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WORKSHOP MANUAL

2007MY N-SERIES

CAB AND CHASSIS ELECTRICAL (LEFT HAND DRIVE MODEL)


SECTION 8

Isuzu Motors Limited Service Marketing Department

NOTICE
Before using this Workshop Manual to assist you in performing vehicle service and maintenance operations, it is recommended that you carefully read and thoroughly understand the information contained in Section-0A under the heading GENERAL REPAIR INSTRUCTIONS.

All material contained in this manual is based on latest product information available at the time of publication. All rights are reserved to make changes at any time without prior notice.

Applicable Model: N-Series This manual is applicable to 2007 year model.

THIS MANUAL INCLUDES THE FOLLOWING SECTIONS:


SECTION No. 8

CONTENTS
CAB AND CHASSIS ELECTRICAL

CAB AND CHASSIS ELECTRICAL

8-1

CAB AND CHASSIS ELECTRICAL


CAB AND CHASSIS ELECTRICAL Contents
GENERAL INFORMATION..................................... 8-2 General Information............................................. 8-2 Notes for Working on Electrical Items ................. 8-2 Symbols and Abbreviations ................................. 8-8 Parts for Electrical Circuit .................................. 8-11 Reading The Circuit Diagram ............................ 8-19 MAIN DATA AND SPECIFICATIONS ................... 8-22 Bulb Specifications ............................................ 8-22 Fuse and Fusible Link Location......................... 8-24 Reference Table of Fuse and Circuit Breaker ... 8-30 Relay Location................................................... 8-33 Diode Location................................................... 8-35 Reference Table of Grounding Point ................. 8-36 Grounding Point Location .................................. 8-37 Cable Harness Routing ..................................... 8-38 SYSTEM REPAIR ................................................. 8-41 Start and Charging ............................................ 8-41 Exhaust Brake System and Engine Control ...... 8-49 Headlight, Fog Light, Rear Fog Light and Cornering Light .. 8-92 Headlight Leveling ........................................... 8-117 Clearance Light, Taillight, License Plate Light and Illumination Light ... 8-126 Turn Signal Light, Hazard Warning Light and Stoplight .... 8-139 Horn, Backup Light and Backup Buzzer.......... 8-154 Dome Light and Backup Buzzer ...................... 8-166 Power Door Lock ............................................. 8-177 Power Window................................................. 8-189 Windshield Wiper and Washer ........................ 8-204 Audio and Cigar Lighter................................... 8-223 Meter and Warning/indicator Light................... 8-231 Heater and Air Conditioning ............................ 8-280 Rear Heater ..................................................... 8-286 ABS/ASR System ............................................ 8-290 Transmission Control System (Smoother)....... 8-296 Tacho Graph.................................................... 8-315 SECTION 8

8-2 CAB AND CHASSIS ELECTRICAL

GENERAL INFORMATION
General Information
The chassis electrical system is of 24-volt specifications with a negative ground polarity. Wire sizes are appropriate to respective circuits, and classified by color. (The classification of harnesses by color is shown on the circuit diagram for ease of harness identification.) The wire size is determined by load capacity and the length of wire required. The vehicle harnesses are: body harness, floor harness, engine harness, frame front harness, frame rear harness, rear body harness, dome light harness, door harness and battery cable. The harnesses are protected either by tape or corrugated tube, depending on harness location. The circuit for each system consists of the power source, wire, fuse, relay switch, load parts and ground, all of which are shown on the circuit diagram. In this manual, each electrical device is classified by system. For major parts shown on the circuit based on the circuit diagram for each system, a summary, diagnosis of troubles, inspection and removal and installation procedures are detailed.

N8B5125E

Notes for Working on Electrical Items


Battery Cable
Disconnecting The Battery Cable 1. All switches should be in the OFF position. 2. Disconnect the battery ground cable 1. 3. Disconnect the battery positive cable 2. 4. Disconnect the battery cable 3. Caution: It is important that the battery ground cable be disconnected first. Disconnecting the battery positive cable first can result in a short circuit. Connecting The Battery Cable Follow the disconnecting procedure in the reverse order. Caution: Clean the battery terminal and apply a light coat of grease to prevent terminal corrosion.

Connector Handling Disconnecting The Connectors Some connectors have a tang lock to hold the connectors together during vehicle operation. Some tang locks are released by pulling them towards you 1. Other tang locks are released by pressing them forward 2. Determine which type of tang lock is on the connector being handled. Firmly grasp both sides (male and female) of the connector. Release the tang lock and carefully pull the two halves of the connector apart.

N8A0003E

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

CAB AND CHASSIS ELECTRICAL

8-3

N8A0004E

N8A0006E

Connecting the Connector Firmly grasp both sides (male and female) of the connector. Be sure that the connector pins and pin holes match. Be sure that both sides of the connector are aligned with each other. Firmly but carefully push the two sides of the connector together until a distinct click is heard.

Never insert the circuit tester test probes into the connector open end to test the continuity. Broken or open connector terminals will result.

N8A0007E

N8A0005E

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

Waterproof Connector Inspection It is not possible to insert the test probes into the connector wire side of a waterproof connector. Use one side of a connector 1 with its wires cut to make the test. Connect the test connector 2 to the connector to be tested. Connect the test probes to the cut wires to check the connector continuity.

8-4 CAB AND CHASSIS ELECTRICAL

N8A0008E

N8A0010E

Connector Pin Removal Connector Housing Tang Lock Type 1. Insert a slender shaft into the connector housing open end. 2. Push the tang lock up (in the direction of the arrow in the illustration). Pull the wire with pin free from the wire side of the connector.

Connector Pin Insertion 3. Check that the tang lock is fully up. 4. Insert the pin from the connector wire side. Push the pin in until the tang lock closes firmly. 5. Gently pull on the wires to make sure that the connector pin is firmly set in place.

N8A0011E N8A0009E

Pin Tang Lock Type 1. Insert a slender shaft into the connector housing open end. 2. Push the tang lock flat (toward the wire side of the connector). Pull the wire with pin free from the wire side of the connector.

Parts Handling Be careful when handling electrical parts. They should not be dropped or thrown, because short circuit or other damage may result.

CAB AND CHASSIS ELECTRICAL

8-5

N8A0012E

N8A0014E

Cable Harness When installing the parts, be careful not to pinch or wedge the wiring harness. All electrical connections must be kept clean and tight.

Position the wiring harness with an enough clearance from the other parts and guard the wiring harness with a vinyl tube and clips to avoid direct contact.

N8A0015E N8A0013E

Use a grommet or guard tube to protect the wiring harness from contacting a sharp edge or surface.

The wiring harness between engine and chassis should be long enough to prevent chafing or damage due to various vibrations.

8-6 CAB AND CHASSIS ELECTRICAL

N8A0016E

N8A0017E

Splicing Wire
1. Open the Harness If the harness is taped, remove the tape. To avoid wire insulation damage, use a sewing seam ripper (available from sewing supply stores) to cut open the harness. If the harness has a block plastic conduit, simply pull out the desired wire. 2. Cut the wire Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 1-2/2 (40 mm) away from other splices, harness branches, or connectors. 3. Strip the insulation When replacing a wire, use a wire of the same size as the original wire. Check the stripped wire for nicks or cut stands. If the wire is damaged, repeat the procedure on a new section of wire. The two stripped wire ends should be equal in length. 4. Crimp the Wires Select the proper clip to secure the splice. To determine the proper clip size for the wire being spliced, follow the directions included with your clips. Select the correct anvil on the crimper. (On most crimpers your choice is limited to either a small or large anvil.) Overlap the two stripped wire ends and hold them between your thumb and forefinger. Then, center the splice clip under the stripped wires and hold it in place.

Open the crimping tool to its full width and rest one handle on a firm flat surface. Center the back of the splice clip on the proper anvil and close the crimping tool to the point where the back of the splice clip touches the wings of the clip. Make sure that the clip and wires are still in the correct position. Then, apply steady pressure until the crimping tool closes.

N8A0018E

Before crimping the ends of the clip, be sure that: The wires extend beyond the clip in each direction. No strands of wire are cut loose, and No insulation is caught under the clip. Crimp the splice again, once on each end. Do not let the crimping tool extend beyond the edge of the clip or you may damage or nick the wires.

CAB AND CHASSIS ELECTRICAL

8-7

N8A0019E

N8A0021E

5. Solder Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment you are using.

If the wire does not belong in a conduit or other harness covering, tape the wire again. Use a winding motion to cover the first piece of tape.

N8A0022E N8A0020E

6. Tape the Splice Center and roll the splicing tape. The tape should cover the entire splice. Roll on enough tape to duplicate the thickness of the insulation on the existing wires. Do not flag the tape. Flagged tape may not provide enough insulation, and the flagged ends will tangle with the other wires in the harness.

8-8 CAB AND CHASSIS ELECTRICAL Symbols and Abbreviations


Symbols
Symbol Meaning of Symbol Contact wiring Symbol Meaning of Symbol

Fuse

N8A5507E

N8A5501E

Battery

Fusible link

N8A5508E

N8A5502E

Diode

Fusible link wire

N8A5509E

N8A5503E

Electronic Parts

Switch

N8A5510E

N8A5504E

Resistor

Switch

N8A5511E

N8A5505E

Speaker

Switch (Normal close type)

N8A5512E

N8A5506E

Buzzer

N8A5513E

CAB AND CHASSIS ELECTRICAL


Symbol Meaning of Symbol Symbol Meaning of Symbol

8-9

Circuit breaker

Connector

N8A5514E

N8A5521E

Bulb

Light emitting diode

N8A5515E

N8A5522E

Double filament bulb

Reed switch

N8A5516E

N8A5523E

Motor

Condenser

N8A5517E

N8A5524E

Variable register Rheostat

Horn

N8A5518E

N8A5525E

Coil (inductor), solenoid, magnetic valve

Vacuum switching valve

N8A5519E

N8A5526E

Relay

N8A5520E

8-10 CAB AND CHASSIS ELECTRICAL


Abbreviations
Abbreviation A ABS ASM AC A/C ACC C/B CSD DIS EBCM ECGI ECM ECU EFE 4X4 FL FRT H/L IC IG Meaning of Abbreviation Ampere (S) Anti-lock brake system Assembly Alternating current Air conditioner Accessories Circuit breaker Cold start device Direct ignition system Electronic brake control module Electronic control gasoline injection Electronic control module Electronic control unit Early fuel evaporation Four-wheel drive Fusible link Front Headlight Integrated circuit Ignition Abbreviation kW LH LWB M/T OD OPT QOS RH RR RWAL ST STD SW SWB V VSV W WOT W/ W/O kilowatt Left hand Long wheel base Manual transmission Over drive Option Quick on start Right hand Rear Rear wheel anti-lock brake system Start Standard Switch Short wheel base Volt Vacuum switching valve Watt (S) Wide open throttle With Without Meaning of Abbreviation

CAB AND CHASSIS ELECTRICAL 8-11 Parts for Electrical Circuit


Wiring
Wire Color All wires have color-coded insulation. Wires belonging to a system's main harness will have a single color. Wires belonging to a system's subcircuit will have a colored stripe. Striped wires use the following codes to show wire sizes and colors.

N8A5023E

Abbreviations are used to indicate wire color within a circuit diagram. Refer to the following table. Wire Color Coding Color-Coding B W R G Y L O Meaning Black White Red Green Yellow Blue Orange Color-Coding BR LG GR P LB V Meaning Brown Light green Grey Pink Light blue Violet

Distinction of Circuit by Wire Base Color Base color B W R G Starter circuit Charging circuit Lighting circuit Signal circuits Circuits Base color Y L, O, BR, LG, GR, P, LB, V Circuits Instrument circuit Other circuit

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

8-12 CAB AND CHASSIS ELECTRICAL

N8A0025E

Wire Size Table Nominal size 0.3 0.5 0.85 1.25 2 3 5 8 15 20 Cross sectional area (mm2) 0.372 0.563 0.885 1.287 2.091 3.296 5.227 7.952 13.36 20.61 Outside diameter (mm) 1.8 2.0 2.2 2.5 2.9 3.6 4.4 5.5 7.0 8.2 Allowable current (A) 9 12 16 21 28 37.5 53 67 75 97 AWG size (cross reference) 22 20 18 16 14 12 10 8 6 4

Fuse, Fusible Link and Circuit Breaker


Fuse Fuses are the most common form of circuit protection used in vehicle wiring. A fuse is a thin piece of wire or strip of metal encased in a glass or plastic housing. It is wired in series with the circuit it protects. When there is an overload of current in a circuit, such as a short of a ground, the wire or metal strip is designed to burn out and interrupt the flow of current. This prevents a surge of high current from reaching and damaging other components in the circuit. Determine the cause of the overloaded before replacing the fuse. The replacement fuse must have the same amperage specifications as the original fuse. Never replace a blown fuse with a fuse of a different amperage specification. Doing so can result in an electrical fire or other serious circuit damage. A blown fuse is easily identified.

N8A0026E

CAB AND CHASSIS ELECTRICAL 8-13


Fusible Link The fusible link is primarily used to protect circuits where high amounts of current flow and where is would not be practical to use a fuse. For example, the starter circuit. When a current overload occurs, the fusible link melts open and interrupts the flow of current so as to prevent the rest of the wiring harness from burning. Determine the cause of the overload before replacing the fusible link. The replacement fusible link must have the same amperage specification as the original fusible link. Never replace a blown fusible link with fusible link of a different amperage specification. Doing so can result in an electrical fire or other serious circuit damage. A blown fusible link is easily identified.

N8A0027E

Fusible Link Specifications Type Connector Connector Bolted Bolted Bolted Rating 30 A 40 A 50 A 60 A 80 A Case Color Pink Green Red Yellow Black Maximum Circuit Current (A) 15 20 25 30 40

Circuit Breaker The circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. The reset knob pops out when the circuit is open. Push the reset knob in place to restore the circuit after repairing it.

Relay Battery and load location may require that a switch be placed some distance from either component. This means a longer wire and a higher voltage drop 1. The installation of a relay between the battery and the load reduces the voltage drop 2. Because the switch controls the relay, amperage through the switch can be reduced.

N8A0029E N8A0028E

8-14 CAB AND CHASSIS ELECTRICAL


Relay Specification, Configuration and Inspection Name/ Color Rated voltage/ Coil resistance Internal circuit Name/ Color Rated voltage/ Coil resistance Internal circuit

MR5C (1T)/ Green

24 V/ Approx. 266 Minimum operating voltage: 16 V at 25C (77F)


1 2 3 5 4

N8A0431E

N8A0433E

MR82C/ Green label

24 V/ Approx. 100 Minimum operating voltage: 16 V at 20C (68F)


N8A0434E

N8A0432E

MR5C (1T)/ Grey

24 V/ Approx. 266 Minimum operating voltage: 20 V at 25C (77F) The way Result

(connector face)

(connector face)

Check to see if there is any continuity between the relay terminals. Result

The way

Check to see if there is any continuity between the relay terminals.

Normal Inspection Abnormal

(When no voltage is applied relay terminals 2 -4) 3 -5 continuity 1 -5 No continuity Inspection (When minimum operating voltage is applied relay terminals between 2 -4) 3 -5 continuity 1 -5 No continuity (When minimum operating voltage is applied relay terminals between 2 -4) 3 -5 No continuity 1 -5 continuity Inspection

Normal

(When no voltage is applied relay terminals 4 -5) 2 -3 No continuity (When minimum operating voltage is applied relay terminals between 4 -5) 2 -3 No continuity (When minimum operating voltage is applied relay terminals between 4 -5) 2 -3 continuity

Abnormal

Normal

Normal

CAB AND CHASSIS ELECTRICAL 8-15


Name/ Color Rated voltage/ Coil resistance Internal circuit

ACM 13222 M01/ Green

24 V/ Approx. 320 Minimum operating voltage: 18 V at 25C (77F)

N8A5571E

N8A5572E

(connector face) The way Result Check to see if there is any continuity between the relay terminals.

Normal Inspection Abnormal

(When no voltage is applied relay terminals 3 - 5) 1 - 4 continuity 1 - 2 No continuity Inspection (When minimum operating voltage is applied relay terminals between 3 - 5) 1 - 4 continuity 1 - 2 No continuity (When minimum operating voltage is applied relay terminals between 3 - 5) 1 - 4 No continuity 1 - 2 continuity

Normal

8-16 CAB AND CHASSIS ELECTRICAL


Diode Diode Specifications and Configurations
THERE SHOULD BE CONTINUITY IN EITHER A OR B WHEN A CIRCUIT TESTER IS CONNECTED WITH DIODE TERMINAL

SHAPE

MARK/ COLOR

CONSTRUCTION

CHECKING

TERMINAL NO. 2 1 CONNECTION PATTERN A B

BLACK

TERMINAL NO. CONNECTION PATTERN A B

BLACK

TERMINAL NO. A B

CONNECTION PATTERN

BLACK

TERMINAL NO.

4 3 2 1
CONNECTION PATTERN B A

BLACK
N8A0032E

Maximum Rating (Temp. = 25C) Items Peak reverse voltage Transient peak reverse voltage Average output current Working ambient temperature Storage temperature Rating 400 V 500 V 1.5 A 30C 80C 40C 100C Temp. = 40C Remarks

CAB AND CHASSIS ELECTRICAL 8-17


Connector The connector pin shape determines whether the connector is male or female. The connector housing configuration does not determine whether a connector is male or female. Connector is identified with a number.

N8A0035E

The applicable terminal number is shown for each connector.


N8A0033E

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

N8A0036E

N8A0034E

Connector terminal numbers are clearly shown. Male side connector terminal numbers are in sequence from upper right to lower left. Female side connector terminal numbers are in sequence from upper left to lower right.

8-18 CAB AND CHASSIS ELECTRICAL


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

N8A0037E

Notice: For those connectors on which specific terminal numbers or symbols are shown (such as ECM), the terminal numbers or symbols are used in the circuit diagram, irrespective of the above rule.

N8A5038E

N8A0038E

CAB AND CHASSIS ELECTRICAL 8-19 Reading The Circuit Diagram


In this manual, each system has its own parts location illustration, circuit diagram and connector configuration used in the circuit diagram.

Parts Location
The parts location shows the location of the parts 1 and the connector 2 used in each harness routing 3.

N8A0040E

8-20 CAB AND CHASSIS ELECTRICAL


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

N8A5040E

CAB AND CHASSIS ELECTRICAL 8-21


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

No.

Connector Face

No.

Connector Face

7
B-341

8
1 2
002-009 000-009

E-5

B-232

1 2
002-009

E-16

1 2

002-014

B-51

1 2 3 4 5 6 7 8

9 1011121314

E-110
014-001

1 2 3 6 7 8

5 9
009-003

B-52

1 7

2 8

E-76
012-003

1 3

2 4

9 10 11 12

N8A0430E

Connector Symbol
Connector Symbol B D E H J Harness name Body harness Door harness Engine harness For joint between harnesses Front frame & Rear frame harness Connector Symbol L N P R Harness name Dome Light harness Floor harness (LH & RH) Battery harness Rear body harness

8-22 CAB AND CHASSIS ELECTRICAL

MAIN DATA AND SPECIFICATIONS


Bulb Specifications
Roof Marker light (NPR/NQR EC Only)
Backup light Dome light License plate light Stoplight/ Taillight Turn signal light

Side turn signal light (EC Only) Headlight Fog light Cornering light / Clearance light
N8B0001E

Turn signal light

Light Name Halogen Headlight Front combination light Fog light Rear combination light Turn signal light Cornering light / Clearance light Front Rear Stoplight / Taillight Turn signal light Backup light

Rated Power 75 W / 70 W 21 W 21 W / 5 W 70 W 21 W 21 W / 5 W 21 W 21 W 5W 12 W 10 W 5W 21 W

No. of Bulb 2 2 2 2 1 2 2 2 2 1 1 2 2

Lens Color Clear Amber Clear Clear Red Red Amber Clear Clear White White Amber

Remarks 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V

License plate For EC light Except EC Dome light Roof marker light Side turn signal light

CAB AND CHASSIS ELECTRICAL 8-23


Rated Power Light Name Glow Engine oil pressure Fuel sedimenter Brake fluid level / Parking brake Charge High beam Indicator / Warning Light (In the meter assembly) Turn signal Fuel level Rear fog Brake booster ABS Check engine P.T.O. Smoother 1st start ECONO ASR Illumination light for meter assembly Hazard warning switch Illumination Dome light switch Front fog light switch Cigar lighter Heater bezel Ashtray Except 4HK1-TC 1.4 W 1.4 W 1.4 W 1.4 W 1.4 W 1.4 W 1.4 W 1.8 W 1.4 W 1.4 W 1.4 W 1.4 W 1.4 W 3W 1.8 W 1.8 W 1.8 W 1.8 W 1.4 W 1.4 W 4HK1-TC 1.8 W 1.8 W 1.8 W 1.8 W 1.8 W 1.8 W 1.8 W 1.8 W 1.8 W 1.8 W 1.8 W 1.8 W 1.8 W LED LED LED 1.8 W No. of Bulb 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Remarks 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V 24 V

8-24 CAB AND CHASSIS ELECTRICAL Fuse and Fusible Link Location
Fuse and Circuit Breaker

Fuse puller Spare fuse Fuse( F-25 F-28 )

Fuse label

Fuse(

F-1

F-24

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

Fuse(

F-29

F-31

Relay box No. 2

N8A0531E

Fuse Label-for 24 Volt (4JJ1 EURO 3) 15A (1) 10 A (2) (3) 15 A (4) 10 A (5) 20 A (6) 10 A (7) 10 A (8) 10 A (9) 15 A (10) 10 A (11) HEATER, AIR CON FUEL HEATER AUDIO (B), DOOR LOCK STOP LIGHT POWER WINDOW TAIL LIGHT FRT FOG LIGHT ENG. (IG) FRONT WIPER & WASHER TURN LIGHT

10A (12) (13) (14) 15 A (15) 10 A (16) (17) (18) 10 A (19) 15 A (20) (21) 10 A (22) 10 A (23) 10 A (24)

H/LAMP LEVEL AUDIO (IG), CIGAR LIGHTER METER ENG. (BACK UP), HSA HORN, HAZARD STARTER HEAD LIGHT RH HEAD LIGHT LH

CAB AND CHASSIS ELECTRICAL 8-25


(25) 15A (26) (27) 10 A (28) ECM. ENG. COND. FAN 10 A (21) 10 A (22) 10 A (23) 10 A (24) 15 A (25) 15 A (26) (27) 10 A (28) ECM. ENG. ABS (IG) STARTER HEAD LIGHT RH HEAD LIGHT LH MARKER LAMP COND. FAN

Fuse Label-for 24 Volt (4HK1 / 4JJ1 EURO 4) 15 A (1) 10 A (2) 15 A (3) 15 A (4) 10 A (5) 20 A (6) 10 A (7) 10 A (8) 10 A (9) 15 A (10) 10 A (11) 10 A (12) 10 A (13) 10 A (14) 15 A (15) 10 A (16) 10 A (17) 10 A (18) 10 A (19) 15 A (20) HEATER, AIR CON FUEL HEATER REAR HEATER AUDIO (B), DOOR LOCK STOP LIGHT POWER WINDOW TAIL LIGHT FRT FOG LIGHT ENG. (IG) FRONT WIPER & WASHER TURN LIGHT H/LAMP LEVEL NEES (B) REAR FOG LIGHT AUDIO (IG), CIGAR LIGHTER METER NEES (IG) HSA SRS ENG. (BACK UP), HSA HORN, HAZARD

Notice: The fuse numbers (1) (28) indicated on the fuse labels are expressed as F-1 F-28 in the circuit diagrams of this manual.

8-26 CAB AND CHASSIS ELECTRICAL


Fusible Link
Relay box (Installed on the left side rear of the cab)
2 6 1 3 7 4 8 5 9

Fusible link

Fusible link

FUSE PULLER

26

25

N8A0047E

For 24 Volt (4HK1 / 4JJ1 EURO 4) 100 A / 120 A (1) 40 A (2) 60 A (3) 30 A (4) 40 A (5) 60 A (6) 60 A (7) MAIN KEY GLOW HEAD LAMP ECM. ENG. CERAMIC HEATER NEES

60 A (8) 40 A (9)

STARTER ABS

For 24 Volt (4JJ1 EURO 3) 100 A (1) 40 A (2) 60 A (3) 30 A (4) 40 A (5) MAIN KEY GLOW HEAD LAMP ECM. ENG.

CAB AND CHASSIS ELECTRICAL 8-27


(6) (7) 60 A (8) (9) STARTER

Notice: The fusible link numbers (1) (26) are expressed as FL-1 FL-26 in the circuit diagrams of this manual.

8-28 CAB AND CHASSIS ELECTRICAL


Fuse Block Circuit
For 4JJ1 (EURO 3) Engine
GENERATOR B FL-25 FL-1 MAIN 100A FL-26

INDICATION ON LABEL

HEATER & A/C RELAY

F-1 F-2

15A

HEATER, AIR CON


CHARGE WARNING RELAY METER (BOOST IND) GENERATOR HEATER RELAY 10A

FUEL HEATER
F-3 F-4 F-5 F-6

15A

AUDIO (B), DOOR LOCK


10A

INDICATION ON LABEL
F-25 TAIL RELAY 15A

STOP LIGHT
20A

POWER WINDOW
F-7 F-8 10A

F-26

TAIL LIGHT COND. FAN


COMBINATION SWITCH 10A

FRT FOG LIGHT


F-9 F-10 10A 15A

F-27

ENG. (IG) FRONT WIPER & WASHER

F-28

10A

ECM. ENG.
FL-2 KEY 40A KEY SW OFF ACC ON ST CONDENSER FAN RELAY

KEY ON RELAY

F-11 F-12 F-13 F-14 F-15 F-16 F-17

10A

TURN LIGHT
10A

H/LAMP LEVEL

15A 10A

AUDIO (IG), CIGAR LIGHTER METER

CONDENSER FAN FL-3 GLOW 60A FL-4 HEAD LAMP 30A FL-5 ECM. ENG. 40A ECM GLOW PLUG RELAY GLOW PLUG

F-18 F-19 F-20

10A

ENG. (BACK UP), HSA


15A

ECM MAIN RELAY ECM ECM HEAD LIGHT RELAY

HORN, HAZARD
F-21 F-22 F-23 F-24

10A

FL-6

STARTER
10A

HEAD LIGHT RH
10A FL-7 COMBINATION SWITCH

HEAD LIGHT LH

FL-8 STARTER 60A

STARTER RELAY STARTER STARTER CUT RELAY

FL-9

ECM ECM

NEUTRAL SWITCH

N8B0002E

CAB AND CHASSIS ELECTRICAL 8-29


For 4HK1 / 4JJ1 (EURO 4) Engine
GENERATOR B FL-25 FL-1 MAIN 100A or 120A FL-26

INDICATION ON LABEL

HEATER & A/C RELAY

F-1 F-2

15A

HEATER, AIR CON


CHARGE WARNING RELAY METER (BOOST IND) GENERATOR MARKER LIGHT RELAY HEATER RELAY 10A

FUEL HEATER
F-3 F-4 F-5 15A

REAR HEATER
15A

AUDIO (B), DOOR LOCK


10A

INDICATION ON LABEL
F-25 15A

STOP LIGHT
MARKER LIGHT
TAIL RELAY F-6 F-7 F-8 COMBINATION SWITCH F-9 F-10 20A

MARKER LAMP
F-26 15A

POWER WINDOW
10A

TAIL LIGHT COND. FAN


10A

FRT FOG LIGHT


10A 15A

F-27

ENG. (IG) FRONT WIPER & WASHER

F-28

10A

ECM. ENG.
FL-2 KEY 40A KEY SW OFF ACC ON ST CONDENSER FAN RELAY

KEY ON RELAY

F-11 F-12 F-13 F-14 F-15 F-16 F-17

10A

TURN LIGHT
10A

H/LAMP LEVEL
10A

NEES (B)
10A

REAR FOG LIGHT


15A 10A

AUDIO (IG), CIGAR LIGHTER METER

CONDENSER FAN FL-3 GLOW 60A FL-4 HEAD LAMP 30A FL-5 ECM. ENG. 40A FL-6 CERAMIC HEATER 60A CERAMIC HEATER FL-7 NEES 60A GEAR SHIFTER RELAY TCM TCM STARTER RELAY STARTER STARTER CUT RELAY FL-9 ABS 40A ABS UNIT NEUTRAL SWITCH ECM ECM ECM GLOW PLUG RELAY GLOW PLUG

10A

F-18 F-19 F-20

NEES (IG) HSA SRS

10A

ENG. (BACK UP), HSA


15A

ECM MAIN RELAY ECM ECM HEAD LIGHT RELAY

HORN, HAZARD
F-21 F-22 F-23 F-24 COMBINATION SWITCH 10A

ABS (IG)
10A

STARTER
10A

HEAD LIGHT RH
10A

HEAD LIGHT LH

FL-8 STARTER 60A

N8B0003E

8-30 CAB AND CHASSIS ELECTRICAL Reference Table of Fuse and Circuit Breaker
Fuse
4JJ1 (EURO 3) Engine Fuse No. F-1 Capacity 15 A Indication on label HEATER, AIR CON Main parts (Load) Blower motor, Blower resistor, Fan switch, A/C switch, A/C thermo relay, Pressure switch, VSV: FICD, Electronic thermostat, A/C compressor, A/C thermo relay, Condenser fan, ECM (A/C compressor SIG.) Exhaust brake solenoid valve, Clutch switch, Accel switch, VSV: Intake throttle Radio & clock, Dome light switch, Dome light, Door switch (RH & LH), Door lock switch, Door lock actuator, Door lock controller, Speedometer, Key cylinder switch Stoplight switch, Stoplight, ECM (brake on SIG.) Power window Tail relay, Illumination light(s), Clearance light(s), Tail light(s), License light(s) Fog light switch, Fog light, Lighting switch, Cornering light relay, Cornering light, Cornering light switch ECM (IG SIG.), Starter cut relay, ECM (Exhaust brake SIG.), Exhaust brake indicator, ECM (brake off SIG.), ECM (clutch on SIG.), ALDL connector Wiper & Washer switch, Wiper motor, Washer motor, Intermittent relay Flasher unit, Front turn signal light, Rear turn signal light, Turn signal light switch, Hazard warning switch Headlight leveling switch, Headlight leveling motor (actuator) Radio, Cigar lighter, Digital clock Backup light switch, Backup light, Neutral switch, Starter relay, Glow relay, Glow indicator (Meter), Coolant temperature gauge, ECT sensor, Vehicle speed sensor (Installed on the meter assembly & transmission), Meter assembly, Power window relay, Cornering light relay, Backup buzzer, Charge relay, Heater A/C relay, VSV ECM (Back up) Horn, Horn relay, Horn switch, Flasher unit, Hazard warning switch, Turn light(s) Starter relay Headlight (RH), Dimmer relay, High beam indicator light Headlight (LH), Dimmer relay

F-2 F-3 F-4 F-5 F-6 F-7 F-8 F-9 F-10 F-11 F-12 F-13 F-14 F-15

10 A 15 A 10 A 20 A 10 A 10 A 10 A 15 A 10 A 10 A 15 A

FUEL HEATER AUDIO (B), DOOR LOCK STOP LIGHT POWER WINDOW TAIL LIGHT FRT FOG LIGHT ENG. (IG) FRONT WIPER & WASHER TURN LIGHT H/LAMP LEVEL AUDIO (IG), CIGAR LIGHTER

F-16

10 A

METER

F-17 F-18 F-19 F-20 F-21 F-22 F-23 F-24 F-25

10 A 15 A 10 A 10 A 10 A

ENG. (BACK UP), HSA HORN, HAZARD STARTER HEAD LIGHT RH HEAD LIGHT LH

CAB AND CHASSIS ELECTRICAL 8-31


Fuse No. F-26 F-27 F-28 Capacity 15 A 10 A Indication on label COND. FAN ECM. ENG. ECM Condenser fan Main parts (Load)

4HK1 / 4JJ1 (EURO 4) Engine Fuse No. F-1 Capacity 15 A Indication on label HEATER, AIR CON Main parts (Load) Blower motor, Blower resistor, Fan switch, A/C switch, A/C thermo relay, Pressure switch, VSV: FICD, Electronic thermostat, A/C compressor, A/C thermo relay, Condenser fan, ECM (A/C compressor SIG.) Exhaust brake solenoid valve, Clutch switch, Accel switch, Fuel heater, VSV: Intake throttle, ABS (Exhaust brake SIG.), Ceramic heater relay Rear heater, Rear heater switch Radio & clock, Dome light switch, Dome light, Door switch (RH & LH), Door lock switch, Door lock actuator, Door lock controller, Speedometer, Key cylinder switch, Side turn signal light(s) Stoplight switch, Stoplight, ABS (Stop on SIG.), ECM (brake on SIG.) Power window Tail relay, Illumination light(s), Clearance light(s), Tail light(s), Roof marker light, License light(s), Marker light relay Fog light switch, Fog light, Lighting switch, Cornering light relay, Cornering light, Cornering light switch ECM (IG SIG.), Starter cut relay, ECM (Exhaust brake SIG.), Exhaust brake indicator, ECM (brake off SIG.), ECM (clutch on SIG.), ALDL connector Wiper & Washer switch, Wiper motor, Washer motor, Intermittent relay Flasher unit, Front turn signal light, Rear turn signal light, Turn signal light switch, Hazard warning switch, Side turn signal light Headlight leveling switch, Headlight leveling motor (actuator) Smoother Rear fog light Radio, Cigar lighter, Digital clock Backup light switch, Backup light, Neutral switch, Starter relay, Glow relay, Glow indicator (Meter), Coolant temperature gauge, ECT sensor, Vehicle speed sensor (Installed on the meter assembly & transmission), Meter assembly, Power window relay, Cornering light relay, Backup buzzer, ABS indicator, Charge relay, Heater A/C relay, VSV Smoother (IGN SIG.) ECM (Back up)

F-2 F-3 F-4

10 A 15 A 15 A

FUEL HEATER REAR HEATER AUDIO (B), DOOR LOCK STOP LIGHT POWER WINDOW TAIL LIGHT FRT FOG LIGHT ENG. (IG) FRONT WIPER & WASHER TURN LIGHT H/LAMP LEVEL NEES (B) REAR FOG LIGHT AUDIO (IG), CIGAR LIGHTER

F-5 F-6 F-7 F-8 F-9 F-10 F-11 F-12 F-13 F-14 F-15

10 A 20 A 10 A 10 A 10 A 15 A 10 A 10 A 10 A 10 A 15 A

F-16

10 A

METER

F-17 F-18 F-19

10 A 10 A 10 A

NEES (IG) HSA SRS ENG. (BACK UP) HSA

8-32 CAB AND CHASSIS ELECTRICAL


Fuse No. F-20 F-21 F-22 F-23 F-24 F-25 F-26 F-27 Capacity 15 A 10 A 10 A 10 A 10 A 15 A 15 A 15 A (4HK1) 10 A (4JJ1) Indication on label HORN, HAZARD ABS (IG) STARTER HEAD LIGHT RH HEAD LIGHT LH MARKER LAMP COND. FAN Main parts (Load) Horn, Horn relay, Horn switch, Flasher unit, Hazard warning switch, Turn light(s), Side turn signal light ABS (IGN SIG.) Starter relay Headlight (RH), Dimmer relay, High beam indicator light Headlight (LH), Dimmer relay Marker light, Marker light relay Condenser fan

F-28

ECM. ENG.

ECM

CAB AND CHASSIS ELECTRICAL 8-33 Relay Location

X-16

X-15

X-14

X-13 Relay box No.2

Relay box No.1

X-5

X-6

X-7

X-8

X-9

X-10

X-11

X-12

X-1

X-2

X-3

X-4

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

X-18

X-19

X-20

X-22

X-23

X-24

X-25

X-26

X-27

X-28 X-21

N8A0054E

8-34 CAB AND CHASSIS ELECTRICAL


Relay List
: Standard, : Option X-1 Charge warning NPR75 (EURO 4) NQR75 (EURO 4) 24V NKR85 (EURO 4) NPR85 (EURO 4) NKR85 (EURO 3) X-7 Power window NPR75 (EURO 4) NQR75 (EURO 4) 24V NKR85 (EURO 4) NPR85 (EURO 4) NKR85 (EURO 3) * : Except EC X-13 Buzzer cancel NPR75 (EURO 4) NQR75 (EURO 4) 24V NKR85 (EURO 4) NPR85 (EURO 4) NKR85 (EURO 3)
*1 *2

X-2 Horn X-8 Heater

X-3 Lamp X-9 Cornering lamp * * * *

X-4 Tail X-10 Thermo A/C

X-5 Fog lamp X-11 Key ON

X-6 Dimmer X-12 Heater & A/C

X-14 Smoother emergency

X-15 NEES main

X-16 Rear fog *1 *1 *1 *1

X-18 ECM main

X-19 Gear shifter *3 *3 *3 *3

*2 *2

: For EC : With HBB *3 : With Smoother X-20 Glow plug NPR75 (EURO 4) NQR75 (EURO 4) 24V NKR85 (EURO 4) NPR85 (EURO 4) NKR85 (EURO 3) *1 : For EC X-21 Starter X-22 Marker lamp *1
*1 *1

X-25 DPD exh. throttle

X-26 Starter cut

X-27 Condenser fan

*1

CAB AND CHASSIS ELECTRICAL 8-35 Diode Location

With Smoother X-32

RELAY BOX ASM (No.1) (Installed on the instrument panel)

B-18 Without Smoother B-17

B-18

RELAY BOX ASM

RELAY BOX ASM (Installed on the cab left side rear) RELAY BOX ASM (No.1)

N8B0004E

Connector No. Usage

B-17 A/C Door switch

B-18 Lighting

L-1 Dome light

L-3 Dome light (Except Taiwan)

Connector No. Usage

X-32 Smoother, Dome light

8-36 CAB AND CHASSIS ELECTRICAL Reference Table of Grounding Point


Notice: Abnormal phenomena of electrical components are considered resulted from defective grounding. In repair, be sure to inspect grounding points and to tighten all fastening parts surrounding the grounding points. Connector No. B-1 Cable harness name Location Frame-LH (FRT) Main parts (Load) Vehicle speed sensor, Turn signal indicator light, Meter, High beam indicator light, PTO lever, TCM Charge relay, Dome light switch, Back up buzzer, Meter, Brake fluid switch, Tail relay, Cornering light switch, Cornering light, Cornering light relay, Fog light switch, Fog light, Dimmer relay, Door lock switch, Door lock relay, Power window switch (RH), Power window relay, Stoplight switch, Mirror switch, Wiper motor, Washer motor intermittent relay, Radio, Cigar lighter, Heater & A/C relay, Fan switch, Horn relay, Rear heater switch, Rear heater, Radio & clock, Blower resistor, A/C switch, Blower motor, Electronic thermostat, Accel switch, Door lock controller, Headlight leveling switch, Headlight leveling motor, Emergency relay, Select switch, Emergency adjust switch, PTO-Smoother switch Marker light relay, Marker light, Water sedimenter switch, Fuel tank unit, Starter relay, Neutral switch, Pressure switch, A/C thermo relay, VSV: FICD, Exhaust brake solenoid valve, Accel switch, Clutch switch, VSV: Intake throttle, Engine stop motor, ECM, ECM main relay, Starter cut relay, Shift 1,3,5 solenoid, Shift 2,4,R solenoid, Select solenoid, License plate light, Taillight, Rear fog light, Rear turn signal light, Stoplight, Stoplight switch, Backup light

Body harness B-7

Headlight bracket-LH

J-9

Frame front harness

Frame-LH (CTR)

CAB AND CHASSIS ELECTRICAL 8-37 Grounding Point Location

N8A5054E

B-7

N8A5055E

N8A5056E

8-38 CAB AND CHASSIS ELECTRICAL Cable Harness Routing

FLOOR HARNESS (RH)

FLOOR HARNESS (LH)

N8A0060E

CAB AND CHASSIS ELECTRICAL 8-39

DOME LIGHT HARNESS

DOOR HARNESS (RH)

BODY HARNESS

DOOR HARNESS (LH)

N8A0061E

8-40 CAB AND CHASSIS ELECTRICAL

REAR BODY HARNESS

REAR FRAME HARNESS

FRONT FRAME HARNESS

N8A0062E

CAB AND CHASSIS ELECTRICAL 8-41

SYSTEM REPAIR
Start and Charging
General Description
The system consists of the starter switch, starter, AC generator, starter relay, charge relay, heater and A/C relay, inhibitor switch and neutral switch. When the starter SW is set to the ST position, the battery voltage is applied to the starter solenoid coil through the starter relay to start the starter. On the 4HK1 / 4JJ1 engine, the function that ECM controls STARTER RELAY is added.

Starting Circuit

N8A0064E

Parts Location

B-51

J-191 ECM H-105

X-1 CHARGE RELAY

8-42 CAB AND CHASSIS ELECTRICAL

FUSE BOX ASM F-4, F-5, F-6, F-16, F-22

FL-1, FL-2, FL-8 FUSIBLE LINK X-21 STARTER RELAY X-26 STARTER CUT RELAY F-28 FUSE

J-1,J-2 GENERATOR B-66

B-67

N8B0005E

0.5W/R STARTER SWITCH RELAY; CHARGE


ACC 1 H-7 ON B-67 X-1 X-1 B-67 4 3 ST B-67

RELAY; HEATER & A/C (2)

3 W/L 3W/L 2
B

FL-2 40A KEY 3W/L 3B/Y 3B/Y 0.5B/Y 3 3B/Y F-16 10A METER 0.5B/Y 4
X-1 1

0.5W/R RELAY; HEATER (3)

For 4HK1 Engine

Circuit Diagram

30B/R FL-8 60A STARTER

P-1

P-2 X-1

0.5W/L

P-3

100A or FL-1 120A F-22 10A STARTER 0.5W/L MAIN

P-4

CHARGE WARNING LIGHT B-51 (10)

0.5W/L

P-5 15 H-5

8W/B

FRAME 3W/B

8B
1

0.3R/W

J-2

0.85W/L

GENERATOR
L J-1 1

J-1

1.25W/L

2L

STARTER RELAY; STARTER


3 X-21 X-21 4 X-21 2 14 H-8

1 J-26

J-27

3B/W 0.5R/W

X-21 5

0.5LG

0.85LG

F-28 15A ECM

1.25R

RELAY; ECM MAIN (2)

X-26

X-26 1 5

0.5R
4 X-26 3

RELAY; STARTER CUT


X-26

0.5W/L

0.5B

FRAME-LH (CENTER)

J-9

2B
14

J-191 ECM

CAB AND CHASSIS ELECTRICAL 8-43

N8B0006E

0.5W/R STARTER SWITCH RELAY; CHARGE FL-2 40A KEY


ACC

RELAY; HEATER & A/C (2)

3W/L
1 H-7 ON B-67 X-1 X-1 B-67 4 3 ST B-67

For 4JJ1 Engine

3W/L 2
B

3B/Y 3B/Y 0.5B/Y 3 3B/Y

F-16 10A METER 0.5B/Y 4


X-1 1

0.5W/R RELAY; HEATER (3)

30B/R FL-8 60A STARTER F-4


X-1 5

P-1

P-2

15A 0.85R RELAY; DOOR LOCK (6) STARTER 0.5W/L F-22 10A 0.5W/L

P-3

FL-1 100A MAIN F-5 STOP LIGHT 0.5G/Y SW; STOP LAMP B-66 (1) 0.5W/L RELAY; P/WINDOW (2)
15 H-5

AUDIO(B), DOOR LOCK 10A

P-4

CHARGE WARNING LIGHT B-51 (10)

8W/B F-6 5W/B


1 J-2 B

2 H-6

P-5

20A 2B/L

FRAME 3W/B 3W/B POWER WINDOW

8-44 CAB AND CHASSIS ELECTRICAL

0.3R/W (NPR85) 0.5R/W (NKR85)

8B
L J-1 H-105 1 8

8W

0.5W/L

GENERATOR 0.5W/L

J-1

2L

STARTER
14 H-8 2

1 J-26

2W

B X-21 X-21 4

2L 3W/B 0.5R/W

RELAY; STARTER

J-27

3B/W

X-21

X-21 5

0.5LG

0.85LG

F-28 10A ECM 1.25R

RELAY; ECM MAIN (2)

X-26

0.5R
4 X-26 3

RELAY; STARTER CUT


X-26 1 5 X-26

0.5W/L

0.5B

FRAME-LH (CENTER)
J-191 ECM

J-9

2B
14

N8B0007E

CAB AND CHASSIS ELECTRICAL 8-45


Connector List
No. Connector Face No. Connector Face

B-51
020-004

J-9
000-001

B-66 (Except 4HK1)

J-26
1 2

002-031

000-002

B-67

J-27
1 3 2 4
004-001 000-009

B-67

J-191
2 4 1 3

004-002

081-001

H-105 (Except 4HK1)

1 5 9

2 6

3 7

4 8

P-1
000-022

10 11 12

012-001

H-105 (Except 4HK1)

4 8

3 7

2 6

1 5 9

P-4
000-014

12 11 10

012-002

J-1
1 2

P-2
000-014

002-003

J-2
000-001

P-3
000-014

8-46 CAB AND CHASSIS ELECTRICAL


No. Connector Face H-6 (Except 4HK1), H-7, H-8

P-5
000-002

H-6

H-7

X-1
005-006

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 H-8

4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14

X-21

1 2 4 3 5

N8A5489E

005-003

Starter Switch
The starter switch positions are LOCK, ACC, ON and START. Turning the starter key to these positions is a circuit for starting the engine, the operation of accessories, or stop the engine.

X-26
005-006

H-5

1 7 13 19 25 31

2 8 14 20 26 32

3 9 15 21 27 33

34

35

36

37

4 10 16 22 28 38

5 11 17 23 29 39

6 12 18 24 30 40

6 12 18 24 30 40

5 11 17 23 29 39

4 10 16 22 28 38

37

36

35

34

3 9 15 21 27 33

2 8 14 20 26 32

1 7 13 19 25 31

N8A0072E

N8A5488E

CAB AND CHASSIS ELECTRICAL 8-47


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

1 3

2 4

Switch side

Connector No. Starter SW key position Removed LOCK ACC Inserted ON START Terminal No. 1 ACC 2 B

B-67 3 ON 4 ST

N8B5106E

Removal Preparation: Disconnect the battery ground cable. 1. Steering Cowl Remove four screws and take off the steering cowl. 2. Starter Switch 1) Disconnect the connector. 2) Remove the screw.

N8A5070E

Installation To install, follow the removal steps in the reverse order.

8-48 CAB AND CHASSIS ELECTRICAL


Neutral Switch
Inspection Check to see if there is any continuity between the switch terminals. Replace the switch when the result of inspection is found abnormal.

N8A5071E

FUSE & RELAY BOX ASM X-1 CHARGE RELAY F-1,F-2,F-7,F-9,F-15,F-16,F-19,F-22 FUSE N-6 SW: PARKING BRAKE B-495 DPD REGENERATE B-31 SW: ENG. WARM J-50 SW: NEUTRAL

TCM (B-426,B-427,B-428) E-114

Parts Location

For 4HK1 Engine

B-39 SW: AIR CON

E-141 E-112 E-169 E-94 E-140 J-206 E-139 E-138 E-98 E-5

J-1,J-2 AC GENERATOR

STARTER SW
J-32 V/SPEED SENSOR

J-182 H-125 E-90 J-8 E-93 E-113 H-120 H-118 H-15 J-191 ECM P-5 P-1 P-2 BATTERY P-3
ABS EHCU (J-177) E-168 E-111

RELAY BOX ASM (NO.1) X-8 HEATER RELAY X-10 THERMO A/C X-12 HEATER & A/C RELAY B-17,B-18,X-32 DIODE BOX J-31
FUEL TANK J-222 J-28

E-3 E-116 H-126

J-223 J-224 J-221

H-105

Exhaust Brake System and Engine Control

DAMU (B-500)

B-7 EARTH: HEADLIGHT BRACKET-LH

P-4

H-4~H-8

RELAY BOX ASM X-18 ECM MAIN RELAY X-20 GLOW RELAY X-21 STARTER RELAY X-25 DPD EXH.THROTTLE RELAY X-26 STARTER CUT RELAY FL-1~FL-3,FL-5,FL-8 FUSIBLE LINK F-26,F-28 FUSE

B-280 SENSOR: ACCEL

B-53 METER

B-422 SENSOR: BARO

B-89 SW: CLUTCH

B-1 EARTH: FRAME-LH (FRT)

H-12

B-69 SW: EXH.BRAKE

B-51 METER

CAB AND CHASSIS ELECTRICAL 8-49

N8B0008E

B-67 IGNITION SW "A" B-52 METER

J-166 SERVICE CONNECTOR J-271 REF HARNESS CONNECTOR J-216 MAINHOLD AIR PRESSURE SENSOR J-9 EARTH: FRAME J-225 DROP RESISTOR J-26,J-27 STARTER B-84 SW: PTO B-281 IDLE UP VOLUME B-79 DATA LINK CONNECTOR B-387 RESISTOR 1 B-497 SW: DPD A, DPD B B-431 RESISTOR 2

J-6 SW: A/C PRESS.

