ELECTRICAL

SYSTEM

SECTION EL
When you read wiring diagrams:
o Read Gl section, "HOW TO READ WIRING
DIAGRAMS''.

CONTENTS
EL- 2
EL- 3
EL- 6
EL- 11
STARTINGSYSTEM EL. 18
STARTINGSYSTEM- Starter- ... EL.20
CHARGINGSYSTEM EL- 28
CHARGINGSYSTEM* Alternator- EL- 30
COMBINATION SWITCH .... EL- J/
HEADLAMP- Without DaytimeLight Systemand Dim-dipLamp System EL. 39
HEADLAMP- DaytimeLight System- EL- 40
HEADLAMP- Dim-dipLampSystem- EL- 42
HEADLAMP- HeadlampAimingControl EL. 44
HEADLAMP EL- 49
EXTERIOR L A M P. . . . . . . . . . . . EL- CI
tNTER|OR 1 A M P. . . . . . . . . . . . EL- 64
M E T E RA N D G A U G E S EL. OO
WARNINGLAMPS AND BUZZER EL- 73
WIPERAND WASHER EL- 80
HORN,CIGARETTELIGHTERAND CLOCK EL- 88
REARWINDOWDEFOGGER EL- 89
I::L- J Z

LOCATIONOF ELECTRICAL UNITS EL- 95

H A R N E S SL A Y O U T. . . , . . . . . . . . EL-101
S U P E RM U L T I P L E
JUNCTION ( S . M . J . .). . . . . . . . . E L -1 2 9

URING DIAGRAMREFERENCECHART

ENGINEROOM FAN LC S€CTION

E.C.C.S. EF & EC SECTION
A/T CONTROL AT SECTION
ANTFLOCKBRAKINGSYSTEM BR SECTION
POWERWINDOU POWEROOOB LOCK, HEATEDSEAT.
S€AT BELT. SUN ROOF.OOORMIRROB BF SECNON
HEATERANO AIB CONDITIONER HA SECNON
 HARNESSCONNECTOR

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

PUSH
( Fo. combinrtbn mri..l

EL-2
 RELAY
STANDARDIZED

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

s1!r eatriq, 5M BATTERY s r i YI

z
o

sEL881t-l

TYPEOF STANDARDIZED
RELAYS
1L4 ... 1 t\,4ake 2M . . . . . . . . . . . . . .2. . t. 4. .a k e
1T l Transler ' 1 N i l
| 18.............1 . .M. . .a k e1

EL.3
 STANDARDIZED RELAY
Description(Cont'd)
Connector iymbol
Tvpe Outa? Yicw Circuit Caa colo.
and connction

IT BLACK

BLUE
IM or
G REEN

2M 8 ROWN

IM,IB GRAY

EL4
 REALY
STANDARDIZED

NOTE

EL.5
 POWERSUPPLYROUTING

WiringDiagram
FOB CENTRALEUBOPE
'a'
Si2 !UE e",9:.e mode :
/:\ CA16!'lE e.9 ne rode s
-:
: GNi !N ACC:!SORY
R:LAY-2 FE!i' I Ll2l en,e -e mrJ. s

4'r \!:- :!ceDt 5F2al: er'. f-- Toae

LAl+ a:l' :!c3pa lalb:l: e.E r.A r.ce

Nfl*
:)'ts+ ..i :!aep:-12J e-a.e riale 5

- ila.i, n:.JF g
,:;.
: !.r: - n,J.le !
-l
;;',ER *a;;* t,'t
s!\ R a I O F: ' s - E | ]
i

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

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

b
.IDIT:I EN r ri: rD
-l-
11 5!
n ast,rage
.TTI
iGNirlOii Sv!ITCH
.|-r,rrTi
-r--- tuL! r @ @
t.ldFF:TTnxTtf i
: _ ao
2 a)
[T--r--To]
40
ET TT TOI
IDT} w L
tr
6ln lil5

-Tre'I

I3\IT:!\:YS-EII
-
:f;...cl
iAD I AT!'rR
-.i\:;iE,
Arr,l F_ : : t s _ : L : \ (
A\: ;-:: 3OX

CD i5A E4
al!i;altr_j:vsTEll

illtr - _ - f;;; . r.i 5

\ot usedO
:!0A E)
Nct Jsed O
t:A ai
zse6 a--- -lREtR Fin-rl.rp l
F!Sl BLE
LIN( EN:I I.E AfOI:

E]
F ; N 5 Y :i : T

'f
AATTERY

MELTOSB]

EL-6
 POWERSUPPLYROUTING
WiringDiagram(Cont'd)

