor throughthe relay operatedby the
sensor'sconductive
secton.The headlamps
willthenmove
in lhe "DOWN"direction.
o The motor continueslo rotate while the rotary unit of the
sensorsmovesfrom pointA to pointB.
at the noncono The powerterminalswilllhen be positioned
ductiveseclion,disconnectingthe power tothe motor.The
motorlhen slops.

Aimingswitch"1" - "0"
o

Whenthe aimingswitchis movedfrom "1" to "0", powerts

applied to the motor through the relay operated by the
conductivesectionof the sensor.The motor will rotateto
movethe headlampsin the "UP" direction.
When the rotaryunit of the sensor moves from point B to
pointA, the motorwill stop.

EL-rts

- HeadlampAimingControlHEADLAMP

EL.45

- HeadlampAimingControlHEADLAMP
WiringDiagram

/:\
6

o *#l
e -{-rl

---t^/A

c
E^
f oc

,a\I*'Ha
)'+t'I
\?

n l

.
a

:
Lrn
-Ll
6
i;

L-l

o
zu

tr
o

EL47

- Headlamp
HEADLAMP
AimingControlA

Troublediagnoses

5rCil

SYMPTOM:Headlampaiming does not operate.

Lightingswrlch lsl

ts

EI
'H)

P O W E RS U P P L YC I R C U I T
CHECK(For aimingswitch)
Check if 12 voltsexistbetween
t e r m i n a l sO a n d a O .

Check 10Afse al luse block.

(Referto "POWERSUPPLY
ROUTING.")

A I M I N GS W I T C HC H E C K
Checkcontinuitybetweenterminals at each switchposition.

mtri

mti

G R O U N DC I R C U I TC H E C K
F O RA I M I N GM O T O R
Checkcontinuitybetweenterminals rj) and body grround.
Continuity exists ... O.K.

Bepairharnessbetweenaiming
motorand body ground.

P O W E RS U P P L YC I R C U I T
CHECK
(For aimingmotor unit)
Check il 12 volts existbetween
t e r m i n a t s' O , @ , @ , @ a n d

Check harnessbetweenaimjng
switchand aimingmotor unit.

Voltmeter
Voltage [V]
termina

o
.;\

Approx.12
o
Approx1
.2

o
o

Aiming
switch
posrtron
"0"
"0"
"1"

"1"

Approx.12

0
A p p r o x .1 2
0

EL.48

,.3,,
"3"

HEADLAMP
Bulb Replacement
PUSHIo

_@.

PUSH
lo

The headlamp is a semi-sealedbeam type which uses a

replaceablehalogenbulb. The bulb can be replacedfrom the
f ront compartmentside withoutremovingthe headlampbody.
r Grasp only the plastic base when handling the bulb. Never
touch the glass envelope.
1. Disconnectthe batterycable.
2. Disconnectthe harnessconnectorfrom the back side ol the
bulb.
3. Pulloff the rubbercap.
4. Remove the headlampbulb carefully.Do not shake or
rotatethe bulb when removingit.
5. Installin the reverseorderof removal.
CAUTION:
o Do not leave the bulb out of the headlamp reflector for a
long period of time as dust, moisture, smoke, etc. may
enter the headlampbody and aflect the pedormance of the
headlamp. Thus, the headlamp bulb should not be
removed from the headlamp reflector until just before a
replacmentbulb is to be installed.

AimingAdjustment
headlampaimingadjustment,
use an aiming
When performing
machine,aimingwall screenor headlamplester. For operating
instructionsof any aimer,it shouldbe in good repair,calibrated
and used accordingto respectiveoperationmanualssupplied
with the unit.
lf any aimeris not available,
aimingadjustment
can be doneas
Iollows:
For details, reter to the regulations in your own country.
CAUTION:
a. Keep all tires inflated to correcl pressures.
b. Place vehicle and tester on one and same flat surfacec. Seethat there is noload in vehicle (coolant,engine oil filled
up to correct level and tull tuel tank) other than the driver
(or equivalent weight placed in driver's position).

lF-bl
l3 2 I 0l

,n

L,\_-! Sl l

CAUTION:
Be sure aiming switch is set to "0" when performing aiming
adiustment on vehicles equipped with headlamp aiming control.

[)
\/

EL-49

HEADLAMP
AimingAdjustment(Cont'd)
LOWBEAM
1. Turn headlamplow beam on.
2. Use adjustingscrewslo performaiming adjustment.
o First tighten the adiusting screw all the way and then make
adiustment by loosening the screw.

lJp and down adlustrng

a. Adiust headlamps so that main axis of light is parallel to

center line ol body and is aligned with point P shown in
illustration.
b. Figure to the left shows headlamp aiming pattern for driving on right side of road; for driving on left side of road,
aiming pattern is reversed.
c. Dotted lines in illustration show cnter of headlamp.
"H":
Horizontal cnter line of headlamps
"W.":
Distanc between each headlamp center
"L":
5,fi)Omm (196.85in)
"C":
53 mm (2.09in)
Varticalcantgrlane
ahrsd of haedlamp,

Heighr ol -

q$ = acceenerenrruce

EL-50