B-51, B-52 METER STARTER SW J-1, J-2 AC GENERATOR N-6 BRAKE SWITCH B-281 IDLE UP VOLUME B-84 PTO SWITCH J-182 MASS AIR FLOW SENSOR J-50 NEUTRAL SWITCH

EXHAUST BRAKE SW

E-13, E-14, E-15, E-16 FUEL INJECTOR E-90 COOLANT E-3 GLOW PLUG TEMPERATURE E-111 ECM SENSOR E-5 H-120 MAGNETIC FRAME CLUTCH HARNESS

For 4JJ1 (EURO 3) Engine

B-31 ENGINE WARMING SWITCH

H-105
E-94 EVRV : EGR E-116 SCV

B-39 AIR CON SWITCH

J-8 OIL PRESSURE SWITCH E-93 FUEL TEMP SENSOR J-206 FUEL SEDIMENTER

8-50 CAB AND CHASSIS ELECTRICAL

RELAY BOX ASM (No.1) B-18 DIODE X-8 HEATER RELAY X-10 A/C THERMO RELAY X-12 HEATER A/C RELAY J-31 EXH. BRAKE SOLENOID VALVE (B) J-32 VEHICLE SPEED SENSOR E-112 CKP SENSOR

FUSE & RELAY BOX ASM X-1 CHARGE RELAY F-1, F-2, F-7, F-9, F-15, F-16, F-19, F-22 FUSE

B-500 DAMU P-5 P-1 P-2

J-166 SERVICE CONNECTOR

B-280 ACCEL SENSOR

BATTERY (24V) P-4 P-3

B-7 J-271 REF HARNESS J-191 ECM J-9 B-1 H-17 B-67, B-69 B-422 BARO SENSOR H-12 J-26, J-27 STARTER B-79 DATA LINK CONNECTOR

H-5~H-8

RELAY BOX FL-1, FL-2, FL-3, FL-5, FL-8 FUSIBLE LINK F-26, F-28 FUSE X-18 ECM MAIN RELAY X-20 GLOW RELAY X-21 STARTER RELAY X-26 STARTER CUT RELAY

E-114 THROTTLE POSITION SENSOR

B-89 CLUTCH SWITCH

J-6 B-431 RESISTOR 1 A/C PRESSURE SWITCH B-387 RESISTOR 2

N8B0009E

B-51, B-52, B-53 METER STARTER SW J-1, J-2 AC GENERATOR N-6 BRAKE SWITCH B-281 IDLE UP VOLUME B-84 PTO SWITCH

EXHAUST BRAKE SW

B-495 DPD REGENERATE SWITCH

E-13, E-14, E-15, E-16 FUEL INJECTOR E-90 COOLANT E-3 GLOW PLUG TEMPERATURE E-111 ECM SENSOR E-5 H-120 MAGNETIC FRAME CLUTCH HARNESS

For 4JJ1 (EURO 4) Engine

B-31 ENGINE WARMING SWITCH

H-105
E-94 EVRV : EGR E-116 SCV

B-39 AIR CON SWITCH J-182 MASS AIR FLOW SENSOR J-50 NEUTRAL SWITCH

E-26 PRESSURE SENSOR J-8 OIL PRESSURE SWITCH E-93 FUEL TEMP SENSOR J-206 FUEL SEDIMENTER

RELAY BOX ASM (No.1) B-17, B-18, X-32 DIODE X-8 HEATER RELAY X-10 A/C THERMO RELAY X-12 HEATER A/C RELAY J-31 EXH. BRAKE SOLENOID VALVE (B) J-32 VEHICLE SPEED SENSOR E-112 CKP SENSOR

FUSE & RELAY BOX ASM X-1 CHARGE RELAY F-1, F-2, F-7, F-9, F-15, F-16, F-19, F-22 FUSE H-118 H-15

J-177 ABS EHCU

B-500 DAMU P-5 P-1 P-2

J-166 SERVICE CONNECTOR

B-280 ACCEL SENSOR

B-426, B-427, B-428 TCM P-4 P-3

BATTERY (24V)

B-7 J-271 REF HARNESS J-191 ECM J-9 B-1 J-26, J-27 STARTER

H-4 (Except NKR) H-5 H-8

E-114 THROTTLE POSITION SENSOR

RELAY BOX FL-1, FL-2, FL-3, FL-5, FL-8 FUSIBLE LINK F-26, F-28 FUSE X-18 ECM MAIN RELAY X-20 GLOW RELAY X-21 STARTER RELAY X-25 DPD EXH.THROTTLE RELAY X-26 STARTER CUT RELAY

B-89 CLUTCH SWITCH

CAB AND CHASSIS ELECTRICAL 8-51

B-79 B-67, B-69 DATA LINK H-12 H-17 CONNECTOR (For NKR) J-6 B-431 RESISTOR 1 B-422 A/C PRESSURE BARO SENSOR SWITCH B-387 RESISTOR 2

N8B0010E

8-52 CAB AND CHASSIS ELECTRICAL


Circuit Diagram
For 4HK1 Engine (1)
5W/B (STD AC GEN.) 8W/B (80A AC GEN.)

8W/B 8W/B FL-2 40A KEY

J-2

AC GEN. J-1

J-1

1 1.25W/L

FL-1 100A/120A MAIN

3W/L

3W/L

FL-8 60A STARTER 2L

FL-5 40A ECM

FL-3 60A GLOW

1 3W/B STARTER + P-1 RELAY:STARTER P-2 C + P-3 P-4 3B/W J-27 1 2 X-21 5 X-21 J-26 B 0.5R/W 0.5R 0.5LG F-26 15A CONDENSER FAN RELAY: CONDENSER FAN 2B/L 0.5Y/B 4 RELAY:GLOW X-20 0.5Y/B 0.5LG

RELAY:STARTER CUT

0.85LG

4 X-26

3 X-26

X-21 3

X-21 4

X-26 1

X-26 5 For SMOOTHER C/U: SMOOTHER

F-28 15A ECM

3W/R

3B/L 3 X-20 X-20 2

X-20 5

P-5 1.25R

0.5LG

3B/Y 1 H-120 3B/Y

0.5LG

0.5LG

5 RELAY:ECM MAIN X-18

3 X-18

J-50 SW:NEUTRAL

RESISTOR:DROP

SOLENOID VALVE: EXH. BRAKE

1 J-31

1 J-225 0.5R/W

1 E-3 X-18 4 X-18 2 GLOW PLUG

J-225 2 0.5G/W

J-31 2 0.5LG/B 0.5W/L 0.5L/B

J-50 1

0.5L/B

2R

35 J-191 PS -MAFBAT 0.5B 0.5B

46 J-191 IS-STARR

15 J-191 OS-EXB

14 J-191 OS -STARTR

21

40

2R

5 J-191 PS-+B

10 J-191 OS-GLOWR

24 J-191 IS-IGKEY

J-191 J-191 J-191 OS OS PS-+B -MAINR -MAINR

ECM ; ENGINE
IS-PN J-191 50 0.5B/L OP -COM2 E-111 116 OP -COM1 E-111 121 OS -INJ1 E-111 119 1.25G/W OS -INJ3 E-111 117 1.25W/Y OS -INJ2 E-111 120 1.25B/L OS -INJ4 E-111 118 1.25B OP -SCVHI E-111 105 0.5W/R OP -SCVHI E-111 113 0.5W/R IA IA -SCVLO -SCVLO E-111 89 0.5G/R E-111 97 0.5G/R IS-REF J-191 33

5 H-125 For SMOOTHER 1.25R 0.5B/L 5 1.25W H-4 C/U: SMOOTHER H-126 5 0.75G

8 H-125 H-126 8 0.75B

7 H-125 H-126 7 0.75Y

6 H-125 H-126 6 0.75L

REF HARNESS 2 E-116 SCV

3 INJECTOR E-138

3 E-141

3 E-140

3 E-139

E-138 2 0.75W

E-141 2 0.75W

E-140 2 0.75R

E-139 2 0.75R E-116 1

J-9

2B

1 H-126

4 H-126 H-125 4

3 H-126 H-125 3

2 H-126 H-125 2

FRAME-LH (CTR)

H-125 1

0.5P 1 J-271

0.5Y/B

0.5B/R

N8B0011E

CAB AND CHASSIS ELECTRICAL 8-53


For 4HK1 Engine (2)
5W/B (STD AC GEN.) 8W/B (80A AC GEN.) 2 5W/B

H-6

1.25W/L F-15 15A AUDIO (IG). CIGAR LIGHTER 3B/Y 3B/Y 3B/Y F-22 10A STARTER 0.5R/W 0.5LG 14 0.3R/W 0.5LG 8 H-105 0.5LG 3B/Y

0.85W/L

15

H-5

0.5W/L

STARTER SW OFF ACC 1 H-7 3W/L 2 B-67 ON ST B-67 B-67 B-67 1 3 4 3R/Y

0.5R/Y

CIGAR LIGHTER RELAY: ON, FUSE: ABS (IG)

3B/Y

F-16 10A METER

H-8

0.5B/Y

0.5LG

F-9 10A ENG.(IG) 0.5Y/B 0.5Y/B

0.5LG

0.5LG

13 E-168 POW GND-SLD E-168 SIG-U E-168 SIG-V E-168 SIG-W E-168 5 0.5B 1 2 3 0.5L/W 0.5Br 0.5L 4 3 2 E-169 E-169 E-169 POSITION SENSOR

0.5Y/B

18

H-5

VGS ACT.

RELAY: DPD EXT.THROTTLE

2 X-25

5 X-25 2 SW : CLUTCH H-4 SW : DPD (CONNECTOR) 0.5LG 0.5G/B

1 B-89

C/U: VGS TURBO

X-25 1

X-25 3 0.5G/O

B-497

B-89 2 0.5BR/Y

POW-SIG E-168 GND-SIG E-168

8 4

0.5R 0.5B

1 5

E-169 E-169

MTR-U E-168 MTR-V E-168 MTR-W E-168

10 11 12

0.5G/R 0.5Y/R 0.5L/R

8 7 6

E-169 E-169 E-169 10 9 0.5L 0.5L/W

3 H-105 H-4 8 0.5G/O 0.5G/B H-5 23 0.5BR/Y

CAN-L E-168 14 E-168 GND CAN-H E-168

16 15

0.5L 0.5L/W

H-105 H-105

0.5R

102 E-111 OS -DPFET

28 J-191 IS-DPF

26 J-191 IS-CL For M/T

ECM ; ENGINE
0.5B PG-POWER J-191 1 1.25B 1 J-221 VSV: DPF EXH. THROTTLE J-221 2 0.5B H-105 0.5L/W 0.5Y/B 0.5Y/R 0.5LG 0.5B 0.5B 12 0.5B 0.5R 2 J-222 SENSOR: EXHAUST TEMP (DOC IN) J-191 3 1.25B J-191 4 1.25B PG-WIGN J-191 43 0.75B J-191 62 0.75B PG -CASE J-191 81 0.5B SG -SLD3 J-191 59 0.3B SG SP-5V3 IA-EXHP1 -5VRT3 J-191 80 J-191 67 J-191 79 0.5B IA-THE1 J-191 73 IA-THE2 J-191 74

3 1.25B J-224

2 J-224 SENSOR: EXHAUST PRESSURE 1 (IN&OUT)

1 J-224

1 J-223

2 J-223

1 J-222

J-9

2B

SENSOR: EXHAUST TEMP (IN)

FRAME-LH (CTR)

N8B0012E

8-54 CAB AND CHASSIS ELECTRICAL


For 4HK1 Engine (3)

RELAY: CHARGE 5W/B 2W/B RELAY: TAIL 0.5W/R 1 X-1 3 0.5B/Y 0.85BR X-1 4 0.5B/Y

0.5W/L RELAY: HEATER & A/C 5 3L F-1 15A HEATER. AIR CON

0.5W/L

X-1

X-1

SW : AIR CON 0.85B/R 0.85L BLOWER MOTOR 1 B-39 B-39 2 0.5LG

3W/B

1 0.5W/R 2

X-12 X-12 X-12 X-12

0.5B

0.5B/Y 0.5W/L

RELAY: HEATER 1 3B/R

F-2 10A FUEL HEATER

3W/B

2 3

X-8 X-8 X-8 X-8

0.5B/R

0.5B 0.5B/Y

0.5B/Y 3W/B 3W/B RELAY: TAIL, FUSE: AUDIO(B), DOOR LOCK FUSE: STOP LIGHT FUSE: POWER WINDOW FUSE: NEES(B) FUSE: HORN, HAZARD

DIAG CONNECTOR
B-79 4 0.5B B-79 5 0.5B B-79 13 0.3W/G B-79 2 0.3W/B B-79 16 0.5R B-79 12 0.5Y B-79 7 0.5LB B-79 14 0.5L B-79 6 0.5L/W RESISTOR2

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

H-8 12

H-8 0.5W/R 13

RESISTOR1

B-431 1

B-431 2

CONT UNIT. ABS


DIAG J-177 ALDL J-177 L J-177 27 H J-177 26 0.5L/W H J-177 14 0.5L/W L J-177 15 0.5L

B-387 1

B-387 2

4 29

0.3W/G 0.3W/B

H-15 H-15

11 6

0.3W/G 0.3W/B

13 B-500 0.5L/W H-5 37 0.5L/W 58 J-191 0.75G 6 E-94 W V 0.5L 0.3B/W 0.3LB 0.5Y H-8 10 H-5 36 0.5L 78 J-191 103 110 8 E-94 U 0.75LG/R 7 E-94 B-428 B-426 52 J-191 IS-DIAG 0.5Y 18 9 E-111 93 E-111 99 E-111 E-111 E-111 111 0.5G/O 3 E-94 0.5P/B 2 E-94 0.75B/O 0.5B/W 0.5R

C/U: DAMU
B-500 8 B-500 2

0.5L

10 H-15 0.5L

5 H-15

14 9

H-15 H-15

0.5L 0.5L/W

8 7

H-8 H-8

0.5L 0.5L/W

Without ABS

0.5L/W 0.5L 0.5L/W 37 J-191 18 J-191

3 B-427 H

2 B-427 L

CONT UNIT. SMOOTHER


For SMOOTHER

2B

CC CC -CAN-L -CAN-H SG IF-CAM -5VRT5 E-111 98 E-111 101 SP -5V5 E-111 87 IA -PFUEL E-111 90

ECM ; ENGINE
SG-SLD5 E-111 100 IA -PFUEL E-111 82 IS IS IS -EBMPOS1 -EBMPOS2 -EBMPOS3 E-111 94

CC CC -ISOCAN-H -ISOCAN-L OM OM OM -EBM1 -EBM2 -EBM3

0.5B

0.5B/W

0.5B/W

0.5L/W

B-7

3B 1 2 E-112 3 E-112 3 E-113 1 E-113 SENSOR; Pc 2 E-113 1 E-94 5 E-94 4 E-94 SENSOR: EGR VALVE

HEADLIGHT BRACKET-LH

5B

E-112

B-1

1.25B

SENSOR; CAM ANGLE (MRE)

0.5W

0.5R

0.5R

0.5Y

MOTOR: EGR BRUSH-LESS DC FRAME-LH (FRT)

N8B0013E

CAB AND CHASSIS ELECTRICAL 8-55


For 4HK1 Engine (4)

RELAY: THERMO A/C SW : A/C PRESS. 0.85BR For M/T DIODE BOX 0.5LG 0.5B/Y 0.5W/L SW: DPD REGENERATE 0.5B/R 0.5B/R 6 2 B-495 B-495 B-495 B-495 3 5 Tail Relay 3W H-8 F-7 10A TAIL LIGHT 0.85LG/R 0.3W/R 6 HBB OIL SENSOR 3 B-17 B-17 4 0.5LG/B 1 2 X-10 X-10 X-10 X-10 4 0.5P/G ELECTRO THERMO A/C COMPRESSOR 0.5B/Y 0.5W/L 5 0.85G/W H-5 2 0.85G/W 1 J-6 J-6 2 0.85G/O 4 H-105 0.75G/O 1 E-5

For SMOOTHER 3 X-32 X-32 4

0.5B/Y 0.5W/R

1 B-18 DIODE BOX B-18 2 0.5W/B For M/T H-12 3

H-5 31 0.5B/R

0.5B/R

5 0.5B/Y SW : EXH. BRAKE For SMOOTHER 10 0.5B B-69

0.85LG/R 0.5B SW : ENG. WARM

0.5B/Y

9 H-118

H-118

0.85LG/R

0.5G/O

0.5B 5 3 B-69 2 0.5LG/R 1

B-31 B-31 B-31

B-31 B-31 B-31

2 0.5LG/R 6 4 0.5LG/L

For SMOOTHER 0.5W/B H-12 5 0.3W/B 1 SW: PARKING BRAKE 19 H-5 H-5 25 SP -5V4 E-111 95 SG IF -5VRT4 -CRANK E-111 109 E-111 107 0.5B 0.5GR/R 0.5W 0.5B 3 E-98 2 E-98 SENSOR; NE, CRANK 0.5Y 1 E-98 N-6 0.5B 0.3Y/G

For SMOOTHER 0.5Y/G H-118 11 0.5Y/G

3B

H-5 6

(EC only)

H-5 29

H-4 11

0.5Y/G

1 J-32

2 J-32 V/SPEED SENSOR

3 J-32 0.5Y/G 0.5LG/L 0.5W/R 0.5W/B 34 J-191 IS-A/C 48 J-191 IS -PBRK SG -SLD4 E-111 108

19 J-191 IF-SPD

45 J-191 IS-EXB

0.5LG/R

0.5B/Y

0.5B

51 J-191 IS-QWS

47 J-191 IS -DPFREG

ECM ; ENGINE
IS-PTO J-191 44 0.5L/O OM -IDM2 E-111 104 OM IA -IDM1 -IDMPOS E-111 112 E-111 85 IA -MAP E-111 91

0.5B

0.5W/O

38 0.75R H-5 0.5L/O

0.5W

0.5B

0.75W/G

2 E-114

6 E-114

5 E-114

4 E-114

1 B-7 3B SW : PTO B-84

0.5W

HEADLIGHT BRACKET-LH

B-84 0.5B 2

E-114 1

B-1

1.25B

J-216 J-216 J-216 SENSOR; MANIHOLD AIR PRESSURE

FRAME-LH (FRT)

0.5R

0.5B

SENSOR; INTAKE THROTTLE DC MOTOR POSITION

H-105 H-105 H-105

5B

0.5W

0.5R

0.5B

0.5W/B H-5 1

0.5B

N8B0014E

8-56 CAB AND CHASSIS ELECTRICAL


For 4HK1 Engine (5)

0.5B/Y 0.5W/L 18 B-51 ENGINE COOLANT TEMPERATURE GAUGE B-52 5 12 0.5LB H-5 CHECK ENG. PARKING BRAKE DPF REGENERATE SEDIMENTER B-52 10 13 0.5LB 0.5BR/W H-5 0.5LG/W EXHBRAKE

OIL PRESS

CHARGE

TACHO

SPEED

GLOW

B-51 10

B-52 20

B-52 17

B-51 13

B-51 For SMOOTHER 5

B-51 7

B-52 15

B-51 6

B-51 4 0.5LG/B

B-53 For SMOOTHER 10 0.5LG/B

B-52 8

B-51 11

B-51 5 For M/T 0.3W/V

B-51 For SMOOTHER 4 0.3W/V

B-52 6

For M/T 0.5L/R

0.5L/R

For M/T

H-5 0.3Y/G 0.5B 24

H-5 30

H-5 40

H-5 7

H-4 19

H-8 3

H-5 39 0.5BR/B

SW: OIL LEVEL

21 0.5Y/R

2 H-105 0.5BR/B 0.5LG/B 0.5O/L 0.5L/R 0.5L/B 0.5L/P 0.5LG

1 J-28 UNIT: FUEL SENSOR J-28 2 0.5B For W/CAB For S/CAB

UNIT: FUEL SENSOR J-28 2 0.5B

SW: OIL PRESSURE

1 J-8

0.5B 0.3Y/G

6 J-191 OS-DIAGL

17

11

9 J-191 OS -DPFREG

8 J-191 OF -TACHO

J-191 J-191 J-191 OS-SVS OS OS -GLOWL -EXBL

ECM ; ENGINE
IA-THL E-111 83 0.5B 0.5G/Y FUEL SEDIMENTER FUEL HEATER 3 E-90 METER 0.5B 0.5LG/W 16 H-105 SW: FUEL SEDIMENTER J-206 1 J-206 2 SW: FUEL LINE CLOGGING IA-THW E-111 84

0.5LG/W

0.5B

1 E-90

1 E-93 B-1 1.25B

2 E-93

SENSOR; FUEL TEMP

ECT SENSOR

ECT SENSOR

FRAME-LH (FRT)

0.5B

2 E-90

0.5LB

H-105

J-9

FRAME-LH (CTR)

0.5R 1 J-28

0.5LG/W H-5

0.5BR/B

0.5O/L

0.5L/B

0.5L/P

0.3LG

FUEL

SVS

N8B0015E

CAB AND CHASSIS ELECTRICAL 8-57


For 4HK1 Engine (6)

ACCEL SENSOR SENSOR; IDLE UP VOLUME B281 2 B-281 1 B-281 3 SENSOR; ACCEL POSITION1 B-280 6 B-280 4 B-280 5 SENSOR; ACCEL POSITION2 B-280 2 B-280 1 B-280 3

0.5L/W

0.5L/R

0.5W

0.5R

0.5L/R

0.5L/Y

0.5L

0.3B

0.5B 0.3B H-5 32

SERVICE CONNECTOR
0.5BR J-166 2 J-166 3 J-166 1 H-5 33 H-8 9 H-5 16 H-5 8 0.3B H-5 9 H-5 26 H-5 20 H-5 27 0.3B

0.5P/B

0.5P/B

0.5L/Y

0.5BR

0.5L

0.5W

0.5W

0.5R

0.5R

0.5R

0.3B

0.5B 0.5B 60 J-191 SG -5VRT2

70 J-191 IA -PTOPOS

66

41

42

20 J-191 SG -SLD1

63 J-191 IA -ACCEL1

64

61

39 J-191 SG -SLD2 0.5B 0.5R 3 B-422

J-191 J-191 J-191 SG SP IA -IDLUP -5VRT1 -5V1

J-191 J-191 SP IA -ACCEL2 -5V2

ECM ; ENGINE
IA-BARO J-191 71 SG PS-12V -12VRT IA-MAF J-191 23 J-191 22 J-191 69 IA-IAT J-191 72 0.5B 0.5G 0.5Y 0.5L

0.5BR/G

0.5R/G

1 14 H-5 0.5BR/G J-182

2 J-182 SENSOR; MASS AIR FLOW

3 J-182

4 J-182

SENSOR; INTAKE AIR TEMP

MAF SENSOR

0.5B 5 J-182

2 B-422

1 B-422 SENSOR; BARO

N8B0016E

8-58 CAB AND CHASSIS ELECTRICAL


For 4JJ1 (EURO 3) Engine (1)
8W/B

8W 8W/B 2W

1 2

J-2 J-1

AC. GEN.

J-1

1 1.25W/L

FL-1 100A MAIN

3W/L 1 FL-2 40A KEY

H-7

3W/L

30B/R STARTER + P-1 P-2 + P-3 P-4 -

2L

2L

8B

FL-8 60A STARTER

FL-5 40A ECM

FL-3 60A GLOW

1 3W/B J-26 B 0.5R/W 0.5R RELAY:STARTER CUT 2 RELAY:STARTER X-21 5 X-21 4 X-26 3 X-26 0.85LG 3B/L 0.5LG F-26 15A CONDENSER FAN RELAY: CONDENSER FAN 2B/L 0.5Y/B 4 RELAY:GLOW X-20 0.5Y/B

C J-27 1 3B/W

3W/R

X-21

X-21

X-26

X-26

F-28 10A ECM

3 X-20

1.25R

X-20 2 3B/Y

X-20 0.5Y/B 0.5B/R 10 J-191 OS-GLOWR 24 J-191 IS-IGKEY PG-WIGN J-191 4 1.25B J-191 43 0.75B J-191 62 0.75B PG -CASE J-191 81 0.75B 5

0.5LG

0.5LG

P-5

0.5LG

5 RELAY:ECM MAIN X-18

3 X-18

SOLENOID VALVE: EXH. BRAKE

1 J-31

RESISTOR:DROP

1 J-50 SW:NEUTRAL

1 J-225

1 H-120 3B/Y X-18 4 X-18 2 1 E-3 GLOW PLUG 0.5L/B 2R 40 2 J-191 PS-+B 2R 5 IS-REF J-191 33 J-191 1 1.25B PG-POWER J-191 3 1.25B 0.5P 1 J-271 REF HARNESS J-9 FRAME-LH (CTR) 2B

J-225 2 0.5G/W 0.5R/W

J-31 2 0.5LG/B 0.5W/L 0.5L/B 21 OP -SCVHI E-111 113 E-111 89

J-50 2 0.5B/L 50 J-191 IS-PN

35 J-191 PS -MAFBAT

46 J-191 IS-STARR

15 J-191 OS-EXB

14 J-191 OS -STARTR

J-191 J-191 J-191 OS OS PS-+B -MAINR -MAINR

ECM ; ENGINE
OP -COM2 0.5B 0.5B E-111 116 OP -COM1 E-111 121 OS -INJ1 E-111 119 1.25G/W OS -INJ4 E-111 117 1.25W/Y OS -INJ3 E-111 120 1.25B/L OS -INJ2 E-111 118 1.25B OP -SCVHI E-111 105 IA IA -SCVLO -SCVLO E-111 97

0.5W/R

0.5W/R

0.5G/R

CYLINDER #1 FUEL INJECTOR

CYLINDER #4 FUEL INJECTOR

CYLINDER #3 FUEL INJECTOR

CYLINDER #2 FUEL INJECTOR

0.5W/R

1.25B

1 E-13

1 E-16

1 E-15

1 E-14

2W

2R

E-13 2

E-16 2

E-15 2

E-14 SCV 2

E-116

E-116 1 J-9 2B 1.25W 1.25R 2W 2R

FRAME-LH (CTR)

0.5G/R 2

0.5G/R

N8B0017E

CAB AND CHASSIS ELECTRICAL 8-59


For 4JJ1 (EURO 3) Engine (2)

8W/B

RELAY: CHARGE H-6 5W/B 2W/B RELAY: TAIL 0.5W/R 1 X-1 3 0.5B/Y 0.85BR 3L F-1 15A HEATER. AIR CON F-2 10A FUEL HEATER 0.85BR 1 B-39 SW : AIR CON 0.85L BLOWER MOTOR 0.5B/Y 0.5W/L 4 3B/Y F-15 15A AUDIO (IG). CIGAR LIGHTER 0.5R/Y RELAY: HEATER 1 3B/R B-39 2 0.5LG X-1 4 0.5B/Y

0.5W/B

H-105

0.85W/L

15

H-5

0.5W/L RELAY: HEATER & A/C RELAY: ON 3B/Y 3W/B 1 X-12 X-12 X-12 X-12 4 0.5B 5

0.5W/L

X-1

X-1

STARTER SW OFF ACC 3W/L 2 B-67 ON ST B-67 B-67 B-67 1 3 3R/Y

0.5W/R 2

3B/Y

F-22 10A STARTER 0.5R/W 14 H-8 0.3R/W

3W/B

2 3

X-8 X-8 X-8 X-8

0.5B/R

5 0.5B 0.5B/Y 0.5B/Y

3B/Y CIGAR LIGHTER F-16 10A METER

F-9 10A ENG.(IG) 0.5Y/B 18 H-5 0.5Y/B 0.5Y/B 3W/B

3B/Y

3W/B

RELAY: TAIL, FUSE: AUDIO(B), DOOR LOCK FUSE: STOP LIGHT FUSE: POWER WINDOW FUSE: HORN, HAZARD

DIAG CONNECTOR
B-79 4 B-79 5 B-79 16 B-79 12 B-79 7 B-79 14 B-79 6

1 SW : CLUTCH B-89

0.5L/W

0.5LB

0.5R

0.5B

0.5B

0.5Y

0.5L

F-19 10A ENG. (BACK UP) HSA 0.5W/R

RESISTOR2

B-431 1

B-431 2

B-89 2

0.5W/R 0.5BR/Y 13 RESISTOR1 B-500

H-5 23 0.5BR/Y B-387 1 0.5L 0.5L/W 37 J-191 18 J-191 8 7 H-8 H-8 0.5L 0.5L/W B-387 2

C/U: DAMU
B-500 8 B-500 2

H-8 10 0.5Y

H-8 5 0.5LB

H-5 36 0.5L

37 0.5L/W 58 J-191 0.5W 6 E-94 W

26 J-191 IS-CL 0.85B 2B

52 J-191 IS-DIAG

38 J-191 CC -KW2000

78 J-191

CC CC -CAN-L -CAN-H SG IF-CAM -5VRT5 E-111 98 E-111 101 SP -5V5 E-111 87 IA -PFUEL E-111 90

ECM ; ENGINE
IA -PFUEL E-111 82 IS IS IS -EBMPOS1 -EBMPOS2 -EBMPOS3 E-111 94 E-111 93 E-111 99

CC CC -ISOCAN-H -ISOCAN-L OM OM OM -EBM1 -EBM2 -EBM3 E-111 E-111 E-111 111 103 110

SG-SLD5 E-111 100

0.5B

0.5B/O

0.5LG/B

0.5W/O

0.5Y/B

0.5LG

0.5LB

0.5B/W

0.5Y/B

0.5Y/B

8 E-94 U

0.5LG

0.5LG

0.5W

B-7

3B 1 2 E-112 3 E-112 3 E-113 1 E-113 SENSOR; Pc 2 E-113 1 E-94 5 E-94 4 E-94 SENSOR: EGR VALVE 3 E-94 2 E-94

HEADLIGHT BRACKET-LH

5B

E-112

B-1

SENSOR; CAM ANGLE (MRE)

MOTOR: EGR BRUSH-LESS DC FRAME-LH (FRT)

0.5O

7 E-94 V

0.5L/W H-5

0.5L

N8B0018E

8-60 CAB AND CHASSIS ELECTRICAL


For 4JJ1 (EURO 3) Engine (3)

RELAY: THERMO A/C SW : A/C PRESS. 0.85BR 0.5LG 10 X-33 DIODE BOX 0.5B/Y 0.5W/L Tail Relay 3W 0.5B/R X-33 3 0.5LG/B 1 2 X-10 X-10 X-10 X-10 4 0.5P/G ELECTRO THERMO A/C COMPRESSOR 0.5B/Y 0.5W/L METER (PARKING BRAKE) 5 0.85G/W H-5 2 0.85G/W 1 J-6 J-6 2 0.85G/O 7 H-105 0.75P 1 E-5

0.5B/Y

F-7 10A TAIL LIGHT

H-5 31

0.85LG/R

0.5B/R

DIODE BOX B-18 4 0.5W/B 0.5G/O

5 B-69 SW : EXH. BRAKE SW : ENG. WARM 0.5B 5 3 1 B-69 2 0.5LG/R B-31 B-31 B-31 B-31 B-31 B-31 2 6 4 0.5LG/R

0.5B/R

0.5W/V 3 B-18

0.5W/B

H-12

3 0.3W/B 1 SW: PARKING BRAKE N-6

0.5B/Y

3B

0.5B

0.5LG/L

H-5 29

H-5 0.5LG/R 0.5Y/G 1 J-32 2 J-32 V/SPEED SENSOR 3 J-32 0.5Y/G 6

0.5W/B H-5 1

19 25 0.5LG/L 0.5W/B

H-5 H-5

0.5B 0.3Y/G

19 J-191 IF-SPD

45 J-191 IS-EXB

51 J-191 IS-QWS

34 J-191 IS-A/C

48 J-191 IS -PBRK

ECM ; ENGINE
IS-PTO J-191 44 0.5L/O OM -IDM2 E-111 104 OM IA -IDM1 -IDMPOS E-111 112 E-111 85 IA -MAP E-111 91 SG -SLD4 E-111 108 SP -5V4 E-111 95 SG IF -5VRT4 -CRANK E-111 109 E-111 107 0.5B 0.5GR/R

0.5B

0.75B/G

0.5V/W

38 H-5 0.5L/O

0.5Y

0.5B

B-7

1 B-84 SW : PTO

0.75G

2 E-114

5 E-114

6 E-114

3 E-114

5B

HEADLIGHT BRACKET-LH

SENSOR; INTAKE THROTTLE DC MOTOR POSITION B-84 2 E-114 1

3 E-98

2 E-98

J-216 J-216 J-216 SENSOR; MANIHOLD AIR PRESSURE

SENSOR; NE, CRANK

B-1

0.85B

0.5B

FRAME-LH (FRT)

0.5R/L 1 E-98

0.5R

0.5B

0.5Y

0.5Y

0.5B

N8B0019E

CAB AND CHASSIS ELECTRICAL 8-61


For 4JJ1 (EURO 3) Engine (4)

0.5B/Y 0.5W/L 18 B-51 ENGINE COOLANT TEMPERATURE GAUGE B-52 5 12 0.5LB H-5 CHECK ENG. PARKING BRAKE SEDIMENTER B-52 10 13 0.5LB 0.5LG/W H-5 0.5LG/W EXHBRAKE

OIL PRESS

CHARGE

TACHO

SPEED

GLOW

B-51 10

B-52 20

B-52 17

B-51 13

B-51 7

B-52 15

B-51 6

B-52 8

B-51 11

B-51 5 0.3W/V

B-52 6

H-5 0.3Y/G 0.5B 24

H-5 30

H-5 40

H-5 7

H-8 3

H-5 39 0.5BR/B

SW: OIL LEVEL

21

6 H-105 0.5BR/B 0.5O/L 0.5L/R 0.5L/B 0.5L/P 0.5LG

SW: OIL PRESSURE

1 0.5BR/B J-8

UNIT: FUEL SENSOR J-28 2 0.5B

0.5B 0.3Y/G

6 J-191 OS-DIAGL 0.85B

17

11

8 J-191 OF -TACHO

16 J-191 OS -LOWOIL

J-191 J-191 J-191 OS-SVS OS OS -GLOWL -EXBL

ECM ; ENGINE
IA-THL E-111 83 IA-THW E-111 84 IS -LOWOIL J-191 53 0.5V/Y

0.5B 0.5G/Y

5 0.5B H-105 3 SW:LOW OIL LEVEL E-90 METER 0.5V/Y FUEL HEATER

FUEL SEDIMENTER SW: FUEL SEDIMENTER J-206 1 J-206 2 SW: FUEL LINE CLOGGING

0.5LG/W

0.5B

1 E-90

2 E-90

1 E-93 B-1

2 E-93

1 E-137

SENSOR; FUEL TEMP

ECT SENSOR

ECT SENSOR

FRAME-LH (FRT)

E-137 2 0.5B 0.5B 0.5LG/W 12

J-9

H-105

0.5LB FRAME-LH (CTR)

H-105

0.5Y/R 1 J-28

0.5LG/W H-5

0.5BR/B

0.5O/L

0.5L/B

0.5L/R

0.5L/P

0.3LG

FUEL

SVS

N8B0020E

8-62 CAB AND CHASSIS ELECTRICAL


For 4JJ1 (EURO 3) Engine (5)

ACCEL SENSOR SENSOR; IDLE UP VOLUME B281 2 B-281 1 B-281 3 SENSOR; ACCEL POSITION1 B-280 6 B-280 4 B-280 5 SENSOR; ACCEL POSITION2 B-280 2 B-280 1 B-280 3

0.5L/W

0.5L/R

0.5W

0.5R

0.5L/R

0.5L/Y

0.5L

0.3B

0.5B 0.3B H-5 32

SERVICE CONNECTOR
0.5BR J-166 2 J-166 3 J-166 1 H-5 33 H-8 9 H-5 16 H-5 8 0.3B H-5 9 H-5 26 H-5 20 H-5 27 0.3B

0.5P/B

0.5P/B

0.5L/Y

0.5BR

0.5L

0.5W

0.5W

0.5R

0.5R

0.5R

0.3B

0.5B 0.5B 60 J-191 SG -5VRT2

70 J-191 IA -PTOPOS

66

41

42

20 J-191 SG -SLD1

63 J-191 IA -ACCEL1

64

61

39 J-191 SG -SLD2 0.5B 0.5R 3 B-422

J-191 J-191 J-191 SG SP IA -IDLUP -5VRT1 -5V1

J-191 J-191 SP IA -ACCEL2 -5V2

ECM ; ENGINE
IA-BARO J-191 71 SG PS-12V -12VRT IA-MAF J-191 23 J-191 22 J-191 69 IA-IAT J-191 72 0.5B 0.5G 0.5Y 0.5L

0.5BR/G

0.5R/G

1 14 H-5 0.5BR/G J-182

2 J-182 SENSOR; MASS AIR FLOW

3 J-182

4 J-182

SENSOR; INTAKE AIR TEMP

MAF SENSOR

0.5B 5 J-182

2 B-422

1 B-422 SENSOR; BARO

N8B0021E

CAB AND CHASSIS ELECTRICAL 8-63


For 4JJ1 (EURO 4) Engine (1)
8W/B

8W 8W/B 2W

1 2

J-2 J-1

AC. GEN.

J-1

1 1.25W/L

FL-1 100A MAIN

3W/L FL-2 40A KEY

30B/R STARTER + P-1 P-2

2L

2L

8B

FL-8 60A STARTER 1

FL-5 40A ECM

FL-3 60A GLOW

J-26 3W/B B 0.5R/W 0.5R RELAY:STARTER CUT 2 RELAY:STARTER X-21 5 X-21 4 X-26 3 X-26 0.85LG 3B/L 0.5LG F-26 15A CONDENSER FAN RELAY: CONDENSER FAN 2B/L 0.5Y/B 4 RELAY:GLOW X-20 0.5Y/B 0.5LG

+ P-3 P-4 3B/W C J-27 1

3W/R

X-21

X-21

X-26

X-26 For SMOOTHER C/U: SMOOTHER

F-28 10A ECM

3 X-20

1.25R

0.5LG

P-5 0.5LG 0.5LG

X-20 2 3B/Y

X-20 0.5Y/B 0.5B/R 10 J-191 OS-GLOWR 24 J-191 IS-IGKEY IA IA -SCVLO -SCVLO E-111 89 E-111 97 IS-REF J-191 33 0.5G/R 0.5G/R 0.5G/R REF HARNESS 2 E-116 SCV E-116 1 0.5P 1 0.5W/R J-271 5

5 RELAY:ECM MAIN X-18

3 X-18

SOLENOID VALVE: EXH. BRAKE

1 J-31

RESISTOR:DROP

1 J-50 SW:NEUTRAL

1 J-225

1 H-120 3B/Y X-18 4 X-18 2 1 E-3 GLOW PLUG 0.5L/B 2R 40 2 J-191 PS-+B OS -INJ3 E-111 120 1.25B/L OS -INJ2 E-111 118 1.25B 2R 5 OP -SCVHI E-111 105 OP -SCVHI E-111 113 0.5W/R CYLINDER #3 FUEL INJECTOR 1 E-15 CYLINDER #2 FUEL INJECTOR 1 E-14 E-15 2 E-14 2 1.25R 2R 0.5W/R

J-225 2 0.5G/W 0.5R/W

J-31 2 0.5LG/B 0.5W/L 0.5L/B 21 OP -COM1 E-111 121 OS -INJ1 E-111 119 1.25G/W

J-50 2

35 J-191 PS -MAFBAT

46 J-191 IS-STARR

15 J-191 OS-EXB

14 J-191 OS -STARTR

J-191 J-191 J-191 OS OS PS-+B -MAINR -MAINR

ECM ; ENGINE
IS-PN 0.5B 0.5B J-191 50 OP -COM2 E-111 116 OS -INJ4 E-111 117 1.25W/Y CYLINDER #4 FUEL INJECTOR 1 E-16 E-16 2 2W

0.5B/L

1.25B

0.5B/L

For SMOOTHER (except NKR) 2W 2R H-4 C/U: SMOOTHER

CYLINDER #1 FUEL INJECTOR

1 E-13

0.5B/L

For SMOOTHER (NKR only) H-17 C/U: SMOOTHER

E-13 2

J-9

2B 1.25W

FRAME-LH (CTR)

N8B0022E

8-64 CAB AND CHASSIS ELECTRICAL


For 4JJ1 (EURO 4) Engine (2)

8W/B

H-6

5W/B

0.5W/B

H-105

8 F-15 15A AUDIO (IG). CIGAR LIGHTER 3B/Y 3B/Y 3B/Y F-22 10A STARTER 3B/Y

0.85W/L

15

H-5

0.5W/L

STARTER SW OFF ACC 1 H-7 3W/L 2 B-67 ON ST B-67 B-67 B-67 1 3 4 3R/Y

0.5R/Y

CIGAR LIGHTER RELAY: ON, FUSE: ABS (IG)

3B/Y

F-16 10A METER

0.5R/W 0.5LG

14

H-8

0.3R/W 0.5B/Y 0.5LG

0.5LG

F-9 10A ENG.(IG) 0.5Y/B 0.5Y/B

2 H-105

0.5LG

0.5LG

0.5Y/B

18

H-5 1 H-17 NKR only 2 H-4

RELAY: DPD EXT.THROTTLE

2 X-25

5 X-25

1 Except NKR SW : CLUTCH B-89

X-25 1

X-25 3 0.5G/O

SW : DPD (CONNECTOR) 0.5LG 0.5G/B

B-497

B-89 2 0.5BR/Y

3 H-105 H-17 2 NKR only 0.5G/O 0.5G/B H-4 8 Except NKR 0.5BR/Y 0.5W/G 96 E-111 OP -EVRV H-5 23

0.5R

102 E-111 OS -DPFET

28 J-191 IS-DPF

26 J-191 IS-CL For M/T

TURBO CONTROL VALVE E-167 2

0.5LG 1 E-167

ECM ; ENGINE
PG-POWER J-191 1 1.25B 1 J-221 VSV: DPF EXH. THROTTLE J-221 0.5L/W 0.5Y/B 0.5Y/R 0.5LG 0.5B 0.5B 2 0.5B 0.5R 2 J-222 SENSOR: EXHAUST TEMP (DOC IN) J-191 3 1.25B J-191 4 1.25B PG-WIGN J-191 43 0.75B J-191 62 0.75B PG -CASE J-191 81 0.75B SG -SLD3 J-191 59 0.3B SG SP-5V3 IA-EXHP1 -5VRT3 J-191 80 J-191 67 J-191 79 0.5B IA-THE1 J-191 73 IA-THE2 J-191 74

3 1.25B J-224

2 J-224 SENSOR: EXHAUST PRESSURE 1 (IN&OUT)

1 J-224

1 J-223

2 J-223

1 J-222

J-9

2B

SENSOR: EXHAUST TEMP (IN)

FRAME-LH (CTR)

N8B0023E

CAB AND CHASSIS ELECTRICAL 8-65


For 4JJ1 (EURO 4) Engine (3)

RELAY: CHARGE 5W/B 2W/B RELAY: TAIL 0.5W/R 1 X-1 3 0.5B/Y 0.85BR X-1 4 0.5B/Y

0.5W/L RELAY: HEATER & A/C 5 3L F-1 15A HEATER. AIR CON

0.5W/L

X-1

X-1

SW : AIR CON 0.85BR 1 0.85L BLOWER MOTOR B-39 B-39 2 0.5LG

3W/B

1 0.5W/R 2

X-12 X-12 X-12 X-12

0.5B

0.5B/Y 0.5W/L

RELAY: HEATER 1 3B/R

F-2 10A FUEL HEATER

3W/B

2 3

X-8 X-8 X-8 X-8

0.5B/R

0.5B 0.5B/Y

0.5B/Y

3W/B 3W/B

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

0.3W/G

0.5W/R

0.3W/B

0.5L/W

RELAY: TAIL, FUSE: AUDIO(B), DOOR LOCK FUSE: STOP LIGHT FUSE: POWER WINDOW FUSE: NEES(B) FUSE: HORN, HAZARD

DIAG CONNECTOR
B-79 4 0.5B B-79 5 0.5B B-79 13 B-79 2 B-79 16 B-79 12 0.5Y B-79 7 0.5LB B-79 14 0.5L B-79 6 RESISTOR2

0.5W/R

RESISTOR1 H-8 H-8 13

B-431 1

B-431 2

0.5W/R

CONT UNIT. ABS


DIAG J-177 ALDL J-177 L J-177 27 H J-177 26 H J-177 14 L J-177 15

4 29

0.3W/G 0.3W/B

H-15 H-15

11 6

12 0.3W/G 0.3W/B

B-387 1

B-387 2

13 0.5L B-500 0.5LB 0.5L/W H-5 37 0.5L/W 58 W

C/U: DAMU
B-500 8 B-500 2

0.5L/W

0.5L/W

0.5L

0.5L

14 9

H-15 H-15

0.5L 0.5L/W

8 7

H-8 H-8

0.5L H-8 0.3B/W 0.5L/W 0.3LB 10 H-8 5 0.5LB H-5 36

10 H-15

5 H-15

0.5Y

0.5Y

Without ABS

3 B-427 H

2 B-427 L

18 B-428

9 B-426

0.5L 0.5L/W 0.85B(NKR85)/1.25B(NPR85) 37 J-191 18 J-191

CONT UNIT. SMOOTHER


For SMOOTHER

52 J-191 IS-DIAG

38

78

2B

CC CC -CAN-L -CAN-H SG IF-CAM -5VRT5 E-111 98 E-111 101 SP -5V5 E-111 87 IA -PFUEL E-111 90

ECM ; ENGINE
SG-SLD5 E-111 100 IA -PFUEL E-111 82 IS IS IS -EBMPOS1 -EBMPOS2 -EBMPOS3 E-111 94 E-111 93 E-111 99

J-191 J-191 J-191 CC -KW2000 CC CC -ISOCAN-H -ISOCAN-L

OM OM OM -EBM1 -EBM2 -EBM3 E-111 E-111 E-111 111 103 110

0.5B

0.5B/O

0.5LG/B

0.5W/O

0.5Y/B

0.5LG

0.5LB

0.5B/W

0.5Y/B

0.5Y/B

8 E-94 U

7 E-94 V

0.5LG

0.5LG

0.5W

B-7

3B 1 2 E-112 3 E-112 3 E-113 1 E-113 SENSOR; Pc 2 E-113 1 E-94 5 E-94 4 E-94 SENSOR: EGR VALVE 3 E-94 2 E-94

HEADLIGHT BRACKET-LH

5B

E-112

B-1

SENSOR; CAM ANGLE (MRE)

MOTOR: EGR BRUSH-LESS DC FRAME-LH (FRT)

0.5W 6 E-94

0.5O

0.5L

N8B0024E

8-66 CAB AND CHASSIS ELECTRICAL


For 4JJ1 (EURO 4) Engine (4)

RELAY: THERMO A/C SW : A/C PRESS. 0.85BR 0.5LG/B DIODE BOX 0.5LG 0.5B/Y 0.5W/L SW: DPD REGENERATE 0.5B/R 0.5B/R 6 2 B-495 B-495 B-495 B-495 3 5 Tail Relay 3W 0.5W/V 10 X-33 X-33 3 1 2 X-10 X-10 X-10 X-10 4 0.5P/G ELECTRO THERMO A/C COMPRESSOR 0.5B/Y 0.5W/L METER (PARKING BRAKE) 0.3W/V F-7 10A TAIL LIGHT 0.85LG/R 0.5W/V 0.3W/B 3 B-18 DIODE BOX 4 3 0.3W/B 5 0.85G/W H-5 2 0.85G/W 1 J-6 J-6 2 0.85G/O 7 H-105 0.75P 1 E-5

J-269 J-269 SHORT CONNECTOR (FOR NPR85)

0.5B/Y 0.5W/R

3 B-18 DIODE BOX B-18 4 (FOR NKR85)

H-5 31

0.85LG/R

0.5B/R

0.5B/R

0.85LG/R 5 B-69 SW : EXH. BRAKE SW : ENG. WARM 0.5B 5 3 1 B-69 2 0.5LG/R B-31 B-31 B-31 B-31 B-31 B-31 2 0.5LG/R 6 4 0.5B

B-18 2 For M/T 0.5W/B 0.5W/B H-12 For SMOOTHER 0.3W/B 1 SW: PARKING BRAKE 19 25 H-5 H-5 IA -EVRV E-111 92 0.5B N-6 0.5B 0.3Y/G 0.5B 1 E-26 H-12 5 3

0.5G/O

0.5B/Y

0.5LG/L

Except NKR NKR only H-4 11 H-17 3

3B

0.5B

(EC only)

H-5 29

H-5 0.5LG/R 0.5Y/G 1 J-32 2 J-32 V/SPEED SENSOR 3 J-32 0.5Y/G 6

0.5LG/L

0.5W/R

19 J-191 IF-SPD

45 J-191 IS-EXB

51 J-191 IS-QWS

47 J-191 IS -DPFREG

34 J-191 IS-A/C

48 J-191 IS -PBRK

ECM ; ENGINE
IS-PTO J-191 44 0.5L/O OM -IDM2 E-111 104 OM IA -IDM1 -IDMPOS E-111 112 E-111 85 IA -MAP E-111 91 SG -SLD4 E-111 108 SP -5V4 E-111 95 SG IF -5VRT4 -CRANK E-111 109 E-111 107

0.5B

0.75B/G

0.5V/W

38 H-5 0.5L/O

0.5Y

0.5B

0.5GR/R

0.5W/B

0.5W/B H-5 1

0.5R/L

0.5R

0.5B

0.5Y

B-7

1 B-84 SW : PTO

0.75G

2 E-114

5 E-114

6 E-114

3 E-114

5B

HEADLIGHT BRACKET-LH

SENSOR; INTAKE THROTTLE DC MOTOR POSITION B-84 2 E-114 1

3 E-98

2 E-98

1 E-98

3 E-26

J-216 J-216 J-216 SENSOR; MANIHOLD AIR PRESSURE

SENSOR; NE, CRANK

SENSOR; PRESSURE

B-1

0.85B(NKR85) 1.25B(NPR85)

0.5B

FRAME-LH (FRT)

0.5G 2 E-26

0.5Y

0.5B

0.5Y

N8B0025E

CAB AND CHASSIS ELECTRICAL 8-67


For 4JJ1 (EURO 4) Engine (5)

0.5B/Y 0.5W/L 18 B-51 ENGINE COOLANT TEMPERATURE GAUGE B-52 5 12 0.5LB H-5 CHECK ENG. PARKING BRAKE DPF REGENERATE SEDIMENTER B-52 10 13 0.5R(W/CAB) 0.5LB 0.5LG/W H-5 0.5LG/W EXHBRAKE

OIL PRESS

CHARGE

TACHO

SPEED

GLOW

B-51 10

B-52 20

B-52 17

B-51 13

B-51 For SMOOTHER 5

B-51 7

B-52 15

B-51 6

B-51 4 0.5LG/B

B-53 For SMOOTHER 10 0.5LG/B

B-52 8

B-51 11

B-51 5 For M/T 0.3W/V

B-51 For SMOOTHER 4 0.3W/V

B-52 6

For M/T 0.5L/R

0.5L/R

For M/T

H-5 0.3Y/G 0.5B 24

H-5 30

H-5 40

H-5 7

H-17 4 NKR only

H-4 19 Except NKR

H-8 3

H-5 39 0.5BR/B

SW: OIL LEVEL

21 0.5Y/R(S/CAB) 1 J-28 UNIT: FUEL SENSOR J-28 2 0.5B 16 J-191 OS -LOWOIL SW: FUEL LINE CLOGGING 0.5BR/B 0.5LG/W 12 H-105 1 H-105

6 H-105

0.5LG/B

0.5O/L

0.5L/R

0.5L/B

0.5L/P

0.5LG

SW: OIL PRESSURE

0.5B 0.3Y/G

0.85B(NKR85)/1.25B(NPR85)

6 J-191 OS-DIAGL

17

11

9 J-191 OS -DPFREG

8 J-191 OF -TACHO

J-191 J-191 J-191 OS-SVS OS OS -GLOWL -EXBL

ECM ; ENGINE
IA-THL E-111 83 IA-THW E-111 84 IS -LOWOIL J-191 53 0.5V/Y

0.5B 0.5G/Y

5 0.5B H-105 3 SW:LOW OIL LEVEL E-90 METER 0.5V/Y FUEL HEATER

FUEL SEDIMENTER SW: FUEL SEDIMENTER J-206 1 J-206 2

0.5LG/W

0.5B

1 E-90

2 E-90

1 E-93 B-1

2 E-93

1 E-137

SENSOR; FUEL TEMP

ECT SENSOR

ECT SENSOR

FRAME-LH (FRT)

E-137 2 0.5B 0.5B

J-9

0.5LB FRAME-LH (CTR)

0.5BR/B

1 J-8

0.5LG/W H-5

0.5BR/B

0.5O/L

0.5L/B

0.5L/P

0.3LG

FUEL

SVS

N8B0026E

8-68 CAB AND CHASSIS ELECTRICAL


For 4JJ1 (EURO 4) Engine (6)

ACCEL SENSOR SENSOR; IDLE UP VOLUME B281 2 B-281 1 B-281 3 SENSOR; ACCEL POSITION1 B-280 6 B-280 4 B-280 5 SENSOR; ACCEL POSITION2 B-280 2 B-280 1 B-280 3

0.5L/W

0.5L/R

0.5W

0.5R

0.5L/R

0.5L/Y

0.5L

0.3B

0.5B 0.3B H-5 32

SERVICE CONNECTOR
0.5BR J-166 2 J-166 3 J-166 1 H-5 33 H-8 9 H-5 16 H-5 8 0.3B H-5 9 H-5 26 H-5 20 H-5 27 0.3B

0.5P/B

0.5P/B

0.5L/Y

0.5BR

0.5L

0.5W

0.5W

0.5R

0.5R

0.5R

0.3B

0.5B 0.5B 60 J-191 SG -5VRT2

70 J-191 IA -PTOPOS

66

41

42

20 J-191 SG -SLD1

63 J-191 IA -ACCEL1

64

61

39 J-191 SG -SLD2 0.5B 0.5R 3 B-422

J-191 J-191 J-191 SG SP IA -IDLUP -5VRT1 -5V1

J-191 J-191 SP IA -ACCEL2 -5V2

ECM ; ENGINE
IA-BARO J-191 71 SG PS-12V -12VRT IA-MAF J-191 23 J-191 22 J-191 69 IA-IAT J-191 72 0.5B 0.5G 0.5Y 0.5L

0.5BR/G

0.5R/G

1 14 H-5 0.5BR/G J-182

2 J-182 SENSOR; MASS AIR FLOW

3 J-182

4 J-182

SENSOR; INTAKE AIR TEMP

MAF SENSOR

0.5B 5 J-182

2 B-422

1 B-422 SENSOR; BARO

N8B0027E

CAB AND CHASSIS ELECTRICAL 8-69


Connector List
For 4HK1 Engine No. Connector Face B-53 B-1
012-009 000-001

No.