FTl
eQ Eo
BOD\ GR!UND

ACCESSORY :GNII]'N
2 RELAY'L
'etffi

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

(i;\ - -.-- o\-I-t.\to-

8/n-1 1)
.. - --l
lB * frlEg
L-r

r-
EE f.
w/6@ BR + E\Grf= CCTTFC;5.5TEfr

;3ffi
",^-m
. * ^.."
IC;A";l':l',.?EiiJ...oo

I AIL, C.EARAN'E IND

L I CE\CE LAIIP5

T A I L , C L : A R A N C E.,I C E N C E
I L L L | l I N A TI O N L A i P s ,
W A R NN I G BUZZER,
tsEADLAI'O AIIJING LONTROL

SIART SI GNAL,
E N G IN E C O N T R O L S Y S T E I ]

G Z A R OW A F N N
I C

R/\1+ffi

l! cr ' Lr']P

R @R/L

F u s E8 - 0 c K E N C IN E i J O T F A N 5 I 3 --E, I ] , C L O C K ,
@ A . ] D IO , ' : . LE!EL I]NI
l - - L r N i N A TI O N C O N T R a I L
SYS:Eir
ref o
|ue @ "'.-'-.L--_

: \TER: OR ANO 5POT LAIIP

rl. 20A ts,
t0i tE) R E A R ! \ I N D O WD E F O G ' E t
i2
L,p REAR ELOW:P I]ITOII
o @

r3 E A C K C C O RL I C K
fn

MELTOSA

EL.7
 POWERSUPPLYROUTING
WiringDiagram(Cont'd)
EXCEPTFOR CENTRALEUROPE

C I R C UT
I
aa S R 2 O D Ee n g l n e m o d eL s AREAKER
(6\ G A1 6 D E e n g l n e m o d e l s IGNITION t-t A C C E-S S O R

II
RELAY.2 R E L A Y3
(6\ LO20 eng lne riode s
t.ql rrr)l
Except S R 2 0 O Ee n g i n e m o d el s -JJt
l--lJ I
@ E x c e p t G A 1 6 O Ee n g i n e m o d el s - ...rT-H
(file)ltrEl 0118
- t )TH GDr#r
-
G;\ Except LD20 eng ine models T T TI
)i
@ Fo. Nonth Euaope fiode s
POWERVYINDOVY
SYSTEI1
SUN ROOFSYSTEI1
@ Except fo. North Europe models

\T/ R H . D . m o d el s
.a-\ f,ceo! R J.O Todc s 6 ti 5a20DL
e.g'.c E.o Foocls w tr -D20 e^g'.c
a-

@ e,..pt 6
g/.1-

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

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

@, r-ooon mooes

@, 5-ooor mooes
r x c e p t L H . O .m o d e s w l t h S R 2 O O E
engln.
./t--
EI]]
lal
@ trFml@
@,
Jat-
O , L . H . o . m o d ct s
"+-
r+n @ wl
--T-T-l @

-gt
r2r3rFE- ]+
-t
I G N I T I O N S W IT C I - ] frEl

S T A R II N G S ' S I E r I

I G N IT I O N 5 . jS T E T

F U S IB L E L I N K
A 6tl AND FUSE BOX
C H A R GN
I G 5Y5TEI1
QtD2s2) *6 4sa @
G L O V VS Y S T E I 1
6l *6 L 0 0 A@
5oAQ&@
25A €) & q-)
l ,jF
\i rl0 5 o Aq & O
2sA (-l)

: : LINK

FIR'!V,?39"cl
^
r R+l ABSO I
TTE

MEL709B1

EL€
 POWERSUPPLYROUTING
WiringDiagram(Cont'd)

oR+@

o"re*@

ACCESSORRY E L A Y I G N IT I O N D O O RI l I R R O R W I T H I I I R R O RH E A T E R ,
-2 -1 RELAY-I REAR WIPER AND WASIIER
T-t r:t T-t
lan I ll /rn l/rnll
a€ ftlt lt-rjl I

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

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

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

G+M
G/B+m
",**ffi
BR+m
I l E T E R A N O G A U G E SW
, ARNIIG LAI1PS,
SIJISTF
iISEI
3}3IEX
HF
E N G I N E R O O t l F A N S Y S T E I l ,C L O C K ,
A U D IO , C I L L E V E L U N IT ,
I L L U I l I N A T I O N C O N T R O LS Y S I E I I
r
airD
'J FUSE BLOCK

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

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

EL.9
POWERSUPPLYROUTING

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

FusibleLink
A meltedfusiblelinkcan be detectedby visualinspection. lf its
conditionis questionable, use circuittesteror test lamp.
CAUTION:
a. ll lusible link should melt, it is possible that critical circuit
(power supply or large current carrying circuit) is shorted.
In such a case, carefully check and eliminate cause of
problem.
b. Never wrap periphery of fusible link with vinyl tape.
Extreme care should be taken with this link to ensure that
it does not come into contact with any other wiring harness
or vinyl or rubber pans.