Connector Face

B-67 B-7
000-001

1 4 3

2 3 4
004-001 004-002

B-17 (For M/ T)

B-67
1 2 3 4

2 4

1 3

004-002 004-004

B-69 B-18
1 2 3 4

1 5

2 3 4 6 7 8
008-001

004-004

B-69 B-31
1 4 2 5 3 6

4 3 2 8 7 6

1 5
008-002

006-001

B-79 B-39
1 2 3
003-019

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
016-005

B-84 B-51
020-004

1 2
002-022

B-89 B-52
020-005

1 2
002-009

8-70 CAB AND CHASSIS ELECTRICAL


No. Connector Face No. Connector Face

B-280

1 2 3 4 5 6

B-495
006-024 006-022

B-281
003-028

B-497

1
001-024

B-387
002-038

B-497

1
001-025

B-422
003-027

B-500

1 7

2 8

3 9 10

11 12 13

013-001

B-426 (For Smoot her)


024-001

E-3
000-009

B-427 (For Smoot her)


017-001

E-5
001-021

B-428 (For Smoot her)


022-006

E-90

1 3

003-004

B-431
002-038

E-93
002-035

CAB AND CHASSIS ELECTRICAL 8-71


No. Connector Face No. Connector Face

E-94

1 2 3 4 5 6 7 8

E-139
008-007 003-031

E-98
003-026

E-140
003-031

121

120

119

E-111

113 112 111 110 109 108 107 106 105 104 103 102 101 100 99 98 97 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82

118 116

117 114

E-141
040-001 003-031

115

2 6

3 7

4 8

E-112
003-026

E-168

9 10 11 12 13 14 15 16

016-008

E-113
003-029

E-169

1 5

23 6 7

4 8
008-027

E-114
006-030

H-4

1 2 3 4 5 10 11 12 13 14 15

6 7 8 9 16 1718 19 20

020-002

E-116
002-036

H-4

9 8 7 6 20 19 18 17 16

5 4 3 2 1 15 14 13 12 11 10

020-003

E-138
003-031

H-12 (For M/ T)

1 2 3 7 8 9 10

4 5 6 11 12 13 14

014-002

8-72 CAB AND CHASSIS ELECTRICAL


No. Connector Face No. H-118 (For Smoot her)
014-003

Connector Face

H-12 (For M/ T)

6 5 4 14 13 12 11

3 2 1 10 9 8 7

4 8

3 7

2 6

1 5 9

12 11 10

012-002

H-12 (For Smoot her)

1 2 3 4 5 11 12 13 14 15 16

6 7 8 9 10 17 18 19 20 21 22

H-120
022-001

001-023

H-12 (For Smoot her)

10 9 8 7 6 22 21 20 19 18 17

5 4 3 2 1 16 15 14 13 12 11

H-120
022-002

001-022

2 6 7

3 8

4 9

H-15

10 11 12 13 14 15 16

H-125
016-003

1 5

2 6

3 7

4 8 008-019

3 8 7

2 6

1 5

H-15

14 13 12 11 10

H-125
016-004

4 8

3 7

2 1 6 5 008-020

16

15

H-105

1 5 9

2 6

3 7

4 8

H-126
016-001

5 1

6 2

7 3

8 4 008-022

10 11 12

13 14 15 16

H-105

4 8

3 7

2 6

1 5 9

H-126
016-002

8 4

7 3

12 11 10

16 15 14 13

2 1 008-021

H-118 (For Smoot her)

1 5 9

2 6

3 7

4 8

H-159
012-001 001-021

10 11 12

CAB AND CHASSIS ELECTRICAL 8-73


No. Connector Face No. Connector Face

J-1

J-31
002-003

2
002-011

J-2
000-001

J-32

003-018

J-6

1 3

2 4
004-001

J-50
002-035

J-8
1

J-166
001-013

3
003-001

J-9
000-001

J-177
034-001

J-26
000-002

J-177
034-002

J-27
000-009

J-182

5
005-008

J-28

2
002-011

J-191
081-001

8-74 CAB AND CHASSIS ELECTRICAL


No. Connector Face No. Connector Face

J-206

N-6
002-001

2 1
002-023

J-216

1 2 3
003-032

P-1
000-022

J-221

2
002-011

P-4
000-014

J-222

P-2
002-052 000-014

J-223

P-3
002-053 000-014

J-224
003-037

P-5
000-002

J-225

2
002-049

X-1

003-018 005-006

J-271

1
001-026

X-8
005-006

CAB AND CHASSIS ELECTRICAL 8-75


No. Connector Face H-5

X-10

1 2 3 5 4

005-001

X-12

1 2 3 5 4

1 7 13 19 25 31

2 8 14 20 26 32

3 9 15 21 27 33

34

35

36

37

4 10 16 22 28 38

5 11 17 23 29 39

6 12 18 24 30 40

6 12 18 24 30 40

5 11 17 23 29 39

4 10 16 22 28 38

37

36

35

34

3 9 15 21 27 33

2 8 14 20 26 32

1 7 13 19 25 31

005-001

X-18

2 4

3 5

N8A5488E
005-003

H-6, H-7, H-8

X-20

2 4

3 5

005-003

H-6

1
1

H-7

X-21

1 2 3 4
3

4 3 2 1 8 7 6 5 H-8 13 12 11 10 9 18 17 16 15 14

2 4

5 6 7 8 9 10 11 12 13

005-003

14 15 16 17 18

X-25
005-006

N8A5489E

X-26
005-006

X-32 (For Smoot her)

1 2 3 4

004-004

8-76 CAB AND CHASSIS ELECTRICAL


For 4JJ1 (EURO 3) Engine No. Connector Face
1

No.

Connector Face

X-21 B-1
000-001

2 4

3 5

005-003

X-26 B-7
005-006 000-001

B-18 X-1

1 2 3 4

004-004 005-006

B-31 X-8
005-006

1 4

2 5

3 6

006-001

B-39 X-10
1 2 3 5 4

1 2 3
003-019

005-001

B-51 X-12
1 2 3 5 4

020-004 005-001

B-52 X-18
1 2 4 3 5

020-004 005-003

B-67
1

X-20

1 3

2 4
004-001

2 4

3 5

005-003

CAB AND CHASSIS ELECTRICAL 8-77


No. Connector Face No. Connector Face

B-67

2 4

1 3

B-387
004-002 002-038

B-69

1 5

2 3 4 6 7 8
008-001

B-387
002-039

B-69

4 3 2 8 7 6

1 5
008-002

B-422
003-027

B-79

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
016-005

B-431
002-038

B-84
1 2
002-022

B-431
002-039

B-89

1 2
002-009

B-500

1 7

2 8

3 9 10

11 12 13

013-001

B-280

1 2 3 4 5 6

H-12
006-024

1 2 3 7 8 9 10

4 5 6 11 12 13 14

014-002

B-281
003-028

H-12

6 5 4 14 13 12 11

3 2 1 10 9 8 7

014-003

8-78 CAB AND CHASSIS ELECTRICAL


No. Connector Face No. Connector Face

H-105

1 5 9

2 6

3 7

4 8

E-15
012-001 002-036

10 11 12

H-105

4 8

3 7

2 6

1 5 9

E-16
012-002 002-036

12 11 10

H-120

E-90
001-022

1 3

003-004

H-120

E-93
001-023 002-035

E-3
000-009

E-94

1 2 3 4 5 6 7 8

008-007

E-5
001-021

E-98
003-026

121

120

119

E-13
002-036

E-111

113 112 111 110 109 108 107 106 105 104 103 102 101 100 99 98 97 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82

118 116

117 114

115

040-001

E-14
002-036

E-112
003-026

CAB AND CHASSIS ELECTRICAL 8-79


No. Connector Face No. Connector Face

E-113
003-029

J-9
000-001

E-114
006-030

J-26
000-002

E-116
002-036

J-27
000-009

E-137

1 2
002-025

J-28

2
002-011

J-1

J-31
002-003

2
002-011

J-2
000-001

J-32

003-018

J-6

1 3

2 4
004-011

J-50
002-035

J-8
1

J-166
001-013

3
003-001

8-80 CAB AND CHASSIS ELECTRICAL


No. Connector Face No. Connector Face

J-182

5
005-004

P-2
000-014

J-191
081-001

P-3
000-014

J-206

P-4
002-001 000-014

J-216

1 2 3
003-032

P-5
000-002

H-5 J-225
1 2
002-049

J-271

1
001-026

1 7 13 19 25 31

2 8 14 20 26 32

3 9 15 21 27 33

34

35

36

37

4 10 16 22 28 38

5 11 17 23 29 39

6 12 18 24 30 40

6 12 18 24 30 40

5 11 17 23 29 39

4 10 16 22 28 38

37

36

35

34

3 9 15 21 27 33

2 8 14 20 26 32

1 7 13 19 25 31

N-6

2 1
002-023

N8A5488E

P-1
000-022

CAB AND CHASSIS ELECTRICAL 8-81


H-6, H-7, H-8

H-6

H-7

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 H-8

4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14

N8A5489E

8-82 CAB AND CHASSIS ELECTRICAL


For 4JJ1 (EURO 4) Engine No. Connector Face
1

No.

Connector Face

X-21 B-1
000-001

2 4

3 5

005-003

X-25 B-7
005-006 000-001

X-26 X-1
005-006 005-006

X-8
005-006

X-32 (For Smoot her)

1 2 3 4

004-004

X-10

1 2 3 5 4

B-17 (For M/ T)

1 2 3 4

004-004 005-001

B-18 X-12
1 2 3 5 4

1 2 3 4

004-004 005-001

B-31 X-18
1 2 4 3

1 4

2 5

3 6

006-001
5

005-003

B-39
1

1 2 3

X-20

2 4

3 5

003-019 005-003

CAB AND CHASSIS ELECTRICAL 8-83


No. Connector Face No. Connector Face

B-51
020-004

B-84
1 2
002-022

B-52
020-004

B-89

1 2
002-009

B-53
012-009

B-280

1 2 3 4 5 6

006-024

B-67

1 3

2 4
004-001

B-281
003-028

B-67

2 4

1 3

B-387
004-002 002-038

B-69

1 5

2 3 4 6 7 8
008-001

B-387
002-039

B-69

4 3 2 8 7 6

1 5
008-002

B-422
003-027

B-79

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
016-005

B-426 (For Smoot her)


024-001

8-84 CAB AND CHASSIS ELECTRICAL


No. B-427 (For Smoot her)
017-001

Connector Face

No.

Connector Face

H-4 (Excep t NKR)

9 8 7 6 20 19 18 17 16

5 4 3 2 1 15 14 13 12 11 10

020-003

B-428 (For Smoot her)


022-006

H-4 (For NKR)

1 5 9

2 6

3 7

4 8

10 11 12

012-001

B-431
002-038

H-4 (For NKR)

4 8

3 7

2 6

1 5 9

12 11 10

012-002

B-431
002-039

H-17 (For M/ T)

1 3

2 4
004-011

B-495
006-022

H-17 (For M/ T)
004-018

B-497

1
001-025

H-17 (For Smoot her)

1 5 9

2 6

3 7

4 8

10 11 12

13 14 15 16

016-001

B-500

1 7

2 8

3 9 10

11 12 13

H-17 (For Smoot her)


013-001

4 8

3 7

2 6

1 5 9

12 11 10

16 15 14 13

016-002

H-4 (Excep t NKR)

1 2 3 4 5 10 11 12 13 14 15

6 7 8 9 16 1718 19 20

H-12 (For M/ T)
020-002

1 2 3 7 8 9 10

4 5 6 11 12 13 14

014-002

CAB AND CHASSIS ELECTRICAL 8-85


No. Connector Face No. Connector Face

H-12 (For M/ T)

6 5 4 14 13 12 11

3 2 1 10 9 8 7

H-118
014-003 008-018

H-12 (For Smoot her)

1 2 3 4 5 11 12 13 14 15 16

6 7 8 9 10 17 18 19 20 21 22

H-120
022-001

001-022

H-12 (For Smoot her)

10 9 8 7 6 22 21 20 19 18 17

5 4 3 2 1 16 15 14 13 12 11

H-120
022-002

001-023

2 6 7

3 8

4 9

H-15

10 11 12 13 14 15 16

E-3
016-003 000-009

3 8 7

2 6

1 5

H-15

14 13 12 11 10

E-5
016-004 001-021

16

15

H-105

1 5 9

2 6

3 7

4 8

E-13
012-001 002-036

10 11 12

H-105

4 8

3 7

2 6

1 5 9

E-14
012-002 002-036

12 11 10

H-118

1 5

2 6

3 7

4 8
008-003

E-15
002-036

8-86 CAB AND CHASSIS ELECTRICAL


No. Connector Face No. Connector Face

E-16
002-036

E-113
003-029

E-26
003-027

E-114
006-030

E-90

1 3

E-116
003-004 002-036

E-93
002-035

E-137

1 2
002-025

E-94

1 2 3 4 5 6 7 8

E-167
008-007

002-016

E-98
003-026

J-1

002-003

121

120

119

E-111

113 112 111 110 109 108 107 106 105 104 103 102 101 100 99 98 97 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82

118 116

117 114

J-2
040-001 000-001

115

E-112
003-026

J-6

1 3

2 4
004-011

CAB AND CHASSIS ELECTRICAL 8-87


No. Connector Face No. Connector Face

J-8
1

J-166
001-013

3
003-001

J-9
000-001

J-177
034-001

J-26
000-002

J-182

5
005-004

J-27
000-009

J-191
081-001

J-28

2
002-011

J-206

002-001

J-31

2
002-011

J-216

1 2 3
003-032

J-32

J-221
003-018

2
002-011

J-50
002-035

J-222
002-056

8-88 CAB AND CHASSIS ELECTRICAL


No. Connector Face No. Connector Face

J-223
002-041

P-5
000-002

H-5 J-224
003-037

J-225

2
002-049

1 7 13 19 25 31

2 8 14 20 26 32

3 9 15 21 27 33

34

35

36

37

4 10 16 22 28 38

5 11 17 23 29 39

6 12 18 24 30 40

6 12 18 24 30 40

5 11 17 23 29 39

4 10 16 22 28 38

37

36

35

34

3 9 15 21 27 33

2 8 14 20 26 32

1 7 13 19 25 31

N-6

2 1
002-023

N8A5488E

H-6, H-7, H-8 P-1


000-022

H-6

P-2
1 2 H-7 2 1

000-014

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 H-8

4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14

P-3
000-014

N8A5489E

Neutral Switch
P-4
000-014

Refer to START AND CHARGING in this section.

Starter Relay
Refer to START AND CHARGING in this section.

Charge Relay
Refer to START AND CHARGING in this section.

CAB AND CHASSIS ELECTRICAL 8-89


Starter Switch
Refer to START AND CHARGING in this section. Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Check to see if the accel pedal has been returned by the return spring to the specified position. 2. Turn the accel switch clockwise until the tip of the threaded portion of the switch contacts the pedal arm. 3. Tighten the lock nut to the specified torque. Tighten: Lock nut to 13 Nm (130 kgfcm / 115 lbfin)

Accel Switch
Inspection 1. Check the continuity between the switch connector terminals. 2. Check to see if switch push rod operates smoothly. Repair or replace the accel switch when result of inspection is found abnormal.

Clutch Switch
Inspection 1. Check the continuity between the switch connector terminals. 2. Check to see if switch push rod operates smoothly. Repair or replace the switch when result of inspection is found abnormal.

N8A5091E

Removal Preparation: Disconnect the battery ground cable. 1. Accel Switch 1) Disconnect the connector. 2) Loosen the lock nut of the switch. 3) Remove the switch by turning it.
N8A0089E

Removal and Installation Refer to Accel Switch in this section.

N8A0088E

8-90 CAB AND CHASSIS ELECTRICAL


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

N8A5095E

Removal and Installation Refer to HEADLIGHT, FOG LIGHT, REAR FOG LIGHT AND CORNERING LIGHT in this section.

CAB AND CHASSIS ELECTRICAL 8-91


Exhaust Brake Solenoid Valve
Inspection Connect the solenoid valve connector terminal No. 1 to the battery (+) terminal and terminal No. 2 to the () terminal and then check the continuity among each port.

Intake Throttle Solenoid Valve


Inspection Connect the solenoid valve connector terminal No. 1 to the battery (+) terminal and terminal No. 2 to the () terminal and then check the continuity among each port. Repair or replace the intake throttle solenoid valve when the result of inspection is found abnormal.

B
J-31

A
2 1

B
J-31

C
Port Operation When battery voltage applied When battery voltage not applied
N8B5133E

C
Port Operation When battery voltage applied When battery voltage not applied
N8B5133E

8-92 CAB AND CHASSIS ELECTRICAL Headlight, Fog Light, Rear Fog Light and Cornering Light
General Description
The circuit consists of headlight, fog light, cornering light, starter switch, combination switch (Lighting switch, dimmer / passing switch, cornering light switch, rear fog light switch), fog light switch, rear foglight, high beam indicator light and relay. When the lighting SW is turned on by setting it at headlight position, the lighting relay is actuated to turn on the headlight. The optical axis of the headlight can be turned up or down by operating the dimmer SW while headlight is on. The passing SW is independent of the lighting SW, and the optical axis of the passing light can be turned up only while the switch lever is pulled up and held in this state. Fog light turns on by switching it to ON position to activate relay only while lighting SW is on. Rear fog light turns on by switching it to ON position to activate relay only while lighting SW is at headlight position. When the headlight is on, turn the turn-signal switch left or right, and then the cornering switch built in the combination switch turns on, followed by the cornering light turning on.

Lighting Circuit
CORNERING LIGHT HEADLIGHT
Battery (+) Starter sw.(ON)

FOG LIGHT

REAR FOG LIGHT

Lighting sw.
OFF RR FOG

Headlight relay

Tail relay

Cornering light relay

Rear fog light relay Headlight

Cornering light sw.


LO HI

Fog light sw. Rear fog light

Dimmer sw. Cornering light Dimmer relay Fog light relay

Fog light

N8B5110E

Notice: Arrow marks indicate the direction of current.

Parts Location

RELAY BOX ASM (No.1) X-5 FOG LIGHT RELAY X-6 DIMMER RELAY X-9 CORNERING LIGHT RELAY STARTER SWITCH R-13 REAR FOG LIGHT (RH) B-67 B-87 FRONT FOG LIGHT SWITCH H-16

COMBINATION SWITCH (LIGHTING SWITCH, CORNERING LIGHT SWITCH, REAR FOG LIGHT SWITCH)

RELAY BOX ASM (No.2) X-16 REAR FOG LIGHT RELAY

H-14 R-12 REAR FOG LIGHT (LH) P-5 P-2 BATTERY P-4 P-3 RELAY BOX ASM FL-1,FL-2,FL-4 FUSIBLE LINK J-9 B-51 HIGH BEAM INDICATOR LIGHT (METER) REAR FOG LIGHT INDICATOR LIGHT (METER) B-3 FOG LIGHT (LH) B-5 CORNERING LIGHT (LH) P-1

FUSE BOX ASM F-7,F-8,F-14,F-16, F-23,F-24 X-3 HEADLIGHT RELAY X-4 TAIL RELAY X-33 DIODE

B-74 CORNERING LIGHT (RH)

B-7

B-73 HEADLIGHT (RH)

B-72

FOG LIGHT (RH)

H-5,H-6,H-7,H-8 B-70 B-1

B-4 HEADLIGHT (LH)

CAB AND CHASSIS ELECTRICAL 8-93

N8B0028E

FL-2 40A 3W/L

KEY SW

(FOR 4HK1)
8W/B 5W/B H-6 1 STARTER SWITCH 2W/B 3W/B OFF ACC 3 B-67 3B/Y RELAY; TAIL F-7 TAIL LIGHT 0.85LG/R 10A TAIL LIGHT X-4 5 F-16 10A METER 3W 0.85LG/R 2R FRT FOG LIGHT, CORNERING LAMP F-8 10A 1 X-4 3 X-4 X-4 2 2 B-67 ON ST 3 X-3 X-3 2 B2 H-7 3W/L 2 2W/R H-7 5W/B 2 5W/B

2L

8B

P-1 2W/R

Circuit Diagram

P-2

FL-1 100A or 120A MAIN

(FOR 4JJ1)

FL-4 30A HEAD LAMP

P-3

P-4

RELAY; HEADLIGHT

X-3 5 0.3R 1

X-3

P-5 0.3R 0.5B/Y 0.3R DIODE X-33 1 0.3L/R 8 1 F-24 HEAD LIGHT (LH) 0.3G/O 0.5R 0.5R/L 7 0.3L X-9 3 B-4 HI LO RELAY; CORNERING LAMP X-9 X-9 1 B-4 1 5 2 0.5R/B 0.5R/G 0.85R/Y 2R X-9 LH 10 4 3 2 RH 3 B-73 HI LO 10A X-33 X-33 F-23 2R 0.85LG/R 2 3 0.5R/L

FRAME

LIGHTING SWITCH

OFF

B-70

0.85LG/R

0.85LG/R

B-70

10A HEAD LIGHT (RH)

8-94 CAB AND CHASSIS ELECTRICAL

For 4HK1 / 4JJ1 Engine (Without Rear Fog Light)

B-70

Hu

B-70

6 B-87

2 B-87

B-70

COMBINATION SWITCH B-4 2 HEADLIGHT (LH) HEADLIGHT (RH) 0.3R/L 0.85R/Y 0.5R/G 0.5R/G 3 X-6 X-6 X-6 2 4 2 B-51 H X-6 5 1 X-6 L RELAY; DIMMER B-51 15 HIGH BEAM INDICATOR LIGHT (METER) 1.25B 0.85B 0.5B 3B 2B 1.25B(except NKR)/0.85B(NKR)

E2

LO

HIGH PASS

B-73 2

B-73 1 B-87 3 0.5R/Y B-87 5

CORNERING LIGHT SWITCH

FOG LIGHT SWITCH

B-70

LH

RH

0.85R/Y 0.5R/G RELAY; FOG LIGHT X-5 1 0.85R/G

2 X-5

3 X-5

B-70 11

B-70 9

X-5 5

0.5P

B-5

0.5P/B

B-74

0.85R/G

0.85R/G

(RH)

CORNERING LAMP

(LH)

B-5

B-74

0.5B

0.5B

1 B-3

1 B-72

3B

2B

0.85B

0.85B

FOG LIGHT (LH)

FOG LIGHT (RH)

FRAME-LH (FRONT)

B-1

B-3 2 0.5B

B-72 2 0.5B

N8B0029E

HEADLIGHT BRACKET (LH)

B-7

3B

5B

2B

3B

3B

2B

(FOR 4HK1)
8W/B 8 W/B
H-6 F-14 (10A) H-7 2W/B 3W/B 3 X-3 3 X-4 TAIL LIGHT 0.85LG/R 0.85LG/R FRT. COMBINATION LIGHT (LH) (4) X-4 F-7 10A 2 X-3 2 2 2W/R REAR FOG LIGHT 5W/B 2 3W/B 3W/B

5W/B

2L

8B

P-1

FL-1 100A or 120A

(FOR 4JJ1)
2W/R

P-2

MAIN

FL-4 30A

HEAD LAMP

P-3

P-4 X-3 5 X-4 X-4 1 0.85LG/R 3W 0.85LG/R FRT FOG LIGHT F-8 10A 0.5LG 5 2R 0.3R 1 X-3

RELAY; TAIL

RELAY; HEAD LIGHT

LIGHTING SW

OFF

RR FOG

P-5 1 0.85LG/R 0.85LG/R 0.85LG/R 8 HEAD LIGHT (LH) 14 0.5GR /B HEAD LIGHT (RH) 0.3G/O F-24 10A F-23 10A 0.3R 2R

B-70

FRAME

B-70

B-70 0.5R 7 LH 3 B-73 HI LO B-87 B-87 RH 6 2 10 3 B-4 HI LO 2R 4 0.3R

5 X-16

2 X-16

0.5R/L

For 4HK1 / 4JJ1 Engine (With Rear Fog Light)

COMBINATION SW FOG LIGHT SWITCH B-4 B-4 2 0.85R/Y 2 1 B-73 1 0.5R/G B-73 B-87 3 0.5R/Y B-87 5 HEADLIGHT (LH) HEADLIGHT (RH) 2 0.85R/Y 0.5R/G 0.5R/G X-5 3 X-5 0.3R/L 0.85R/Y 0.5R/G 3 X-6 X-6 RELAY; DIMMER X-6 2 4 RELAY; FOG LIGHT X-5 1 0.85R/G X-5 5 H 0.5R/G X-6 5 2 B-51 1 X-6 L 0.5R/G 0.85R/G 0.85R/G 19 0.5B 0.5B 1 B-3 B-51 15 0.5B B-3 2 0.5B 1 B-72 B-51 1.25B(Except NKR)/0.85B(NKR) HIGH BEAM INDICATOR LIGHT (METER) 1.25B 0.85B B-51 B-72 2 0.5B 15 0.5B FOG LIGHT (LH) FOG LIGHT (RH) 3B 2B 3B 3B 2B 2B 2B H-14 1.25B 7 1.25B H-16 7 1.25B 0.85B

B-70

Hu

B-70

B-70

RELAY; RR FOG LIGHT X-16 3 0.5LG/R 0.5R/G X-16 1

E2

LO

HIGH PASS

H-8 H-5 5 1 0.85R/G

LICENSE LIGHT 3 H-14 0.85R/G 3 H-16 0.85R/G METER INDICATOR (REAR FOG LIGHT)

1 R-12

0.85R/G

1 R-13

0.85R/G

FRAME-LH (FRONT)

B-1

RR FOG LIGHT (LH)

RR FOG LIGHT (RH)

0.85B

0.85B

HEADLIGHT BRACKET (LH)

B-7

3B

5B

R-12 2

R-13 2

FRAME-LH (CENTER)

J-9

CAB AND CHASSIS ELECTRICAL 8-95

N8B0030E

8-96 CAB AND CHASSIS ELECTRICAL


Connector List
No. Connector Face No. Connector Face

B-1
000-001

B-5

1 3

2 4
004-012

B-7
000-001

B-5

2 1 4 3
004-013

B-3

B-74
1 2

1 3

2 4
004-012

002-001

B-3

B-74
2 1

2 1 4 3
004-013

002-002

B-72

X-33
1 2

1 2 3
003-034

002-001

B-72

X-3
2 1

002-002

005-006

B-4

X-4
005-006

003-007

B-73

X-5
005-006

003-007

CAB AND CHASSIS ELECTRICAL 8-97


No. Connector Face No. Connector Face

X-6
005-006

B-87

1 4

2 5

3 6

006-006

X-9
005-006

H-14 (With ABS)

1 5 6

2 7

3 8

4 9

10 11 12 13 14 15 16

016-003

X-16
005-006

H-14 (With ABS)

4 9 8

3 7

2 6

1 5

14 13 12 11 10

16

15

016-004

B-51
020-004

H-14 (Without ABS)

1 5

2 6

3 7

4 8
008-003

B-67

1 3

2 4
004-001

H-14 (Without ABS)

4 8

3 7

2 6

1 5
008-004

B-67

2 4

1 3

H-16
004-002

1 5

2 6

3 7

4 8
008-003

B-70

1 2 3 7 8 9 10

4 5 6 11 12 13 14

H-16
014-002

4 8

3 7

2 6

1 5
008-004

B-70

6 5 4 14 13 12 11

3 2 1 10 9 8 7

J-9
014-003 000-001

8-98 CAB AND CHASSIS ELECTRICAL


No. Connector Face No. Connector Face

P-1
000-022

R-13

002-002

H-5 P-4
000-014

P-2
000-014

1 7 13 19 25 31

2 8 14 20 26 32

3 9 15 21 27 33

34

35

36

37

4 10 16 22 28 38

5 11 17 23 29 39

6 12 18 24 30 40

6 12 18 24 30 40

5 11 17 23 29 39

4 10 16 22 28 38

37

36

35

34

3 9 15 21 27 33

2 8 14 20 26 32

1 7 13 19 25 31

P-3
000-014

N8A5488E

H-6, H-7, H-8 P-5


000-002

H-6

R-12

H-7

1 2 3 4

4 3 2 1 8 7 6 5 H-8 13 12 11 10 9 18 17 16 15 14

002-001

5 6 7 8 9 10 11 12 13 14 15 16 17 18

R-12

002-002

N8A5489E

R-13

002-001

CAB AND CHASSIS ELECTRICAL 8-99


Diagnosis
Quick Chart for Check Point 1. Headlight Check point Fuse F-23 (10 A) 1-1. Both Headlights inoperative 1-2. Headlight on the left (or right) side inoperative 1-3. Headlight in low-beam inoperative 1-4. Headlight in high-beam inoperative Trouble mode 1-5. Headlight on the left (or right) side in low (or high)-beam inoperative 1-6. Headlight beam does not change 1-7. Headlights remain on when the lighting switch turned off 1-8. Headlights come on with the lighting SW at the clearance light position Notice: Figure in parenthesis ( ) indicates the order of inspection. (1) (2) (2) (1) (2) (1) ((1)) (1) (1) F-24 (10 A) Fusible link FL-4 (30A) (2) Headl ight relay Lighting SW Dimmer / Passing SW Dimmer relay Headlight bulb LH RH Cable harness

DIOD E

(1)

(4)

(5) (2) (2) (3)

(3)

(1)

((1))

(2)

(3) (3)

(1)

8-100 CAB AND CHASSIS ELECTRICAL


2. Fog Light Check point Fog light bulb Fuse F-7 (10 A) F-8 (10 A) Taillight relay Fog light SW Cable harness Fog light relay (Except 4JJI (EURO 3)) (3)

LH

RH

2-1. Both fog lights inoperative (while lighting switch is on) Trouble mode 2-2. Fog light on the left (or right) side inoperative (while lighting switch is on) 2-3. Fog lights remain on

(1)

(2)

(4) (1) ((1))

(5) (2) (4)

(1)

(3)

(2)

Notice: Figure in parenthesis ( ) indicates the order of inspection. 3. Cornering Light Check point Fuse F-8 (10 A) 3-1. Both cornering lights inoperative Trouble mode 3-2. Cornering light on the left (or right) side inoperative 3-3. Cornering light remains on even when steering wheel is in the straight ahead position (2) F-16 (10 A) (1) Cornering light SW (5) (2) (1) (1) Cornering light bulb Cornering light relay (3) Cable harness (4) (3)

4. Rear Fog Light Check point Fuse F-14 (10 A) Trouble mode 4-1. Rear fog light inoperative (while headlight is ON) (2) Rear fog light SW (4) Rear fog light relay (3) Rear fog light bulb (1) Cable harness (5)

CAB AND CHASSIS ELECTRICAL


1. Headlight 1-1. Both Headlights Inoperative

8-101

N8B0085E

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

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

YES REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN FUSE F-24 (10A) AND 3 B-4 , FUSE F-23 (10A) AND 3 B-73

NO REPLACE THE FUSE

N8B5141E

8-102 CAB AND CHASSIS ELECTRICAL


1-3. Headlight in Low-beam Inoperative

IS THE DIMMER RELAY NORMAL?

YES REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 1 B-4 (OR 1 B-73 ) AND 4 X-6

NO REPLACE THE RELAY

N8B5142E

1-4. Headlight in High-beam Inoperative

IS THE DIMMER RELAY NORMAL?

YES DISCONNECT THE DIMMER / PASSING SW CONNECTOR IS THERE ANY CONTINUITY BETWEEN SW SIDE CONNECTORS 4 B-70 AND 10 B-70 WHEN THE SW IS AT HIGH-BEAM POSITION?

NO REPLACE THE RELAY

YES DISCONNECT THE HEADLIGHT RELAY IS THERE ANY CONTINUITY BETWEEN CHASSIS SIDE CONNECTORS 10 B-70 AND 1 X-3 ?

NO REPAIR OR REPLACE THE SW

YES REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 2 X-6 AND 2 B-4 ( 2 B-73 )

NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 10 B-70 AND 1 X-3

N8B0086E

CAB AND CHASSIS ELECTRICAL


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

8-103

IS THE BULB NORMAL?

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

NO REPLACE THE BULB

N8B5143E

1-6. Headlight Beam Does Not Change

IS THE DIMMER RELAY NORMAL?

YES DOES THE DIMMER / PASSING SW LEVER OPERATE SMOOTHLY AND SECURELY?

NO REPLACE THE RELAY

YES DISCONNECT THE DIMMER / PASSING SW CONNECTOR (COMBINATION SW) CHECK IF THERE IS CONTINUITY BETWEEN 4 B-70 AND 10 B-70 DIMMER SW "LO" POSITION ......... NO CONTINUITY "HI" POSITION .......... CONTINUITY

NO REPAIR OR REPLACE THE DIMMER / PASSING SW

NO REPAIR OR REPLACE THE DIMMER / PASSING SW (COMBINATION SW)


N8B5144E

8-104 CAB AND CHASSIS ELECTRICAL


1-7. Headlight Remains On When The Lighting SW is Turned Off

IS THE HEADLIGHT RELAY NORMAL?

YES

NO REPLACE THE HEADLIGHT RELAY

DISCONNECT THE LIGHTING SW CONNECTOR IS THE CONTINUITY BETWEEN THE SWITCH CONNECTOR TERMINALS 1 B-70 AND 4 B-70 NORMAL?

YES REPAIR A SHORT CIRCUIT BETWEEN 5 X-3 AND 1 B-70

NO REPAIR OR REPLACE THE LIGHTING SW

N8B5145E

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

DISCONNECT THE LIGHTING SW CONNECTOR WITH THE LIGHTING SW AT THE CLEARANCE LIGHT POSITION, IS THE CONTINUITY BETWEEN 1 B-70 AND 4 B-70 NORMAL? (NO CONTINUITY NORMAL)

NO REPAIR OR REPLACE THE LIGHTING SW

N8A0125E

CAB AND CHASSIS ELECTRICAL


2. Fog Light 2-1. Both Fog Lights Inoperative (while Lighting Switch is On)

8-105

IS THE FUSE F-7 (10A) OR F-8 (10A) NORMAL?

YES IS THE TAIL RELAY NORMAL?

NO REPLACE THE FUSE

YES IS THE FOG LIGHT RELAY NORMAL?

NO REPLACE THE RELAY

YES

NO REPLACE THE RELAY

REMOVE THE FOG LIGHT SW WHEN THE SWITCH IS "ON", IS THERE CONTINUITY BETWEEN THE SWITCH CONNECTOR TERMINALS 3 B-87 AND 6 B-87 ?

YES IS THE BATTERY VOLTAGE APPLIED BETWEEN THE HARNESS SIDE CONNECTOR 6 B-87 (2 X-5 , 2 B-87 ) AND THE GROUND, WHILE THE LIGHTING SW IS ON?

NO REPAIR OR REPLACE THE SW

YES IS THE BATTERY VOLTAGE APPLIED BETWEEN THE HARNESS SIDE CONNECTOR 3 B-87 AND THE GROUND, WHILE THE LIGHTING SW IS ON?

NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 6 B-87 (OR 2 X-5 ) AND F-8 , 2 B-87 AND F-7

YES REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 1 X-5 AND 1 B-3 (OR 1 B-72 ), 5 X-5 AND B-7

NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 3 B-87 AND 3 X-5

N8B5146E

8-106 CAB AND CHASSIS ELECTRICAL


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

IS THE BULB NORMAL?

YES

NO REPLACE THE BULB

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

N8A0127E

Notice: Figures in parenthesis ( ) indicate place of inspection for the fog light on the right. 2-3. Fog Light Remains On

DO THE TAILLIGHTS GO OFF?

YES

NO

IS THE FOG LIGHT RELAY NORMAL?

REPLACE THE TAIL RELAY

YES

NO REPLACE THE RELAY


N8B0087E

REPAIR OR REPLACE THE FOG LIGHT SWITCH

CAB AND CHASSIS ELECTRICAL


3. Cornering Light 3-1. Both Cornering Lights Inoperative
DO THE HEADLIGHT LIGHT COME ON?

8-107

YES IS THE FUSE F-16 (10A) NORMAL?

NO TURN THE HEADLIGHT ON (REFER TO DIAGNOSIS CHART FOR HEADLIGHT)

YES IS THE FUSE F-8 (10A) CONNECTED?

NO REPLACE THE FUSE

YES IS B-7 GROUNDED SECURELY?

NO REPLACE THE FUSE

YES IS THE CORNERING LAMP RELAY NORMAL?

NO GROUND IT SECURELY

YES REMOVE THE CORNERING LAMP RELAY TURN THE STARTER SWITCH ON IS THERE A BATTERY VOLTAGE APPLIED BETWEEN THE RELAY HARNESS SIDE CONNECTOR 3 X-9 (OR 2 X-9 ) AND GROUND?

NO REPAIR OR REPLACE THE RELAY

YES TURN THE STARTER SWITCH ON REMOVE THE HEADLIGHT RELAY DISCONNECT THE COMBINATION SWITCH CONNECTOR IS THERE A BATTERY VOLTAGE APPLIED BETWEEN SWITCH HARNESS SIDE CONNECTOR 1 B-70 AND THE GROUND?

NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN FUSE F-16 (10A) AND 3 X-9 , F-8 (10A) AND 2 X-9

YES IS THERE ANY CONTINUITY BETWEEN THE SWITCH CONNECTORS 2 B-70 AND 11 B-70 (WHEN TURNING LEFT) OR 2 B-70 AND 9 B-70 (WHEN TURNING RIGHT) RESPECTIVELY?

NO REPAIR A POOR CONNECTION OR AN OPEN CIRCUIT AT THE CONNECTORS BETWEEN 5 X-9 AND 1 B-70

YES REPAIR A POOR CONNECTION OR AN OPEN CIRCUIT BETWEEN THE HARNESS SIDE CONNECTORS 1 X-9 AND 2 B-70

NO REPAIR OR REPLACE THE SW

N8B0088E

8-108 CAB AND CHASSIS ELECTRICAL


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

N8A5149E

Notice: Figures in parenthesis ( ) indicate place of inspection for the cornering light on the right. 3-3. Cornering Light Remains On Even When Steering Wheel is in Straight Ahead Position

DOES THE CORNERING LIGHT SWITCH OPERATE SMOOTHLY?

NO REPAIR OR REPLACE THE CORNERING LIGHT SWITCH (COMBINATION SWITCH)

N8A0131E

CAB AND CHASSIS ELECTRICAL


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

8-109

IS THE REAR FOG LIGHT BULB NORMAL?

YES IS THE FUSE F-14 (10A) NORMAL?

NO REPLACE THE BULB

YES IS J-9 GROUNDED SECURELY?

NO REPLACE THE FUSE

YES IS THE REAR FOG LIGHT RELAY NORMAL?

NO GROUND IT SECURELY

YES

NO REPAIR OR REPLACE THE RELAY

DISCONNECT THE REAR FOG LIGHT SWITCH CONNECTOR IS THERE ANY CONTINUITY BETWEEN THE SWITCH CONNECTORS 1 B-70 AND 14 B-70 WHEN THE SWITCH IS ON?

YES

NO REPAIR OR REPLACE THE SWITCH

RECONNECT THE RELAYS AND REAR FOG LIGHT SWITCH CONNECTOR IS THERE A BATTERY VOLTAGE APPLIED BETWEEN SWITCH HARNESS SIDE CONNECTOR 1 B-70 AND GROUND WHEN REAR FOG LIGHT SWITCH IS ON?

YES

NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 5 X-3 AND 1 B-70

CONTINUED ON THE FOLLOWING PAGE

N8B5033E

8-110 CAB AND CHASSIS ELECTRICAL

CONTINUED FROM THE PREVIOUS PAGE

SET THE REAR FOG LIGHT SWITCH TO ON POSITION IS THERE BATTERY VOLTAGE APPLIED BOTH BETWEEN REAR FOG LIGHT RELAY HARNESS SIDE CONNECTOR 2 X-16 (OR 5 X-16 ) AND GROUND?

YES DISCONNECT THE REAR FOG LIGHT CONNECTOR IS THERE A BATTERY VOLTAGE APPLIED BETWEEN REAR FOG LIGHT HARNESS SIDE CONNECTOR 1 R-12 (OR 1 R-13 ) AND GROUND WHEN REAR FOG LIGHT SWITCH IS ON?

NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN F-14 (10A) AND 2 X-16 , 14 B-70 AND 5 X-16

YES REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 2 R-12 (OR 2 R-13 ) AND J-9 (GROUND)

NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 1 R-12 (OR 1 R-13 ) AND 1 X-16

N8B5147E

Starter Switch
Refer to START AND CHARGING in this section.

High Beam Indicator Light


Refer to METER AND WARNING/INDICATOR LIGHT in this section.
1 2 3

Headlight Bulb Replacement


Removal 1. Remove the battery ground cable at the battery. 2. Remove the headlight assembly. (Refer to Headlight Replacement below.) 3. Remove the headlight bulb. Remove the dust cover (3). Remove the clip (1). Remove the headlight bulb (2). Caution: Do not touch the glass portion of the bulb with your fingers.
N8A5468E

Installation 1. Install the headlight bulb. Set the headlight bulb (2). Fix the headlight bulb with clip (1). Install the dust cover (3). 2. Install the headlight assembly. (Refer to Headlight Replacement below.) 3. Connect the battery ground cable at the battery. 4. Check if the light lights.

CAB AND CHASSIS ELECTRICAL

8-111

Remove the front combination light connector. 4. Remove the front grille (4). Remove the bolt at the center of the front grille. Remove the four clips securing the front grille.
1 2 3

The grille is secured by 4 clips (2 clips at the inside of each headlight). Pull the grille toward you to remove it. 5. Remove the front corner panel. 6. Remove the headlight (1). Remove the four bolts securing the headlight (loosen the fixing bolts at the bottom of the front side panel to create working space). Remove the headlight clips. Remove the headlight connector.
N8A5468E

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

Headlight Replacement
Removal Preparation: Disconnect the battery ground cable. 1. Remove the battery ground cable at the battery. 2. Remove the seal rubber (3). Remove the seal rubber from beneath the headlight. 3. Remove the front combination light (2). Open the cab door. Insert a screwdriver (1) into the space between the cab and the cab door. Use the screwdriver to force out the stud pin at the center of the grommet (the pin securing the front combination light).