EL-l0
 BATTERY

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

How to HandleBattery
METHODS OF PREVENTINGOVER-DISCHARGE
The followingprecaulionsmust be taken to preventoverdis-
charginga battery.
o The batterysurface(particularlyils top) should always be
keptcleanand dry.
lf the top surface of a battery is wet wilh electrolyteor
water, leakagecurrentwill cause the batteryto discharge.
Always keep the batteryclean and dry.

Whenthe vehicleis not goingto be usedovera longperiod

ol time, disconnectthe negativebatteryterminal.(ll the
vehiclehas an extendedstorageswitch,turn it off.)

Check the chargeconditionof the battery.

Periodicallycheck the specific gravity of the electrolyte.
Keep a close check on charge conditionto preventover-
t discharge.
)
,r/ "

s E L1 9 1

CHECKING ELECTROLYTE LEVEL

WARNING:
Do not allow battery fluid to come in contact with skin, eyes,
fabrics, or painted surfaces, After touching a battery, do not
touch or rub your eyes until you have thoroughly washed your
hands. lf the acid contacts the eyes, skin or clothing, immedi-
ately flush with water for 15 minutes and seek medical atten-
tion.
Normally the battery does not require additional water.
However,when the battery is used under severe condilions,
addingdistilledwater may be necessaryduringthe batterylife.

EL-11
 BATTERY
How to HandleBattery(Cont'd)
- No.mal batia.y
____- S{rloharadb.riarv
Chrti't|
SULPHATION
volrrt
When a bafteryhas been left unattendedfor a long period of
I "_j:= Ch.rginf Yolt.g. time and has a specificgravity ot less than 1.100, it will be
completely discharged, resulting in sulphation on the cell
Chartingcsr..nr plates.
Ch|rgin' curr.nl Comparedwith a batterydischargedunder normalconditions,
I the current flow in a "sulphated" battery is not as smooth
althoughits voltageis high duringthe initialstage of charging,
Ogr.rion ol ch.rt as shown in the figureat the left.

Rad top Lvcl SPECIFIC

GRAV]TYCHECK
with rcalc 1. Read hydrometerand thermometerindicationsat eye level.
o When electrolytelevel is too low, tilt batterycase to raiseit
for easy measurement.

)
Th6rmorn€t6a

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

Hydro.n t.r Examole:
o When electrolytetemperatureis 35"C (95'F) and specific
e gravityof electrolyteis 1.230, convertedspecificgravityat
U 20'C (68'F) is 1.240.
,-a
,rt a o When electrolytetemperalureis 0"C (32"F) and specific
Thsmoniatea gravityof electrolyteis 1.210, convertedspecificgravityat
20'C (68'F) is 1.196.

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

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

a t.t2
r.ro

||al t32t t50] tat| tr]

'C
Elactrolvta latnoaratura fF,

SEL197P

EL.l2
 BATTERY

BatteryTest and ChargingChart

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

o.K

R.9l.cr bfiarY.
C H E C KI N G S P E C I FI C G R A V I T Y
'Sp.cilic Gr.v(y Ch.ck"
Rrl.. ro

SLOWCXARGE CAPACITY T€ST

R.l.r to 'Ar slow STANOARO CHARGE O U I C KC H A R G € R.l.r to "Ch.rl ll
'

Ch.rg.'. R.l.r to "B: St.ndard Ft.l.r lo 'C Ou|ck

c,r.rF . Ch..ga".
o.K. N,G.

CAPACITYT€ST Rcady tot ura

R.lcr to "Chart ll CAPACITY TEST . Mount batlary .earn
R.{.. io "Ch..l ll
a.id ch.ck loot lar'
o.K. N.G mrnalt. Alao, chack
N,G orhar r.latad o.curlt

Radv Ra9l.c.
lor ura battary.
O U I C KC H A R G E
C H € C KI N G S P C C I FI C G R A V I T Y
Rrl.. !o "C: Ouicl
R.l.r to "sgacilic GravilY Ch'ck"
Chrrta"
. tiir tlu-td: ta6 tri|r.

RECHARGE CAPACITYTEST
Rclcr to
'Cr Ourcl Ch.tg. . n.1.. ro "Ch..r ll
. tt btna.Y |rtFa.aol?t ri- -cvt 'dC
t rad F l, rrog dr4i.r.. Alt.v. clr'{' o.K N.G,
b.rtaw th-r in |.|rF?atuna i. b'lot
R.-v Rtlact
8dC fiadFl.