4
N8A5472E

Installation 1. Assemble the headlight assembly (1). Connect the connector. Fix it to body panel with four bolts (5). 2. Assemble the front panel side. (Refer to DOOR in section 2.) 3. Install the front grille (4). 4. Install the front combination assembly (2). 1) Position it by aligning two pawls with the groove of H/L. 2) Fit the iron PIN in the upper portion by aligning it with the center of corresponding grommet. Notice: Push it into securely with a force of approx. 250 N (25 kgf) until click is heard.

Door side

Cab side

1
N8A5471E

Remove the fixing screw. Remove the two catches.

3) Pull the front combination light assembly lightly toward the front of vehicle to make sure that the PIN and grommet are engaged securely. 4) Tighten one bolt (6) in the lower portion of front combination light assembly. 5) Hook the seal rubber (3) on two projections under H/L.

8-112 CAB AND CHASSIS ELECTRICAL


5. Connect the battery ground cable. 6. Check the operation and lighting of each lamp.
1 2

6 3

5 4
N8A0441E

N8A5474E

Horizontal Adjustment
Insert the tip of a screwdriver into the hole beneath the headlight (the shaft of the screwdriver must be slanted up) until contact is made with the head of the adjusting screw. Turn the screw to adjust headlight focus to the left or right.

Aiming of Headlight
Preparation: Place the unloaded vehicle on a level surface and check to see if the inflation pressure of the tires is correct, the lenses are clean, and the battery is sufficiently charged. Adjust the aim with the headlight tester. When adjusting, follow the procedure of the tester manufacturers.

N8A5475E

N8A5473E

Vertical Adjustment
Insert the tip of a screwdriver into the hole beneath the headlight (the shaft of the screwdriver must be slanted up) until contact is made with the head of the adjusting screw. Turn the screw to adjust headlight focus up or down. Two vertical aim screws should be turned in the same direction at the same time to adjust aiming.

CAB AND CHASSIS ELECTRICAL


Cornering Light Bulb Replacement
Removal 1. Remove the battery ground cable at the battery. 2. Remove the front combination light. Open the cab door. Insert a screwdriver (1) into the space between the cab and the cab door. Use the screwdriver to force out the stud pin at the center of the grommet (the pin securing the front combination light). Installation 1. Install the cornering / clearance bulb.

8-113

While pressing the bulb (2), turn it clockwise to fit. Notice: Do not let the glass portion dirty with sebum etc. Turn the bulb socket (3) clockwise to fit.

Door side

Cab side 3

2 1
N8A5471E N8A0442E

Remove the fixing screw. Remove the two catches. Remove the front combination light (1) connector.

2. Installation procedure of front combination light assembly Connect the connector of the front combination light assembly. Position it by aligning two pawls with the groove of H/L. Fit the iron PIN (1) in the upper portion of the side by aligning it with the center of corresponding grommet. Notice: Push it into securely with a force of approx. 250 N (25 kgf) until click is heard.

3 1

Pull the front combination light assembly lightly toward the front of vehicle to make sure that the PIN and grommet are engaged securely. Tighten one bolt in the lower portion of front combination light assembly. 3. Hook the seal rubber on two projections under H/L. 4. Connect the battery ground cable. 5. Check lighting of each light.
N8A5477E

3. Remove the cornering light bulb. Turn the cornering / clearance bulb socket (3) to the left to remove it. Press the bulb (2) in and turn it to the left to remove it from the socket.

8-114 CAB AND CHASSIS ELECTRICAL


Fog Light Bulb
Notice: The configuration of the fog light assembly is different in each manufacturer. Removal 1. Remove the battery ground cable at the battery. 2. Remove the screws (1). 3. Remove the cover which holds fog light assembly. (If equipped) 4. Remove the connector (3). 5. Remove the fog light assembly (2). Installation 1. Install the fog light bulb. Set the fog light bulb (2). Hook the clip (1) to secure fog light bulb. Install the back cover. (If equipped)

N8A0443E

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

Hold the fog light (2) with right and left covers (1) and secure it with screws (3). (If equipped)
N8A5478E

Notice: Make sure that TOP mark on the lens comes upside. 4. Connect the battery ground cable. 5. Check lighting.

6. Bulb Remove the back cover. (If equipped) Push the clip (1) inward as arrow to remove. Remove the bulb (2).

1 2 4 2 3
N8A0444E

N8A5479E

CAB AND CHASSIS ELECTRICAL


Fog Light Switch
Inspection Check the continuity between the connector terminals while operating the switch. Replace the switch when the result of inspection is found abnormal.

8-115

or

B-87

2
Terminal SW No. position ON OFF 3 6 2 5

N8B5134E

Removal Preparation: Disconnect the battery ground cable. 1. Meter Cluster Refer to METER AND WARNING/INDICATOR LIGHT in this section. 2. Fog Light Switch Release the lock pushing the switch from the back side of the meter cluster.

N8B5138E

Installation To install, follow the removal steps in the reverse order.

8-116 CAB AND CHASSIS ELECTRICAL


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

Terminal No. SW position

10

11

12

13

14

Lighting SW

REAR FOG SW OFF High beam Passing Turning left

Cornering light SW

Neutral Turning right

N8A0143E

Removal Preparation: Disconnect the battery ground cable. 1. Horn Pad 1) Hold the horn pad and pull it upward. 2. Steering Wheel 1) Remove the steering shaft nut. 2) Remove the steering wheel by using steering wheel remover. (Refer to Section 3B4 STEERING COLUMN for steering wheel removal steps.) 3. Steering Cowl Remove the four screws.

4. Combination Switch 1) Remove the four screws. 2) Disconnect the connector.

CAB AND CHASSIS ELECTRICAL


Operation of The Circuit
Notice: Arrow marks indicate the direction of current.

8-117

1. When headlight leveling SW is turned to 1 position


STARTER SW "ON"

IG SW

FUSE Converter DC-DC HEADLIGHT LEVELING RESISTOR

N8A0144E
4 3 2 1 0

Installation To install, follow the removal steps in the reverse order, noting the following point. 1. Tighten the steering shaft nut to the specified torque. Tighten: Shaft nut to 49 Nm (5 kgfm / 36 lbfft)

HEADLIGHT LEVELING SW

HEADLIGHT LEVELING ACTUATOR - LH

HEADLIGHT LEVELING ACTUATOR - RH

N8B5119E

Headlight Leveling
General Description
The circuit consists of starter SW, headlight leveling SW and headlight leveling actuator. When the headlight leveling SW is operated with the starter SW at ON position, the actuator is operated to change the angle of the optical axis of the headlight.

2. When headlight leveling SW is turned to 0 position


STARTER SW "ON"

IG SW

FUSE Converter DC-DC HEADLIGHT LEVELING RESISTOR

HEADLIGHT LEVELING SW

HEADLIGHT LEVELING ACTUATOR - LH

HEADLIGHT LEVELING ACTUATOR - RH

N8B5120E

Parts Location

RELAY BOX ASM (No.1) X-11 KEY ON RELAY B-421 HEADLIGHT LEVELING RESISTOR B-420 DC-DC CONVERTER STARTER SW B-156 HEADLIGHT LEVELING SWITCH P-5

8-118 CAB AND CHASSIS ELECTRICAL

FUSE BOX ASM F-12

B-7 P-1 P-2 BATTERY P-3 P-4

B-152 HEADLIGHT H-7 LEVELING ACTUATOR (RH) B-155 HEADLIGHT LEVELING ACTUATOR (LH) B-67 RELAY BOX ASM FL-1,FL-2 FUSIBLE LINK

B-1

N8B0032E

(FOR 4JJ1)

2L 8W/B

ACG B

(FOR 4HK1)

2L 8W/B

8B

FL-1 100A or 120A MAIN

Circuit Diagram

FUSE BLOCK STARTER SWITCH


ACC

P-1

P-2

FL-2 40A KEY SW

3W/L
H-7 ON B-67 ST 3 1 B-67 2

3W/L 3W/L

0.5B
4 1 X-11 X-11

P-3

P-4

3B/Y

RELAY; KEY ON
X-11 2 5 X-11

2B 3B/Y

P-5

FRAME

F-12

3L 0.5L/O
1 6

10A H/LAMP LEVEL B-420 B-420

0.5B

CONVERTER; DC-DC(HLL)

B-420 B-420

3 0.5B/W 2 0.5R/W

0.5R/W 0.5B/W

H/L LEVELING SWITCH


B-156 4 3 B-156 2 10

R1

0.5O/G

B-421 R2 9

B-421

1 0.5R/W

0.5B/W

0.5B/W

0.5R/W

0.5R/W

1.25B(Except NKR)/0.85B(NKR)

B-7 B-155 B-155 B-155

CAB AND CHASSIS ELECTRICAL

HEADLIGHT FRAME-LH (FRONT) BRACKET (LH)

3B 0.5R/Y
4 B-156

0.5O/B

3 B-421 R3 B-156 8

0.5O/W

B-421 R4 1 0 B-156 6 B-156 7

RESISTOR; H/L LEVELING

0.5R/Y

0.5R/Y

0.5O/L

B-421 R5 R6

5B
3 1 2

B-1

0.5O

B-152

B-152

B-152

B-421

B-421

14 0.5B/W

ACTUATOR; HLL (RH) (AS SIDE HEAD LAMP)

ACTUATOR; HLL (LH) (DR SIDE HEAD LAMP)

N8B0033E

8-119

8-120 CAB AND CHASSIS ELECTRICAL


Connector List
No. Connector Face No. Connector Face

B-1
000-001

P-1
000-022

B-7
000-001

P-2
000-014

B-67

P-3
1 3 2 4
004-001 000-014

B-67

2 4

1 3

P-4
000-014

004-002

B-152

1 2 3
003-016

P-5
000-002

B-155

1 2 3
003-016

B-420

1 4

2 5

3 6

006-019

B-156

1 2 5 6 7 8

3 4 9 10

B-421

1 2 3 7 8 9 10

4 5 6 11 12 13 14

010-002

014-002

X-11

1 2 3 5 4

005-001

CAB AND CHASSIS ELECTRICAL


H-7

8-121

H-6

H-7

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 H-8

4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14

N8A5489E

Diagnosis
Quick Chart for Check Points Check point Fuse F-12 (10 A) 1. Both actuators inoperative Trouble mode 2. Actuator on the left (right) side inoperative 3. When leveling SW is turned to a certain position, actuator inoperative (1) (2) (1) DC-DC converter (2) Headlight leveling resistor (3) Headlight leveling switch (4) (1) (3) Headlight leveling actuator Cable harness (5) (2) (4)

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

8-122 CAB AND CHASSIS ELECTRICAL


1. Both Actuators Inoperative
IS THE FUSE F-12 (10A) NORMAL?

YES IS B-7 GROUNDED SECURELY?

NO REPLACE THE FUSE

YES

NO GROUND IT SECURELY

TURN THE STARTER SW TO ON POSITION IS THE BATTERY VOLTAGE APPLIED BETWEEN THE FUSE TERMINAL AND THE GROUND?

YES IS THE DC-DC CONVERTER NORMAL?

NO REPAIR AN OPEN CIRCUIT BETWEEN STARTER SW AND FUSE F-12 (10A)

YES IS THE HEADLIGHT LEVELING RESISTOR NORMAL?

NO REPLACE THE DC-DC CONVERTER

YES IS THERE CONTINUITY BETWEEN HEADLIGHT LEVELING RESISTOR AND THE HEADLIGHT LEVELING SWITCH?

NO REPLACE THE HEADLIGHT LEVELING RESISTOR

YES IS THE CONTINUITY IN THE HEADLIGHT LEVELING SW NORMAL?

NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN THE CIRCUITS

YES IS THERE CONTINUITY BETWEEN 4 B-156 AND 2 B-152 (OR 2 B-155 )?

NO REPAIR OR REPLACE THE SWITCH

YES REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 3 B-420 AND 1 B-152 (OR 1 B-155 ), 2 B-420 AND 2 B-152 (OR 2 B-155 )

NO

REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN THE CIRCUITS
N8B0089E

CAB AND CHASSIS ELECTRICAL


2. Actuator on the Left (Right) Side Inoperative

8-123

IS THE ACTUATOR ON THE LEFT (RIGHT) SIDE NORMAL?

YES IS THERE CONTINUITY BETWEEN 4 B-156 AND 2 B-152 (OR 2 B-155 )?

NO REPLACE THE ACTUATOR

YES REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 3 B-420 AND 1 B-152 (OR 1 B-155 ), 2 B-420 AND 2 B-152 (OR 2 B-155 )

NO

REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN THE CIRCUITS

N8B0091E

8-124 CAB AND CHASSIS ELECTRICAL


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

IS THE HEADLIGHT LEVELING RESISTOR NORMAL?

YES IS THERE CONTINUITY BETWEEN HEADLIGHT LEVELING RESISTOR AND THE HEADLIGHT LEVELING SWITCH?

NO REPLACE THE HEADLIGHT LEVELING RESISTOR

YES IS THE CONTINUITY IN THE HEADLIGHT LEVELING SW NORMAL?

NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN THE CIRCUITS

YES IS THE ACTUATOR ON THE RIGHT (LEFT) SIDE NORMAL?

NO REPAIR OR REPLACE THE SWITCH

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

NO REPLACE THE ACTUATOR

N8B0092E

Inspect and repair the circuit that is corresponding to the headlight leveling switch position where the actuator becomes inoperative. Actuator - LH Headlight leveling SW position 0 1 2 3 4 Circuit Between 6 B-156 and 2 B-155 Between 7 B-156 and 2 B-155 Between 8 B-156 and 2 B-155 Between 9 B-156 and 2 B-155 Between 10 B-156 and 2 B-155

Actuator - RH Headlight leveling SW position 0 1 2 3 4 Circuit Between 6 B-156 and 2 B-152 Between 7 B-156 and 2 B-152 Between 8 B-156 and 2 B-152 Between 9 B-156 and 2 B-152 Between 10 B-156 and 2 B-152

Starter Switch
Refer to START AND CHARGING in this manual.

Headlight Leveling Switch


Inspection Check the continuity between the switch connector terminals.

CAB AND CHASSIS ELECTRICAL


Repair or replace the switch when the result of inspection is found abnormal.

8-125

B-156

4 3 10 9 8 7

2 1 6 5

Switch side

If the power supply is not 12 V, the SIGNAL output varies in proportion to its voltage. 2. Connect the connector of actuator and vehicle harness connector. Make sure that the reflector of headlight moves to the position indicated by HEAD LAMP LEVELING SW.

Terminal No. SW position 0 4 6 7 8 9 10

B-152 B-155
2

1 2 3

Actuator side

N8B5121E

Removal Preparation: Disconnect the battery ground cable. 1. Switch Bezel 2. Headlight Leveling Switch Disconnect the connector. SIGNAL

N8A0154E

2 + Input signal voltage ratio for SIGNAL when the voltage difference between positive and negative is specified as 100%

Position 0 Position 1 Position 2 Position 3 Position 4

10.0% (1.2 V) 23.4% (2.8 V) 36.7% (4.4 V) 50.0% (6.0 V) 63.4% (7.6 V)

0V 0V 0V 0V 0V

12 V 12 V 12 V 12 V 12 V

N8A5175E

Installation To install, follow the removal steps in the reverse order.

HEAD LAMP POSITION

Headlight Leveling Actuator


Inspection This actuator has a mechanism that the angle of head light leveling varies according to input voltage of SIGNAL. 1. Make sure that the voltage specified in table is output to vehicle harness connector which will be connected to actuator.

Caution: 1. For vehicles with 12 V and 24 V, this leveling input voltage is 12 V. 2. Input to SIGNAL must be less than 65% of the input voltage to positive terminal.

8-126 CAB AND CHASSIS ELECTRICAL Clearance Light, Taillight, License Plate Light and Illumination Light
General Description
The circuit consists of the lighting switch, clearance light, taillight, license plate light and the illumination light for each of switch, meter and ashtray. All these lights come on when the lighting switch is turned on with the switch to either clearance or headlight position.

Lighting Circuit

N8A0156E

Parts Location

L-34 ROOF MARKER LIGHT (RH) (FOR EC / TURKEY N2 CATEGORY ONLY) LIGHTING SW B-87 FOG LIGHT SW B-46 ASHTRAY B-17 DIODE B-18 DIODE B-33 HEATER BEZEL SW

L-33 ROOF MARKER LIGHT (LH) (FOR EC / TURKEY N2 CATEGORY ONLY)

FUSE & RELAY BOX ASM F-7 FUSE X-4 TAIL RELAY

B-501 DIODE H-14

B-28

B-7

B-1 B-335 B-52 METER B-51 METER B-31 ENGINE WARM UP SW F-25 X-22 H-10 B-5

H-5, H-6

CAB AND CHASSIS ELECTRICAL

B-86 DOME LIGHT SW

N8B0034E

8-127

8-128 CAB AND CHASSIS ELECTRICAL


Circuit Diagram
(Except EC) CORNERING LIGHT SWITCH (9) (COMBINATION SWITCH) 0.85LG/R CLEARANCE LIGHT (RH) B-74 3

B-74

0.85B

B-5

0.85LG/R

H-14

H-16

7 H-16

1.25B 2B 3B 2B 1.25B 0.85B (NKR only) 2B 5B B-7 J-9 FRAME-LH (FRONT) B-1 3B 2B HEADLIGHT BRACKET (LH) FRAME-LH (CENTER) 2B 1.25B

LICENSE PLATE LIGHT H-14 H-16 1 R-3 Except NKR85 (CHILE/TAIWAN) H-5 R-2 0.85LG/R 0.5LG/R 0.5LG/R 0.5LG/R 0.5B 1 5 5 5

7 H-14

H-5

R-1 6

1 R-1

0.85LG/R

0.5G/R

0.5G/R

TAILLIGHT-LH (REAR COMBINATION LIGHT) 0.5LG/R 1.25B

R-6 6

1 R-6

TAILLIGHT-RH (REAR COMBINATION LIGHT) 0.5LG/R 1.25B

B-5

0.85LG/R

(Except EC) CORNERING LIGHT SWITCH (11) (COMBINATION SWITCH)

CLEARANCE LIGHT (LH) 3 B-5

B-74

0.85B

1.25B

MARKER LIGHT

0.5LG/R
RELAY: MARKER LIGHT MARKER LIGHT

X-22

J-24

X-22

3W/B

2LG/W

X-22

X-22

0.5B

ASH TRAY ILLUMINATION B-46 B-46 0.5LG/R 1 0.3B 2

HEATER BEZEL B-33 B-33 0.5LG/R 1 0.3B 2

RADIO 10 B-28 B-28 0.5LG/R 0.5B 9

(NKR85 only)

ILLUMINATION LIGHT (METER) 17 B-51 B-51 0.5LG/R 0.5B 15

TAILLIGHT

0.85LG/R

10A

CIGAR LIGHTER B-43 B-43 0.5LG/R 1 0.3B 2

RELAY; TAIL X-4


3W/B 3W/B

H-6

X-4

X-4

8W/B

5W/B

2W/B

X-4

3W

F-7

B-495

B-495

(EC only) NKR85 (CHILE) only 3 DIODE RELAY; DIMMER (5) B-501 2

DPD REGENERATE SWITCH 0.85LG/R 2 5

Except NKR (CHILE) 0.5B

B-501

J-25

1.25LG/B

0.85B

ENG. WARM SWITCH B-31 B-31 0.5LG/R 2

EC only 0.5B

DIODE B-17 B-17 0.3R 3 2

FOG LIGHT & ROOM LIGHT SWITCH B-87 B-87 0.85LG/R 2 0.5B 5

RELAY; HEADLIGHT (5)

0.3L/R 0.3R (EC only)

8W/B

0.3G/O

10 0.3R/L

0.3R

TACHO GRAPH (METER) 0.5LG/R 4 6 B-70 B-335 B-335

EC only 0.5B

B-70

B-70

FL-1 100A or 120A

B-70

B-70

HAZARD SWITCH PASS Hu B-30 B-30 0.5LG/R 8 H T 0.3B 7 E

MAIN

LIGHTING SWITCH

HIGH PASS

(NKR85 only)

1.25B
0.5LG/R

OFF

LO

1 L-33

L-33 2

2L

H-10

0.5R/G

0.5B

COMBINATION SWITCH FRAME

1 L-34

P-1

P-2

P-3

P-4

P-5

NPR / NQR (EC)

L-34 2

0.5R/G

0.5B

ROOF MARKER LIGHT (RH)

H-10

0.5B

ROOF MARKER LIGHT (LH)

3B

N8B0035E

1.25B (NPR85/NKR85)

F-25

15A

CAB AND CHASSIS ELECTRICAL


Connector List
No. Connector Face No. Connector Face

8-129

B-1
000-001

B-33
1 2
002-022

B-5

1 3

2 4
004-012

B-33

2 1
002-023

B-5

2 1 4 3
004-013

B-43

1 2
002-009

B-7
000-001

B-43

1 2
002-010

B-17

B-46
1 2 3 4 1 2
004-004 002-022

B-28

1 7

2 8

3 9 10

B-46

11 12 13

2 1
002-023

013-001

B-30

B-51
1 5 2 6 3 7 4 8

008-005

020-004

B-31

B-70
1 4 2 5 3 6

1 2 3 7 8 9 10

4 5 6 11 12 13 14

006-001

014-002

8-130 CAB AND CHASSIS ELECTRICAL


No. Connector Face No. Connector Face

B-70

6 5 4 14 13 12 11

3 2 1 10 9 8 7

H-10
014-003

3 4 5 6
006-029

B-74

1 3

2 4
004-012

H-14 (With ABS)

1 5 6

2 7

3 8

4 9

10 11 12 13 14 15 16

016-003

B-74

2 1 4 3
004-013

H-14 (With ABS)

4 9 8

3 7

2 6

1 5

14 13 12 11 10

16

15

016-004

B-87

1 2 4 5

3 6
006-028

H-14 (Without ABS)

1 5

2 6

3 7

4 8
008-003

B-335

1 2 3 4

5 6 7 8 008-014

H-14 (Without ABS)

4 8

3 7

2 6

1 5
000-011 008-004

B-495
006-022

H-16

1 5

2 6

3 7

4 8
008-003

B-501

1 2 3 4

H-16
004-004

4 8

3 7

2 6

1 5
000-011 008-004

H-10

6 5 4 3

J-9
006-003 000-001

CAB AND CHASSIS ELECTRICAL


No. Connector Face No. Connector Face

8-131

J-24
000-010

P-1
000-022

J-24
000-011

P-4
000-014

J-25
000-010

P-2
000-014

J-25
000-011

P-3
000-014

L-33

2 1
002-054

P-5
000-002

L-33

1 2
002-055

R-1

1 4

2 5

3 6

006-004

L-34

2 1
002-054

R-1

3 6

2 5

1 4
006-005

L-34

1 2
002-055

R-2
000-011

8-132 CAB AND CHASSIS ELECTRICAL


No. Connector Face H-5

R-2
000-010

R-3
000-011

1 7 13 19 25 31

2 8 14 20 26 32

3 9 15 21 27 33

34

35

36

37

4 10 16 22 28 38

5 11 17 23 29 39

6 12 18 24 30 40

6 12 18 24 30 40

5 11 17 23 29 39

4 10 16 22 28 38

37

36

35

34

3 9 15 21 27 33

2 8 14 20 26 32

1 7 13 19 25 31

R-3
000-010

N8A5488E

H-6

R-6

1 4

2 5

3 6

006-004

H-6

H-7

R-6

3 6

2 5

1 4
006-005

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 H-8

4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14

X-4
005-006

N8A5489E

X-22
005-006

CAB AND CHASSIS ELECTRICAL


Diagnosis
Quick Chart for Check Point Check point Fuse F-7 (10 A) 1. Both clearance lights inoperative 2. Clearance light on the left (or right) side inoperative Trouble mode 3. Both taillights inoperative 4. Taillight on the left (or right) side inoperative 5. License plate light inoperative 6. Marker light inoperative (2) (1) (3) (1) (1) (3) (2) F-25 (15 A) Ligh ting SW Taillight bulb Tail light relay Clearance light bulb (1) (1) License plate light bulb Marker light relay Cable harness (2) (2) (4) (2) (2) (4)

8-133

Marker light bulb

(1)

Notice: Figure in parenthesis ( ) indicates the order of inspection. 1. Both Clearance Lights Inoperative
ARE BOTH TAILLIGHTS OPERATIVE?

YES IS THE CLEARANCE LIGHT BULB NORMAL?

NO TURN TAILLIGHTS ON (REFER TO TAILLIGHT DIAGNOSIS IN THIS SECTION) NO REPLACE THE BULB

YES IS B-7 SECURELY GROUNDED?

YES TURN THE LIGHTING SWITCH TO OR POSITION IS THERE BATTERY VOLTAGE APPLIED TO CLEARANCE LIGHT CONNECTOR 4 B-5 (OR 4 B-74 ) AND GROUND?

NO GROUND IT SECURELY

YES

NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN FUSE F-7 (10A) AND 4 B-5 (OR 4 B-74 )
N8B5148E

REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN CLEARANCE LIGHT CONNECTOR TERMINALS 1 B-5 (OR 1 B-74 ) AND B-7

8-134 CAB AND CHASSIS ELECTRICAL


Notice: Figure in parenthesis ( ) indicates place of inspection for clearance light on the right side. 2. Clearance Light on the Left (or Right) Side Inoperative

N8B5149E

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

CAB AND CHASSIS ELECTRICAL


3. Both Taillights Inoperative

8-135

IS THE FUSE F-7 (10A) NORMAL?

YES IS J-9 SECURELY GROUNDED?

NO REPLACE THE FUSE

YES IS THE TAIL RELAY NORMAL?

NO GROUND IT SECURELY

YES IS THE LIGHTING SWITCH NORMAL?

NO REPLACE THE RELAY

YES

NO REPAIR OR REPLACE THE LIGHTING SWITCH

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

YES TURN THE LIGHTING SWITCH TO OR POSITION IS THERE BATTERY VOLTAGE APPLIED TO 4 H-16 AND GROUND?

NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN THE HARNESS SIDE CONNECTOR 5 X-4 AND 8 B-70

YES

NO

REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN LIGHTING SWITCH HARNESS SIDE CONNECTORS 7 H-16 AND J-9

REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN TAILLIGHT RELAY CONNECTORS 1 X-4 AND 4 H-16

N8B0082E

8-136 CAB AND CHASSIS ELECTRICAL


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

IS TAILLIGHT BULB ON THE LEFT (OR RIGHT) SIDE NORMAL?

YES REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN CONNECTOR TERMINAL 4 H-16 AND TAILLIGHT CONNECTOR 1 R-1 ( 1 R-6 )

NO REPLACE THE BULB

N8A0163E

Notice: Figure in parenthesis ( ) indicates place of inspection for taillight on the right side. 5. License Plate Light Inoperative

ARE BOTH TAILLIGHTS OPERATIVE?

YES IS THE LICENSE PLATE LIGHT BULB NORMAL?

NO TURN THE TAILLIGHTS ON (REFER TO TAILLIGHT DIAGNOSIS IN THIS SECTION)

YES IS THERE BATTERY VOLTAGE APPLIED BETWEEN 1 R-3 AND THE GROUND WHEN TURNING THE LIGHTING SWITCH ON?

NO REPLACE THE BULB

YES REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 1 R-2 AND 7 H-16

NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT IN THE CIRCUIT

N8B5107E

CAB AND CHASSIS ELECTRICAL


6. Marker Light Inoperative

8-137

N8B5151E

Lighting Switch
Refer to HEADLIGHT, FOG LIGHT, REAR FOG LIGHT AND CORNERING LIGHT in this section.

Clearance Light Bulb


Removal 1. Remove the battery ground cable at the battery. 2. Remove the front combination light. Open the cab door. Insert a screwdriver (1) into the space between the cab and the cab door. Use the screwdriver to force out the stud pin at the center of the grommet (the pin securing the front combination light).
Door side Cab side

1
N8A5471E

Remove the fixing screw.

8-138 CAB AND CHASSIS ELECTRICAL


Remove the two catches. Remove the front combination light (1) connector. Position it by aligning two pawls with the groove of H/L. Fit the iron PIN (1) in the upper portion of the side by aligning it with the center of corresponding grommet. Notice: Push it into securely with a force of approx. 250 N (25 kgf) until click is heard. Pull the front combination light assembly lightly toward the front of vehicle to make sure that the PIN and grommet are engaged securely.
3 1

Tighten one bolt in the lower portion of front combination light assembly. 3. Hook the seal rubber on two projections under H/L. 4. Connect the battery ground cable. 5. Check lighting of each light.

Taillight Bulb
2
N8A5477E

3. Remove the clearance light bulb. Turn the bulb socket (3) to the left to remove it. Press the bulb (2) in and turn it to the left to remove it from the socket. Installation Installation procedure of cornering/clearance light bulb 1. Install the cornering/clearance light bulb. While pressing the bulb (2), turn it clockwise to fit. Notice: Do not let the glass portion dirty with sebum etc. Turn the bulb socket (3) clockwise to fit.

Removal 1. Lens 2. Bulb

1
N8A0167E

Installation To install, follow the removal steps in the reverse order.


3

2
N8A0442E

2. Installation procedure of front combination light assembly Connect the connector of the combination light assembly.

CAB AND CHASSIS ELECTRICAL


License Plate Light Bulb
Removal 1. Cover 2. Lens 3. Bulb

8-139

Installation Follow the removal procedure in the reverse order.

Turn Signal Light, Hazard Warning Light and Stoplight


General Description
The circuit consists of the starter switch, turn signal light (front and rear), turn signal light switch, hazard warning light, flasher unit, stoplight and stoplight switch. When turning on the respective switches with the starter switch on, the turn signal light will operate. When the turn signal light is flashing, the indicator light in the meter also starts flashing. When the hazard warning switch is turned on, the current flows to the flasher unit through the hazard warning switch to cause the hazard warning light to flash, independent of the position of the starter switch. At the same time, the indicator lights in the meter also start flashing. The stoplight switch will turn on and the light comes on once the brake pedal is depressed, independent of the position of the starter switch.
N8A0168E

Installation To install, follow the removal steps in the reverse order.

Roof Marker Light


Removal Preparation : Disconnect the battery ground cable. 1. Lens 2. Bulb

1 2

N8B5128E

Legend 1. Lens 2. Bulb 3. Base with Gasket

RELAY BOX ASM (No.1) X-11 ON RELAY B-30 HAZARD WARNING SW TURN SIGNAL / CORNERING LIGHT SW STARTER SW

Parts Location

FUSE & RELAY BOX ASM F-4, F-5, F-7, F-11, F-20 FUSE

B-16 FLASHER UNIT

J-104 R-6 STOPLIGHT (RH) SIDE TURN SIGNAL LIGHT (RH) R-1 STOPLIGHT (LH) (FOR EC N2 CATEGORY S/CAB ONLY) H-16

8-140 CAB AND CHASSIS ELECTRICAL

H-22

H-14 P-5 P-1 P-2 BATTERY P-3 P-4 J-9 RELAY BOX ASM

D-20 SIDE TURN SIGNAL LIGHT (RH) (FOR EC N2 CATEGORY W/CAB ONLY)

J-103 SIDE TURN SIGNAL LIGHT (LH) (FOR EC N2 CATEGORY S/CAB ONLY)

B-7

B-74 FRONT COMBINATION LIGHT (RH) B-1 B-67 H-20

FL-1, FL-2 FUSIBLE LINK B-51 TURN SIGNAL INDICATOR LIGHT (LH) (METER) B-52 TURN SIGNAL INDICATOR LIGHT (RH) (METER)

H5 - H7 B-66 STOPLIGHT SW

D-21 SIDE TURN SIGNAL LIGHT (LH) (FOR EC N2 CATEGORY W/CAB ONLY) B-5 FRONT COMBINATION LIGHT (LH)

N8B0036E

CAB AND CHASSIS ELECTRICAL


Circuit Diagram
11

8-141

B-66

B-66

H-14

H-16

2 R-6

H-5

H-5

0.85R F-4 15A

0.85R

0.85R

28

STOPLIGHT (LH)

AUDIO (B), DOOR LOCK SIDE TURN SIGNAL LIGHT (RH) (S/CAB)
J-104 J-104 1

(S/CAB EC ONLY)

0.5B

0.5LG/W 0.5G/W (NKR85(INDP))

0.5B

3W/B

F-20 15A HORN, HAZARD

RELAY: ON
X-11

J-103

J-103 1

0.5G/B

0.5B (Except NKR85(INDP))

3W/B

X-11

3B/Y
2

3B/Y

X-11

X-11

F-11 10A 0.5Y/R TURN LIGHT

HAZARD SWITCH

(NPR/NQR W/CAB EC ONLY)

3L
5

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

3W/L

0.5G

B-67

STARTER SWITCH

ACC

ON

B-30

ST

SIDE TURN SIGNAL LIGHT (RH) (DOOR)


4 H-20 D-20 D-20 H-20

0.5G/W

0.5B

10

0.5B

OFF

RH

B-16

B-30

0.5G/W 0.5G/B

B-67

TB

FLASHER UNIT

B-16

B-30

B-30

0.5BR
5

LH

0.5G/W

5W/B

B-30

IG

0.5LG/B
1

FU

B-30

H-6

0.85LG/R 0.5LG/R (THAI only) 0.5LG/R

B-30

B-30

0.3B
7

TURN SIGNAL INDICATOR LIGHT (RH) (METER)


B-52 B-52

3W/L

0.5G/W

0.5B

0.5BR

B-16

B-74

B-74

TURN SIGNAL LIGHT (FRONT COMBINATION LIGHT-RH) 0.85B 0.5G/W


2

3W/L

F-7 10A TAIL LIGHT

5W/B

0.85LG/R

3W

RELAY; TAIL (1)


17 H-5 H-14 8

(NPR75/NQR75)

B-70 13

H-16

3 R-6

H-7

12 B-70

LH

10 H-5

H-14

H-16

B-70 5

3 R-1

3W/L

FL-2 40A

TURN SIGNAL LIGHT SWITCH (COMBINATION SWITCH) 0.5G/B

B-5

KEY

B-5

0.85B 1.25B 1.25B (NPR/NQR) 0.85B (NKR85) 2B (NPR75/NQR75) 1.25B 1.25B FRAME-LH (CENTER)
J-9 7 H-14

8W/B

TURN SIGNAL LIGHT (FRONT COMBINATION LIGHT-LH)

FL-1 100A or 120A

MAIN

0.5G/B

TURN SIGNAL INDICATOR LIGHT (LH) (METER)

B-51

B-51

0.5G/B

15

0.5B

H-16

TURN SIGNAL LIGHT (REAR COMBINATION LIGHT-LH)

0.3B

R-1 6

0.5G/B

0.5G/B

R-6 6

0.5G/W

TURN SIGNAL LIGHT (REAR COMBINATION LIGHT-RH) 0.5G/W 1.25B

RH

20

1.25B

R-1 6

R-1

POWER SOURCE (SERVICE)

0.5G

R-6 6

3W/B

F-5 10A STOP LIGHT

STOPLIGHT SWITCH 0.5G/Y 0.5G

(Except NKR) 0.5G 0.5G 0.5G 0.5G


2 2

STOPLIGHT (RH) 1.25B

1.25B

(NPR/NQR W/CAB EC ONLY)

2L

SIDE TURN SIGNAL LIGHT (LH) (DOOR)


4 H-22 D-21 D-21 H-22

2B

5B
B-1

FRAME

P-1

P-2

P-3

P-4

P-5

FRAME-LH (FRONT)

HEADLIGHT BRACKET (LH)

B-7

3B

N8B0037E

2B

0.5G/B

0.5B 2B

0.5B

3B

2B

2B

1.25B

8-142 CAB AND CHASSIS ELECTRICAL


Connector List
No. Connector Face No. Connector Face

B-1
000-001

B-66
1 2

002-031

B-5

1 3

2 4
004-012

B-67

1 3

2 4
004-001

B-5

2 1 4 3
004-013

B-67

2 4

1 3

004-002

B-7
000-001

B-70

6 5 4 14 13 12 11

3 2 1 10 9 8 7

014-003

B-16

1 4

2 5

3 6
006-010

B-70

1 2 3 7 8 9 10

4 5 6 11 12 13 14

014-002

B-30

B-74
1 5 2 6 3 7 4 8

1 3

2 4
004-012

008-005

B-51
020-004

B-74

2 1 4 3
004-013

B-52
020-005

D-20

1 2 3
003-036

CAB AND CHASSIS ELECTRICAL


No. Connector Face No. Connector Face

8-143

D-21

1 2 3
003-036

H-20

1 2

3 4

5 6 7 8 9 10

010-003

H-14 (With ABS)

1 5 6

2 7

3 8

4 9

10 11 12 13 14 15 16

H-22
016-003

4 3

2 1

10 9 8 7 6 5

010-004

H-14 (With ABS)

4 9 8

3 7

2 6

1 5

14 13 12 11 10

H-22
016-004

1 2

3 4

5 6 7 8 9 10
16 15

010-003

H-14 (Without ABS)

1 5

2 6

3 7

4 8
008-003

J-9
000-001

H-14 (Without ABS)

4 8

3 7

2 6

1 5
008-004

J-103
000-010

H-16

1 5

2 6

3 7

4 8
008-003

J-103
000-011

H-16

4 8

3 7

2 6

1 5
008-004

J-104
000-010

H-20

4 3

2 1

10 9 8 7 6 5

J-104
010-004 000-011

8-144 CAB AND CHASSIS ELECTRICAL


No. Connector Face No. Connector Face

P-1
000-022

R-6

3 6

2 5

1 4
006-005

P-4
000-014

X-11

1 2 3 5 4

005-001

H-5 P-2
000-014

P-3
000-014

1 7 13 19 25 31

2 8 14 20 26 32

3 9 15 21 27 33

34

35

36

37

4 10 16 22 28 38

5 11 17 23 29 39

6 12 18 24 30 40

6 12 18 24 30 40

5 11 17 23 29 39

4 10 16 22 28 38

37

36

35

34

3 9 15 21 27 33

2 8 14 20 26 32

1 7 13 19 25 31

P-5
000-002

N8A5488E

H-6, H-7 R-1


1 4 2 5 3 6

006-004

H-6

R-1

3 6

2 5

1 4
006-005

H-7

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 H-8

4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14

R-6

1 4

2 5

3 6

006-004

N8A5489E

CAB AND CHASSIS ELECTRICAL


Diagnosis
Quick Chart for Check Point 1. Turn Signal Light, Hazard Warning Light Check point Fuse F-20 (15 A) 1-1. Turn signal lights inoperative Trouble mode 1-2. Turn signal lights flash too quickly 1-3. Hazard warning lights inoperative (1) (2) F-11 (10 A) (1) Turn signal light SW (4) Hazard warning light SW (2) Flasher unit (3) (1) Turn signal light bulb

8-145

Cable harness (5) (1)

Notice: Figure in parenthesis ( ) indicates the order of inspection. 2. Stoplight Check point Fuse F-5 (10 A) Trouble mode 2-1. Both stoplights inoperative 2-2. Stoplight on the left (or right) side inoperative (1) Stoplight SW (2) (1) Stoplight bulb Cable harness (3) (2)

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

8-146 CAB AND CHASSIS ELECTRICAL


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

N8A0169E

CAB AND CHASSIS ELECTRICAL

8-147

CONTINUED FROM THE PREVIOUS PAGE IS THERE ANY CONTINUITY BETWEEN THE HARNESS SIDE CONNECTORS 3 B-16 AND B-7 ?

CONTINUED FROM THE PREVIOUS PAGE GROUND IT SECURELY

YES

NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN THE CIRCUIT

DISCONNECT THE COMBINATION SWITCH CONNECTOR IS THERE ANY CONTINUITY BETWEEN THE SWITCH CONNECTORS 5 B-70 AND 12 B-70 (WHEN TURNING LEFT), 13 B-70 AND 12 B-70 (WHEN TURNING RIGHT) RESPECTIVELY?

YES REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN THE HARNESS SIDE CONNECTORS 5 B-16 AND 12 B-70

NO REPAIR OR REPLACE THE SWITCH

N8B5108E

1-2. Turn Signal Lights Flash Too Quickly

DOES ANY TURN SIGNAL LIGHT REMAIN UNLIGHTED?

YES

DISCONNECT AND REINSTALL THE BULB, OR REPLACE IT, OR REPAIR AN OPEN CIRCUIT IN THE CIRCUIT OF THE INOPERATIVE BULB, OR CHECK THE GROUND

N8A0171E

8-148 CAB AND CHASSIS ELECTRICAL


1-3. Hazard Warning Lights Inoperative

IS FUSE F-20 (15A) NORMAL?

F-20 (15A) AND

N8B5041E

2. Stoplight 2-1. Both Stoplights Inoperative

IS FUSE F-5 (10A) NORMAL?

YES IS J-9 GROUNDED SECURELY?

NO REPLACE THE FUSE

YES IS BATTERY VOLTAGE APPLIED TO 1 B-66 OF THE STOPLIGHT SW?

NO GROUND IT SECURELY

YES IS STOPLIGHT SWITCH NORMAL?

NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN THE FUSE F-5 (10A) AND 1 B-66

YES DOES THE PUSH ROD OF THE STOPLIGHT SW OPERATE SMOOTHLY?

NO REPLACE THE STOPLIGHT SW

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

NO REPLACE THE STOPLIGHT SW

N8A0173E

CAB AND CHASSIS ELECTRICAL


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

8-149

IS THERE CONTINUITY BETWEEN THE STOPLIGHT CONNECTORS 2 R-1 AND 2 H-16 ( 2 R-6 AND 2 H-16 )?

REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN THE STOPLIGHT CONNECTORS 6 R-1 AND 7 H-16 ( 6 R-6 AND 7 H-16 )
N8B5109E

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

Starter Switch
Refer to START AND CHARGING in this section.

Front Turn Signal Light Bulb


Removal 1. Remove the battery ground cable at the battery. 2. Remove the front combination light. Open the cab door. Insert a screwdriver (1) into the space between the cab and the cab door. Use the screwdriver to force out the stud pin at the center of the grommet (the pin securing the front combination light).

Remove the front combination light (1) connector. 3. Remove the front turn signal light bulb. Turn the bulb socket (2) to the left to remove it. Press the bulb (3) in and turn it to the left to remove it from the socket.

2 1

Door side

Cab side

N8A5484E

Installation 1. Install the front turn signal light bulb.


1
N8A5471E

While pressing the bulb (2), turn it clockwise to fit. Notice: Do not let the glass portion dirty with sebum etc. Turn the bulb socket (3) clockwise to fit.

Remove the fixing screw. Remove the two catches.

8-150 CAB AND CHASSIS ELECTRICAL

1 2

N8A0445E

N8A0176E

2. Installation procedure of front combination light assembly Connect the connector of the front combination light assembly. Position it by aligning two pawls with the groove of H/L. Fit the iron PIN (1) in the upper portion of the side by aligning it with the center of corresponding grommet. Notice: Push it into securely with a force of approx. 250 N (25 kgf) until click is heard. Pull the front combination light assembly lightly toward the front of vehicle to make sure that the PIN and grommet are engaged securely. Tighten one bolt in the lower portion of front combination light assembly. 3. Hook the seal rubber on two projections under H/L. 4. Connect the battery ground cable. 5. Check lighting of each light.

Installation To install, follow the removal steps in the reverse order.

Side Turn Signal Light Bulb


Removal Preparation: Disconnect the battery ground cable. 1. Lens 2. Bulb

Rear Turn Signal Light Bulb


Removal Preparation: Disconnect the battery ground cable. 1. Lens 2. Bulb
2 1

N8B5129E

Installation To install, follow the removal steps in the reverse order.

CAB AND CHASSIS ELECTRICAL


Turn Signal Light Switch (Combination Switch)
Inspection Check the continuity between the terminals of the turn signal light switch. Repair or replace the switch when the result of inspection is found abnormal.

8-151

Terminal No. SW position Turning left Turn signal light SW Neutral Turning right

11

12

13

N8A0177E

Removal and Installation


Refer to HEADLIGHT, FOG LIGHT, REAR FOG LIGHT AND CORNERING LIGHT in this section.

Flasher Unit
Inspection When a 55W bulb is connected to the unit side terminals L and E while connecting the battery (+) terminal to terminal B, and the battery () terminal to terminal E, does the bulb light on and off? Replace the unit when the result of inspection is found abnormal.

N8B5002E

Stoplight Bulb
Removal and Installation Refer to CLEARANCE LIGHT, TAILLIGHT, LICENSE PLATE LIGHT AND ILLUMINATION LIGHT for TAILLIGHT BULB removal and installation steps in this section.

8-152 CAB AND CHASSIS ELECTRICAL


Stoplight Switch
Inspection 1. Check to see if the stoplight switch is installed correctly to the specified position. Adjust the position when the result of the inspection is found abnormal. 2. Check to see if there is any continuity between the terminals of the stoplight switch. Replace the switch when the result of inspection is found abnormal. Installation To install, follow the removal steps in the reverse order, noting the following points. 1) Check to see if the brake pedal has been returned by the return spring to the specified position. 2) Turn the stoplight switch clockwise until the tip of the threaded portion of the switch contacts the pedal arm. 3) Turn the switch counterclockwise until the space between the tip of the threaded portion and the pedal arm is 0.5 to 1.0 mm (0.02 0.04 in.).

B-66
1 2

Switch side

Terminal No. SW position Depress brake pedal (Push rod out) Release brake pedal (Push rod in)

N8A0179E

Removal Preparation: Disconnect the battery ground cable. 1. Stoplight Switch 1) Disconnect the connector. 2) Loosen the lock nut of the switch. 3) Remove the switch by turning it.

N8A0181E

Hazard Warning Switch


Inspection Check the continuity between the terminals of the hazard warning switch. Repair or replace the switch when the result of inspection is found abnormal.

B-30

Terminal No. SW position

ON OFF
N8A0180E N8A0182E

CAB AND CHASSIS ELECTRICAL


Removal Preparation: Disconnect the battery ground cable. 1. Meter Cluster Refer to the METER AND WARNING/INDICATOR LIGHT in this section. 2. Hazard Warning Switch Release the lock pushing the switch from the back side of the meter cluster.

8-153

N8A0436E

Installation To install, follow the removal steps in the reverse order noting the following point. 1. Push the switch with your fingers until locks securely.

8-154 CAB AND CHASSIS ELECTRICAL Horn, Backup Light and Backup Buzzer
General Description
The circuit consists of the starter switch, horn, horn switch, backup light (Rear combination light), backup light switch, backup buzzer and the relay. When the horn switch is turned on independent of the position of the starter switch, the relay is activated to sound the horn. When the backup light switch turns on with the starter switch on, the backup light will operate. Backup Light and Backup Buzzer Circuit

N8A5216E

Parts Location

X-2 HORN RELAY STARTER SW R-6 REAR COMBINATION LIGHT (RH) (BACKUP BUZZER)

FUSE & RELAY BOX ASM F-16, F-20 FUSE J-49 BACKUP LIGHT SW

RELAY BOX ASM (No.1)

H-16

H-119

H-14

P-5 P-1 P-2 BATTERY P-3 P-4 RELAY BOX ASM (No.1) FL-1, FL-2 FUSIBLE LINK R-6 REAR COMBINATION LIGHT (LH)

H-5

H-7

J-4 HORN (RH)

B-70 J-5 HORN (LH) B-67 B-51 METER "A"

CAB AND CHASSIS ELECTRICAL

J-9 EARTH: FRAME

N8B0038E

8-155

STARTER SWITCH FL-2 40A KEY 3W/L


1 H-7 ON B-67 3 B ACC

F-16 10A 3B/Y 0.5B/Y METER B-51 (18) 3B/Y 0.5B/Y METER

3W/L 2 B-67
ST

Circuit Diagram

FL-1 100A or 120A 0.5B/Y 5W/B


H-6 H-5 22 2

2L 5W/B 3W/B 3W/B

(NPR75/NQR75 only)

8B

MAIN

8W/B

P-1

P-2

0.5B/Y F-20 15A 0.5B/Y


H-119

0.5B/Y
11 H-119

HORN, HAZARD 0.5B/Y


10

(4HK1 with Smoother)

0.5B/Y

0.5G

P-3 1 J-49

(4JJ1(EURO-4) with Smoother)

P-4

BACKUP LIGHT SWITCH

X-2

0.5G
2 X-2 5

P-5

J-49 2

FRAME
X-2 1 3 X-2

8-156 CAB AND CHASSIS ELECTRICAL

RELAY; HORN 0.3G/R

0.5R/L
9

0.5R/L 0.5R/L
H-119 H-119

(4HK1 with Smoother)


12

(4JJ1(EURO-4) with Smoother)

3 H-5

HORN (LH)

HORN SWITCH (COMBINATION SWITCH)

1.25B

1.25B

(Except NPR75/NQR75)
J-9

HORN (RH)
J-4 J-5

0.5G/W 0.5G/W
3 B-70

0.5R/L

0.5R/L

6 H-14

H-16

0.5R/L
6

0.5G/W HORN CONTACT


1 1

5 R-6

BACKUP LIGHT (REAR COMBINATION LIGHT-RH)

R-6 6

0.5R/L 0.5R/L
5 R-1

BACKUP LIGHT (REAR COMBINATION LIGHT-LH)


R-1 6

N8B0039E

FRAME-LH (CENTER)

2B

1.25B

1.25B

H-14

1.25B

H-16

CAB AND CHASSIS ELECTRICAL


Connector List
No. Connector Face No. Connector Face

8-157

X-2
005-006

J-49

2 1

002-026

B-51
020-004

H-14 (Without ABS)

1 5

2 6

3 7

4 8
008-003

B-67

1 3

2 4
004-001

H-14 (Without ABS)

4 8

3 7

2 6

1 5
008-004

B-67

2 4

1 3

H-14 (With ABS)


004-002

1 5 6

2 7

3 8

4 9

10 11 12 13 14 15 16

016-003

B-70

1 2 3 7 8 9 10

4 5 6 11 12 13 14

H-14 (With ABS)


014-002

4 9 8

3 7

2 6

1 5

14 13 12 11 10

16

15

016-004

B-70

6 5 4 14 13 12 11

3 2 1 10 9 8 7

H-16

1 5

2 6

3 7

4 8
008-003

014-003

J-9
000-001

H-16

4 8

3 7

2 6

1 5
008-004

J-49

1 2
002-025

H-119 (With Smoot her)

1 5 9

2 6

3 7

4 8

10 11 12

13 14 15 16

016-001

8-158 CAB AND CHASSIS ELECTRICAL


No. H-119 (With Smoot her) Connector Face No. Connector Face

4 8

3 7

2 6

1 5 9

12 11 10

R-1
016-002

1 4

2 5

3 6

16 15 14 13

006-004

J-4

R-1
001-018

3 6

2 5

1 4
006-005

J-5

R-6
001-018

1 4

2 5

3 6

006-004

P-1
000-022

R-6

3 6

2 5

1 4
006-005

H-5 P-4
000-014

P-2
000-014

1 7 13 19 25 31

2 8 14 20 26 32

3 9 15 21 27 33

34

35

36

37

4 10 16 22 28 38

5 11 17 23 29 39

6 12 18 24 30 40

6 12 18 24 30 40

5 11 17 23 29 39

4 10 16 22 28 38

37

36

35

34

3 9 15 21 27 33

2 8 14 20 26 32

1 7 13 19 25 31

P-3
000-014

N8A5488E

P-5
000-002

CAB AND CHASSIS ELECTRICAL


H-6, H-7

8-159

H-6

H-7

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 H-8

4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14

N8A5489E

Diagnosis
Quick Chart for Check Point 1. Horn Check point Fuse F-20 (15 A) Trouble mode 1-1. Horn does not sound 1-2. Horn does not shut off (1) Horn (6) Horn SW (4) (2) Horn relay (2) (1) Horn contact (3) Cable harness (5) (3)

Notice: Figure in parenthesis ( ) indicates the order of inspection. 2. Backup Light Check point Fuse F-16 (10 A) 2-1. Both backup lights inoperative Trouble mode 2-2. Backup light on the left (or right) side inoperative 2-3. Backup light remains on Notice: Figure in parenthesis ( ) indicates the order of inspection. (1) (1) Backup light SW (Inhibitor SW) (3) (1) Backup light bulb Backup buzzer Cable harness (2) (2)

8-160 CAB AND CHASSIS ELECTRICAL


1. Horn 1-1. Horn Does Not Sound

IS FUSE F-20 (15A) NORMAL?

YES IS THE HORN RELAY NORMAL?

NO REPLACE THE FUSE

YES IS THE HORN NORMALLY GROUNDED?

NO REPLACE THE HORN RELAY

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

NO CLEAN UP THE FITTING SURFACE AND THE GROUND FIRMLY

YES

NO CONNECT THE CONNECTOR SECURELY

DISCONNECT THE HORN SWITCH CONNECTOR IS THERE BATTERY VOLTAGE APPLIED BETWEEN 3 B-70 AND THE GROUND?

YES

NO

IS THERE ANY CONTINUITY BETWEEN THE HORN RELAY HARNESS SIDE CONNECTORS 3 H-5 AND 1 J-4 (OR 1 J-5 )?

REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT OR REPAIR A POOR CONNECTION AT THE HORN CONNECTOR

YES

NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT IN THE CIRCUIT

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

NO REPLACE THE HORN

N8B0040E

CAB AND CHASSIS ELECTRICAL


1-2. Horn Does Not Shut Off

8-161

IS THE HORN RELAY NORMAL?

YES REMOVE THE HORN SW IS THE MOVABLE PORTION OF THE HORN SW ALWAYS OUT OF CONTACT WITH THE GROUND BRACKET?

NO REPLACE THE HORN RELAY

YES REPAIR A SHORT CIRCUIT BETWEEN HORN RELAY HARNESS SIDE CONNECTORS 3 X-2 AND 3 B-70

NO REPAIR OR REPLACE THE HORN SW


N8B0041E

2. Backup Light 2-1. Backup Lights Inoperative

IS FUSE F-16 (10A) NORMAL?

YES IS J-9 SECURELY GROUNDED?

NO REPLACE THE FUSE

YES TURN THE STARTER SW ON IS THE BATTERY VOLTAGE APPLIED BETWEEN THE BACKUP LIGHT SWITCH HARNESS SIDE CONNECTOR 1 J-49 AND THE GROUND?

NO GROUND IT SECURELY

YES

NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN FUSE F-16 (10A) AND 1 J-49

ENTER THE TRANSMISSION SHIFT LEVER TO REVERSE POSITION WHEN REMOVE THE CONNECTOR OF THE BACKUP LIGHT SWITCH, IS THERE ANY CONTINUITY BETWEEN THE SW SIDE CONNECTORS 1 J-49 AND 2 J-49 ?

YES

NO REPAIR OR REPLACE THE BACKUP LIGHT SWITCH OR INHIBITOR SW

REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN THE BACKUP LIGHT SWITCH HARNESS SIDE CONNECTORS 2 J-49 AND 6 H-14 (OR 6 H-16 )

N8B5046E

8-162 CAB AND CHASSIS ELECTRICAL


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

IS THERE BATTERY VOLTAGE APPLIED BETWEEN THE BACKUP LIGHT HARNESS SIDE CONNECTOR 5 R-1 (5 R-6 ) AND 6 H-16 ?

REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN BACKUP LIGHT HARNESS SIDE CONNECTORS 6 R-1 (6 R-6 ) AND J-9

N8B5047E

2-3. Backup Light Remains On

REPAIR OR REPLACE THE BACKUP LIGHT SW OR INHIBITOR SW

N8A0191E

Starter Switch
Refer to START AND CHARGING in this section.

Horn
Inspection Check to see if horn sounds when a battery voltage is between horn terminal and the fixing bracket. Repair or replace the horn when the result of inspection is found abnormal.

N8A0192E

CAB AND CHASSIS ELECTRICAL


Removal Preparation: Disconnect the battery ground cable. 1. Bumper Refer to BUMPER in section 2. 2. Horn Disconnect the connector (3).

8-163

Removal Preparation: Disconnect the battery ground cable. 1. Horn Pad 1) Hold the horn pad and pull it upward. 2. Steering Wheel 1) Remove the steering shaft nut. 2) Remove the steering wheel by using steering wheel remover. (Refer to Section 3B4 STEERING COLUMN for steering wheel removal steps.) 3. Horn Switch

1 2 3

N8A5485E

Installation To install, follow the removal steps in the reverse order.

Horn Switch
Inspection With the contact point of the horn switch pressed to the switch bracket, check the continuity between the connector terminal and the bracket of the switch. Check the contact condition between horn contact of the combination switch and contact plate of steering wheel. Repair or replace the switch when the result of inspection is found abnormal.
N8A0476E

Installation To install, follow the removal steps in the reverse order, noting the following point. 1. Tighten the steering shaft nut to the specified torque. Tighten: Shaft nut to 49 Nm (5 kgfm / 36 lbfft)

N8A0194E

8-164 CAB AND CHASSIS ELECTRICAL


Backup Light Bulb
Removal Preparation: Disconnect the battery ground cable. 1. Lens 2. Bulb

N8A0196E

N8A0195E

Installation To install, follow the removal steps in the reverse order.

Backup Light Switch


Inspection 1. With the switch installed to the transmission, check the continuity between the terminals of the switch connectors. When the continuity is found between the terminals only with the switch shifted to the reverse position, the switch is normal. 2. When the result of the above inspection is found abnormal, remove the switch from the transmission and conduct a test on the switch alone. If the continuity appears between the connector terminals when the ball of the switch is pushed, the switch is normal. (When the ball is released, the continuity disappears.) 3. If there is no continuity with the switch installed to the transmission, even though the switch is found to be normal, then adjust the stroke of the switch by changing the thickness of the switch gasket.

Removal Preparation: Disconnect the battery ground cable. 1. Backup Light Switch 1) Disconnect the connectors. 2) Remove the switch by turning it counterclockwise. Installation 1. Backup Light Switch Apply liquid gasket to the screw portion of the switch to prevent oil leak.

Backup Buzzer
Inspection Apply battery voltage to the backup buzzer connector to check the buzzer sound. Repair or replace the buzzer when the result of inspection is found abnormal.

N8A0197E

CAB AND CHASSIS ELECTRICAL


Removal Preparation: Disconnect the battery ground cable. 1. Rear Combination Light Cover 2. Backup Buzzer 1) Remove the rear combination light connector fixing screw. 2) Remove buzzer fixing screw. 3) Disconnect the connector.

8-165

N8A0198E

Installation To install, follow the removal steps in the reverse order.

8-166 CAB AND CHASSIS ELECTRICAL Dome Light and Backup Buzzer
General Description
The circuit consists of the starter switch, dome light, dome light switch, door switch, backup light switch and the backup buzzer. The dome light lights up when the left or right side door is opened with the switch set at the door mode. It can be lit by operating ON or OFF of the dome light switch. The dome light can be lit by respective switch independent of the position of the starter switch. By operating the dome light switch fitted on the instrument panel, the dome light can be lit independent of the switch position of dome light.

Lighting Circuit

BATTERY (+)

OFF

DOOR DOME LIGHT ON

DOME LIGHT (FOR CREW CAB)

DOME LIGHT SW : Lighting circuit by door sw : Lighting circuit by dome light sw

DOOR SW (FRT PASSENGER SIDE)

DOOR SW (DRIVER SIDE)

NOTE: Arrow marks "

" indicate the direction of current

N8A0199E

RELAY BOX ASM (No.1) L-3 DIODE (W/CAB) L-1 DIODE L-4 DOME LIGHT

Parts Location

L-2 DOME LIGHT

W/CAB

N-7 DOOR SW (RH)

J-49 H-119

N-2 DOOR SW (LH)

X-38 DIODE

FUSE & RELAY BOX ASM F-4, F-16 FUSE

H-16 H-14
P-5 P-1 P-2 BATTERY P-3 P-4 RELAY BOX ASM FL-1, FL-2 FUSIBLE LINK

H-3

STARTER SW

B-7

H-5

H-8

B-51 H-10 B-67 H-12 B-83 BACKUP BUZZER B-87 DOME LIGHT SW

CAB AND CHASSIS ELECTRICAL

N8B0042E

8-167

FL-2
OFF 11 H-119 ACC

STARTER SWITCH

(4HK1 with Smoother)

40A KEY 0.5B/Y 0.5B/Y


H-7 2 3 ST ON B-67

3W/L
B-67 B

3W/L 3B/Y (4JJ1(EURO-4) with Smoother)


10 H-119

Except Europe

Circuit Diagram

3B/Y

F-16 10A METER 0.5B/Y 0.5B/Y

2L
H-6 3 H-10 H-5 22

0.5B/Y

8B 0.5B/Y 0.5B/Y

FL-1 100A or 120A MAIN 3W/B 3W/B F-4 15A AUDIO(B), DOOR LOCK 0.85R 0.5R

8W/B

(NPR75/NQR75) 5W/B

P-1

P-2

0.5B/Y

0.5R METER B-51 (18)

1 J-49

0.5B/Y

1 L-2

P-3

(NPR/NQR only)

P-4

BACKUP SWITCH

OFF ON L-2 B-83 3 2 L-2 6

DOOR

0.5B/Y

DOME LIGHT

P-5

J-49 2

FRAME

(Smoother for NPR75/NQR75) 0.5R/L

(Smoother) 0.5R/L

8-168 CAB AND CHASSIS ELECTRICAL

BACK BUZZER
B-83 B-83 5 2 H-119 12 H-119 9

0.5GR/B

0.5R/L

H-10

0.5GR
2 1 H-10

0.5R/L

0.5B

0.5GR/B
1 X-38

0.5R/L
H-8

0.5R/L

(M/T)

(Smoother)

0.5R/L

DIODE

X-38 2

0.5GR 0.5GR/R

0.5GR/B

H-14

0.5R/L

H-3 2 B-87 B-87 4

0.5GR/R

0.5GR/R

RELAY; TAIL (1)


3

3W

F-7 10A TAIL LIGHT 0.85LG/R 0.85LG/R 0.85LG/R

6 H-16 H-12 6 H-12

0.5R/L

1.25GR/B
1

1.25GR/R
1 B-87 5 B-87 1 N-7 N-2

DOME LIGHT SWITCH 0.5B 0.5B

BACKUP LIGHT

DOOR SWITCH (LH)

DOOR SWITCH (RH)

DOOR SWITCH (RH)


N-2

1.25GR/R
1

N8B0043E
3B

HEADLIGHT BRACKET (LH)

B-7

3B

FL-2
OFF ACC 11 H-119

STARTER SWITCH (4HK1 with Smoother)

40A KEY 3W/L 0.5B/Y 0.5B/Y


2 3 ST B-67 ON B-67 B

3W/L 3B/Y 3B/Y

For Europe

H-7

(4JJ1(EURO-4) with Smoother)


10 H-119

FL-1

F-16 10A METER F-4 15A AUDIO(B), DOOR LOCK 0.5B/Y 0.5B/Y 0.85R (Except NKR)
6 H-10 H-5 22 3 H-10

0.5B/Y

2L 3W/B 0.5B/Y 0.5B/Y 3W/B 0.5R

8B

100A or 120A MAIN

(NPR75/NQR75) 8W/B 8W/B 5W/B

P-1

H-6

P-2

(W/CAB only) 0.5B/Y 0.5R


H-20 1 L-2 2

0.5R

1 J-49

0.5B/Y

P-3

METER B-51 (18) 0.5B/Y

P-4

BACKUP SWITCH

OFF 6 B-83 ON L-2 3 B-83 2 2 L-2

DOOR

DOME LIGHT

P-5

J-49

FRAME
B-83 5

(Smoother for NPR75/NQR75) 0.5R/L

(Smoother) 0.5R/L

1 L-1 3 2 X-32

0.5GR

L-4

0.5R 0.5Y 0.5GR/B (Except NKR)


1 4 H-10 1 L-1 H-10

BACK BUZZER

H-119

H-119

0.5R/L

H-8

0.5R/L 0.5B

12

0.5R/L
2

0.5R/L

DIODE 0.5GR/B
1 X-38

0.5R/L
6 H-14 X-38

(W/CAB for NPR75 /NPR85/NQR75)

0.5GR

DIODE
L-3 H-20 2

L-4

0.5Y 1
1

L-3

0.5GR 0.5GR/B

0.5GR

X-32

(NPR/NQR with Smoother) DIODE

(NKR with Smoother) DIODE 0.5GR/R

CAB AND CHASSIS ELECTRICAL

N8B0044E

8-169

HEADLIGHT BRACKET (LH)

DOME LIGHT (Except NKR)


5 H-10 H-10 2

0.5GR/B

0.5GR/R

0.5GR/R

0.5GR/B

H-16

0.5R/L
6

0.5GR

(W/CAB with M/T)

0.5R/L

RELAY; TAIL (1)


2 B-87 B-87 4

3W

F-7 10A TAIL LIGHT 0.85LG/R 0.85LG/R 0.85LG/R


4 H-12

3 H-3

6 H-12

3 H-3

1.25GR/R

0.5GR/B

1.25GR/B (S/CAB) 0.5GR/B (W/CAB)

1.25GR/R

B-87 5

B-87 1

1 N-2

1 N-7

1 N-2

DOME LIGHT SWITCH 0.5B 0.5B

BACKUP LIGHT

DOOR SWITCH (LH)


N-7

DOOR SWITCH (LH)

DOOR SWITCH (RH)

DOOR SWITCH (RH)

B-7

3B

3B

8-170 CAB AND CHASSIS ELECTRICAL


Connector List
No. Connector Face No. Connector Face

B-7
000-001

H-3

3 6

2 5

1 4

006-015

B-51
020-004

H-10 (Excep t 4HK1)

1 2 3
003-009

B-67

1 3

2 4
004-001

H-10 (Excep t 4HK1)

3 2 1
003-010

B-67

2 4

1 3

H-10 (4HK1)
004-002

3 4 5 6
006-029

B-83

1 4

2 5

3 6
006-010

H-10 (4HK1)

6 5 4 3

006-003

B-87

1 2 4 5

3 6
006-028

H-12 (For M/T)

1 2 3 7 8 9 10

4 5 6 11 12 13 14

014-002

X-38

1 2
002-050

H-12 (For M/T)

6 5 4 14 13 12 11

3 2 1 10 9 8 7

014-003

H-3

1 4

2 5

3 6

H-12 (For Smoot her)


006-014

1 2 3 4 5 11 12 13 14 15 16

6 7 8 9 10 17 18 19 20 21 22

022-001

CAB AND CHASSIS ELECTRICAL


No. H-12 (For Smoot her) Connector Face No. Connector Face

8-171

10 9 8 7 6 22 21 20 19 18 17

5 4 3 2 1 16 15 14 13 12 11

H-20
022-002

1 2
002-010

H-14 (Without ABS)

1 5

2 6

3 7

4 8
008-003

H-119 (For Smoot her)

1 5 9

2 6

3 7

4 8

10 11 12

13 14 15 16

016-001

H-14 (Without ABS)

4 8

3 7

2 6

1 5
008-004

H-119 (For Smoot her)

4 8

3 7

2 6

1 5 9

12 11 10

16 15 14 13

016-002

H-14 (With ABS)

1 5 6

2 7

3 8

4 9

10 11 12 13 14 15 16

J-49
016-003 002-035

H-14 (With ABS)

4 9 8

3 7

2 6

1 5

14 13 12 11 10

L-1
016-004

2
002-027

16

15

H-16

1 5

2 6

3 7

4 8
008-003

L-2
1 2 3
003-009

H-16

4 8

3 7

2 6

1 5
008-004

L-2

3 2 1
003-010

H-20

1 2
002-009

L-3

2
002-027

8-172 CAB AND CHASSIS ELECTRICAL


No. Connector Face No. Connector Face

L-4
1 2
002-022

P-5
000-002

H-5 L-4

2 1
002-023

N-2

1
001-009

1 7 13 19 25 31

2 8 14 20 26 32

3 9 15 21 27 33

34

35

36

37

4 10 16 22 28 38

5 11 17 23 29 39

6 12 18 24 30 40

6 12 18 24 30 40

5 11 17 23 29 39

4 10 16 22 28 38

37

36

35

34

3 9 15 21 27 33

2 8 14 20 26 32

1 7 13 19 25 31

N-7

1
001-009

N8A5488E

H-6, H-7, H-8 P-1


000-022

H-6

P-4
000-014

H-7

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 H-8

4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14

P-2
000-014

N8A5489E

Starter Switch
Refer to START AND CHARGING in this section. P-3
000-014

Backup Light Switch


Refer to HORN, BACKUP LIGHT AND BACKUP BUZZER in this section.

CAB AND CHASSIS ELECTRICAL


Dome Light Bulb
Removal Preparation: Disconnect the battery ground cable. 1. Lens Hold the lens and pull it downward.

8-173

Dome Light Switch


Inspection Check the continuity between the dome light switch connector terminals. Repair or replace the switch when the result of inspection is found abnormal.

1 2 4 5
Terminal SW No. position

3 6

B-87

ON OFF

N8A5243E

N8B0093E

2. Bulb Installation To install, follow the removal steps in the reverse order.

Dome Light Bulb (for Crew Cab)


Removal Preparation: Disconnect the battery ground cable. 1. Lens Hold the lens and pull it down. 2. Bulb

Removal Preparation: Disconnect the battery ground cable. 1. Meter cluster Refer to the METER AND WARNING/INDICATOR LIGHT in this section. 2. Dome Light Switch Release the lock pushing the switch from the back side of the meter cluster.

N8A0203E

Installation To install, follow the removal steps in the reverse order.

8-174 CAB AND CHASSIS ELECTRICAL

Connector No. Te rm ina lN SW o. operation

N-2

N-7

Body

Push Release

N8A5160E

N8A0206E

Installation To install, follow the removal steps in the reverse order noting the following point. 1. Push the switch with your fingers until locks securely.

Door Switch
Inspection Check to see if there is any continuity between the terminals and the body while operating the door switch. Repair or replace the switch, when the result of inspection is found abnormal.

Removal Preparation: Disconnect the battery ground cable. 1. Door Switch 1) Remove the screw. 2) Disconnect the connector of the switch.

N8A0207E

Installation To install, follow the removal steps in the reverse order.

CAB AND CHASSIS ELECTRICAL


Backup Buzzer
Warning function Warning to reverse driving Operative conditions When the transmission shift lever is engaged to the reverse position.

8-175

N8A5249E

Inspection of the Buzzer Circuit Disconnect the backup buzzer connector, measure the continuity and voltage between the harness side connector terminals.

N8B5153E

8-176 CAB AND CHASSIS ELECTRICAL


Starter Switch
Inspection Check to see if there is any continuity between the connector terminals of the key cylinder switch. Repair or replace the switch when the result of inspection is found abnormal.

ST

AC

ON

B-67

1 3

2 4

Switch side Terminal No. Starter key position Key removed LOCK Key inserted ACC ON START

N8B0045E

CAB AND CHASSIS ELECTRICAL Power Door Lock


General Description

8-177

The circuit consists of the door lock switch, actuator for the front passenger door, rear doors and the door lock controller. The door lock controller is always provided with battery voltage. The key or the inside lock knob on the drivers door can activate the lock mechanism of all the doors. When the drivers door lock switch is turned on, current flows for about one second to the door lock actuator of each door connected in parallel with the controller to activate the actuator to lock and unlock the doors.

Operation of Door Lock Controller

When locking the door.

When locking the door.

Battery(+)

Battery(+)

Relay;Door lock

Relay;Door lock

To actuator (Actuator operates to lock side)

To actuator (Actuator operates to unlock position)

Door lock sw. (Lock position)

Door lock sw. (Unlock position)

N8A0211E

Notice: Arrow marks indicate the direction of current.

Parts Location

D-10 REAR DOOR LOCK ACTUATOR (W/CAB) (RH) <REAR DOOR (W/CAB) (RH)>

F-4 H-18 (W/CAB) <REAR DOOR (W/CAB) (LH)> H-19 (W/CAB)

D-9 REAR DOOR LOCK ACTUATOR (W/CAB) (LH)

8-178 CAB AND CHASSIS ELECTRICAL

H-2(S/CAB), H-20(W/CAB)

H-11(S/CAB), H-22(W/CAB)

B-7

H-18 (W/CAB)

N8B0046E

CAB AND CHASSIS ELECTRICAL


Circuit Diagram
Except 4JJ1 / 4HK1 80A ACG 8W/B
FL-1 100A or 120A MAIN

8-179

5W/B F-4 15A AUDIO(B), DOOR LOCK


H-6

8W/B 4JJ1 / 4HK1 80A ACG

5W/B

3W/B

0.85R

0.5R

DOME LIGHT

2L

8B

0.85R
P-1 P-2

RELAY; DOOR LOCK


P-3 P-4

6 B-12

B-12

0.85BR/R
5

0.5BR/R

B-12 P-5

0.85BR/Y 0.5BR/Y
4

0.5BR/R

FRAME 0.85BR/R
1 2 3

0.85BR/Y

B-12

B-12

B-12

0.3R/G

0.3G/B

FOR M/T
5 H-12 7 H-12

FOR M/T
13 H-12 19 H-12 1 H-3 4 H-3

0.5BR/W

(FOR W/CAB EC) (FOR W/CAB EC) (FOR W/CAB EC)

0.5BR/Y

0.5BR/R

0.5BR/R

2 H-22

5 H-22

2 H-11

4 H-11

FOR SMOOTHER

0.5BR/Y

(FOR S/CAB)

FOR SMOOTHER

5 H-20

4 H-2

3 H-20

3 H-2

2 H-18

1 H-18

2 H-19

0.85BR/R

0.85BR/R

0.85BR/Y

0.85BR/R

UNLOCK

LOCK 0.85B

2 D-4

3 D-4

2 D-8

0.85BR/Y

0.3R/G

0.3G/B

1 D-8

1 D-9

2 D-9

1 D-10

0.85BR/Y
2 D-10

(FOR S/CAB)

(FOR S/CAB)

0.5BR/Y
1 H-19

0.5BR/Y

UNLOCK

UNLOCK

DOOR LOCK SWITCH-LH D-4


1

2B

(FOR W/CAB EC)

0.3B

(FOR S/CAB) 3

3 H-22

H-11

DOOR LOCK ACTUATOR-RH

DOOR LOCK ACTUATOR-LH (W/CAB)

DOOR LOCK ACTUATOR-RH (W/CAB)

HEADLIGHT BRACKET (LH) FRAME-LH (FRONT)

B-7

3B 5B

3B

2B

2B

B-1

N8B0047E

UNLOCK

LOCK

LOCK

LOCK

8-180 CAB AND CHASSIS ELECTRICAL


Connector List
No. Connector Face No. Connector Face

B-1
000-001

D-9

002-002

B-7
000-001

D-10

002-001

B-12

1 4

2 5

3 6
006-010

D-10

002-002

D-4

3
003-003

H-18 (W/ CAB)

002-001

D-4

H-18 (W/ CAB)


003-011

002-002

D-8

H-19 (W/ CAB)


002-001

002-001

D-8

H-19 (W/ CAB)


002-002

002-002

D-9

H-2 (S/ CAB)


002-001

1 2

4 5 6 7 8

008-009

CAB AND CHASSIS ELECTRICAL


No. Connector Face No. Connector Face

8-181

H-2 (S/ CAB)

2 1

8 7 6 5 4

H-20 (W/ CAB)


008-010

4 3

2 1

10 9 8 7 6 5

010-004

H-11 (S/ CAB)

1 2

4 5 6 7 8

H-22 (W/ CAB)


008-009

1 2

3 4

5 6 7 8 9 10

010-003

H-11 (S/ CAB)

2 1

8 7 6 5 4

H-22 (W/ CAB)


008-010

4 3

2 1

10 9 8 7 6 5

010-004

H-3

1 4

2 5

3 6

P-1
006-014 000-022

H-3

3 6

2 5

1 4

P-4
006-015 000-014

H-12

1 2 3 7 8 9 10

4 5 6 11 12 13 14

P-2
014-002 000-014

H-12

6 5 4 14 13 12 11

3 2 1 10 9 8 7

P-3
014-003 000-014

H-20 (W/ CAB)

1 2

3 4

P-5
010-003 000-002

5 6 7 8 9 10

8-182 CAB AND CHASSIS ELECTRICAL


H-6

H-6

H-7

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 H-8

4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14

N8A5489E

Diagnosis
Quick Chart for Check Point Check point Fuse F-4 (15 A) 1. All the doors do not lock and unlock 2. All the doors do not get locked (or unlocked) 3. Driver side door does not get locked (or unlocked) 4. Front passenger side door does not get locked (or unlocked) 5. Rear door-RH side does not get locked (or unlocked) 6. Rear door-LH side does not get locked (or unlocked) Notice: Figure in parenthesis ( ) indicates the order of inspection. (1) Door lock controller (3) (2) Door lock SW (Driver side) (2) (1) (1) (1) (1) (1) Door lock actuator Front (Passenger side) Rear (RH) Rear (LH) Cable harness (4) (3) (2) (2) (2) (2)

Trouble mode

CAB AND CHASSIS ELECTRICAL


All the Doors Do Not Lock and Unlock

8-183

N8A5256E

All the Doors Do Not Get Locked (or Unlocked)

N8A5257E

8-184 CAB AND CHASSIS ELECTRICAL


Driver Side Door Does Not Get Locked (or Unlocked)

REPLACE THE DOOR LOCK SWITCH

N8A0216E

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

REPLACE THE DOOR LOCK ACTUATOR

N8A0217E

CAB AND CHASSIS ELECTRICAL


Inspection of the Door Lock Circuit Check the voltage and the continuity between the controller harness side connector terminals.

8-185

B-12

1 4

2 5

3 6

Harness side

Terminal No. 1 2 3 4 5 6

Wire color R/G G/B B BR/Y BR/R R

Connected to Door lock SW (Unlock) Door lock SW (Lock) Ground Actuator (Unlock) Actuator (Lock) Fuse F-4 (15A)

Item to be checked

Connecting terminal 1-Ground 2-Ground

Checking conditions Driver seat side door Driver seat side door Unlock Lock Unlock Lock

Standard Continuity No continuity No continuity Continuity Continuity Continuity (There is some resistance) Continuity (There is some resistance) Battery voltage

Continuity (Resistance)

3-Ground 4-5 5-4

Voltage

6-Ground

N8B5118E

8-186 CAB AND CHASSIS ELECTRICAL


Door Lock Controller The door lock controller sends out to each door lock actuator the lock/unlock signals received from door lock switch of driver seat side. door lock controller, apply battery voltage to each of the terminals to conduct the operation test. When the door lock will not operate, check the door lock actuator for any trouble.

B-12 Harness side

1 4

2 5

3 6

Connecting terminal 4 (BR/Y) 5 (BR/R)

Operation Unlock Lock

N8B5116E

N8A0221E

Inspection Remove the connector of the door lock controller, and check the continuity and the voltage between the controller side connector terminals. (Connect the (+) terminal of the battery to 6 B-12 and the () terminal to 3 B-12 .) 3 B-12 5 B-12 .................Continuity 3 B-12 4 B-12 .................Continuity (Then, ground 2 B-12 .) 5 B-12 ..................Voltage for approx. 1 second (Disconnect the ground of 2 B-12 , and ground 1 B-12 .) 4 B-12 ..................Voltage for approx. 1 second Replace the controller when the result of inspection is found abnormal.

Door Lock Switch (Driver Seat Side)


The door lock switch on the drivers door is connected with the door lock cylinder and the inside lock knob with a rod. The switch sends lock/unlock signals to the door lock controller.

B-12
N8A0223E

3 6

2 5

1 4

Controller side

Inspection Check to see if there is any continuity between the connector terminals of the door lock switch. Replace the switch when the result of inspection is found abnormal.

N8A0220E

Door Lock Operation Test After confirming that there is continuity between the harness side connector terminals 4 B-12 and 5 B-12 of the

CAB AND CHASSIS ELECTRICAL

8-187

D-4

Switch side
1 2 3

Operation

Terminal No.

Lock Unlock

N8A0224E

Removal and Installation Refer to Section 2 FRAME AND CAB for DOOR LOCK ASSEMBLY.

Door Lock Actuator


Receiving forward or reverse current from the door lock controller, the door lock actuator locks or unlocks the door with the rod connected to the door lock mechanism.

N8A0225E

Inspection of the Door Lock Actuator Apply the battery voltage to the connector terminals of the door lock actuator to check the operation. When the door lock actuator is checked on the vehicle and there is no continuity, and when the door lock actuator itself is checked and no trouble is found, check the circuit between the door lock actuator and the door lock controller for any failure.

8-188 CAB AND CHASSIS ELECTRICAL

D-8 Door lock ASM

D-9

D-10

Actuator side

Actuator side

Door Actuator Connector No. Terminal No. Operation Lock Unlock

FRT Passenger

RR-LH D-9

RR-RH D-10

D-8 1 2 1

N8A0226E

Removal and Installation Refer to Section 2 FRAME AND CAB for DOOR LOCK ASSEMBLY.

CAB AND CHASSIS ELECTRICAL Power Window


General Description

8-189

The circuit consists of the starter switch, power window switch for each of the windows and power window motor. When the starter switch is turned on, the battery voltage is applied to each of the power window switches through the circuit breaker and the power window relay on the circuit. By operating the switches of each window to select UP or DOWN, the revolving direction of the power window motor changes to open or close the window. The drivers power window switch has a built-in one-touch operating circuit which allows to automatically open the window by operating the switch to the AUTO position. When the drivers power lock switch at the driver side is depressed, the power source to the passengers power window switches will be shut off and passengers side power window motor will not operate if the switch is operated.

Operation of Passenger Side Window

NOTE: Arrow marks "

" indicate the direction of current

N8A0227E

Parts Location

F-6, F-16

X-7

8-190 CAB AND CHASSIS ELECTRICAL

H-11(S/CAB), H-22(W/CAB)

H-2(S/CAB), H-20(W/CAB)

B-7

FL-1, FL-2 FUSIBLE LINK

N8B0048E

FL-1

Except 4JJ1 / 4HK1 80A ACG RELAY; POWER WINDOW


2 X-7 X-7 H-2 H-20 1 1 1

2L 3W/B 1.25L/B 2L/B


OFF 3 X-7 5 X-7

8B 2L/B 2L/B FOR W/CAB EC FOR S/CAB POWER WINDOW SWITCH (DRIVER)
6 D-3 B

100A or 120A MAIN FOR S/CAB 2L/B 1.25L/B 1.25L/B F-6 20A POWER WINDOW 2B/L 1.25L/B

8W/B 5W/B

Circuit Diagram

8W/B

H-6

5W/B

P-1 ACC ON B-67 3 H-22 1 1 H-11

4JJ1 / 4HK1 80A ACG 0.5B/Y F-16 10A METER 3B/Y 2L/B 2L/B 0.5B/Y

STARTER SWITCH

P-2

3W/L
ST

H-7

3W/L

B-67

FL-2 40A

KEY SW 2L/B
8 D-3 E

P-3

P-4

0.3B

WINDOW LOCK SWITCH


FL SW UP D-3 5 4 D-3

WINDOW SWITCH (PASSENGER)

METER B-51 (18)

P-5

2B

FRAME

DOWN

1.25G/Y

1.25R/Y

1.25L/B

AUTO CIRCUIT

FOR S/CAB

WINDOW SWITCH (DRIVER)

3 3 H-22 H-11

9 H-22

8 H-11

5 H-11

6 H-22

FOR W/CAB EC

FOR S/CAB 2B 2B

1.25R/Y

1.25G/Y

1.25G/Y

1.25R/Y

FOR W/CAB EC

FOR W/CAB EC

UP D-3 1

DOWN D-3 2

9 H-20

8 H-2

5 H-2

6 H-20

1.25G/Y
D-7

1.25R/Y
2

4 D-7

1 D-7

1.25L

POWER WINDOW SWITCH (PASSENGER)

1.25L/W

UP D-7 3

DOWN D-7 5

1.25L/Y

1.25BR/Y

HEADLIGHT BRACKET (LH)

B-7

3B

3B

1 D-2

2 D-2

1 D-6

2 D-6

5B

CAB AND CHASSIS ELECTRICAL

FRAME-LH (FRONT)

B-1

UP

DOWN

UP

DOWN

N8B0049E

8-191

POWER WINDOW MOTOR (DRIVER)

POWER WINDOW MOTOR (PASSENGER)

8-192 CAB AND CHASSIS ELECTRICAL


Connector List
No. Connector Face No. Connector Face

X-7
005-006

D-6

002-029

B-1
000-001

D-3

1 4

2 5 6 7

3 8

008-011

B-7
000-001

D-7

005-005

B-67

1 3

2 4
004-001

H-2 (S/ CAB)

1 2

4 5 6 7 8

008-009

B-67

2 4

1 3

H-2 (S/ CAB)


004-002

2 1

8 7 6 5 4

008-010

D-2

H-11 (S/ CAB)


002-028

1 2

4 5 6 7 8

008-009

D-2

H-11 (S/ CAB)


002-029

2 1

8 7 6 5 4

008-010

D-6

H-20 (W/ CAB)


002-028

1 2

3 4

5 6 7 8 9 10

010-003

CAB AND CHASSIS ELECTRICAL


No. Connector Face H-6, H-7

8-193

H-20 (W/ CAB)

4 3

2 1

10 9 8 7 6 5

010-004

H-6

H-7

H-22 (W/ CAB)

1 2

3 4

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

4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14

5 6 7 8 9 10

010-003

14 15 16 17 18

H-22 (W/ CAB)

4 3

2 1

10 9 8 7 6 5

N8A5489E
010-004

P-1
000-022

P-4
000-014 000-004

P-2
000-014 000-004

P-3
000-014 000-004

P-5
000-002 000-004

8-194 CAB AND CHASSIS ELECTRICAL


Diagnosis
Quick Chart for Check Point Check point Fuse F-16 (10A) All windows do not operate Lock SW does not function Driver side window Window does not operate One-touch operation does not operate Window operates in only one direction Front passenger side window Trouble mode Window does not operate Window does not operate when operating the driver side SW Window does not operate when operating the passenger side SW Window operates in only one direction when operating the driver side SW Window operates in only one direction when operating the passenger side SW Notice: Figure in parenthesis ( ) indicates the order of inspection. (1) (2) (1) (1) (3) (4) (2) (1) (1) (1) (2) (3) (1) Fuse F-6 (20A) (2) Power window relay (3) Power window SW Driver side (4) (1) Passenger side Power window motor Driver side Passenger side Cable harness (5)

(1)

(2)

(2)

(1)

(2)

CAB AND CHASSIS ELECTRICAL


All Windows Do Not Operate

8-195

IS THE FUSE F-16 (10A) NORMAL?

YES IS THE FUSE F-6 (20A) NORMAL?

NO REPLACE THE FUSE

YES IS THE POWER WINDOW RELAY NORMAL?

NO REPLACE THE FUSE

YES IS B-7 SECURELY GROUNDED?

NO REPLACE THE RELAY

YES DISCONNECT THE POWER WINDOW SW CONNECTOR ON THE DRIVER SEAT SIDE TURN THE STARTER SWITCH ON IS THE BATTERY VOLTAGE APPLIED BETWEEN THE HARNESS SIDE CONNECTOR 6 D-3 AND THE GROUND?

NO GROUND IT SECURELY

YES IS THE POWER WINDOW SW ON THE DRIVER SIDE NORMAL?

NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 6 D-3 AND 1 X-7

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

NO REPLACE THE SWITCH

NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 8 D-3 AND B-7

N8B5117E

8-196 CAB AND CHASSIS ELECTRICAL


Lock SW Does Not Function

REPAIR OR REPLACE THE POWER WINDOW SW ON THE DRIVER SEAT SIDE

N8A0231E

Window on the Driver Side Does Not Operate

IS THE POWER WINDOW SWITCH ON THE DRIVER SEAT SIDE NORMAL?

YES DISCONNECT THE CONNECTOR OF THE POWER WINDOW MOTOR ON THE DRIVER SEAT SIDE WHEN CONNECTING THE MOTOR CONNECTOR 1 D-2 TO THE BATTERY (+) TERMINAL AND 2 D-2 TO THE (-) TERMINAL, DOES THE MOTOR ROTATE IN THE "UP" DIRECTION OF THE WINDOW (OR WHEN CONNECTING 2 D-2 TO THE (+) TERMINAL AND 1 D-2 TO THE (-) TERMINAL, DOES THE MOTOR ROTATE IN THE "DOWN" DIRECTION OF THE WINDOW)?

NO REPLACE THE POWER WINDOW SWITCH ON THE DRIVER SEAT SIDE

YES

NO REPAIR OR REPLACE THE POWER WINDOW MOTOR

REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN HARNESS SIDE CONNECTOR TERMINALS 1 D-3 AND POWER WINDOW MOTOR 1 D-2 OR 2 D-3 AND 2 D-2

N8A0232E

CAB AND CHASSIS ELECTRICAL


Window on the Front Passenger Side Does Not Operate
IS THE FRONT PASSENGER SIDE POWER WINDOW SW NORMAL?

8-197

YES IS THE DRIVERS POWER WINDOW SW NORMAL?

NO REPAIR OR REPLACE THE SW

YES REMOVE THE CONNECTOR OF THE FRONT PASSENGER SIDE POWER WINDOW MOTOR WHEN CONNECTING THE MOTOR CONNECTOR 1 D-6 TO THE BATTERY (+) TERMINAL AND 2 D-6 TO THE (-) TERMINAL, DOES THE MOTOR ROTATE IN THE "UP" DIRECTION OF THE WINDOW? (OR WHEN CONNECTING 2 D-6 TO THE (+) TERMINAL AND 1 D-6 TO THE (-) TERMINAL, DOES THE MOTOR ROTATE IN THE "DOWN" DIRECTION OF THE WINDOW?)

NO REPAIR OR REPLACE THE SW

YES WITH THE SWITCH AT THE NEUTRAL POSITION, IS THERE ANY CONTINUITY BETWEEN THE HARNESS SIDE CONNECTORS 1 D-6 AND 2 D-6 ?

NO REPAIR OR REPLACE THE POWER WINDOW MOTOR

YES

NO

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

REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN THE PASSENGER SIDE POWER WINDOW SW AND THE MOTOR CONNECTOR
N8A0233E

8-198 CAB AND CHASSIS ELECTRICAL


Starter Switch
Refer to START AND CHARGING in this section.

Power Window Switch-Driver Side


Circuit Inspection Disconnect the switch connectors to check the voltage and the continuity between the harness side connector terminals.

D-3

Harness side

Terminal No. 1 2 4 5 6 8

Wire color L/W L G/Y R/Y L/B B

Connected to Driver seat side motor Passenger side power window SW Power window relay Ground

Item to be checked Continuity (resistance) Voltage Continuity (resistance)

Connecting terminal 1-2 4-5 5-4 6-Ground 8-Ground

Checking conditions

Standard

Continuity

Starter SW "ON" -

Battery voltage Continuity

N8A0234E

CAB AND CHASSIS ELECTRICAL


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

8-199

D-3

Switch side

Window SW Terminal position No. UP OFF DOWN UP LOCK OFF 6

Driver side 1 2 8

Passenger side 6 5 4 8

DOWN

N8A0235E

8-200 CAB AND CHASSIS ELECTRICAL


Removal Preparation: Disconnect the battery ground cable. 1. Switch 1) Insert the screw driver to the cut off portion to remove the switch. 2) Disconnect the connector.

N8A0236E

Installation To install, follow the removal steps in the reverse order.

Power Window Switch-Passenger Side


Circuit Inspection Disconnect the switch connectors to check the voltage and the continuity between the harness side connector terminals.

N8A5280E

CAB AND CHASSIS ELECTRICAL


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

8-201

D-7

Switch side

SW position UP OFF

Terminal No.

DOWN

N8A0238E

Removal Preparation: Disconnect the battery ground cable. 1. Switch 1) Insert the screw driver to the cut off portion to remove the switch. 2) Disconnect the connector.

N8A0239E

Installation To install, follow the removal steps in the reverse order.

8-202 CAB AND CHASSIS ELECTRICAL


Driver Seat Side Power Window Motor
Inspection Before checking to see if the motor functions correctly, be sure to check the circuit through the connector D-3 of the drivers power window switch. If the motor does not operate smoothly, either the motor or the circuit between the switch and the motor is defective. 1. Circuit inspection of the driver side window switch Disconnect the switch connector and apply battery voltage to the harness side connector terminals to check its function. Removal Preparation: Disconnect the battery ground cable. 1. Window Regulator Assembly Refer to Section 2 for Window Regulator and Glass. 2. Power Window Motor Remove three screws.

D-3 Harness side

Connecting terminal 1 (L/W) 2 (L)

Operation DOWN UP
N8A0242E

Installation To install, follow the removal steps in the reverse order.


N8A0240E

2. Inspection of the driver seat side motor Remove the motor connector and apply battery voltage to the motor side connector terminals to check its function. Replace the motor when the result of inspection is found abnormal.

D-2

Direction of operation

Terminal No.

DOWN UP
N8A0241E

CAB AND CHASSIS ELECTRICAL


Front Passenger Seat Side Power Window Motor
Inspection Before checking to see if the motor functions correctly, be sure to check the circuit through the front passengers switch connector D-7 and the drivers power window switch connector D-3 . If the motor does not operate smoothly, either the motor or the circuit between the switch and the motor is defective. 1. Circuit inspection of the front passenger seat side window Disconnect the switch connector and apply battery voltage to the harness side connector terminals to check its function.

8-203

3. Inspection of the front passenger window motor Disconnect the motor connector and apply battery voltage to the motor side connector terminals to check its function. Repair or replace the motor when the result of inspection is found abnormal.

M D-6

Direction of operation
D-7

Terminal No.

DOWN UP
Harness side
N8A0245E

Connecting terminal 3 (L/Y) 5 (BR/Y)

Direction of operation DOWN UP

N8A0243E

Removal Preparation: Disconnect the battery ground cable. 1. Window Regulator Assembly Refer to Section 2 for Window Regulator and Glass. 2. Power Window Motor Remove three screws.

2. Circuit inspection of the driver seat side switch Disconnect the switch connector and apply battery voltage to the harness side connector terminals to check its function.

D-3

Harness side

Connecting terminal 4 (G/Y) 5 (R/Y) + +

Direction of operation DOWN UP


N8A0246E

Installation To install, follow the removal steps in the reverse order.


N8A0244E

8-204 CAB AND CHASSIS ELECTRICAL Windshield Wiper and Washer


General Description
The circuit consists of the starter switch, windshield wiper & washer switch, wiper motor, washer motor and the intermittent relay. When the wiper & washer switch is turned on with starter switch on, the battery voltage is applied to the wiper motor to activate the wiper. The washer motor squirts glass cleaning fluid while the washer switch is being pushed. The intermittent relay is used to control motion of the wiper.

Operation of Windshield Wiper Motor


(When wiper LO or INT position)

N8A0250E

Notice: Arrow marks indicate the direction of current.

CAB AND CHASSIS ELECTRICAL


Parts Location

8-205

RELAY BOX ASM (No.1)

X-11 KEY ON RELAY

B-7

N8B0084E

8-206 CAB AND CHASSIS ELECTRICAL


Circuit Diagram

3W/L FL-1 100A or 120A MAIN 2L 8B FL-2 40A KEY SW 3W/L FUSE BLOCK STARTER SWITCH
ACC 1 H-7 2

P-2

ST

3B/Y
2
X-11

P-1

3W/L

B-67

ON

B-67

1
X-11

P-3 P-4
X-11 X-11

RELAY KEY ON

0.5B

P-5

3L FRAME F-10 15A FRONT WIPER & WASHER 0.5L

0.5L

0.5L

2B

1 B-69

WIPER, WASHER SWITCH (COMBINATION SWITCH)

0.5L

OFF P 8 B-69 3 PS B-9 3 6

(WITHOUT RELAY; INTERMITTENT)

SHORT CIRCUIT CONNECTOR

B-9

B-9 B

B-69 8

B-69 7

B-69 4

B-69 6

0.5L/R 0.5BR/W
2 B-11 LO B-11 B-11 B P

RELAY; INTERMITTENT

B-9

0.5L/O

0.5BR/R
3 B-11 HI

0.85L/R

4 PM B-9 W B-9 E B-9 2 7 4

B-9

0.5BR/Y

0.85L/R

WIPER MOTOR
B-11 1

0.5L/B
1 B-8

0.5L/B
B-8

0.5B

0.5B

HEADLIGHT BRACKET (LH)

B-7

3B

2B

0.3B

WASHER MOTOR

N8B0050E

CAB AND CHASSIS ELECTRICAL


Connector List
No. Connector Face No. Connector Face

8-207

B-7
000-001

B-69

4 3 2 8 7 6

1 5
008-002

B-8

1 2
002-009

P-1
000-022

B-9

P-4
1 5 2 6 3 7 4 8

008-012

000-014

B-11

P-2
1 4 2 5 3 6

006-001

000-014

B-11

3 6

2 5

1 4

P-3
000-014

006-016

B-67

P-5
1 3 2 4
004-001 000-002

B-67

2 4

1 3

X-11

1 2 3 5 4

004-002

005-001

B-69

1 5

2 3 4 6 7 8
008-001

8-208 CAB AND CHASSIS ELECTRICAL


H-7

H-6

H-7

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 H-8

4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14

N8A5489E

Diagnosis
Quick Chart for Check Point 1. Windshield Wiper and Washer Check point Fuse F-10 (15A) 1. Windshield wiper does not operate at any switch position 2. Windshield wiper does not operate at INT position 3. Windshield wiper does not operate at LO position Trouble mode 4. Windshield wiper does not operate at HI position 5. Auto-stop function of the windshield wiper motor does not operate 6. Rotation of the windshield wiper motor does not stop 7. Windshield washer motor does not operate Notice: Figure in parenthesis ( ) indicates the order of inspection. (1) Wiper& washer SW (3) (1) (1) (1) (1) (1) (1) (4) (3) (3) (2) (2) (2) (3) (2) Intermittent relay Wiper motor (4) Washer motor Cable harness (2) (2) (2) (3) (3)

CAB AND CHASSIS ELECTRICAL


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

8-209

IS THE FUSE F-10 (15A) NORMAL?

YES

NO REPLACE THE FUSE

DISCONNECT THE CONNECTOR OF THE WINDSHIELD WIPER & WASHER SWITCH TURN THE STARTER SWITCH ON IS THE BATTERY VOLTAGE APPLIED BETWEEN THE SWITCH HARNESS SIDE CONNECTOR 1 B-69 AND THE GROUND?

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

NO

REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN THE FUSE F-10 (15A) AND 1 B-69

YES IS B-7 GROUNDED SECURELY?

NO REPAIR OR REPLACE THE SWITCH

YES DISCONNECT THE CONNECTOR OF THE WINDSHIELD WIPER MOTOR WITH THE MOTOR CONNECTOR 2 B-11 CONNECTED TO THE BATTERY (+) TERMINAL, AND THE CONNECTOR 1 B-11 TO THE (-) TERMINAL, DOES THE MOTOR ROTATE AT A LOW SPEED? AND WITH THE CONNECTOR 3 B-11 CONNECTED TO THE (+) TERMINAL, DOES THE MOTOR ROTATE AT A HIGH SPEED?

NO GROUND IT SECURELY

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

NO REPAIR OR REPLACE THE WINDSHIELD WIPER MOTOR

N8B5154E

8-210 CAB AND CHASSIS ELECTRICAL


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

IS CONTINUITY IN THE WINDSHIELD WIPER & WASHER SWITCH NORMAL?

YES

NO REPAIR OR REPLACE WINDSHIELD WIPER & WASHER SWITCH

DISCONNECT THE CONNECTOR OF THE INTERMITTENT RELAY IS THERE CONTINUITY BETWEEN THE RELAY AND THE WINDSHIELD WIPER & WASHER SWITCH HARNESS SIDE CONNECTOR 6 B-9 AND 8 B-69 , OR 3 B-9 AND 3 B-69 RESPECTIVELY?

YES REPLACE THE INTERMITTENT RELAY

NO REPAIR A POOR CONNECTION OR AN OPEN CIRCUIT BETWEEN THE CIRCUITS

N8A0255E

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

IS CONTINUITY IN THE WINDSHIELD WIPER & WASHER SWITCH NORMAL?

YES DISCONNECT THE WINDSHIELD WIPER MOTOR CONNECTOR CONNECT THE BATTERY (+) TERMINAL TO THE WINDSHIELD WIPER MOTOR CONNECTOR 2 B-11 AND THE (-) TERMINAL TO 1 B-11 DOES THE MOTOR ROTATE AT A LOW SPEED?

NO REPAIR OR REPLACE THE WINDSHIELD WIPER & WASHER SWITCH

YES

NO REPAIR OR REPLACE THE WINDSHIELD WIPER MOTOR

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

N8A0256E

CAB AND CHASSIS ELECTRICAL


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

8-211

IS CONTINUITY IN THE WINDSHIELD WIPER & WASHER SWITCH NORMAL?

YES DISCONNECT THE WINDSHIELD WIPER MOTOR CONNECTOR CONNECT THE BATTERY (+) TERMINAL TO THE WINDSHIELD WIPER MOTOR CONNECTOR 3 B-11 AND THE (-) TERMINAL TO 1 B-11 DOES THE MOTOR ROTATE AT A HIGH SPEED?

NO REPAIR OR REPLACE THE WINDSHIELD WIPER & WASHER SWITCH

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

NO REPAIR OR REPLACE THE WINDSHIELD WIPER MOTOR

N8A0257E

8-212 CAB AND CHASSIS ELECTRICAL


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

IS CONTINUITY IN THE WINDSHIELD WIPER & WASHER SWITCH NORMAL?

YES

NO REPAIR OR REPLACE THE WINDSHIELD WIPER & WASHER SWITCH

DISCONNECT THE CONNECTOR OF THE WINDSHIELD WIPER MOTOR CONNECT THE MOTOR CONNECTOR 2 B-11 TO THE BATTERY (+) TERMINAL, AND 1 B-11 TO THE BATTERY (-) TERMINAL, AND THEN CHANGE THE CONNECTION OF THE BATTERY (+) TERMINAL TO THE CONNECTOR 4 B-11 WHILE ROTATING THE MOTOR AT A LOW SPEED WHEN CONNECTING THE CONNECTOR TERMINALS 2 B-11 AND 5 B-11 IN THIS CONDITION, DOES THE MOTOR STOP AT AUTO-STOP POSITION?

YES TURN THE STARTER SWITCH ON IS THERE BATTERY VOLTAGE APPLIED BETWEEN THE WINDSHIELD WIPER MOTOR HARNESS SIDE CONNECTOR TERMINAL 4 B-11 AND GROUND?

NO REPAIR OR REPLACE THE WINDSHIELD WIPER MOTOR

YES DISCONNECT THE CONNECTOR OF THE WINDSHIELD INTERMITTENT RELAY IS THERE CONTINUITY BETWEEN THE RELAY HARNESS SIDE CONNECTOR 7 B-9 AND THE WINDSHIELD WIPER MOTOR HARNESS SIDE CONNECTOR 5 B-11 ?

NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN THE FUSE F-10 (15A) AND 4 B-11

YES REPLACE THE WINDSHIELD INTERMITTENT RELAY

NO

REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN THE CIRCUITS

N8A0258E

CAB AND CHASSIS ELECTRICAL


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

8-213

IS CONTINUITY IN THE WINDSHIELD WIPER & WASHER SWITCH NORMAL?

YES

NO REPAIR OR REPLACE THE WINDSHIELD WIPER & WASHER SWITCH

THE MOMENT THE WINDSHIELD WIPER COMES TO AUTO-STOP POSITION, TURN THE STARTER SWITCH OFF (ALTERNATIVELY, CONNECT THE BATTERY (+) TERMINAL TO THE WINDSHIELD WIPER MOTOR CONNECTOR 2 B-11 AND THE (-) TERMINAL TO 1 B-11 , AND THEN MOVE THE WINDSHIELD WIPER MOTOR TO AUTO-STOP POSITION AND STOP IT)

YES

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

N8A0259E

8-214 CAB AND CHASSIS ELECTRICAL


1-7. Windshield Washer Motor Does Not Operate

IS CONTINUITY IN THE WINDSHIELD WIPER & WASHER SWITCH NORMAL?

YES TURN THE STARTER SWITCH ON IS THE BATTERY VOLTAGE APPLIED BETWEEN THE WINDSHIELD WIPER & WASHER SWITCH HARNESS SIDE CONNECTOR TERMINAL 1 B-69 AND THE GROUND?

NO REPAIR OR REPLACE THE WINDSHIELD WIPER & WASHER SWITCH

YES

NO

DISCONNECT THE CONNECTOR OF THE WINDSHIELD WASHER MOTOR TURN THE STARTER SWITCH ON WITH THE WASHER BUTTON OF THE WINDSHIELD WIPER & WASHER SWITCH DEPRESSED, IS THE BATTERY VOLTAGE APPLIED BETWEEN THE WASHER MOTOR HARNESS SIDE CONNECTOR TERMINAL 1 B-8 AND THE GROUND?

REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN FUSE F-10 (15A) AND 1 B-69

YES IS B-7 GROUNDED SECURELY?

NO

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

YES CONNECT THE MOTOR SIDE CONNECTOR 1 B-8 OF THE WINDSHIELD WASHER MOTOR TO THE BATTERY (+) TERMINAL, AND THE CONNECTOR 2 B-8 TO THE (-) TERMINAL DOES THE MOTOR ROTATE?

NO GROUND IT SECURELY

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

NO REPAIR OR REPLACE THE WINDSHIELD WASHER MOTOR

N8A0260E

CAB AND CHASSIS ELECTRICAL


Starter Switch
Refer to START AND CHARGING in this section.

8-215

Windshield Wiper & Washer Switch


With the starter switch on, the windshield wiper and washer switch controls the start and stop operation as well as the change of operating speeds. Both the windshield washer motor and the wiper motor jointly operate while the washer button is pushed.

N8A0261E

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

B-69

1 5

2 3 4 6 7 8

Switch side

Washer SW

Wiper SW OFF INT

Terminal No. 3 7 1 4 8 6

OFF

LO HI

ON

MIST,OFF INT,LO,HI

N8A0262E

Removal and Inspection Refer to HEADLIGHT, FOG LIGHT, REAR FOG LIGHTY AND CORNERING LIGHT in this section.

8-216 CAB AND CHASSIS ELECTRICAL


Windshield Wiper Motor
2. Windshield Wiper Motor 1) Disconnect the connector. 2) Remove four screws. 3) Remove the ball joint between crank arm and wiper link.

N8A0263E

Inspection 1. Operation in low speed With the motor connector terminal 2 B-11 connected to the battery (+) terminal and the connector 1 B-11 to the () terminal, check to see if the motor rotates in low speed. 2. Operation in high speed With the motor connector terminal 3 B-11 connected to the battery (+) terminal and the connector 1 B-11 to the () terminal, check to see if the motor rotates in high speed. 3. Stop operation Operate the windshield wiper at the low speed in item No. 1 and stop them at the position in the way. When the connectors 2 B-11 and 5 B-11 are connected, while connecting the motor connector terminal 4 B-11 to the battery (+) terminal, check to see if the motor rotates at low speed and stops at the auto-stop position. Repair or replace the motor when the results of the above inspections are found abnormal. Removal Preparation: Disconnect the battery ground cable. 1. Glove Box Refer to INSTRUMENT PANEL of section 2.

N8A0264E

Installation To install, follow the removal steps in the reverse order, noting the following points. Windshield Wiper Motor When the crank arm is removed from the windshield wiper motor, tighten the motor shaft nut with the specified torque. Tighten: Shaft nut to 17 Nm (170 kgfcm/147 lbfin) Temporarily fit the motor by using one of the four wiper motor fixing screws. Put the crank arm ball joint in the wiper link hole and fix them together while pulling the wiper link.

CAB AND CHASSIS ELECTRICAL


Windshield Washer Motor
Inspection With the battery (+) terminal connected to the washer motor connector terminal 1 B-8 and the () terminal to the connector 2 B-8 , check to see if the cleaning fluid pushes out. Replace the tank/motor when the result of inspection is found abnormal.

8-217

Installation To install, follow the removal steps in the reverse order.

B-8

N8A0265E

Removal Preparation: Disconnect the battery ground cable. 1. Instrument Panel Under Cover Refer to INSTRUMENT PANEL of section 2. 2. Washer Tank 1) Disconnect the washer motor connector. 2) Disconnect the washer hose. 3) Remove three fixing screws. 3. Clip Band 4. Windshield Washer Motor Hold the motor and pull it out from the washer tank.

2 1

N8A0266E

8-218 CAB AND CHASSIS ELECTRICAL


Intermittent Relay
Circuit Diagram

N8A0267E

CAB AND CHASSIS ELECTRICAL


Removal Preparation: Disconnect the battery ground cable. 1. Glove Box Open the lid and remove the four screws. 2. Intermittent Relay 1) Press A position with your finger and pry up B position with the tip of a screwdriver. 2) When the relay moves up by about 2/3 of its size, tilt and take off the relay to avoid interference with the instrument panel. 3) Disconnect the connector.

8-219

Windshield Wiper Arm & Blade


Removal 1. Cover 2. Wiper Arm Nut 3. Wiper Arm & Blade

A Instrumental panel 2 S
N8A0269E

B 1

Instrument panel reinforcement

Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Before installing the wiper arm & blade to the shaft, confirm that the motor stops at the auto-stop position. 2. Set the wiper arm & blade so that the tips of both blades are positioned as shown in the illustration. 3. Tighten the wiper arm nut to the specified torque. Tighten: Wiper arm nut to 17 Nm (170 kgfcm/147 lbfin)

2 View S

N8A0268E

Installation To install, follow the removal steps in the reverse order.

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

N8A0270E

8-220 CAB AND CHASSIS ELECTRICAL


Windshield Wiper Linkage
Location of Rod and Pivot

Pivot (Wiper: LH)

Pivot (Wiper: RH)

Rod

Rod

Wiper motor
N8A0271E

Removal Preparation: Disconnect the battery ground cable. 1. Wiper Arm & Blade Remove the cover, nut and wiper arm & blade.

2. Pivot Nut Remove the rubber seal, nut and retaining rubber.

Cover

Nut 1 Rubber seal Retaining rubber

N8A0273E

N8A0272E

CAB AND CHASSIS ELECTRICAL


3. Instrument Panel Assembly Refer to INSTRUMENT PANEL of section 2.

8-221

5. Instrument Panel Reinforcement Refer to INSTRUMENT PANEL of section 2.

N8A0274E

N8A0276E

4. Wiper Motor 1) Remove the four screws. 2) Disconnect the ball joint between the crank arm and the wiper link.

6. Wiper Link Assembly Remove two retaining nuts from right hand side of pivot.

Pivot (Wiper: LH)

N8A0277E N8A0275E

8-222 CAB AND CHASSIS ELECTRICAL


Remove two retaining nuts from left hand side of pivot. Notice: When the wiper blade has been removed, wrap the tip of the wiper arm with cloth, to avoid damaging the glass.

Pivot (Wiper: RH)

N8A0278E

Installation To install, follow the removal steps in the reverse order, noting the following points. Temporarily fit the wiper motor by using one of the four wiper motor fixing screws. Put the crank arm ball joint in the wiper link hole and fix them together while pulling the wiper link. Fit the motor with four screws. Tighten the pivot nut with the specified torque. Tighten: Pivot nut to 8 Nm (80 kgfcm/70 lbfin) Tighten the wiper arm nut with the specified torque. Tighten: Wiper arm nut to 17 Nm (170 kgfcm/147 lbfin)

N8A0477E

2. Wiper Blade Rubber 1) Pull the end of rubber and remove the projection from the click of the blade stay. 2) Pull the rubber out in the same direction.

Wiper Blade Rubber


Removal 1. Wiper Blade Push the wiper blade lock while pulling the wiper blade in the arrow direction.
N8A0280E

CAB AND CHASSIS ELECTRICAL


Installation 1. Wiper Blade Rubber Install the click of the blade stay in the groove of the new rubber and slide it in. Complete installation by pushing the click.

8-223

2
N8A0486E

Audio and Cigar Lighter


General Description
N8A0281E

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

The circuit consists of the starter switch, radio, cigar lighter and the relay. The audio circuit is designed for the current to flow through the receiver circuit when the radio switch is turned on with the starter switch in ACC or ON. Current runs through the memory circuit of the audio regardless of the position of the starter switch. When the cigar lighter is pushed in with the starter switch at either ACC or ON position, a circuit is formed in the cigar lighter case to heat the lighter coil. The cigar lighter is spring back to its original position after the lighter coil is heated.

N8A0282E

2. Wiper Blade Push the lock of wiper blade (1) into the retentive portion on the tip of wiper arm (2).

Parts Location

8-224 CAB AND CHASSIS ELECTRICAL

X-4 TAIL RELAY

H-2(S/CAB), H-20(W/CAB) H-11(S/CAB), H-22(W/CAB)

D-5 SPEAKER (RH)

F-4, F-7, F-15

N8B0051E

D-1 SPEAKER (LH)

CAB AND CHASSIS ELECTRICAL


Circuit Diagram

8-225

STARTER SWITCH FL-2 40A KEY SW 3W/L FL-1 100A or 120A 2L


P-1 P-2 1 H-7 2 B-67 B OFF ACC B-67 1

3W/L

ON ST

8B

MAIN 4JJ1 /4HK1 80A ACG Except 4JJ1 /4HK1 80A ACG 8W/B

8W/B

P-3

2 H-6

5W/B

P-4

3W/B

5W/B

3W/B F-4 15A AUDIO (B), DOOR LOCK

3R/Y F-15 15A AUDIO (IG) CIGAR LIGHTER 0.5R 0.5R/Y 0.5R/Y

P-5

2W/B

FRAME

3 X-4

3W/B
2 X-4 X-4

RELAY; TAIL

X-4 5

3W 0.85LG/R

F-7 10A TAIL LIGHT

0.85LG/R 0.85LG/R

0.5LG/R

0.85LG/R

0.5LG/R
10 B-28 11 B-28 4 B-28 1 1 B-44

0.3G/O

CIGAR LIGHTER

B-43

RADIO & CLOCK


B-28 9 B-28 12 B-28 5 B-28 13 B-28 6

0.5G

0.5GR

0.5B

0.5O

B-43 2

0.5R/Y
B-45 1

0.3B

LIGHTING SWITCH(8) (COMBINAITION SWITCH)

CLEARANCE LIGHT (LH)

0.5B

8 H-22

7 H-11

6 H-11

7 H-22

8 H-20

7 H-2

6 H-2

7 H-20

0.5GR

0.5G

1 D-1 D-1

1 D-5 D-5

0.5O

0.5B

For W/CAB EC

For S/CAB

For For W/CAB W/CAB EC EC

For S/CAB

For W/CAB EC
2

2B

SPEAKER (LH)

SPEAKER (RH)

HEADLIGHT BRACKET (LH)

B-7

3B

2B

2B

N8B0052E

8-226 CAB AND CHASSIS ELECTRICAL


Connector List
No. Connector Face No. Connector Face

X-4
005-006

D-5

1 2
002-010

B-7
000-001

B-44

1
001-011

B-28

1 7

2 8

3 9 10

B-45

1
001-009

11 12 13

013-001

B-43

1 2
002-009

B-67

1 3

2 4
004-001

B-43

1 2
002-010

B-67

2 4

1 3

004-002

D-1

1 2
002-009

H-2 (S/ CAB)

1 2

4 5 6 7 8

008-009

D-1

1 2
002-010

H-2 (S/ CAB)

2 1

8 7 6 5 4

008-010

D-5

1 2
002-009

H-11 (S/ CAB)

1 2

4 5 6 7 8

008-009

CAB AND CHASSIS ELECTRICAL


No. Connector Face No. Connector Face

8-227

H-11 (S/ CAB)

2 1

8 7 6 5 4

P-3
008-010 000-014

H-20 (W/ CAB)

1 2

3 4

P-5
010-003 000-002

5 6 7 8 9 10

H-6, H-7 H-20 (W/ CAB)


4 3 2 1

10 9 8 7 6 5

010-004

H-6

H-22 (W/ CAB)

1 2

3 4 1 2 H-7 2 1

5 6 7 8 9 10

1 2 3 4

4 3 2 1 8 7 6 5 H-8 13 12 11 10 9 18 17 16 15 14

010-003

5 6 7 8 9 10 11 12 13 14 15 16 17 18

H-22 (W/ CAB)

4 3

2 1

10 9 8 7 6 5

010-004

N8A5489E

P-1
000-022

P-4
000-014

P-2
000-014

8-228 CAB AND CHASSIS ELECTRICAL


Diagnosis
Cigar Lighter Does Not Heat Sufficiently

IS FUSE F-15 (15A) NORMAL?

YES IS B-7 GROUNDED SECURELY?

NO REPLACE THE FUSE

YES

NO GROUND IT SECURELY

REMOVE THE CIGAR LIGHTER SET THE STARTER SWITCH TO EITHER "ACC" OR "ON" POSITION IS THE BATTERY VOLTAGE APPLIED BETWEEN THE BIMETAL AT THE CENTER OF THE CASE AND OUTER OF THE CASE?

YES SET THE STARTER SWITCH TO EITHER "ACC" OR "ON" IS THE BATTERY VOLTAGE APPLIED BETWEEN B-7 AND GROUND?

NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN FUSE F-15 (15A) AND 1 B-44

YES REPLACE THE CIGAR LIGHTER ASSEMBLY

NO

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

N8A0285E

The Cigar Lighter Does Not Spring Out After Being Heated

IS THE FORM OF CIGAR LIGHTER NORMAL?

YES REPLACE THE CIGAR LIGHTER ASSEMBLY (INCLUDE OUTER CASE)

NO REPLACE THE CIGAR LIGHTER

N8A0286E

CAB AND CHASSIS ELECTRICAL


Starter Switch
Refer to START AND CHARGING in this section.

8-229

Radio
Removal Preparation: Disconnect the battery ground cable. 1. Center Cluster 1) Pull it to remove. Pry off three clips by the tip of screwdriver. 2) Remove the cigar lighter power source and its illumination connector. Notice: To remove the center cluster, do not force to pry off three clips at upper portion of the center cluster.
1

N8A0393E

Legend 1. Radio Installation To install, follow the removal steps in the reverse order.

Antenna
Inspection The metal A is connected to the pole D at the top of the antenna through the core of the feeder. The metal B is fitted in the feeder shielding the core, and grounded at the screw C to avoid the core hampered by noise. Defective grounding would cause noise.
N8A0392E

Legend 1. Center Cluster 2. Radio 1) Remove the two radio fixing screws. 2) Disconnect the connector and feeder plug.

N8A0289E

8-230 CAB AND CHASSIS ELECTRICAL


In checking, measure the following three points with the circuit tester in the range of resistance x 1 (). Between A and B No continuity (No reading at the indicator) Normal Continuity (A bite in the feeder. The core grounded) Lower reception Between B and C Continuity (Indicator reading: 0) Normal No continuity (Shielded core disconnected or defective grounding at the screw Hampered by noise) Between A and D Continuity or no continuity There are some antenna feeders and relay feeders with a condenser built in their connections. Measuring resistance between the two points does not result in correct judgment. Connect temporarily another normal antenna to the radio and check to see if its reception is audible. Most antenna now available are slide type. Rust at the screw C and the cab panel where grounded would lead no continuity, followed by lower reception. Keep this portion clean to avoid rust. Removal Preparation: Disconnect the battery ground cable. 1. Antenna 1) Disconnect the joint connector. 2) Remove the upper and lower side antenna bracket. 3) Pull out the antenna feeder. Notice: For easier fitting, tie the lead wire to the end of the antenna feeder in advance.

5 4 7 6

N8A0394E

Legend 1. 2. 3. 4. 5. 6. 7. Antenna Antenna Bracket Feeder Joint Connection Feeder Clip Radio

Installation To install, follow the removal steps in the reverse order.

Speaker
Inspection 1. With the circuit tester set to the range of 1 (), connect the circuit tester probes (red and black) to the (+) and () terminals of the speaker. 2. When the speaker is normal, a low buzzing sound is heard. 3. When the speaker is defective, no sound is heard. However, the distortion or chattering of the sound cannot be identified. When the speaker is installed to the vehicle, disconnect the connectors before checking. When no sound is heard, the following are considered as the cause. The speaker wiring is disconnected at the speaker terminals. The speaker body is defective.

CAB AND CHASSIS ELECTRICAL


There is an open circuit somewhere in the speaker harness on the vehicle side. The speaker harness on the vehicle side is grounded or caught up. Removal Preparation: Disconnect the battery ground cable. 1. Door Pad Refer to FRONT DOOR TRIM PAD of section 2. 2. Speaker Panel Disconnect the speaker connector. 3. Speaker 4. Waterproof Sheet

8-231

Cigar Lighter
Removal Preparation: Disconnect the battery ground cable. 1. Center Cluster Refer to RADIO in this section. 2. Cigar Lighter Assembly Remove the nut, then remove cigar lighter assembly, bezel and outer case.

2 4 1

N8A0395E

Legend
N8A5341E

Legend 1. 2. 3. 4. Trim Panel Speaker Panel Speaker Waterproof Sheet

1. 2. 3. 4. 5.

Bezel Cigar Lighter Assembly Center Cluster Outer Case Nut

Installation To install, follow the removal steps in the reverse order.

Installation To install, follow the removal steps in the reverse order.

Meter and Warning/indicator Light


General Description
The circuit consists of the starter switch, meter assembly, vacuum tank switch, oil pressure switch, fuel sedimenter switch, brake fluid switch, parking brake switch, vehicle speed sensor, fuel tank unit, thermo unit and engine speed sensor. The meter assembly contains the speedometer, tachometer, fuel meter, thermometer and the warning/indicator light. The meter warning/indicator lights and their bulb sockets are a unit, they are installed from the back of the speedometer assembly.

TCM (B-425,B-427) N-6 SW: PARKING BRAKE N-19 SW: SELECT J-1,J-2 AC GENERATOR J-206 SW: FUEL SEDIMENTER J-32 V/SPEED SENSOR FUEL TANK E-111

Parts Location

For 4HK1 Engine

RELAY BOX ASM (NO.1) X-8 HEATER RELAY X-12 HEATER & A/C RELAY B-18, X-32 DIODE BOX STARTER SW J-8 E-90 H-118 H-14
H-16 H-105

8-232 CAB AND CHASSIS ELECTRICAL

FUSE & RELAY BOX ASM X-1 CHARGE RELAY F-1,F-2,F-4,F-7,F-16 FUSE J-28

B-502 DIODE

ABS EHCU (J-177)

H-15 P-5 P-1 P-2 BATTERY P-4 P-3


RELAY BOX ASM FL-1,FL-2 FUSIBLE LINK

RELAY BOX ASM (NO.2) X-13 BUZZER CANCEL RELAY

B-7 EARTH: HEADLIGHT BRACKET-LH

H-4 H-8

J-191 ECM

B-53 METER H-12

J-128 SW: HBB LEVEL J-9 EARTH: FRAME J-26,J-27 STARTER

B-57 METER

B-51 METER B-52 METER

B-85 SW: BRAKE OIL LEVEL B-71 SW: VACUUM TANK

B-1 EARTH: FRAME-LH (FRT)

B-67 IGNITION SW "A"

N8B0053E

B-236 SW: PRESSURE

B-425,B-427 TCM (EURO-4) N-6 SW: PARKING BRAKE N-19 SW: SELECT (EURO-4) J-1,J-2 AC GENERATOR J-206 SW: FUEL SEDIMENTER J-32 V/SPEED SENSOR H-105 FUEL TANK J-28

For 4JJ1 Engine

E-90 COOLANT TEMPERATURE SENSOR FRAME HARNESS

RELAY BOX ASM (NO.1) X-8 HEATER RELAY X-12 HEATER & A/C RELAY B-18, X-32(EURO-4) DIODE BOX STARTER SW

FUSE & RELAY BOX ASM X-1 CHARGE RELAY F-1,F-2,F-4,F-7,F-16 FUSE

J-8 SW: OIL PRESSURE H-14


H-16 J-177 ABS EHCU (EURO-4)

H-15 (EURO-4) P-5 P-1 P-2 BATTERY P-4 P-3


RELAY BOX ASM FL-1,FL-2 FUSIBLE LINK

H-5 H-8

B-7 EARTH: HEADLIGHT BRACKET-LH

H-4 (EURO-4 NKR)

J-191 ECM

B-53 METER (EURO-4) B-51 METER H-12


J-9 EARTH: FRAME J-26,J-27 STARTER

B-57 METER

H-17 (EURO-4 NKR)

B-85 SW: BRAKE OIL LEVEL B-52 METER

CAB AND CHASSIS ELECTRICAL

B-1 EARTH: FRAME-LH (FRT)

B-67 IGNITION SW "A" B-71 SW: VACUUM TANK

N8B0054E

8-233

8-234 CAB AND CHASSIS ELECTRICAL


Circuit Diagram
For 4HK1 Engine
RELAY: CHARGE
1

STARTER

J-26 B 1 H-7

FL-2 40A KEY


3W/L 2 J-1 AC GEN. J-1 J-2 1 1 1.25W/L 0.85W/L 15 H-5 8W/B

FL-1 100A or 120A MAIN


0.5W/L

0.5W/R 1

X-1 X-1

0.5B/Y

2L

0.5W/L 5

X-1

X-1

0.5B/Y

Relay: Thermo A/C F-1 15A HEATER, AIR CON SW: Thermo F-2 10A FUEL HEATER

8W/B

0.5W/L

RELAY: HEATER & A/C


X-12 X-12 X-12 X-12 4 0.5B 5 3L

5W/B (STD AC GEN.) 8W/B (80A AC GEN.) 3W/L C J-27 1 2 H-6 5W/B

3W/B

1 0.5W/R 2

3W/B

RELAY: STARTER
2 B-67 0.5W/L

RELAY: HEATER
3W/B 3W/B 2 X-8 X-8 1 3B/R

STARTER SW

3W/B

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


0.85R 0.5R

X-8

X-8

5 0.5B

ST

ON

30B/R

ACC

OFF

10 B-67 3 + DPF REGENERATE B-51

16 B-52

18 B-51

CHARGE

BRAKE

P-2 + P-3 P-4 -

EXH BRAKE

FUEL

3B/Y

0.5B/Y

F-16 10A METER

POWER SUPPLY CIRCUIT

I/F & METER IC

LAMP DRIVER

FUEL

SVS

TACHO

SPEED

ENGINE COOLANT TEMPERATURE GAUGE

B-51 5

B-51 4

B-51 5 0.5L/R

B-51 13

B-51 7

B-51 4

B-53 10

B-52 15

B-51 6 0.5L/P

B-51 15 0.5B

B-52 6 0.5LG/W

B-52 8 0.3LG

B-52 17 0.3Y/G

B-52 20 0.5B

B-52 5 0.5LB

Smoother

Smoother

0.5B/Y

FRAME

0.3W/V 0.5B/Y 0.3W/L 0.5W/B

13 21 0.5B H-5 0.3W/V 0.5B/Y 0.3Y/G H-5 0.5LG/W 12 H-5 0.5LB 1 H-5 16 H-105 0.5LG/W 1

0.5Y/R (S/CAB) 0.5R (W/CAB)

2 LEVEL SW: B & C OIL B-85

24 H-5

30 H-5

19 H-4

40 H-5

7 H-5

31 H-5

3 H-8 0.5LG

25 H-5 0.5Y/G

19 H-5 0.5B

1.25B

1 J-28 UNIT: FUEL SENSOR J-28 2

2B

SW: FUEL SEDIMENTER

B-85 9 0.5O/L 0.5L/P H-118 10 H-118 11 H-118

Smoother

0.5LG/B

0.5L/R

0.5L/B

3 E-90

0.5LB

0.5B

0.5W/B

H-105

3B

1 0.5B J-32 5B B-1 J-9 3B 6 J-191 OSDIAGL B-7 17 J-191 OS-SVS 9 J-191 OSDPFREG 11 J-191 OSGLOWL 7 J-191 OSEXBL

2 J-32

3 J-32 8 J-191 OFTACHO 0.5Y/G

METER ECT SENSOR48

V/SPEED SENSOR

19 J-191 IF-SPD

J-191 ISPBRK

ECM: ENGINE

FRAME-LH (FRT)

FRAME-LH (CTR)

HEADLIGHT BRACKET-LH

N8B0055E

0.5BR/W 2 J-206 J-206 1

P-5

10

M/T

M/T

M/T

0.5LG/B

0.5LG/B

0.3W/V

0.3W/V

0.5O/L

0.5L/R

0.5L/B

SEDIMENTER B-52

CHECK ENG.

P-1

3B/Y

GLOW

W/CAB only
17 0.5LG/R 0.85LG/R 0.85LG/R 3W 0.5B/Y ILL B-51 0.3W/L 0.5W/B 0.3W/V

2B

1.25B

RELAY: TAIL

J-9 ILL ILL ILL ILL

FRAME-LH (CTR)
0.5B 2 J-128 6 4

34 0.5W/R 0.3W/R 1 H-8 J-128 B-18

0.5BR

J-128

F-7 10A TAIL LIGHT

3B 2B 0.3B 1 3 4 0.3BR 0.3BR B-57 BUZZER X-13 X-13 3

H-5

35

0.5W/B

J-128

H-5

SW: HBB LEVEL M/T EC only


REAR FOG B-51 0.5R/G 0.5R/G 19 2 3

SW: PARKING BRAKE DIODE


0.5W/B B-18 H-12

0.3W/B

SW: PRESSURE

N-6

RELAY: RR FOG
8 8 0.5G/W H-14 0.5G/W 0.5G/W H-16 17 H-5

Smoother
3 0.3W/B 1 TURN (LH) 1 H-5 H-14 B-51 0.5G/B 0.5G/B 0.5G/B 10

5 H-12 3 B-18 TURN (RH) B-52 0.5G/B 0.5G/W 0.5G/W 1 5 3 2 X-13 X-13 B-51 HIGH BEAM 0.5R/G

TURN SIGNAL LAMP (R-1)


0.5G/B H-16

TURN SIGNAL LAMP (R-6)

0.3BR

HEAD LAMP (RH/LH)

B-236

B-236

B-7 B-502

HEADLIGHT BRACKET-LH RELAY; BUZZER CANCEL


B-502 BOOST 9 B-51 2 39 11 OIL PRESS 0.5BR/B B-51 H-5 0.3BR 0.3BR 0.3W/V 0.3W/B 0.3W/R
0.3BR/Y 0.3BR/Y

B-502

5B

DIODE

B-1

FRAME-LH (FRT)
10 6 3 4 5 1 20 ASR 0.3W/L B-51 12

SW: VACUUM TANK

B-71

SW: OIL PRESSURE


2 1 0.5BR/B 0.5BR/B H-105 J-8

1.25B

SHORT CONNECTOR (With HBB)


30 18 4 0.3W/L H-8 0.3W/L H-15

ASR IND
J-177 6 17 3 0.3W/V B-51 INVERTER CIRCUIT 0.3W/V H-8 0.3W/V H-15

With ABS

C/U: ABS

0.5B ABS 21 3 0.5Y/R H-12 0.5Y/R N-19 8 0.3G/O B-53 7 0.3Y/G B-53 2 1 6 0.5Y/R X-32 0.5Y/R 0.5Y X-32 B-53 1 0.3P B-53 METER IC

J-177

SHORT CONNECTOR (Without HBB)

METER IND

15

CAB AND CHASSIS ELECTRICAL

Smoother

SELECTOR LEVER

0.5B

0.5B

H-12

N-19

0.3B 2B

11

Without ABS

FRAME-LH (CTR)

SMOOTHER

J-9

B-425

12

ECONO

B-425

TCM

1st START

B-427

14

SHIFT IND

B-425

N8B0056E

8-235

8-236 CAB AND CHASSIS ELECTRICAL


For 4JJ1 (EURO 3) Engine
RELAY: CHARGE
1 J-2 2W 2 J-1 AC GEN. J-1 1 0.5W/L H-105 8 0.5W/L 15 H-5 0.5W/L 0.5W/L 5 X-1 X-1 3 0.5B/Y 0.5W/R 1 X-1 X-1 4 0.5B/Y

Relay: Thermo A/C F-1 15A HEATER, AIR CON SW: ENG. WARM, DPD REGENERATE F-2 10A FUEL HEATER

8W

FL-2 40A KEY


8W/B 3W/L

FL-1 100A MAIN


0.5W/L

RELAY: HEATER & A/C


X-12 X-12 X-12 X-12 4 0.5B 5 3L

8B

3W/B

1 0.5W/R 2

1 H-7 2L

2 H-6 5W/B

3W/L

30B/R

2L

RELAY: HEATER
3W/B 2 X-8 X-8 1 3B/R

1 J-26 B

STARTER
+ P-1 P-2 + P-3 P-4 -

3W/B

2 B-67

3W/B

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

X-8

X-8

5 0.5B 0.85R

C J-27 1

STARTER SW

OFF

10 B-51

18 B-51

RELAY: STARTER

ON B-67 3

ACC

ST

SEDIMENTER

P-5

3B/Y

F-16 10A METER

BUZZER

FRAME

B-51 5

B-57 3

B-52 10 0.5LG/W

11 0.5BR/B

0.5B/Y

0.5W/V

OIL PRESS B-51

CHARGE

3B/Y

BRAKE

0.5W/V 0.5B/Y 0.5LG/W

H-5

0.5Y/R

LEVEL SW: B & C OIL

0.5W/V 2 B-85 H-5 13 0.3BR 0.5LG/W H-5 39 0.5BR/B 6 H-105 0.5BR/B 2B B-85 1 0.5B

21

1 J-28 UNIT: FUEL SENSOR J-28 2

12 H-105 0.5LG/W 1 B-71

3B

SW: FUEL SEDIMENTER

J-206

SW: OIL PRESSURE

SW: VACUUM TANK

1 J-8

0.5B

J-9

3B B-7

J-206 1

FRAME-LH (CTR)

HEADLIGHT BRACKET-LH

N8B0057E

CAB AND CHASSIS ELECTRICAL


TURN SIGNAL LAMP (R-1) TURN SIGNAL LAMP (R-6)

8-237

RELAY: TAIL

0.5G/W

3W

H-16 8 0.5G/W

F-7 10A TAIL LIGHT


0.85LG/R

H-14 8 0.5G/W

0.5G/B H-14 1 0.5G/B

0.5G/B H-16 1

17 0.85LG/R H-5 0.5G/W

10 H-5 0.5G/B

0.85R

0.5LG/R

0.5G/W

0.5G/B

16 B-52

17 B-51

3 B-52

1 B-51

CHECK ENG.

EXH BRAKE

FUEL

FUEL

SVS

TACHO

SPEED

ENGINE COOLANT TEMPERATURE GAUGE

GLOW

ILL

ILL

ILL

ILL

B-51 13 0.5L/R

B-51 7 0.5L/B

B-52 15 0.5O/L

B-51 6 0.5L/P

B-51 15 0.5B

B-52 6 0.5LG/W

B-52 8 0.3LG

B-52 17 0.3Y/G

B-52 20 0.5B

B-52 5 0.5LB

0.5W/V 0.5B/Y 0.5LG/W 0.5B

3 B-18

DIODE

B-18 0.3Y/G 4 0.5B 0.5W/B

0.5W/B H-5 24 H-5 30 H-5 40 H-5 7 H-5 31 H-8 3 0.5LG H-5 25 0.5Y/G H-5 19 0.5B H-5 12 0.5LB H-5 1

0.5B/Y

0.85B

1 0.5W/B H-105 0.5LB H-12 3 0.3W/B

0.5O/L

0.5L/R

0.5L/B

0.5L/P

1 J-32

2 J-32

3 J-32 0.5Y/G

3 E-90

V/SPEED SENSOR

METER SW: PARKING BRAKE ECT SENSOR

6 B-1 J-191 OSDIAGL

17 J-191 OS-SVS

11 J-191 OSGLOWL

7 J-191 OSEXBL

8 J-191 OFTACHO

19 J-191 IF-SPD

48 J-191 ISPBRK

FRAME-LH (FRT)

ECM: ENGINE

0.5W/B

1 N-6

ILL

POWER SUPPLY CIRCUIT

I/F & METER IC

LAMP DRIVER

HIGH BEAM

TURN (RH)

TURN (LH)

0.5R/G 2 B-51

0.5R

N8B0058E

HEAD LAMP (RH/LH)

8-238 CAB AND CHASSIS ELECTRICAL


For 4JJ1 (EURO 4) Engine
RELAY: CHARGE
1 J-2 2W 2 J-1 AC GEN. J-1 1 0.5W/L H-105 8 0.5W/L 15 H-5 0.5W/L 0.5W/L 5 0.5W/R 1 X-1 X-1 3 0.5B/Y 4 0.5B/Y

X-1

X-1

Relay: Thermo A/C F-1 15A HEATER, AIR CON SW: ENG. WARM, DPD REGENERATE F-2 10A FUEL HEATER

FL-2 40A KEY


3W/L 8W/B 8B 1 H-7 3W/L 2 B-67 B

FL-1 100A MAIN STARTER SW


OFF ACC ON ST B-67 3 3B/Y 3B/Y 3W/B 0.5W/L

8W

RELAY: HEATER & A/C


X-12 X-12 X-12 X-12 4 0.5B 5 3L

2 H-6 3W/B 5W/B

1 0.5W/R 2

2L

RELAY: HEATER
3W/B 2 X-8 X-8 1 3B/R

30B/R

2L

STARTER
+ P-1

J-26 B

F-16 10A METER


0.5B/Y

3W/B

P-2 + P-3 P-4 C J-27 1 10 B-51

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

X-8

X-8

5 0.5B

0.85R

0.5R

16 B-52

18 B-51

DPF REGENERATE

EXH BRAKE

FUEL

P-5

FRAME POWER SUPPLY CIRCUIT LAMP DRIVER

I/F & METER IC

FUEL

SVS

TACHO

SPEED

ENGINE COOLANT TEMPERATURE GAUGE

B-51

B-51 4

B-51 5

B-51 13

B-51 7

B-51 4

B-53 10

B-52 15

B-51 6 0.5L/P

B-51 15 0.5B

B-52 6 0.5LG/W

B-52 8 0.3LG

B-52 17 0.3Y/G

B-52 20 0.5B

B-52 5 0.5LB

M/T

10 0.5BR/W (NPR) 0.5LG/W (NKR) 0.5W/B 13 H-5 1 H-5 12 H-105 0.5LG/W 2 J-206 J-206 1 J-191 ISPBRK

Smoother

Smoother

M/T

M/T

0.5LG/B

0.5LG/B

0.3W/V (NPR) 0.5W/V (NKR)

0.3W/V (NPR) 0.5W/V (NKR)

0.5O/L

0.5L/R

0.5L/R

0.5L/B

0.3W/V (NPR) 0.5W/V (NKR)

0.3Y/G

0.5B/Y

0.5Y/R (S/CAB) 0.5R (W/CAB)

2 LEVEL SW: B & C OIL B-85

24 H-5

30 H-5

4 H-17

19 H-4

40 H-5

7 H-5

31 H-5

3 H-8

25 H-5 0.5Y/G

19 H-5

12 H-5

2B

0.5LG

NKR

1.25B (NPR) 0.85B (NKR)

1 J-28 UNIT: FUEL SENSOR J-28 2

NPR

0.5LB

0.5B

B-85 1 0.5B 0.5LG/B 0.5O/L 0.5L/R 0.5L/B 0.5L/P

1 0.5W/B H-105 0.5LB

1 J-32

2 J-32

3 J-32 0.5Y/G

3 E-90

0.5B

V/SPEED SENSOR
5B 3B 6 J-191 OSDIAGL 17 J-191 OS-SVS 9 J-191 OSDPFREG 11 J-191 OSGLOWL 7 J-191 OSEXBL 8 J-191 OFTACHO

METER ECT SENSOR48

19 J-191 IF-SPD

B-1

J-9

B-7

ECM: ENGINE

FRAME-LH (FRT)

FRAME-LH (CTR)

HEADLIGHT BRACKET-LH

N8B0059E

SW: FUEL SEDIMENTER

3B

0.5B/Y

0.5LG/W

H-5

0.3W/V (NPR) 0.5W/V (NKR)

0.5B

21

SEDIMENTER B-52

CHECK ENG.

CHARGE

RELAY: STARTER

BRAKE

GLOW

CAB AND CHASSIS ELECTRICAL


TURN SIGNAL LAMP (R-1) TURN SIGNAL LAMP (R-6) C/U: ABS ASR IND METER IND

8-239

SW: OIL PRESSURE

RELAY: TAIL

0.5G/W

0.5G/B

J-8 1 0.5BR/B

J-177 30 0.3W/L

J-177 6 0.3W/V H-15 3 0.3W/V

3W

H-16 8 0.5G/W

H-16 1 0.5G/B

EC only

RELAY: RR FOG

F-7 10A TAIL LIGHT


0.85LG/R

H-105

H-14 8 0.5G/W

H-14 1 0.5G/B

H-15 4 0.3W/L

HEAD LAMP (RH/LH)

6 0.5BR/B

Without ABS (RIGID)


0.3B 2B

Without ABS (INDP)


0.3B 1.25B 2B

17 H-5

10 H-5 0.5G/B

0.85LG/R

39 H-5

18 H-8

17 H-8 J-9 0.3W/V

0.5R/G

0.5G/W

0.5BR/B

J-9

0.5LG/R

0.5G/W

0.5G/B

0.5R/G

0.5R/G

0.3W/L

FRAME-LH (CTR)

FRAME-LH (CTR)

17 B-51

19 B-51

3 B-52

1 B-51

2 B-51

11 B-51

20 B-51

12 B-51

INVERTER CIRCUIT

SMOOTHER

SHIFT IND ECONO 1st START

BUZZER

HIGH BEAM

REAR FOG

TURN (RH)

TURN (LH)

OIL PRESS

ILL

ILL

ILL

ILL

ILL

With ABS
B-57 3 0.3BR B-53 8 B-53 7 B-53 6 0.5Y B-53 1

NPR
0.3BR 0.3BR 1

1 X-32

NKR

0.5W/B

2 (NPR) 4 (NKR)

DIODE
B-18 B-18 3

0.3W/V 4 0.3W/B 3 10 6

SHORT CONNECTOR

DIODE

0.3W/V (NPR) 0.5W/V (NKR)

NKR

X-32 2 0.5Y/R

0.5Y/R 21 H-12 0.5Y/R

0.5W/B

SW: VACUUM TANK

1 B-71

0.3G/O

0.3Y/G

0.5Y/R

Smoother

3 N-19

M/T

H-12 3

H-12 5

SELECTOR LEVER
N-19 9 0.5B 11 B-425 12 B-425 1 B-427 14 B-425

0.3W/B

1 N-6

TCM

SW: PARKING BRAKE

15 1.25B (NPR) 0.85B (NKR) H-12 0.5B

B-1

Smoother

FRAME-LH (FRT)

0.5B

0.3P

METER IC

ASR

ABS

N8B0060E

8-240 CAB AND CHASSIS ELECTRICAL


Connector List
For 4HK1 Engine No. Connector Face B-71
1

No.

Connector Face

B-1
001-013 000-001

B-85 B-7
000-001

1 2
002-009

B-236 B-18
1 2 1 2 3 4
002-022 004-004

B-51
020-004

B-425 (For Smoot her)


031-001

B-52
020-005

B-427 (For Smoot her)


017-001

B-53 (For Smoot her)


012-009

B-57

3 2 1
003-035

B-502 B-67
1 3 2 4
004-001

1 2 3
003-033

E-90 B-67
2 4 1 3

1 3

003-004 004-002

CAB AND CHASSIS ELECTRICAL


No. Connector Face No. H-14 (Without ABS)
020-002

8-241

Connector Face

H-4

1 2 3 4 5 10 11 12 13 14 15

6 7 8 9 16 1718 19 20

1 5

2 6

3 7

4 8
008-003

H-4

9 8 7 6 20 19 18 17 16

5 4 3 2 1 15 14 13 12 11 10

H-14 (Without ABS)


020-003

4 8

3 7

2 6

1 5
008-004

H-12 (For M/T)

2 6 7

3 8

4 9

1 2 3 7 8 9 10

4 5 6 11 12 13 14

H-15
014-002

10 11 12 13 14 15 16

016-003

H-12 (For M/T)

3 8 7

2 6

1 5

6 5 4 14 13 12 11

3 2 1 10 9 8 7

H-15
014-003

14 13 12 11 10

16

15

016-004

H-12 (For Smoot her)

1 2 3 4 5 11 12 13 14 15 16

6 7 8 9 10 17 18 19 20 21 22

H-16
022-001

1 5

2 6

3 7

4 8
008-003

H-12 (For Smoot her)

10 9 8 7 6 22 21 20 19 18 17

5 4 3 2 1 16 15 14 13 12 11

H-16
022-002

4 8

3 7

2 6

1 5
008-004

H-14 (With ABS)

1 5 6

2 7

3 8

4 9

10 11 12 13 14 15 16

H-105
016-003

1 5 9

2 6

3 7

4 8

10 11 12

13 14 15 16

016-001

H-14 (With ABS)

4 9 8

3 7

2 6

1 5

14 13 12 11 10

H-105
016-004

4 8

3 7

2 6

1 5 9

12 11 10
16 15

16 15 14 13

016-002

8-242 CAB AND CHASSIS ELECTRICAL


No. H-118 (For Smoot her) Connector Face No. Connector Face

1 5 9

2 6

3 7

4 8

J-28
012-001

10 11 12

2
002-011

H-118 (For Smoot her)

4 8

3 7

2 6

1 5 9

J-32
012-002

12 11 10

003-018

J-1

J-128
002-003 004-018

J-2
000-001

J-177 (With ABS)


034-001

J-8
1

J-191
001-013 081-001

J-9
000-001

J-206

002-001

J-26
000-002

N-6

2 1
002-023

J-27
000-009

N-19 (For Smoot her)

1 2

3 4

5 6 7 8 9 10

010-003

CAB AND CHASSIS ELECTRICAL


No. Connector Face No. Connector Face

8-243

P-1
000-022

X-13
005-006

P-4
000-014

X-32 (For Smoot her)

1 2 3 4

004-004

H-5 P-2
000-014

P-3
000-014

1 7 13 19 25 31

2 8 14 20 26 32

3 9 15 21 27 33

34

35

36

37

4 10 16 22 28 38

5 11 17 23 29 39

6 12 18 24 30 40

6 12 18 24 30 40

5 11 17 23 29 39

4 10 16 22 28 38

37

36

35

34

3 9 15 21 27 33

2 8 14 20 26 32

1 7 13 19 25 31

P-5
000-002

N8A5488E

H-6, H-7, H-8 X-1


005-006

H-6

X-8
005-006

H-7

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
1 2 3 5 4

4 3 2 1 8 7 6 5 H-8 13 12 11 10 9 18 17 16 15 14

X-12

005-001

N8A5489E

8-244 CAB AND CHASSIS ELECTRICAL


For 4JJ1 Engine No. Connector Face B-71
1

No.

Connector Face

B-1
001-013 000-001

B-85 B-7
000-001

1 2
002-009

B-18

1 2 3 4

B-425 (For EURO 4 with Smoot her) B-427 (For EURO 4 with Smoot her)

031-001

004-004

B-51
020-004

017-001

B-57 B-52

3 21 1
003-035 001-013

020-005

B-53 (For EURO 4 with Smoot her)

E-90

1 3

003-004 012-009

B-67

1 3

2 4
004-001

H-4 (For NPR85 )

1 2 3 4 5 10 11 12 13 14 15

6 7 8 9 16 1718 19 20

020-002

B-67

2 4

1 3

H-4 (For NPR85 )


004-002

9 8 7 6 20 19 18 17 16

5 4 3 2 1 15 14 13 12 11 10

020-003

CAB AND CHASSIS ELECTRICAL


No. Connector Face No. H-15 (For EURO 4 with ABS) H-15 (For EURO 4 with ABS) Connector Face

8-245

H-12 (For M/ T)

1 5 6

2 7

3 8

4 9

1 2 3 7 8 9 10

4 5 6 11 12 13 14

10 11 12 13 14 15 16

014-002

016-003

H-12 (For M/ T)

4 9 8

3 7

2 6

1 5

6 5 4 14 13 12 11

3 2 1 10 9 8 7

14 13 12 11 10

16

15

014-003

016-004

H-12 (For EURO 4 with Smoot her) H-12 (For EURO 4 with Smoot her)

1 2 3 4 5 11 12 13 14 15 16

6 7 8 9 10 17 18 19 20 21 22

H-16
022-001

1 5

2 6

3 7

4 8
008-003

10 9 8 7 6 22 21 20 19 18 17

5 4 3 2 1 16 15 14 13 12 11

H-16
022-002

4 8

3 7

2 6

1 5
008-004

H-14 (With ABS)

1 5 6

2 7

3 8

4 9

10 11 12 13 14 15 16

016-003

H-17 (For NKR85 , Smoot her) H-17 (For NKR85 , Smoot her) H-17 (For NKR85 , M/T)

4 8

3 7

2 6

1 5 9

12 11 10

16 15 14 13

016-002

H-14 (With ABS)

4 9 8

3 7

2 6

1 5

1 5 9

2 6

3 7

4 8

14 13 12 11 10

10 11 12

16

15

13 14 15 16

016-004

016-001

H-14 (Without ABS)

1 5

2 6

3 7

4 8
008-003

004-018

H-14 (Without ABS)

4 8

3 7

2 6

1 5
008-004

H-17 (For NKR85 , M/T)

1 3

2 4
004-011

8-246 CAB AND CHASSIS ELECTRICAL


No. Connector Face No. Connector Face

H-105

1 5 9

2 6

3 7

4 8

J-28
012-001

10 11 12

2
002-011

H-105

4 8

3 7

2 6

1 5 9

J-32
012-002

12 11 10

003-018

J-1

J-177 (With ABS)


002-003 034-001

J-2
000-001

J-191
081-001

J-8
1

J-206
001-013

002-001

J-9
000-001

N-6

2 1
002-023

J-26
000-002

N-19 (For EURO 4 with Smoot her)

1 2

3 4

5 6 7 8 9 10

010-003

J-27
000-009

P-1
000-022

CAB AND CHASSIS ELECTRICAL


No. Connector Face H-5

8-247

P-4
000-014

P-2
000-014

1 7 13 19 25 31

2 8 14 20 26 32

3 9 15 21 27 33

34

35

36

37

4 10 16 22 28 38

5 11 17 23 29 39

6 12 18 24 30 40

6 12 18 24 30 40

5 11 17 23 29 39

4 10 16 22 28 38

37

36

35

34

3 9 15 21 27 33

2 8 14 20 26 32

1 7 13 19 25 31

P-3
000-014

N8A5488E

H-6, H-7, H-8

P-5
000-002

H-6

H-7

X-1
005-006

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 H-8

4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14

X-8
005-006

N8A5489E

X-12

1 2 3 5 4

005-001

X-32 (For EURO 4 with Smoot her)

1 2 3 4

004-004

8-248 CAB AND CHASSIS ELECTRICAL


Diagnosis
Quick Chart for Check Point 1. Speedometer Check point Speedometer 1-1. Speedometer and odometer do not function 1-2. Speedometer does not function (odometer is normal) Trouble mode 1-3. Odometer does not function (Speedometer is normal) 1-4. Speedometer needle fluctuates (May be wide fluctuation) 1-5. Speedometer needle jumps erratically Notice: Figure in parenthesis ( ) indicates the order of inspection. 2. Tachometer Check point Tachometer 2-1. Tachometer does not function Trouble mode 2-2. Tachometer needle fluctuates (May be wide fluctuation) 2-3. Tachometer needle jumps erratically Notice: Figure in parenthesis ( ) indicates the order of inspection. 3. Coolant Temperature Gauge Check point Meter ASM 3-1. Coolant temperature gauge needle does not move Trouble mode 3-2. Coolant temperature gauge reading is too low (or high) 3-3. Needle overshoots (or goes up to the H range) (3) (4) (3) Thermo meter (4) (5) (4) ECT sensor (2) (3) (1) (1) Thermostat Cable harness (1) (2) (2) (3) (3) (3) ECM (1) (1) (1) Cable harness (2) (2) (2) (3) (1) (1) (3) (3) (1) (1) (2) (2) Vehicle speed sensor (1) Cable harness (2)

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

CAB AND CHASSIS ELECTRICAL


4. Fuel Gauge Check point Meter ASM 4-1. Fuel gauge needle does not move Trouble mode 4-2. Even when the tank is filled up with fuel, the needle does not reach F 4-3. When the tank is not full of fuel, the needle overshoots (or goes to F) Notice: Figure in parenthesis ( ) indicates the order of inspection. 5. Warning/indicator Light Check point Light Parking bulb brake SW 5-1. When the parking brake lever is pulled, the indicator light does not light up 5-2. Even when the parking brake lever is released, the indicator light does not go off 5-3. While the engine operating, the oil pressure warning light does not go off 5-4. Even when the tank is full with fuel, the fuel warning light lights up Trouble mode 5-5. Even when the tank is empty, the low fuel warning light does not light up 5-6. Even when the float in the water sedimenter goes up above the drain warning level, the indicator light does not light up 5-7. Even when the brake fluid is lower than specified level, the level warning light does not light up 5-8. Even when the vacuum tank is empty vacuum warning buzzer does not sound Notice: Figure in parenthesis ( ) indicates the order of inspection. (1) (1) (2) (1) (1) (2) (1) (2) (2) Brake fluid SW Oil pressure SW Fuel tank unit (3) (3) (3) Fuel gauge (4) (4) (4) Fuel tank unit (2) (2) (2)

8-249

Cable harness (1) (1) (1)

SediVacuum Cable menter SW harness SW (3) (2) (1) (2) (3) (3)

(2)

(1) (1)

(3) (2)

8-250 CAB AND CHASSIS ELECTRICAL


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

DOES THE VEHICLE SPEED SENSOR OUTPUT IN NORMALLY?

YES ARE THE CIRCUITS BETWEEN THE VEHICLE SPEED SENSOR AND THE METER, AND THE FUSE F-16 (10A) AND THE GROUND NORMAL?

NO REPLACE THE VEHICLE SPEED SENSOR

YES

NO REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT IN THE CIRCUIT

REPLACE THE SPEEDOMETER


N8B5155E

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

REPLACE THE SPEEDOMETER ASSEMBLY

N8A0300E

CAB AND CHASSIS ELECTRICAL


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

8-251

REPLACE THE SPEEDOMETER ASSEMBLY

N8A0300E

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

N8A5366E

1-5. Speedometer Needle Jumps Erratically

N8A5366E

8-252 CAB AND CHASSIS ELECTRICAL


Inspection of waveform by oscilloscope 1. Connect a resistance of 1.3 to 5k ohm (1.4W or more) between the harness side connectors 18 B-51 and 17 B-52 of the meter.
B-51 B-52

2. 3. 4.

Install a speedometer tester. Turn on the starter SW. Check the waveform at the time when the vehicle speed is at 60 Km (37 mph).

Normal waveform Approximate battery voltage

0V 23.6 m sec. 2V or less


N8B0061E

2. Tachometer 2-1. Tachometer Does Not Function 2-2. Tachometer Needle Fluctuates (May Be Wide Fluctuation) 2-3. Tachometer Needle Jumps Erratically

IS THE PULSE INPUT NORMAL?

YES

NO REPAIR A POOR CONNECTION AT THE CONNECTORS IN THE CIRCUIT OR A FAILURE IN THE CABLE HARNESS, OR REPLACE ECM

REPLACE THE TACHOMETER

N8B5161E

CAB AND CHASSIS ELECTRICAL


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

8-253

IS THE CONNECTOR OF THE ECT SENSOR CONNECTED SECURELY?

YES

NO CONNECT THE CONNECTOR SECURELY

DISCONNECT THE CONNECTOR OF THE ECT SENSOR CONNECT A 3.4W BULB BETWEEN THE HARNESS SIDE CONNECTOR 3 E-90 AND THE GROUND OF THE ECT SENSOR WHEN THE STARTER SW IS TURNED ON, DOES THE TEMPERATURE GAUGE NEEDLE MOVE ABOUT 10 SECONDS AFTER THAT?

YES IS THE ECT SENSOR NORMAL?

NO IS THE CIRCUIT BETWEEN THE TEMPERATURE GAUGE AND THE ECT SENSOR NORMAL?

YES

NO REPLACE THE ECT SENSOR

YES

NO

REPAIR A POOR CONNECTION AT THE CONNECTOR

IS THERE A BROKEN WIRE IN THE PRINTED CIRCUIT OF THE METER ASSEMBLY?

REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT IN THE CIRCUIT

YES

NO REPLACE THE PRINTED CIRCUIT BOARD

CHECK THE COOLANT TEMPERATURE GAUGE AND REPLACE IT WITH A CORRECT ONE IF NECESSARY

N8B5066E

8-254 CAB AND CHASSIS ELECTRICAL


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

DOES THE THERMOSTAT OPERATE NORMALLY?

YES

NO REPLACE THE THERMOSTAT

TURN THE STARTER SWITCH ON WHEN INSERTING AND PULLING OUT THE THERMOSTAT CONNECTOR 3 E-90 SEVERAL TIMES, DOES THE INDICATION OF THE COOLANT TEMPERATURE GAUGE VARY?

YES IS THE ECT SENSOR NORMAL?

NO REPAIR A POOR CONNECTION AT THE CONNECTOR OF THE ECT SENSOR

YES IS THERE AN OPEN CIRCUIT IN THE METER ASSEMBLY PRINTED CIRCUIT BOARD?

NO REPLACE THE ECT SENSOR

YES

NO REPLACE THE PRINTED CIRCUIT BOARD

CHECK THE COOLANT TEMPERATURE GAUGE AND REPLACE IT IF FOUND DEFECTIVE

N8B5067E

CAB AND CHASSIS ELECTRICAL


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

8-255

DISCONNECT THE CONNECTOR OF THE ECT SENSOR WHEN THE STARTER SW IS TURNED ON, DOES THE POINTER REACH TO THE "H" RANGE?

YES

NO REPLACE THE ECT SENSOR

IS THERE A SHORT CIRCUIT BETWEEN THE ECT SENSOR AND THE COOLANT TEMPERATURE GAUGE?

YES IS THE PRINTED CIRCUIT OF THE METER ASSEMBLY GROUNDED SECURELY?

NO REPAIR A SHORT CIRCUIT

YES

NO REPAIR OR REPLACE THE PRINTED CIRCUIT BOARD

CHECK THE COOLANT TEMPERATURE GAUGE AND REPLACE IT IF FOUND ABNORMAL

N8B5156E

8-256 CAB AND CHASSIS ELECTRICAL


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

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

YES

NO CONNECT THE CONNECTOR SECURELY

DISCONNECT THE CONNECTOR OF THE FUEL TANK UNIT CONNECT A 3.4W BULB BETWEEN THE HARNESS SIDE CONNECTOR 1 J-28 AND THE GROUND OF THE FUEL TANK UNIT WHEN THE STARTER SW IS TURNED ON, DOES THE FUEL GAUGE NEEDLE FLUCTUATE AFTER ABOUT 90 SECONDS?

YES IS THERE CONTINUITY BETWEEN THE FUEL TANK UNIT CONNECTOR TERMINALS 1 J-28 AND 2 J-28 ?

NO IS THE CIRCUIT BETWEEN THE FUEL GAUGE AND THE FUEL TANK UNIT NORMAL?

YES

NO REPLACE THE FUEL TANK UNIT

YES IS THERE A BROKEN WIRE IN THE PRINTED CIRCUIT OF THE METER ASSEMBLY?

NO

REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT IN THE CIRCUIT

REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN THE FUEL TANK UNIT AND THE METER

YES

NO

CHECK THE FUEL METER, AND REPLACE IT IF NECESSARY

REPLACE THE PRINTED CIRCUIT BOARD

N8B5068E

CAB AND CHASSIS ELECTRICAL


4-2. Even when The Tank Is Filled Up with Fuel, The Needle Does Not Reach F
WHEN INSERTING AND PULLING OUT THE CONNECTOR J-28 OF THE FUEL TANK UNIT SEVERAL TIMES, DOES THE POINTER OF THE FUEL GAUGE STAY AT THE SAME POSITION?

8-257

YES

NO REPAIR A POOR CONNECTION AT THE CONNECTOR OF THE FUEL TANK UNIT

DISCONNECT THE CONNECTOR OF THE FUEL TANK UNIT CONNECT THE FUEL TANK UNIT HARNESS SIDE CONNECTOR 1 J-28 AND 2 J-28 WITH A LEAD WIRE WHEN THE STARTER SW IS TURNED ON, DOES THE NEEDLE OVERSHOOT TO "F" AFTER ABOUT 5 MINUTES?

YES IS THERE A BROKEN CIRCUIT IN THE PRINTED CIRCUIT OF THE METER ASSEMBLY?

NO REMOVE THE FUEL TANK UNIT DOES THE FLOAT ARM OPERATE SMOOTHLY?

YES

NO REPLACE THE PRINTED CIRCUIT BOARD

YES IS THE RESISTANCE VALUE OF THE FUEL TANK UNIT NORMAL?

CHECK THE FUEL GAUGE AND REPLACE IT IF FOUND ABNORMAL

NO REPLACE THE FUEL TANK UNIT


N8B5069E

8-258 CAB AND CHASSIS ELECTRICAL


4-3. When The Tank Is Not Full of Fuel, The Needle Overshoots (or Goes Up to F)

DISCONNECT THE CONNECTOR OF THE FUEL TANK UNIT WHEN THE STARTER SW IS TURNED ON, DOES THE NEEDLE STILL POINT TO "F"?

YES IS THE CIRCUIT BETWEEN THE FUEL TANK UNIT AND THE FUEL METER NORMAL?

NO REMOVE THE FUEL TANK UNIT DOES THE FLOAT ARM OPERATE SMOOTHLY?

YES IS THE PRINTED CIRCUIT OF THE METER ASSEMBLY GROUNDED SECURELY?

NO

YES ARE THE RESISTANCE VALUES OF THE FUEL TANK UNIT AT "E" AND "F" POINTS NORMAL?

REPAIR A SHORT CIRCUIT IN THE CIRCUIT

YES

NO

NO

REPAIR OR REPLACE THE PRINTED CIRCUIT BOARD

REPLACE THE FUEL TANK UNIT

CHECK THE FUEL GAUGE, AND REPLACE IT IF NECESSARY

N8A0313E

CAB AND CHASSIS ELECTRICAL


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

8-259

IS THERE CONTINUITY IN THE CIRCUIT BETWEEN THE PARKING BRAKE SWITCH CONNECTOR 1 N-6 AND 5 B-51 (METER)?

N8B5070E

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

REPAIR A SHORT CIRCUIT BETWEEN THE PARKING BRAKE SWITCH CONNECTOR 1 N-6 AND 5 B-51
N8B5071E

8-260 CAB AND CHASSIS ELECTRICAL


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

IS THE ENGINE OIL PRESSURE NORMAL?

YES WITH THE OIL PRESSURE SWITCH CONNECTOR J-8 DISCONNECTED, DOES THE WARNING LIGHT GO OFF?

NO REFER TO THE "ENGINE" SECTION

YES WHILE THE ENGINE IS OPERATING, IS THERE CONTINUITY BETWEEN THE OIL PRESSURE SWITCH CONNECTOR J-8 AND THE BODY GROUND?

NO REPAIR A SHORT CIRCUIT BETWEEN 1 J-8 AND 11 B-51 (METER)

NO REPLACE THE OIL PRESSURE SWITCH

N8B5072E

5-4. Even When The Fuel Tank Is Full with Fuel, The Fuel Warning Light Lights Up
WHEN THE FUEL TANK UNIT CONNECTOR J-28 IS DISCONNECTED, DOES THE WARNING LIGHT GO OFF?

YES IS THE FUEL TANK UNIT NORMAL?

NO REPAIR A SHORT CIRCUIT BETWEEN THE FUEL TANK UNIT HARNESS SIDE CONNECTORS 1 J-28 AND 6 B-52 (METER)

NO REPLACE THE FUEL TANK UNIT


N8B5073E

CAB AND CHASSIS ELECTRICAL


5-5. Even When The Fuel Tank Is Empty, The Low Fuel Warning Light Does Not Light Up

8-261

DOES THE WARNING LIGHT HAVE A BURNED OUT BULB, OR IS THE SOCKET POORLY CONNECTED?

YES IS THE FUEL TANK UNIT NORMAL?

NO REPLACE THE BULB, OR REPAIR A POOR CONNECTION AT THE SOCKET

YES

NO REPLACE THE FUEL TANK UNIT

REPAIR A POOR CONNECTION AT THE CONNECTOR OR AN OPEN CIRCUIT BETWEEN THE HARNESS SIDE CONNECTORS 1 J-28 AND 6 B-52 (METER) OR 2 J-28 AND J-9

N8B5074E

8-262 CAB AND CHASSIS ELECTRICAL


5-6. Even When The Float in The Water Sedimenter Goes Up above The Drain Warning Level, The Indicator Light Does Not Light Up

DOES THE INDICATOR LIGHT HAVE A BURNED-OUT BULB OR IS THE SOCKET POORLY CONNECTED?

YES IS THE WATER SEDIMENTER SWITCH NORMAL?

NO REPLACE THE BULB, OR REPAIR A POOR CONNECTION AT THE SOCKET

YES

NO REPLACE THE WATER SEDIMENTER SWITCH

REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT IN THE CIRCUIT BETWEEN THE WATER SEDIMENTER SWITCH HARNESS SIDE CONNECTOR 2 J-206 AND 10 B-52 (METER) OR 1 J-206 AND J-9

N8B5075E

CAB AND CHASSIS ELECTRICAL

8-263

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

REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN THE BRAKE FLUID SWITCH HARNESS SIDE CONNECTOR 2 B-85 AND 5 B-51

N8B5076E

5-8. Vacuum Warning Buzzer Does Not Sound

REPAIR A POOR CONNECTION AT THE CONNECTORS OR AN OPEN CIRCUIT BETWEEN 3 B-57 AND 1 B-71

N8B5077E

Starter Switch
Refer to START AND CHARGING in this section.

Turn Signal Light Switch


Refer to TURN SIGNAL LIGHT, HAZARD WARNING LIGHT AND STOPLIGHT in this section.

Exhaust Brake Switch


Refer to EXHAUST BRAKE in this section.

8-264 CAB AND CHASSIS ELECTRICAL


Meter Assembly
Layout for Gauges, Warning, Indicator and Illumination Lights

Speedometer

Warning lens

Tachometer

Warning lens Smoother

Without Smoother

1ST START

Fuel gauge

Coolant temperature gauge

N8B0141E

CAB AND CHASSIS ELECTRICAL


Bulb Location for Warning Lens

8-265

*2 : Without Smoother *3 : For EURO4 *

1 : Smoother

1ST START

N8B0062E

8-266 CAB AND CHASSIS ELECTRICAL


Table for Meter Connector Terminal Connections

B-52

20

20

B-57

B-53

B-51
N8B5115E

CAB AND CHASSIS ELECTRICAL


B-53 (With Smoother) Terminal No. 1 2 3 4 5 6 7 8 9 10 11 12 B-51 Terminal No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Illumination + Ignition Rear Fog ASR Ground Brake Booster Charge Oil Pressure ABS (*1) / Check Engine (*2) Turn LH Beam Brake (*1) / DPD (*2, *3) Check Engine (*1) / Brake (*2) Exhaust Brake SVS B-57 Terminal No. 1 2 3 Ground Battery Connected to Connected to DPD (*3) 1st Start ECONO Smoother TCM Connected to B-52 Terminal No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Ground Glow Battery Vehicle Speed Sensor Sedimenter Front Fog TACHO Thermal Fuel Turn RH Connected to

8-267

*1: With Smoother *2: Without Smoother *3: EURO 4

8-268 CAB AND CHASSIS ELECTRICAL


Removal Preparation: Disconnect the battery ground cable. 1. Meter Cluster

N8A0327E

Speedometer
N8A0325E

2. Meter Assembly Remove the five screws.

The speedometer is made up of the cross coil type ammeter (movement) that displays indications, the stepper motor that drives and adds up the odometer and trip meter, and the driving circuit (printed circuit board) that makes exchanges between the pulse signals and the current.

N8B5157E N8B5158E

Disconnect the meter connectors. Installation To install, follow the removal steps in the reverse order.

CAB AND CHASSIS ELECTRICAL

8-269

Replace the speedometer when the result of inspection is found abnormal.


4 Pulse output B

SENSOR

GND

N8B5159E

On-vehicle Service Check the meter display accuracy and the operation of the odometer with the speedometer tester. Notice: Inappropriate tire inflation may affect the accuracy of the odometer. (To conduct this test, refer to the tester manufacturer's instruction manual.) Since the meter display permissible levels above are specifications solely for the meter, they are to be used as reference values when conducting on-vehicle service. For General Export Tester display speed 40 km/h 60 80 100 120 140 For Europe Tester display speed 20 km/h 40 60 80 Meter display permissible level 20 22.5 km/h 40 42.5 60 63.2 79.7 83.4 Meter display permissible level 37 41 km/h 58 62 77.5 82.5 97.5 103 117 122.5 137.5 143

IGN

N8A0332E

Terminal symbol IGN GND SEN GND 4P GND

Resistance value 5820 k 7020 k

Removal Preparation: Disconnect the battery ground cable. 1. Remove the meter assembly/speedometer (1). Notice: Speedometer cannot be removed as a single unit since it is integrated into the meter assembly. Refer to Meter Assembly in this section. 2. Remove the meter plate (2) and meter glass (3). Remove the two installing screws on the meter surface. Remove the meter plate by pushing the catches with your finger.

Individual Inspection Remove the speedometer from the meter assembly and measure the resistance and the current consumption between each terminals.

8-270 CAB AND CHASSIS ELECTRICAL


Tester display speed 750 2000 3000 4000 Meter display permissible level 700 800 1900 2150 2950 3200 3950 4200

Individual Inspection Remove the tachometer from the meter assembly and measure the resistance value and the current consumption between each terminals. Replace the tachometer when the result of inspection is found abnormal.

N8A0485E

Installation To install, follow the removal steps in the reverse order.

Tachometer
The tachometer is made up of the cross coil type ammeter (movement) that displays indications, and the drive circuit (printed board) that makes exchange between the pulse signals and the current.

N8A0336E

1. Resistance value Use the analog type circuit tester. (Range: 1K) Terminal symbol IGN GND
N8B5160E

Tester terminal Red (+) IGN PIN GND 335 k Black () GND Black ( ) IGN PIN Red (+) GND GND

305 k 500 1000 k

PIN GND

On-vehicle Service Inspection 1. Set up the tune-up tester to the engine. 2. Start the engine and compare the readings displayed by the tachometer and the tester. When the difference between these two readings differs largely from the specified value, replace it with a correct one. Notice: Since the meter display permissible levels above are specifications solely for the meter, they are to be used as reference values when conducting on-vehicle inspection.

2. Current value Use the analog type circuit tester. Since the current consumption fluctuates as the power voltage varies, check to be sure that the voltage applied is 241 V. Voltage 24Volt Connecting terminal IGN GND Current consumption 241 V (when 241 V applied) Remarks No signal input

CAB AND CHASSIS ELECTRICAL


Removal Preparation: Disconnect the battery ground cable. 1. Remove the meter assembly/tachometer (1). Notice: Tachometer cannot be removed as a single unit since it is integrated into the meter assembly. Refer to Meter Assembly in this section. 2. Remove the meter plate (2) and meter glass (3). Remove the two installing screws on the meter surface. Remove the meter plate by pushing the catches with your finger.

8-271

N8A0485E

Installation To install, follow the removal steps in the reverse order.

Coolant Temperature Gauge


Circuit Diagram

Engine coolant temperature gauge IGN UNIT

ECT sensor +

GND

N8B5162E

Inspection Remove the coolant temperature gauge from the meter assembly, and measure the resistance value between each terminal. Replace the coolant temperature gauge when the result of inspection is found abnormal.

8-272 CAB AND CHASSIS ELECTRICAL


Notice: Coolant temperature gauge and fuel gauge cannot be removed as a single unit since they are integrated into the meter assembly. Refer to Meter Assembly in this section. 2. Remove the meter plate (2) and meter glass (3). Remove the two installing screws on the meter surface. Remove the meter plate by pushing the catches with your finger.

N8A0339E

Terminal symbol IG U UE IG E

Resistance value 169 10% 333 10% 242 10%

Removal Preparation: Disconnect the battery ground cable. 1. Remove the meter assembly (1).

N8A0485E

Installation To install, follow the removal steps in the reverse order.

Fuel Gauge
Circuit Diagram

N8A0341E

CAB AND CHASSIS ELECTRICAL


Inspection Remove the fuel gauge from the meter assembly, and measure the resistance value between each terminal. Replace the meter when the result of inspection is found abnormal.

8-273

1 4 3

N8A5404E

N8A0342E

Legend 1. Meter Assembly 2. Meter Glass 3. Meter Plate 4. Warning Lens Installation To install, follow the removal steps in the reverse order.

Terminal symbol IG U UE IG E

Resistance value 108.1 10% 103 10% 211.1 10%

Warning Light Bulb, Indicator Light Bulb and Illumination Light Bulb
Removal Preparation: Disconnect the battery ground cable. 1. Meter Assembly Refer to METER ASSEMBLY in this section. 2. Socket and Bulb Hold the bulb socket by hand and rotate it counterclockwise to remove them from the meter body. 3. Bulb Pull out the bulb from the socket.

Removal and Installation Refer to the COOLANT TEMPERATURE GAUGE in this section.

Warning Lens
Removal Preparation: Disconnect the battery ground cable. 1. Meter Assembly Refer to METER ASSEMBLY in this section. 2. Meter Glass Remove it by pushing the catches with your finger. 3. Meter Plate Remove it by pushing the catches with your finger. 4. Warning Lens

8-274 CAB AND CHASSIS ELECTRICAL


The voltage, with one rotation of shaft, fluctuates four times in the following range: 10 to 14V 24 or less. Replace the sensor when the result of inspection is found abnormal.

N8A0344E

Installation To install, follow the removal steps in the reverse order.

Vehicle Speed Sensor


The vehicle speed sensor is installed on the rear portion of the transmission or transfer case. The number of pulses generated is four pulses per one rotation of the pinion shaft.

N8A0346E

Removal Preparation: Disconnect the battery ground cable. 1. Vehicle Speed Sensor Disconnect the connector.

N8A0345E

Connector Parking brake drum 1

Inspection 1. Connect a resistance of 390 5%, 2W between connector terminal 1 J-32 and battery (+) terminal and connect the connector terminal 2 J-32 to the battery () terminal. Caution: Be extremely careful not to connect the battery (+) terminal to the connector 3 J-32 . This may damage the vehicle speed sensor. 2. Rotate the shaft of the vehicle speed sensor slowly and measure the voltage between 3 J-32 and 2 J-32 with a digital tester.

N8A0347E

CAB AND CHASSIS ELECTRICAL


Installation 1. Tighten the vehicle speed sensor to the specified torque. Tighten: Vehicle speed sensor to 25 Nm (2.5 kgfm/18 lbfft) Caution: Tightening must be made at the hexagonal part of the sensor. To tighten the connector itself would cause damage.

8-275

Oil Pressure Switch


Inspection Check the continuity between the switch terminal and the body ground with the starter switch is OFF position. Replace the switch when the result of inspection is found abnormal.

ECT Sensor
Inspection The ECT sensor is thermistor type and must be inspected under the conditions as shown below. 1. Put the deviation of the galvanometer to 0 by using the variable resistor, switch the ECT sensor off and then measure the resistance of the resistor through the bridge. Confirm that the resistance is continuously variable in any other points than those shown below. 2. Dip the ECT sensor into 80 90C (176 194F) water and confirm that there is no bubble continuously coming out of inside of the sensor. Replace the sensor when the result of inspection is found abnormal.

N8A5410E

Circuit Inspection
1. Start the engine. 2. When disconnecting the oil pressure switch connector then connecting the harness side connector to the ground, check to see if the oil pressure warning light lights up. When the light will not light up, check the circuit between the meter and the oil pressure switch, and repair an open circuit if necessary.

N8A0348E

Temperature Check condition 50C (112F) +33.6 33.6 226.0 115C (239F) +1.71 2.21 26.4 +2.68 3.68 24.3

7 V 55 Gauge 7 V 25 Gauge

Resistance value ( )

N8A5411E

8-276 CAB AND CHASSIS ELECTRICAL


Fuel Tank Unit
The tank unit varies the internal resistance according to the float position (fluid level) to operate the fuel meter needle. Also available is the build-in switch type to warn the driver of low fuel level (about 5 liters left in the tank) by illuminating the fuel warning light.

N8A5412E

CAB AND CHASSIS ELECTRICAL


Inspection
91.5 mm (Fuel tank capacity: 75L) 91.5 mm (Fuel tank capacity: 100L)

8-277

330.2 mm (Fuel tank capacity: 75L) 330.2 mm (Fuel tank capacity: 100L)

207.7 mm (Fuel tank capacity: 75L) 207.7 mm (Fuel tank capacity: 100L)

N8B0063E

J-28

(Level Switch type of warn low fuel level) 1. Check the resistance between the connector terminals 1 J-28 F-1 and 2 J-28 F-1 while shifting the float from E to F point. 2. Check if the low fuel warning switch turns on and off at the specified positions. If found defective, replace the fuel tank unit.

N8B0064E

Float position F 1/2 E

Resistance value () 2.5 33.0 98.3

8-278 CAB AND CHASSIS ELECTRICAL


Vacuum Switch
Inspection When the pressure value is below 25030 mm Hg (33.34.0 kPa), check to see if there is continuity between the terminal and the ground. If no continuity, replace the switch with a normal one.

N8A0358E

Legend 1. Meter Assembly 2. Vacuum Warning Buzzer


N8A0357E

Installation To install, follow the removal steps in the reverse order.

Removal Preparation: Disconnect the battery ground cable. 1. Vacuum Switch 1) Disconnect the connector. 2) Remove the vacuum switch. Installation Apply liquid gasket to the screw portion of the switch to prevent vacuum leak.

Water Sedimenter Switch


Inspection 1. When the float in the water sedimenter is above the drain warning level, confirm if there is continuity between the switch connector terminals. 2. Turn the starter switch on, disconnect the water sedimenter connector and connect the harness side connector terminals. Then confirm that the sedimenter warning light turns on. If found defective, replace the switch or repair a poor connection or an open circuit between the connector terminals.

Vacuum Warning Buzzer


Inspection Apply battery voltage to the buzzer connector terminals to check the buzzer sound. Replace the buzzer when the result of inspection is found abnormal. Removal Preparation: Disconnect the battery ground cable. 1. Meter Assembly Refer to METER ASSEMBLY in this section. 2. Vacuum Warning Buzzer 1) Disconnect the connector. 2) Remove the buzzer fixing screw.

Sedimenter Switch

Sedimenter Switch

N6B6083E

CAB AND CHASSIS ELECTRICAL


Brake Fluid Switch
Inspection 1. Confirm there is continuity between the switch connector terminals when the brake fluid in the tank is between 60 75 cc level. 2. Turn the switch on, disconnect the brake fluid switch connector and connect the harness side connector terminals. Then confirm that brake warning light turns on. If found defective, replace the tank, or repair a poor connection or an open circuit between the connector terminals.

8-279

N8A0361E

Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Bleed the air from brake and clutch fluid pipe line. 2. Check to see if the brake fluid level in the tank within specified level. 3. Check to see if brake warning light comes on when starter switch is turned on and then warning light goes off after the engine running.

Parking Brake Indicator Light


N8A0360E

Removal Preparation: Disconnect the battery ground cable. 1. Instrument Panel Assembly Refer to INSTRUMENT PANEL of section 2. 2. Brake Fluid Tank (Brake Fluid Switch) 1) Disconnect the switch connector. 2) Remove four fixing nuts. 3) Drain brake fluid in the tank. 4) Disconnect the tubes. Caution: Be very careful not to allow the brake fluid to come in contact with painted surfaces or resin parts surfaces.

The parking brake indicator light is connected in series with the parking brake switch installed to the parking brake lever bracket. The light comes on when the parking brake lever is pulled, and goes out when the parking brake lever is fully released. Notice: The parking brake indicator light illuminates to warn the driver that the parking brake is on. This light does not indicate the condition of the operability of the parking brake. Circuit Inspection 1. Disconnect the parking brake switch connector. 2. Connect the harness side connector terminal to the ground. 3. Check to see if the indicator light comes on with the starter switch ON. Check the bulb or the harness when the result of inspection is found abnormal.

8-280 CAB AND CHASSIS ELECTRICAL

N8A0362E

N8A0364E

Parking Brake Switch


Inspection 1. Disconnect the parking brake switch connector. 2. Check to see if there is any continuity between the switch terminal and the body ground with the circuit tester connected between them. When parking brake applied When parking brake released Continuity No continuity

Installation To install, follow the removal steps in the reverse order.

Heater and Air Conditioning


General Description The air conditioning consists of compressor, evaporator, condenser, A/C switch, fan switch, etc. When the engine is rotating, the A/C starts to work with both the A/C and fan switches ON, followed by the engagement of the magnetic clutch. It stops to work when either the fan switch or the A/C switch turns OFF. In addition to the switches, the A/C has the function of temporary stop of its operation by the sensing system in the A/C cycle, such as: sensing abnormal rise of the refrigerant pressure by means of the pressure switch. sensing temperature of the blowing-off air by means of the thermo switch preventing the evaporator from freezing. sensing the coolant temperature by the thermo switch (available for limited models only).

Repair the parking brake switch or replace it when the result of inspection is found abnormal.

N8A0363E

Removal Preparation: Disconnect the battery ground cable. 1. Parking Brake Switch 1) Disconnect the connector. 2) Remove the fixing screw.

B-18 DIODE (4JJ1 NKR) B-17,X-32 DIODE <4JJ1>

Parts Location

X-10

X-12 HEATER X-12 & A/C RELAY

E-5 MAGNETIC CLUTCH

H-105

FUSE BOX ASM F-1

J-191 ECM

H-105 < 4HK1>

CAB AND CHASSIS ELECTRICAL

J-6 PRESSURE SW1 (4HK1) J-257 PRESSURE SW & CONDENSER FAN SW (4JJ1)

J-51 CONDENSER FAN1 (4HK1)

F-26 FUSE FL-1 FUSIBLE LINK X-27 CONDENSER FAN RELAY

H-105

N8B0065E

8-281

F-1 15A HEATER, AIR CON 0.85BR 0.85BR


1 X-10 X-10 J-6 J-6 X-10 4 4 3 2 X-10 5 H-5 2 J-6 J-6 J-191 1 2

For 4HK1 Engine

Circuit Diagram

30B/R ECM

2L 0.85G/W 0.85G/O 0.5G/O 34

FL-1 100A or 120A 8B MAIN 8W/B 0.85G/W

PRESSURE SWITCH 1

P-1

P-2

0.5LG/B RELAY; A/C THERMO

8W/B (80A ACG) 5W/B (STD ACG)

0.85L

P-3

3L

0.85G/O

(M/T)

P-4 B-17 X-32

2 4 4

0.5G/Y

H-6

0.85BR DIODE

(SMOOTHER) DIODE

5W/B
1 B-14 3 3 B-17 X-32

RELAY; CONDENSER FAN 0.5B


5 X-27 X-27 X-27 1 J-51 1 3 4 H-105

0.5P/G

RELAY; HEATER & A/C


X-12 4 2 1 2 B-39 B-15 B-15 B-39 3 1 B-14 5

3W/B

P-5

FRAME 0.5LG CONDENSER FAN 1 0.5LG


X-12

X-12

0.85B 2 J-51

0.85L 2 X-27

BLOWER MOTOR

X-12

8-282 CAB AND CHASSIS ELECTRICAL

0.5W/R ELECTRONIC THERMOSTAT A/C SWITCH


2 3 B-39 B-15

0.85L/Y

0.75G/O

RELAY; CHARGE (1) 0.85L/B RELAY; GLOW (3) 0.5G/Y 0.5G/Y

2B/L

F-26 15A COND. FAN


1 E-5

0.5B 0.5G/Y
B-13 1 3

0.85L/B
B-42 2 4 6 B-42 3

B-42

MAGNETIC CLUTCH (COMPRESSOR)

B-13

0.5L/O
2 5 B-42 2

B-13

0.5L/Y
3 4 B-42 1 OFF

2B
B-13

0.5L/W

BLOWER RESISTOR

HEADLIGHT BRACKET (LH) 0.85B 2B


B-42

B-7

3B 2B
1

5B

FRAME-LH (FRONT)

B-1

FAN SWITCH

FRAME-LH (CENTER)

J-9

N8B0066E

F-1 15A HEATER, AIR CON 0.85BR 0.85BR


1 X-10 X-10 J-257 J-257 X-10 4 4 5 2 X-10 5 H-5 2 J-257 J-257 J-191 1 2

30B/R

2L 0.85G/W ECM 0.85G/O 0.5G/O 34

FL-1 100A 8B MAIN 8W/B 0.85G/W

PRESSURE SWITCH

P-1

P-2

For 4JJ1 (EURO 4) Engine

0.5LG/B

H-6

RELAY; A/C THERMO

0.85L

5W/B

P-3

3L
4 B-17 X-32 B-18 4 2

0.85G/O

0.5G/Y

P-4

(NKR) DIODE

(NPR with M/T) DIODE

0.85BR
B-17 3 3 1 X-32 B-18

1 B-14

RELAY; CONDENSER FAN 0.5B


5 X-27 J-257 6 X-27 X-27 3 7 1 H-105

(NPR with SMOOTHER) DIODE

3W/B 0.5P/G

RELAY; HEATER & A/C


X-12 4 2 1 2 B-39 B-15 B-15 B-39 3 1 B-14 5

P-5

FRAME 0.5LG CONDENSER FAN 0.5LG


X-12

X-12

0.85B 3 J-257

0.85L 2 X-27

BLOWER MOTOR

X-12

0.5W/R ELECTRONIC THERMOSTAT A/C SWITCH


2 3 B-39 B-15

0.75P 0.85L/Y

RELAY; CHARGE (1) 0.85L/B RELAY; GLOW (3) 0.5G/Y 0.5G/Y

2B/L

F-26 15A COND. FAN


1 E-5

0.5B 0.5G/Y
B-13 1 3

0.85L/B
B-42 2 4 6 B-42 3

B-42

MAGNETIC CLUTCH (COMPRESSOR)

B-13

0.5L/O
2 5 B-42 2

B-13

0.5L/Y
3 4 B-42 1 OFF

2B
B-13

0.5L/W

BLOWER RESISTOR

HEADLIGHT BRACKET (LH) 0.85B 2B


B-42

B-7

3B 2B
1

5B

FRAME-LH (FRONT)

B-1

FAN SWITCH

CAB AND CHASSIS ELECTRICAL

FRAME-LH (CENTER)

J-9

N8B0067E

8-283

8-284 CAB AND CHASSIS ELECTRICAL


Connector List
No. Connector Face No. Connector Face

B-1
000-001

X-10

1 2 3 5 4

005-001

B-7
000-001

X-12

1 2 3 5 4

005-001

J-9
000-001

X-27
005-006

B-13

1 3

2 4
004-010

X-32

1 2 3 4

004-004

B-14

1 2
002-009

B-39

1 2 3
003-019

B-15
1 2 3
003-009

B-42

1 4

2 5

3 6

006-001

J-51 (4HK1)

E-5
1 2
1

002-001

001-013

B-17

E-5
1 2 3 4

004-004

001-014

CAB AND CHASSIS ELECTRICAL


No. Connector Face No. Connector Face

8-285

J-6 (4HK1)

1 3

2 4
004-011

H-105

1 5 9

2 6

3 7

4 8

10 11 12

012-001

J-257 (4JJ1)

1 4

2 5

3 6
006-031

H-105

4 8

3 7

2 6

1 5 9

12 11 10

012-002

J-191
081-001

B-18 (For 4JJ1 NKR)

1 2 3 4

004-004

H-5 P-1
000-022

P-4
000-014

1 7 13 19 25 31

2 8 14 20 26 32

3 9 15 21 27 33

34

35

36

37

4 10 16 22 28 38

5 11 17 23 29 39

6 12 18 24 30 40

6 12 18 24 30 40

5 11 17 23 29 39

4 10 16 22 28 38

37

36

35

34

3 9 15 21 27 33

2 8 14 20 26 32

1 7 13 19 25 31

P-2
000-014

N8A5488E

P-3
000-014

P-5
000-002

8-286 CAB AND CHASSIS ELECTRICAL


H-6

H-6

H-7

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 H-8

4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14

N8A5489E

Rear Heater
General Description
The circuit consists of rear heater, rear heater switch and the heater relay.

Parts Location

RELAY BOX ASM (No.1) REAR HEATER UNIT (W/CAB)

X-8 HEATER RELAY

F-3

CAB AND CHASSIS ELECTRICAL

N8B0068E

8-287

8-288 CAB AND CHASSIS ELECTRICAL


Circuit Diagram
For 4HK1 / 4JJ1 (EURO 4) Engine

FL-1 100A/120A MAIN

Except 4JJ1/4HK1 80A ACG 8W/B 5W/B


2 H-6

RELAY; HEATER 5W/B 3W/B 0.5W/R


2 X-8 X-8 1

3B/R

F-3 15A REAR HEATER

8B

8W/B 4JJ1/4HK1 80A ACG

RELAY; CHARGE(5)

X-8

X-8

2L

0.5B/R
6 H-3

P-1 P-2

30B/R

P-3

0.5B

P-4

0.5B/R
1 H-25

P-5

FRAME

0.85B/R
3

REAR HEATER

N-8

N-8 2

N-8 1

0.85L/W

H-25 2

0.85L/R
H-25 3 2

0.85L/W

2B

H-3

0.85L/R
H-3 5 1

0.5L/W

0.5L/R
4 B-59 HI B-59

B-59 LO

OFF

HEADLIGHT BRACKET (LH)

B-7

3B 5B

FRAME-LH(FRONT)

B-1

3B

0.5B

REAR HEATER SW

N8B0069E

CAB AND CHASSIS ELECTRICAL


Connector List
No. Connector Face No. Connector Face

8-289

X-8
005-006

N-8

003-022

B-1
000-001

N-8

003-023

B-7
000-001

P-2
000-014

B-59

P-1
1 3 2 4

004-015

000-022

H-3

1 4

2 5

3 6

P-4
000-014

006-014

H-3

3 6

2 5

1 4

P-3
000-014

006-015

H-25

1 2 3
003-020

P-5
000-002

H-25

1 3 2
003-021

8-290 CAB AND CHASSIS ELECTRICAL


H-6

H-6

H-7

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 H-8

4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14

N8A5439E N8A5489E

ABS/ASR System
General Description
ABS (Anti-lock Brake System) and ASR (Anti-Slip Regulator) are the system to prevent the wheels from locking and wheel spin, and to assure stability and steering ability of the vehicle. When a malfunction occurs in the system, fail-safe deactivate the ABS and ASR, and the warning lamp comes on. Also, the self-diagnosis function is equipped to improve serviceability.

Rear Heater Switch


Inspection Check the continuity between the connector terminals while operating the switch. Replace the switch when the result of inspection is found abnormal.

N8A5438E

Rear Heater Motor


Inspection Disconnect the rear heater connector. Connect the battery positive terminal to the NO.3 terminal of the rear heater motor side connector and negative to the NO.2. Check to see if rear heater motor operates low-speed correctly. Connect the battery positive terminal to the NO.3 terminal of the rear heater motor side connector and negative to the NO.1. Check to see if rear heater motor operates high-speed correctly. Replace the rear heater motor when the result of inspection is found abnormal.

Parts Location

B-125 ASR OFF SW STARTER SW B-387 RESISTOR 1 J-149 R/LH SENSOR(4HK1) J-148 R/RH SENSOR(4HK1) J-78 RR SENSOR(4JJ1)

FL-1, FL-2, FL-9 FUSIBLE LINK

FUSE BOX ASM F-5, F-7, F-16, F-21

P-5

H-5~H-8

H-14, H-15

J-177 ABS EHCU P1~P4 BATTERY

J-74 F/RH SENSOR J-191 ECM J-9 EARTH ; FRAME

B-66 STOPLIGHT SW (BRAKE SW)

B-1 EARTH ; FRAME (FR) B-7 EARTH ; HEADLIGHT B/T

B-79 DATA LINK CONNECTOR J-75 F/LH SENSOR B-51 ABS WARNING LIGHT (METER) ASR WARNING LIGHT (METER)

CAB AND CHASSIS ELECTRICAL

B-67 IGNITION SW "A"

N8B0083E

8-291

8-292 CAB AND CHASSIS ELECTRICAL


Circuit Diagram
For 4HK1 Engine
FL-2 40A KEY SW TAIL RELAY X-4 3 3B/Y

OFF 3W/L 8W/B H-7 1 3W/L 2 B-67 B ACC ON ST STARTER SWITCH F-16 0.5B/Y 10A METER 0.5B/Y B-67

2L

3W
F-7 3B/Y F-21 10A TAIL LIGHT 18 8 B-125

8B

FL-1 100A/120A MAIN FL-9 40A ABS

ACG(B) H-6 2 5W/B

P-2

3W/B

P-1

5W/B

F-5 10A STOP LIGHT

P-3 P-4

0.5G/Y

0.5LG/R
5 B-125 B-125 6 3 5 3B B-7

15 H-8

B-51 ASR STOP LIGHT SWITCH ABS

0.5B/Y

B-66

P-5 FRAME

3R

METER

ASR SWITCH B-125

B-66 2

B-51

B-51

0.3W/L

0.3W/V

20

12

0.5G

1 H-15

0.5B/Y

3R

3R

11 H-5

18 H-8

17 H-8

0.5G

0.5B/Y

H-14

H-14

H-14

0.5L

15

16

0.3W/L

0.3W/V

0.5L

16 H-8

4 H-15 STOP LIGHT

3 H-15

2 H-15

0.3W/V

0.3W/L

0.5G

24 J-177 MTR +B

2 J-177 VLV +B VLV MTR GND GND J-177 J-177 1 3B 3B 23 DIAG ALDL J-177 J-177 0.3W/G 0.3W/B 4 29

16 J-177 BRK SW

30 J-177 ASR W/L

6 J-177 ABS W/L FL FL GND SIG J-177 J-177 33 32

3 J-177 IG FR FR GND SIG J-177 J-177 11 10

EHCU
CAN CAN CAN CAN L H L H J-177 J-177 J-177 J-177 15 14 27 26

J-177 ASR SW

RL RL RR RR GND SIG SIG GND J-177 J-177 J-177 J-177 34 22 21 12

16

15 0.3W/G

11 0.3W/B

6 0.5L/W 0.5L/W 0.5R/B 0.5W 0.5R 0.5V 0.5Y 0.5P 0.5L 0.5L 0.5L 0.5L

H-15 H-15 3B 3B

H-15 H-15

12 0.5L 0.5L/W 0.3W/G 0.3W/B H-8

13 H-8

14 H-15

9 H-15

10 H-15

5 H-15

12 H-15

7 H-15

13 H-15

8 H-15

0.5L/W

0.5L

0.5R/B

0.5V

13 B-79

2 B-79 H-8 0.5L 8 H-8 0.5L/W 7

DATA LINK CONNECTOR B-79 B-79 B-79 12 0.5Y 0.5B 5 0.5B 4

1 H-8 10 0.5Y 3B 37 J-191 CAN L 18 J-191 CAN H ECM 52 J-191 ISDIAG 1.25B

2 1 1 2 J-149 J-149 J-148 J-148 2 1 J-75 J-75 FRONT WHEEL -LEFT 2 1 J-74 J-74 FRONT WHEEL -RIGHT W W B B

B-387 B-387

REAR WHEEL -LEFT RESISTOR 1

REAR WHEEL -RIGHT

SPEED SENSOR

J-9 FRAME-LH (CENTER)

B-1 FRAME-LH (FRONT)

0.5P

0.5L

HEADLIGHT BRACKET (LH)

0.5L

3R

3R

2B

0.5B

0.85LG/R

10A ABS(IG)

N8B0070E

CAB AND CHASSIS ELECTRICAL


For 4JJ1 Engine
FL-2 40A KEY SW

8-293

OFF 3W/L H-7 1 3W/L 2 B-67 B ACC ON ST 8W/B 2 5W/B STARTER SWITCH F-16 0.5B/Y 10A METER 0.5B/Y B-67 3 3B/Y

TAIL RELAY X-4

2L

3W
F-7 3B/Y F-21 10A TAIL LIGHT 18 8 B-125

8B

FL-1 100A MAIN FL-9 40A ABS

P-2

3W/B

P-1

F-5 10A STOP LIGHT

P-3 P-4

0.5G/Y

0.5LG/R
5 B-125 B-125 6 3 5 3B B-7

15 H-8

B-51 ASR STOP LIGHT SWITCH ABS

0.5B/Y

B-66

P-5 FRAME

3R

METER

ASR SWITCH B-125

B-66 2

B-51

B-51

0.3W/L

0.3W/V

20

12

0.5G

1 H-15

0.5B/Y

3R

3R

11 H-5

18 H-8

17 H-8

0.5G

0.5B/Y

H-14

H-14

H-14

0.5L

15

16

0.3W/L

0.3W/V

0.5L

16 H-8

4 H-15 STOP LIGHT

3 H-15

2 H-15

0.3W/V

0.3W/L

0.5G

24 J-177 MTR +B

2 J-177 VLV +B VLV MTR GND GND J-177 J-177 1 3B 3B 23 DIAG ALDL J-177 J-177 0.3W/G 0.3W/B 4 29

16 J-177 BRK SW

30 J-177 ASR W/L

6 J-177 ABS W/L FL FL GND SIG J-177 J-177 33 32

3 J-177 IG FR FR GND SIG J-177 J-177 11 10

EHCU
CAN CAN CAN CAN L H L H J-177 J-177 J-177 J-177 15 14 27 26

J-177 ASR SW

RL RL RR RR GND SIG SIG GND J-177 J-177 J-177 J-177 34 22 21 12

16

15 0.3W/G

11 0.3W/B

6 0.5L/W 0.5L/W 0.5R/B 0.5W 0.5R 0.5V 0.5Y 0.5P 0.5L 0.5L 0.5L 0.5L

H-15 H-15 3B 3B

H-15 H-15

12 0.5L 0.5L/W 0.3W/G 0.3W/B H-8

13 H-8

14 H-15

9 H-15

10 H-15

5 H-15

12 H-15

7 H-15

13 H-15

8 H-15

0.5L/W

0.5L

0.5R/B

0.5V

13 B-79

2 B-79 H-8 0.5L 8 H-8 0.5L/W 7

DATA LINK CONNECTOR B-79 B-79 B-79 12 0.5Y 0.5B 5 0.5B 4

1 H-8 1.25B(Except NKR)/ 0.85B(NKR) 10 0.5Y 3B 37 J-191 CAN L 18 J-191 CAN H ECM 52 J-191 ISDIAG

1 2 4 3 J-78 J-78 J-78 J-78 2 1 J-75 J-75 FRONT WHEEL -LEFT 2 1 J-74 J-74 FRONT WHEEL -RIGHT W W B B

B-387 B-387

REAR WHEEL -LEFT RESISTOR 1

REAR WHEEL -RIGHT

SPEED SENSOR

J-9 FRAME-LH (CENTER)

B-1 FRAME-LH (FRONT)

0.5P

0.5L

HEADLIGHT BRACKET (LH)

0.5L

3R

3R

2B

0.5B

0.85LG/R

H-6

10A ABS(IG)

N8B0071E

8-294 CAB AND CHASSIS ELECTRICAL


Connector List
No. Connector Face No. Connector Face

B-1
000-001

B-387
002-038

B-7
000-001

B-387
002-039

3 8 7

2 6

1 5

B-51
020-004

H-14

14 13 12 11 10

16

15

016-004

2 6 7

3 8

4 9

B-66
1 2

H-14

10 11 12 13 14 15 16

002-031

016-003

2 6 7

3 8

4 9

B-67

2 4

1 3

H-15

10 11 12 13 14 15 16

004-002

016-003

3 8 7

2 6

1 5

B-67

1 3

2 4
004-001

H-15

14 13 12 11 10

16

15

016-004

B-79

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
016-005

J-9
000-001

B-125

1 5

2 3 4 6 7 8
008-001

J-74

1
002-012

CAB AND CHASSIS ELECTRICAL


No. Connector Face No. Connector Face

8-295

J-74

2
002-011

J-149 (4HK1 )

2
002-011

J-75

1
002-012

J-177
034-001

J-75

2
002-011

J-177
034-002

J-78 (4JJ1)

1 3

2 4
004-011

J-191
081-001

J-78 (4JJ1)
004-018

P-1
000-022

J-148 (4HK1 )

1
002-012

P-2
000-014

J-148 (4HK1 )

2
002-011

P-3
000-014

J-149 (4HK1 )

1
002-012

P-4
000-014

8-296 CAB AND CHASSIS ELECTRICAL


No. Connector Face

Transmission Control System (Smoother)


General Description
Smoother is the name of a new-generation drive train that provides benefits in terms of both life cycle costs (low initial cost and maintenance cost, lower fuel consumption, etc.) and easy driving. Smoother is a system that adds an automatic transmission to the existing Smoother, for even better fuel consumption and easier driving. This is accomplished by installing a solenoid system shift control box on the Smoother, which combines a manual transmission with fluid coupling, so all shifting is performed automatically in accordance with signals from the transmission control module (TCM). When starting moving the vehicle, depressing the brake pedal and operating the change lever as on an automatic vehicle causes a change lever position signal to be detected by the TCM. This actuates the shift control box solenoid and shifts the gear into the starting position or the reverse position, and then engages the shift change clutch (wet multi-disc clutch). (After the shift clutch engages, creep force is generated the same as on an AT vehicle.) Releasing the foot from the brake pedal and pressing the accelerator pedal starts the vehicle moving forward. If there is an up-shift or down-shift while running, the control unit determines the vehicle status based on vehicle speed, accelerator opening angle, and other factors, and shifts to the optimal gear automatically. If the driver moves the change lever in the + or - direction, a gear change is indicated, so sequential manual shifting is also possible. (Even during sequential manual shifting, the transmission shifts to the starting position when the vehicle is stopped.)

P-5
000-002

X-4
005-006

H-5

1 7 13 19 25 31

2 8 14 20 26 32

3 9 15 21 27 33

34

35

36

37

4 10 16 22 28 38

5 11 17 23 29 39

6 12 18 24 30 40

6 12 18 24 30 40

5 11 17 23 29 39

4 10 16 22 28 38

37

36

35

34

3 9 15 21 27 33

2 8 14 20 26 32

1 7 13 19 25 31

N8A5488E

H-6, H-7, H-8

H-6

H-7

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 H-8

4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14

N8A5489E

CAB AND CHASSIS ELECTRICAL


Parts Location
For 4HK1 / 4JJ1 (EURO 4) Engine (Except NKR Model)
N-7 DOOR SW (RH) X-32 DIODE RELAY BOX ASM (No. 1) RELAY BOX ASM (No. 2) X-14 SMOOTHER EMERGENCY RELAY X-15 SMOOTHER MAIN RELAY FUSE BOX ASM F-5,F-13, F-16, F-17, F-22

8-297

N-19 SELECT SW N-17 EMERGENCY SW N-18 EMERGENCY SHIFT SW B-417 PTO SWITCH B-425, B-426, B-427, B-428 TCM J-26, J-27 STARTER N-2 DOOR SW (LH) H-118 H-119 ECM (J-191)

STARTER SW

H-3

P-5 P-1 P-2 BATTERY P-4 P-3

B-431 RESISTOR 2 H-4, H-5, H-6, H-7, H-8 B-66 STOPLIGHT SW B-51, B-53 METER B-67 STARTER SW B-1 J-9 H-17 B-7 H-12

RELAY BOX ASM F-28 FUSE SBF1, SBF2, SBF5, SBF7, SBF8 FUSIBLE LINK X-18 ECM MAIN RELAY X-19 GEAR SHIFTER RELAY X-21 STARTER RELAY X-26 STARTER CUT RELAY

B-106 ADJUST SW B-105 RESET SW B-79 DATA LINK CONNECTOR J-232 TURBINE SPEED SENSOR J-234 SELECT SOLENOID

B-387 RESISTOR 1 J-237 SOLENOID & ATF TEMPERATURE SENSOR

J-50 NEUTRAL SW J-223 SELECT STROKE SENSOR

H-118 J-142 SHIFT STROKE SENSOR J-139 INPUT SPEED SENSOR J-236 SHIFT SOLENOID 2, 4, R J-235 SHIFT SOLENOID 1, 3, 5 H-119
N8B0072E

8-298 CAB AND CHASSIS ELECTRICAL


For 4JJ1 (EURO 4) Engine (NKR Model)
N-7 DOOR SW (RH) N-19 SELECT SW X-32 DIODE RELAY BOX ASM (No. 1) RELAY BOX ASM (No. 2) X-14 SMOOTHER EMERGENCY RELAY X-15 SMOOTHER MAIN RELAY FUSE BOX ASM F-5,F-13, F-16, F-17, F-22 N-17 EMERGENCY SW N-18 EMERGENCY SHIFT SW B-417 PTO SWITCH B-425, B-426, B-427, B-428 TCM J-26, J-27 STARTER STARTER SW ECM (J-191) N-2 DOOR SW (LH)

H-118 H-119

H-3

P-5 P-1 P-2 BATTERY P-4 P-3

B-431 RESISTOR 2 H-5, H-6, H-7, H-8 H-4 B-66 STOPLIGHT SW B-51, B-53 METER B-67 STARTER SW H-17 B-1 J-9 B-7 H-12 B-105 RESET SW B-79 DATA LINK CONNECTOR

RELAY BOX ASM F-28 FUSE SBF1, SBF2, SBF5, SBF7, SBF8 FUSIBLE LINK X-18 ECM MAIN RELAY X-19 GEAR SHIFTER RELAY X-21 STARTER RELAY X-26 STARTER CUT RELAY

B-106 ADJUST SW J-232 TURBINE SPEED SENSOR J-234 SELECT SOLENOID

B-387 RESISTOR 1 J-237 SOLENOID & ATF TEMPERATURE SENSOR

J-50 NEUTRAL SW J-223 SELECT STROKE SENSOR

H-118 J-142 SHIFT STROKE SENSOR J-139 INPUT SPEED SENSOR J-236 SHIFT SOLENOID 2, 4, R J-235 SHIFT SOLENOID 1, 3, 5 H-119
N8B0073E

CAB AND CHASSIS ELECTRICAL


Circuit Diagram
For 4HK1 Engine

8-299

FL-2 40A KEY

OFF 3W/L 1 H-7 2 3W/L B-67 ACC ON ST IGNITION SWITCH 4 8W/B 5W/B 2 H-6 5W/B 0.5B/Y 3W/B 0.5B/Y F-5 10A STOP LIGHT 1.25G/W F-13 10A NEES (B) 14 H-12 0.5B/Y 0.5Y/R 2 N-17 DIODE B-1 X-32 X-32 1 0.5B/Y 18 B-51 IPC 6 B-53 B-53 1 0.3P 8 0.3G/O B-53 7 0.3Y/G 12 B-425 B-428 18 0.3B/W 12 B-79 B-79 4 0.5B 5 0.5B B-79 B-79 14 B-425 11 B-425 F-16 10A METER 3 B-67 B-67 3B/Y 3B/Y 3B/Y 3B/Y 3W/B

2L

P-1 P-2

FL-8 60A STARTER 0.5R/W 14 H-8 0.5R/W

F-22 10A STARTER 3W/R

FL-5 40A ECM

FL-1 100A or 120A MAIN

0.5L/B 4 X-18 RELAY:MAIN

X-18

3W/B

1 SW: BRAKE PEDAL B-66

0.5G/Y

1 SW: EMERGENCY 5 X-15 0.3L/R 4 H-12 0.3L/R

P-3 2 P-4 RELAY:STARTER X-21 4 X-21

X-18 5 2

X-18

B-66 2 RELAY: SMOOTHER MAIN

0.5G/W

OIL PUMP ASM

1.25G/W

N-17

1.25R

2 X-15

ECM X-21 3 5 X-21

J-237 2 0.5Y/R F-28 10A ECM

J-237 4 0.5L/W

J-237 1 0.5R/Y

J-237 3 0.5Y/B

P-5 1 STARTER

0.85LG

J-26 B C 1 J-27 0.5LG 3B/W

2 7 15 6 H-118 H-119 H-118 H-118 0.5L/W 0.5Y/R 0.5R/Y

X-15 1 5

X-15

0.5Y/B

0.5G

1.25W/O

0.5W/V

0.5R

3 H-4 0.5Y/R

4 H-4 0.5L/W

1 H-17 0.5R/Y

3 H-17 0.5Y/B

0.3L/R

0.5LG

2 J-50 SW: NEUTRAL

0.5R 0.5R

6 B-427 J-50 1 0.5B/L

12 B-427

29 B-425

30 B-425

3 B-428

STOP LIGHT

3 B-426

15 B-425

4 B-428

TCM
5 H-4 0.5B/L B-428 10 B-425 16 B-428 12 B-426 4 B-426 8 B-426 12 B-426 17 B-428 19 B-427 2 0.5L/W B-427 3 0.5L B-426 9 0.3LB

5 H-17

0.3L/R

0.5R

0.5B

ECM 0.5W/L

0.5GR/R

RESISTOR 1

1.25B

RELAY: SMOOTHER EMERGENCY

1.25B

12 H-4

0.5W/L

2 0.5B 0.5B B-387 1 B-387 7 H-8 0.5L/W 0.5L 0.5L 8 H-8

4 RELAY: STARTER CUT X-26

3 X-26

1 X-14

3 X-14

X-26 1 0.5B 5

X-26 0.5W/L

X-14 5 0.3B 2

X-14 0.3B

ROOM LAMP 0.5GR/R 0.5GR/R

0.5L/W 37 TAIL LIGHT RESISTOR 2 0.5LG/R ECM 2 B-431 1 B-431 0.5L/W 0.5LB 0.5Y 0.5L 0.3L/W H-5 36 H-5

6 ECM H-12 1.2GR/R

3 H-3 0.5GR/B

SW: DOOR (ASSISTANT)

1 SW: DOOR (DRIVER) N-2

1 N-7 SW:PTO

1 B-417

B-417

2B

2B

DATA LINK CONNECTOR

6 B-79

14 B-79

B-417 3 2B

B-417 2

HEADLIGHT BRACKET

B-7

3B

2B

0.5B

5B

FRAME-LH(FRT) FRAME-LH(CTR)

B-1 J-9

1.25B 2B

2B

N8B0074E

0.5Y B-53

8-300 CAB AND CHASSIS ELECTRICAL

FL-7 60A NEES 3B/Y 3R F-17 10A NEES (IG) 3 0.5B/O RELAY: GEAR SHIFT CONTROL BOX X-19 2R 4 X-19 0.5B/O 0.5B/O X-19 2 GEAR SHIFT POSITION SENSOR GEAR SELECT POSITION SENSOR TURBINE SPEED SENSOR INPUT SHAFT SPEED SENSOR 3P 5

X-19

SW: HALF-CLUTCH ADJUSTMENT

B-105 SW: RESET

B-106 SLOW FAST

J-142 1 0.5R

J-142 2 0.5W

J-142 3 0.5B

J-223 1 0.5Y/B

J-223 2 0.5Y/W

J-223 3 0.5Y/R

J-232 1 0.5O/L

J-232 2 0.5W/L

J-139 1 0.5BR

J-139 2 0.5Y

18 1 H-160 H-4 3P

B-105 6

B-106 B-106 2 1

3 2 7 H-119 H-119 H-119

6 10 14 H-119 H-119 H-119 0.5Y/W

5 H-119 0.5O/L

9 H-119 0.5W/L

8 H-118 0.5BR

3 H-118

0.5Y/R

0.5Y/B

0.5W

0.5R

0.3GR/R

0.3GR/B

0.3GR/L

0.5B/O

0.5B/O

6 H-4

7 H-4

17 H-4

0.5B

13 H-4

14 H-4 0.5Y/W

15 H-4

20 H-4 0.5O/L

9 H-4 0.5W/L

10 H-4 0.5BR

1 H-4

0.5Y/R

0.5Y/B

0.5W

0.5Y

0.5Y

1 B-426

2 B-426

17 B-428

18 B-426

19 B-426

20 B-426

10 B-426

11 B-426

13 B-426

10 B-427

4 B-427

11 B-427

5 B-427

4 B-425

5 B-425

5 B-426

6 B-426

1 B-428

8 B-428

18 B-425

B-428 B-428

TCM
B-428 20 0.5R B-428 6 0.5W B-428 14 0.5G B-427 B-428 B-427 B-427 B-427 B-427 13 0.5R/B 21 0.5W/B 14 0.5O 15 0.5L/B 7 0.5P/B 8 0.5G/B B-427 1 0.5Y/R B-428 13 0.5L B-425 21 1.25B/R B-425 31 1.25B/R B-425 8 1.25B/L B-425 9 1.25B/L B-428 16 1.25W/B B-428 22 1.25W/B B-425 6 1.25B B-425 7 1.25B B-425 1 1.25B B-425 2 1.25B B-428 7 1.25B B-428 15 1.25B 9 H-17 1.25B H-17 1.25B

3 H-12

1.25W/B

1.25B/R

1.25B/L

13 H-12 0.5W

9 H-12 0.5G

8 H-12 0.5R/B

20 2 12 1 11 H-12 H-12 H-12 H-12 H-12 0.5W/B 0.5G/B 0.5P/B 0.5L/B 0.5O

21 H-12 0.5Y/R

10 H-12

1.25B

0.5R

0.5L

4 H-17 1.25B/R

6 H-17 1.25B/L

2 H-17 1.25W/B

7 H-17 1.25B

1.25B

1 N-18

2 N-18 N 1

3 N-18

2 N-19

6 N-19

7 N-19

10 N-19

8 N-19

4 N-19 SW:1ST GEAR START

3 N-19 4 SW:ECHO MODE N-20

5 N-19 6 N-20

R N-18 SW: EMERGENCY 5 SHIFT

5 H-118 2G

1 H-119 2L

13 H-119 2W/B

N-20 1

N-20 3 1-3-5 SHIFT SOLENOID

2 J235 2-4-R SHIFT SOLENOID

2 J236 SELECT SOLENOID

2 J234

A N-19 9

SELECT LEVER

J-235 1 2B

J-236 1 2B

J-234 1 2B

4 H-118 1.25B

4 H-119 1.25B

16 H-119 1.25B

0.5B

0.5B 2B

15 H-12

0.5B

N8B0075E

1.25B

0.5V/W

0.5R

0.5B

1.25P

1.25P

1.25P

1.25P

1.25P

1.25P

0.5V/W

CAB AND CHASSIS ELECTRICAL


For 4JJ1 (EURO 4) Engine (Except NKR Model) (1)

8-301

FL-2 40A KEY

OFF 3W/L 1 H-7 3W/L 2 B-67 ACC ON ST IGNITION SWITCH 4 8W/B F-16 10A METER H-6 5W/B 0.5B/Y F-5 10A STOP LIGHT 1.25G/W F-13 10A NEES (B) 14 H-12 0.5B/Y 0.5Y/R 2 N-17 DIODE B-1 X-32 X-32 1 0.5B/Y 18 B-51 IPC 6 B-53 B-53 1 0.3P 8 0.3G/O B-53 7 0.3Y/G 12 B-425 B-428 18 0.3B/W 12 B-79 B-79 4 0.5B 5 0.5B B-79 B-79 14 B-425 11 B-425 0.5B/Y 3W/B 3 B-67 B-67 3B/Y 3B/Y 2 3W/B 3B/Y

2L

P-1 P-2

FL-8 60A STARTER 0.5R/W 14 H-8 0.5R/W

F-22 10A STARTER 3W/R

FL-5 40A ECM

FL-1 100A MAIN

0.5L/B 4 X-18 RELAY:MAIN

X-18

3W/B

1 SW: BRAKE PEDAL B-66

0.5G/Y

1 SW: EMERGENCY 5 X-15 0.3L/R 4 H-12 0.3L/R

P-3 2 P-4 RELAY:STARTER X-21 4 X-21

X-18 5 2

X-18

B-66 2 RELAY: SMOOTHER MAIN

0.5G/W

OIL PUMP ASM

1.25G/W

N-17

1.25R

2 X-15

ECM X-21 3 5 X-21

J-237 2 0.5Y/R F-28 10A ECM

J-237 4 0.5L/W

J-237 1 0.5R/Y

J-237 3 0.5Y/B

P-5 1 STARTER

0.85LG

J-26 3B/W B C 1 J-27 0.5LG

6 H-118 0.5Y/R

14 H-119 0.5L/W

3 H-118 0.5R/Y

7 H-118 0.5Y/B

X-15 1 5

X-15

0.5G

1.25W/O

0.5W/V

0.5R

3 H-4 0.5Y/R

4 H-4 0.5L/W

1 H-17 0.5R/Y

3 H-17 0.5Y/B

0.3L/R

0.5LG

2 J-50 SW: NEUTRAL

0.5R 0.5R

6 B-427 J-50 1 0.5B/L

12 B-427

29 B-425

30 B-425

3 B-428

STOP LIGHT

3 B-426

15 B-425

4 B-428

TCM
5 H-4 0.5B/L B-428 10 B-425 16 B-428 12 B-426 4 B-426 8 B-426 12 B-426 17 B-428 19 B-427 2 0.5L/W B-427 3 0.5L B-426 9 0.3LB

5 H-17

0.3L/R

0.5R

0.5B

ECM 0.5W/L

0.5GR/R

RESISTOR 1

1.25B

RELAY: SMOOTHER EMERGENCY

1.25B

12 H-4

0.5W/L

2 0.5B 0.5B B-387 1 B-387 7 H-8 0.5L/W 0.5L 0.5L 8 H-8

4 RELAY: STARTER CUT X-26

3 X-26

1 X-14

3 X-14

X-26 1 0.5B 5

X-26 0.5W/L

X-14 5 0.3B 2

X-14 0.3B

ROOM LAMP 0.5GR/R 0.5GR/R

0.5L/W 35 TAIL LIGHT RESISTOR 2 0.5LG/R ECM 2 B-431 1 B-431 0.5L/W 0.5LB 0.5Y 0.5L 0.3L/W H-5 36 H-5

6 ECM H-12 1.2GR/R

3 H-3 0.5GR/B

SW: DOOR (ASSISTANT)

1 SW: DOOR (DRIVER) N-2

1 N-7 SW:PTO

1 B-417

B-417

2B

2B

DATA LINK CONNECTOR

6 B-79

14 B-79

B-417 3 2B

B-417 2

HEADLIGHT BRACKET

B-7

3B

2B

0.5B

5B

FRAME-LH(FRT) FRAME-LH(CTR)

B-1 J-9

1.25B 2B

2B

N8B0076E

0.5Y B-53

8-302 CAB AND CHASSIS ELECTRICAL


For 4JJ1 (EURO 4) Engine (Except NKR Model) (2)

FL-7 60A NEES 3B/Y 3R F-17 10A NEES (IG) 3 0.5B/O RELAY: GEAR SHIFT CONTROL BOX X-19 2R 4 X-19 0.5B/O 0.5B/O X-19 2 GEAR SHIFT POSITION SENSOR GEAR SELECT POSITION SENSOR TURBINE SPEED SENSOR INPUT SHAFT SPEED SENSOR 3P 5

X-19

SW: HALF-CLUTCH ADJUSTMENT

B-105 SW: RESET

B-106 SLOW FAST

J-142 1 0.5R

J-142 2 0.5W

J-142 3 0.5B

J-223 1 0.5Y/B

J-223 2 0.5Y/W

J-223 3 0.5Y/R

J-232 1 0.5O/L

J-232 2 0.5W/L

J-139 1 0.5BR

J-139 2 0.5Y

18 1 H-160 H-4 3P

B-105 6

B-106 B-106 2 1

2 H-119

3 H-119

6 H-119

7 H-119 0.5Y/B

11 H-119 0.5Y/W

15 H-119 0.5Y/R

8 H-119 0.5O/L

12 H-119 0.5W/L

5 H-118 0.5BR

2 H-118

0.5W

0.5R

0.3GR/R

0.3GR/B

0.3GR/L

0.5B/O

0.5B/O

6 H-4

7 H-4

17 H-4

0.5B

13 H-4

14 H-4 0.5Y/W

15 H-4

20 H-4 0.5O/L

9 H-4 0.5W/L

10 H-4 0.5BR

1 H-4

0.5Y/R

0.5Y/B

0.5W

0.5Y

0.5Y

1 B-426

2 B-426

17 B-428

18 B-426

19 B-426

20 B-426

10 B-426

11 B-426

13 B-426

10 B-427

4 B-427

11 B-427

5 B-427

4 B-425

5 B-425

5 B-426

6 B-426

1 B-428

8 B-428

18 B-425

B-428 B-428

TCM
B-428 20 0.5R B-428 6 0.5W B-428 14 0.5G B-427 B-428 B-427 B-427 B-427 B-427 13 0.5R/B 21 0.5W/B 14 0.5O 15 0.5L/B 7 0.5P/B 8 0.5G/B B-427 1 0.5Y/R B-428 13 0.5L B-425 21 1.25B/R B-425 31 1.25B/R B-425 8 1.25B/L B-425 9 1.25B/L B-428 16 1.25W/B B-428 22 1.25W/B B-425 6 1.25B B-425 7 1.25B B-425 1 1.25B B-425 2 1.25B B-428 7 1.25B B-428 15 1.25B 9 H-17 1.25B H-17 1.25B

3 H-12

1.25B/R

1.25W/B

1.25B/L

13 H-12 0.5W

9 H-12 0.5G

8 H-12 0.5R/B

20 2 12 1 11 H-12 H-12 H-12 H-12 H-12 0.5W/B 0.5G/B 0.5P/B 0.5L/B 0.5O

21 H-12 0.5Y/R

10 H-12

1.25B

0.5R

0.5L

4 H-17 1.25B/R

6 H-17 1.25B/L

2 H-17 1.25W/B

7 H-17 1.25B

1.25B

1 N-18

2 N-18 N 1

3 N-18

2 N-19

6 N-19

7 N-19

10 N-19

8 N-19

4 N-19 SW:1ST GEAR START

3 N-19 4 SW:ECHO MODE N-20

5 N-19 6 N-20

R N-18 SW: EMERGENCY SHIFT

8 H-118 2G

4 H-119

16 H-119 2W/B

N-20 1

N-20 3 1-3-5 SHIFT SOLENOID

2 J235 2-4-R SHIFT SOLENOID

2 J236 SELECT SOLENOID

2L

2 J234

A N-19 9

SELECT LEVER

J-235 1 2B

J-236 1 2B

J-234 1 2B

1 H-118 1.25B

1 H-119 1.25B

13 H-119 1.25B

0.5B

0.5B 2B

15 H-12

0.5B

N8B0077E

1.25B

0.5V/W

0.5R

0.5B

1.25P

1.25P

1.25P

1.25P

1.25P

1.25P

0.5V/W

CAB AND CHASSIS ELECTRICAL


For 4JJ1 (EURO 4) Engine (NKR Model) (1)

8-303

FL-2 40A KEY

OFF 3W/L 1 H-7 2 3W/L B-67 ACC ON ST IGNITION SWITCH 4 8W/B F-16 10A METER H-6 5W/B 0.5B/Y F-5 10A STOP LIGHT 1.25G/W F-13 10A NEES (B) 14 H-12 0.5B/Y 0.5Y/R 2 N-17 DIODE B-1 X-32 X-32 1 0.5B/Y 18 B-51 IPC 6 B-53 B-53 1 0.3P 8 0.3G/O B-53 7 0.3Y/G 12 B-425 B-428 18 0.3B/W 12 B-79 B-79 4 0.5B 5 0.5B B-79 B-79 14 B-425 11 B-425 0.5B/Y 3W/B 3 B-67 B-67 3B/Y 3B/Y 2 3W/B 3B/Y

2L

P-1 P-2

FL-8 60A STARTER 0.5R/W 14 H-8 0.5R/W

F-22 10A STARTER 3W/R

FL-5 40A ECM

FL-1 100A MAIN

0.5L/B 4 X-18 RELAY:MAIN

X-18

3W/B

1 SW: BRAKE PEDAL B-66

0.5G/Y

1 SW: EMERGENCY 5 X-15 0.3L/R 4 H-12 0.3L/R

P-3 2 P-4 RELAY:STARTER X-21 4 X-21

X-18 5 2

X-18

B-66 2 RELAY: SMOOTHER MAIN

0.5G/W

OIL PUMP ASM

1.25G/W

N-17

1.25R

2 X-15

ECM X-21 3 5 X-21

J-237 2 0.5Y/R F-28 10A ECM

J-237 4 0.5L/W

J-237 1 0.5R/Y

J-237 3 0.5Y/B

P-5 1 STARTER

0.85LG

J-26 3B/W B C 1 J-27 0.5LG

6 H-118 0.5Y/R

14 H-119 0.5L/W

3 H-118 0.5R/Y

7 H-118 0.5Y/B

X-15 1 5

X-15

0.5G

1.25W/O

0.5W/V

0.5R

7 H-17 0.5Y/R

8 H-17 0.5L/W

9 H-17 0.5R/Y

11 H-17 0.5Y/B

0.3L/R

0.5LG

2 J-50 SW: NEUTRAL

0.5R 0.5R

6 B-427 J-50 1 0.5B/L

12 B-427

29 B-425

30 B-425

3 B-428

STOP LIGHT

3 B-426

15 B-425

4 B-428

TCM
6 H-17 0.5B/L B-428 10 B-425 16 B-428 12 B-426 4 B-426 8 B-426 12 B-426 17 B-428 19 B-427 2 0.5L/W B-427 3 0.5L B-426 9 0.3LB

11 H-4

0.3L/R

0.5R

0.5B

ECM 0.5W/L 5

RESISTOR 1

1.25B

RELAY: SMOOTHER EMERGENCY

1.25B

H-17

0.5GR/R

0.5W/L

2 0.5B 0.5B B-387 1 B-387 7 H-8 0.5L/W 0.5L 0.5L 8 H-8

4 RELAY: STARTER CUT X-26

3 X-26

1 X-14

3 X-14

X-26 1 0.5B 5

X-26 0.5W/L

X-14 5 0.3B 2

X-14 0.3B

ROOM LAMP 0.5GR/R 0.5GR/R

0.5L/W 35 TAIL LIGHT RESISTOR 2 0.5LG/R ECM 2 B-431 1 B-431 0.5L/W 0.5LB 0.5Y 0.5L 0.3L/W H-5 36 H-5

6 ECM H-12 1.2GR/R

3 H-3 0.5GR/B

SW: DOOR (ASSISTANT)

1 SW: DOOR (DRIVER) N-2

1 N-7 SW:PTO

1 B-417

B-417

2B

2B

DATA LINK CONNECTOR

6 B-79

14 B-79

B-417 3 2B

B-417 2

HEADLIGHT BRACKET

B-7

3B

2B

0.5B

5B

FRAME-LH(FRT) FRAME-LH(CTR)

B-1 J-9

0.85B 2B

2B

N8B0078E

0.5Y B-53

8-304 CAB AND CHASSIS ELECTRICAL


For 4JJ1 (EURO 4) Engine (NKR Model) (2)

FL-7 60A NEES 3B/Y 3R F-17 10A NEES (IG) 3 0.5B/O RELAY: GEAR SHIFT CONTROL BOX X-19 2R 4 X-19 0.5B/O 0.5B/O X-19 2 GEAR SHIFT POSITION SENSOR GEAR SELECT POSITION SENSOR TURBINE SPEED SENSOR INPUT SHAFT SPEED SENSOR 3P 5

X-19

SW: HALF-CLUTCH ADJUSTMENT

B-105 SW: RESET

B-106 SLOW FAST

J-142 1 0.5R

J-142 2 0.5W

J-142 3 0.5B

J-223 1 0.5Y/B

J-223 2 0.5Y/W

J-223 3 0.5Y/R

J-232 1 0.5O/L

J-232 2 0.5W/L

J-139 1 0.5BR

J-139 2

12 1 H-160 H-4 3P

B-105 6

B-106 B-106 2 1

2 H-119

3 H-119

6 H-119

7 H-119 0.5Y/B

11 H-119 0.5Y/W

15 H-119 0.5Y/R

8 H-119 0.5O/L

12 H-119 0.5W/L

5 H-118 0.5BR

2 H-118

0.5W

0.5R

0.3GR/R

0.3GR/B

0.3GR/L

0.5B/O

0.5B/O

5 H-4

6 H-4

7 H-4

0.5B

1 H-4

2 H-4 0.5Y/W

3 H-4

8 H-4 0.5O/L

4 H-4 0.5W/L

10 H-4 0.5BR

9 H-4

0.5Y/R

0.5Y/B

0.5W

0.5Y

0.5Y

0.5Y

1 B-426

2 B-426

17 B-428

18 B-426

19 B-426

20 B-426

10 B-426

11 B-426

13 B-426

10 B-427

4 B-427

11 B-427

5 B-427

4 B-425

5 B-425

5 B-426

6 B-426

1 B-428

8 B-428

18 B-425

B-428 B-428

TCM
B-428 20 0.5R B-428 6 0.5W B-428 14 0.5G B-427 B-428 B-427 B-427 B-427 B-427 13 0.5R/B 21 0.5W/B 14 0.5O 15 0.5L/B 7 0.5P/B 8 0.5G/B B-427 1 0.5Y/R B-428 13 0.5L B-425 21 1.25B/R B-425 31 1.25B/R B-425 8 1.25B/L B-425 9 1.25B/L B-428 16 1.25W/B B-428 22 1.25W/B B-425 6 1.25B B-425 7 1.25B B-425 1 1.25B B-425 2 1.25B B-428 7 1.25B B-428 15 1.25B 16 H-17 1.25B

3 H-12

1.25B/R

1.25W/B

1.25B/L

13 H-12 0.5W

9 H-12 0.5G

8 H-12 0.5R/B

20 2 12 1 11 H-12 H-12 H-12 H-12 H-12 0.5W/B 0.5G/B 0.5P/B 0.5L/B 0.5O

21 H-12 0.5Y/R

10 H-12

1.25B

0.5R

0.5L

1 N-18

2 N-18 N 1

3 N-18

2 N-19

6 N-19

7 N-19

10 N-19

8 N-19

4 N-19 SW:1ST GEAR START

3 N-19 4 SW:ECHO MODE N-20

5 N-19 6 N-20

13 H-17 1.25B/R

12 H-17 1.25B/L

10 H-17 1.25W/B

14 H-17 1.25B

1.25B

15 H-17 1.25B

R N-18 SW: EMERGENCY 5 SHIFT

8 H-118 2G

4 H-119

16 H-119 2W/B

N-20 1

N-20 3 1-3-5 SHIFT SOLENOID

2 J235 2-4-R SHIFT SOLENOID

2 J236 SELECT SOLENOID

2L

2 J234

A N-19 9

SELECT LEVER

J-235 1 2B

J-236 1 2B

J-234 1 2B

1 H-118 1.25B

1 H-119 1.25B

13 H-119 1.25B

0.5B

0.5B 2B

15 H-12

0.5B

N8B0079E

1.25B

0.5V/W

0.5R

0.5B

1.25P

1.25P

1.25P

1.25P

1.25P

1.25P

0.5V/W

CAB AND CHASSIS ELECTRICAL


Connector list
For 4HK1 / 4JJ1 (EURO 4) Engine (Except NKR Model) No.
l

8-305

Connector Face

No.

Connector Face

B-1
000-001

B-105
006-021

B-7
000-001

B-106

1 2 3

003-014

B-51
020-004

B-387
002-038

B-53
012-009

B-387
002-039

B-66

B-417
1 2

1 3

2 4
004-001

002-031

B-67

2 4

1 3

B-425
031-001

004-002

B-67

1 3

2 4
004-001

B-426
024-001

B-79

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
016-005

B-427
017-001

8-306 CAB AND CHASSIS ELECTRICAL


No. Connector Face No. Connector Face

B-428
022-006

H-160

001-023

B-431
002-038

H-12

10 9 8 7 6 22 21 20 19 18 17

5 4 3 2 1 16 15 14 13 12 11

022-002

B-431
002-039

H-12

1 2 3 4 5 11 12 13 14 15 16

6 7 8 9 10 17 18 19 20 21 22

022-001

H-3

1 4

2 5

3 6

H-17
006-014

1 2 3 4 5 6 7 8 9
009-004

H-3

3 6

2 5

1 4

H-17
006-015

3 2 1 6 5 4 9 8 7
009-005

H-4

9 8 7 6 20 19 18 17 16

5 4 3 2 1 15 14 13 12 11 10

H-118 (4HK1 )
020-003

1 5 9

2 6

3 7

4 8

10 11 12

012-001

H-4

1 2 3 4 5 10 11 12 13 14 15

6 7 8 9 16 1718 19 20

H-118 (4HK1 )
020-002

4 8

3 7

2 6

1 5 9

12 11 10

012-002

H-160

H-118 (4JJ1)
001-022

1 5

2 6

3 7

4 8
008-003

CAB AND CHASSIS ELECTRICAL


No. Connector Face No. Connector Face

8-307

H-118 (4JJ1)
008-018

J-142

003-005

H-119

1 5 9

2 6

3 7

4 8

J-223
016-001

10 11 12

13 14 15 16

003-005

3 7

2 6

1 5 9

H-119

12 11 10

J-232
016-002 002-040

16 15 14 13

J-9
000-001

J-234

002-003

J-26
000-002

J-235

002-003

J-27
000-009

J-236
002-042

J-50
002-035

J-237
004-020

J-139
002-040

P-1
000-022

8-308 CAB AND CHASSIS ELECTRICAL


No. Connector Face No. Connector Face

P-2
000-014

X-21

2 4

3 5

005-003

P-3
000-014

X-26
005-006

P-4
000-014

X-32

1 2 3 4

004-004

P-5
000-002

N-2
001-020

X-14
005-006

N-7
001-020

X -15
005-006

N-17

1 5

2 6

3 7

4 8

008-005

X-18
005-006

N-18

1 2 3 4 5 6
006-007

X-19

2 4

3 5

N-19
005-003

1 2

3 4

5 6 7 8 9 10

010-003

CAB AND CHASSIS ELECTRICAL


H-5

8-309

1 7 13 19 25 31

2 8 14 20 26 32

3 9 15 21 27 33

34

35

36

37

4 10 16 22 28 38

5 11 17 23 29 39

6 12 18 24 30 40

6 12 18 24 30 40

5 11 17 23 29 39

4 10 16 22 28 38

37

36

35

34

3 9 15 21 27 33

2 8 14 20 26 32

1 7 13 19 25 31

N8A5488E

H-6, H-7, H-8

H-6

H-7

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 H-8

4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14

N8A5489E

8-310 CAB AND CHASSIS ELECTRICAL


For 4JJ1 (EURO 4) Engine (NKR Model) No.
l

Connector Face

No.

Connector Face

B-1
000-001

B-105
006-021

B-7
000-001

B-106

1 2 3

003-014

B-51
020-004

B-387
002-038

B-53
012-009

B-387
002-039

B-66

B-417
1 2

1 3

2 4
004-001

002-031

B-67

2 4

1 3

B-425
031-001

004-002

B-67

1 3

2 4
004-001

B-426
024-001

B-79

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
016-005

B-427
017-001

CAB AND CHASSIS ELECTRICAL


No. Connector Face No. Connector Face

8-311

B-428
022-006

H-12

1 2 3 4 5 11 12 13 14 15 16

6 7 8 9 10 17 18 19 20 21 22

022-001

B-431
002-038

H-17

1 5 9

2 6

3 7

4 8

10 11 12

13 14 15 16

016-001

3 7

2 6

1 5 9

B-431
002-039

H-17

12 11 10

16 15 14 13

016-002

H-3

1 4

2 5

3 6

H-118
006-014

1 5

2 6

3 7

4 8
008-003

H-3

3 6

2 5

1 4

H-118
006-015 008-018

3 7

2 6

1 5 9

H-4

H-119
012-002

1 5 9

2 6

3 7

4 8

12 11 10

10 11 12

13 14 15 16

016-001

H-4

1 5 9

2 6

3 7

4 8

3 7

2 6

1 5 9

H-119
012-001

10 11 12

12 11 10

16 15 14 13

016-002

H-12

10 9 8 7 6 22 21 20 19 18 17

5 4 3 2 1 16 15 14 13 12 11

H-160
022-002

001-022

8-312 CAB AND CHASSIS ELECTRICAL


No. Connector Face No. Connector Face

H-160

J-232
001-023 002-040

J-9
000-001

J-234

002-003

J-26
000-002

J-235

002-003

J-27
000-009

J-236
002-042

J-50
002-035

J-237
004-020

J-139
002-040

P-1
000-022

J-142

P-2
003-005 000-014

J-223

P-3
003-005 000-014

CAB AND CHASSIS ELECTRICAL


No. Connector Face No. Connector Face

8-313

P-4
000-014

X-32

1 2 3 4

004-004

P-5
000-002

N-2
001-020

X-14
005-006

N-7
001-020

X -15
005-006

N-17

1 5

2 6

3 7

4 8

008-005

X-18
005-006

N-18

1 2 3 4 5 6
006-007

X-19

2 4

3 5

N-19
005-003

1 2

3 4

5 6 7 8 9 10

010-003

X-21

2 4

3 5

N-20
005-003 006-022

X-26
005-006

8-314 CAB AND CHASSIS ELECTRICAL


H-5

1 7 13 19 25 31

2 8 14 20 26 32

3 9 15 21 27 33

34

35

36

37

4 10 16 22 28 38

5 11 17 23 29 39

6 12 18 24 30 40

6 12 18 24 30 40

5 11 17 23 29 39

4 10 16 22 28 38

37

36

35

34

3 9 15 21 27 33

2 8 14 20 26 32

1 7 13 19 25 31

N8A5488E

H-6, H-7, H-8

H-6

H-7

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 H-8

4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14

N8A5489E

Tacho Graph

Parts Location

J-32 V/SPEED SENSOR

FUSE & RELAY BOX ASM X-4 TAIL RELAY F-4,F-7,F-16 FUSE J-191 ECM

H-118

B-338 TACHO GRAPH

H-5,H-6,H-7

P-1 P-2

BATTERY P-4 P-5 P-3

B-337 PULS CONVERTER

B-1 B-67 STARTER SW

CAB AND CHASSIS ELECTRICAL

B-51, B-52 METER

RELAY BOX ASM FL-1, FL-2 FUSIBLE LINK

N8B0080E

8-315

8-316 CAB AND CHASSIS ELECTRICAL


Circuit Diagram
For 4HK1 / 4JJ1 (EURO 4) Engine (For Europe)
FOR 4HK1 FL-1 2L 100A /120A MAIN 8W/B 5W/B
2 H-6

30B/R

8B

8W/B FOR 4JJ1

5W/B

3W/B

2W/B

P-1 P-2

3W/L

3 1 X-4

3W/B
2 X-4

FL-2 40A KEY SW

F-4 15A RELAY; TAIL AUDIO(B) DOOR LOCK

H-7 P-3 P-4

3W/L

2 B-67

X-4 5

X-4 1

P-5

OFF STARTER SWITCH ST ON ACC

B-67

F-7 10A TAIL LIGHT F-16 10A METER 0.85LG/R

METER
18

3B/Y

0.5LG/R 0.5LG/R
7 6

IGN
20

B-51

0.5B/Y 0.5B/Y 0.5R 0.5R


5

17

B-52

SPEED

B-52

0.5B

0.3Y/G DIGITAL 0.3Y/G 0.5B/Y

4 3 5 B-338 B-338 B-338

0.5B 1.25B (NPR/NQR) / 0.85B (NKR)


H-5 19

H-5 25

H-5 31

TACHO GRAPH "A" / "B"

ECM
19

0.5B

0.5B/Y

B-335 B-335 B-335

0.5Y/G

IFSPD

J-191

0.5Y/G

0.5B/Y

IG

ILL

(4HK1 SMOOTHER ONLY)

10 H-118

11 H-118

9 H-118

SIG OUT GND GND


B-334 B-335 B-335

0.5W/R

0.5Y/G

0.5B/Y

0.85R +B
2

TAIL LIGHT SWITCH

FOG LAMP SWITCH

3W

0.5B 0.5B 0.85B

0.5B

0.3W/R

J-32

G V/SPEED SENSOR SIG V

0.5B/Y

J-32

B-338 B-338 B-338 1 2 6

J-32

FOR NKR

0.3B

B-337 B-337 B-337 B-337

B-337 B-337 B-337 B-337

FOR NPR/NQR

SIG OUT

IG

SIG GND IN

0.85B (NKR) / 1.25 (NPR/NQR)


B-1

CONVERTER ; PULS

FRAME-LH

0.5B

0.3W/B
1

0.5B

N8B5102E

CAB AND CHASSIS ELECTRICAL


Connector list
No.
l

8-317

Connector Face

No.

Connector Face

B-1
000-001

B-338

6 5 4 3

006-003

B-51
020-004

B-338

3 4 5 6
006-002

B-52
020-005

X-4
005-006

B-67

2 4

1 3

H-118

1 5

2 6

3 7

4 8
008-003

004-002

B-67

1 3

2 4
004-001

H-118
008-018

B-334

1 2

3 4
004-014

J-32

003-018

B-335

1 2 3 4

5 6 7 8 008-014

J-191
081-001

B-337

P-1
8765 1234
008-013 000-022

8-318 CAB AND CHASSIS ELECTRICAL


No. Connector Face H-6, H-7

P-2
000-014

H-6

H-7

P-3
000-014

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 H-8

4 3 2 1 8 7 6 5 13 12 11 10 9 18 17 16 15 14

P-4
N8A5489E
000-014

P-5
000-002

H-5

1 7 13 19 25 31

2 8 14 20 26 32

3 9 15 21 27 33

34

35

36

37

4 10 16 22 28 38

5 11 17 23 29 39

6 12 18 24 30 40

6 12 18 24 30 40

5 11 17 23 29 39

4 10 16 22 28 38

37

36

35

34

3 9 15 21 27 33

2 8 14 20 26 32

1 7 13 19 25 31

N8A5488E

LGCEL-WE-0761LH

You are requested to order this manual using the manual number that is shown above.

This manual is applicable for vehicles in all countries except the USA, Canada and Mexico.

All rights reserved. This manual may not be reproduced in whole or in part, without the permission in writing of ISUZU MOTORS LIMITED. Issued by

ISUZU MOTORS LIMITED


SERVICE MARKETING DEPARTMENT Tokyo, Japan First edition August, 2006

No.LGCEL-WE-0761LH