CAPACITYTEST
R.t.r to "Ch.n ll

N.G.
R..dy R.pl.E.
tor uat br(arv

. 'STAIIDARO CHABOE" la ..conmandad ll th. vahlcla l. In ttot'g"tltr ch"g|ng'

EL.13
 BATTERY
BatteryTestand ChargingChart(Cont'd)

. Chd( b.nary ryp. rnd

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

F i g .1 O I S C H A R G I N G
CURRENT
(Lo.d re5t6r)

Tatr ul|ng load taata.

cuiienr (A)

28819R 90

Follow mrnut.crur!r'r 46824A

Rrrd losd lrrtr. volt46
inrtrudion. io chck and wh.n .p.citi.d dirch.rging 55D23R 180
d.t.rmr^Grl ba[ary il curr.ni {Fl.l.r ro Fi9. I )
l l o w 3 r h r o u g hb a i t . r y l o r 80D268 195

95D31R 244

I15D31R 244
R..dy tor u.. Go to nlri ittp

EL-14
 BATTERY
BatteryTestand ChargingChart(Cont'd)
A SLOW CHARGE
F 1 9 .2 l N l T l A L C H A R G I N G C U R R E N T S € T T | N G l s t o w c h . r g . ,

\8ATTERY
\ TYPE
c! tr cc cc cc
coN-\
VERTEO\ t! (D o o o
ft
SPEC|FtC \
Dctarmrna Iniiral charcant currant trom GRAVITY \
rp.citic arrvily .ct..ring to Fig. 2
4.0 5.0 7.0 8.0 lo.0 14.O
Bdow I .l0O
tA) {a) {A' tAt (At

. C h a . g cb € r t . r y . Chact banary ryp..nd drtrtmin th. ,p.citht currant uriq th.

. C h . c k c h . r g a n 9v o l t . g . 3 0 m r n u r c r a l t c r tabl€ sho$rn abov?.
rra.tinq tha batla.y chrrgc Aft r rtrrting chrgirE, sdjuttr.nt ol chrging clJrrrnt ir no!

t2 ro l5 voltr Salow l2 voltr or sbor€

15volr3 Frs 3 ADOITIONAL CHARGE {Slow ch.rg.)

r 150 1 200

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

l2 hou.5
C h s r g ct o , 5 h o u . s Cha.g? lor 4 hourr Charg! tor 2 hourt
ar 'nrlr.r charoin9

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

',CAPACIIY
Go Io TEST,'

Conduct addriional charga a! par

Fig 3. il nacaatary

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

CAUTION:
a. Set charging current to value specified in Fig. 2. lf charger
is not capable of producing specified current value, set its
charging current as close to that value as possible.
b. Keep battery away lrom open flame while it is being
charged.
c, When connecting charger, connect leads first, then turn on
charger. Do not turn on charger first, as this may cause a
spark.
d. lf battery temperaturerises above 60"C (140'F),stop charg-
ing. Always charge battery when its temperature is below
60"c (140"R.

EL-15
 BATTERY
BatteryTest and ChargingChart(Cont'd)
F i s . 4 l N t T l A LC H A R G I N GC U R R E N T
SETTING
A. STANOAROCHARGE lst.nd.rd ch.rerl

\BATTERY
\ TYPE c
coN. \
V€RTEO\ o o
S P E C | F T\C
I
Oatarhina ihit|.l charging curranl t.om
rp.citrc gr.vity. rcl.rri.9 lo F19. 4 GRAVITY \

r . 1 m- 1 . 1 3 04 . 0 t A t 5.0 {A) 6.0 {At 7.OtAl 9.O(a) 1 3 . Ot A l

1 . 1 3 0- 1 . 1 6 0 3.O{At 1.0 tAt 5.0 {Al 6.0 tAt 8.0 (A) l r . o t a l

Cha.g. b.ttrry lor S hou13 r . 1 6 0- 1 . 1 $ 2.0 la) 3.0{At 4 . 0( a ) 5.0{At 7.0(Al LO {A)

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

Ch.ck b.tr.ry typ. 5nd dct.rmrn. rh..rifiad cu.r.nr rrint th. i.bl.

C T I E C KI N G S P E C I F I CG R A V I T Y Altcr 3iarlrng cha.girE, adiu.tmGnt ol ch.rging cur.ant r. nol n.odta.Y.

R.t.r ro "Spacitrc Gravny Ch.ck"

Cor€uct addrt|onal charg?.3 Pcr

Fq 5, it nccgrary

F r 9 .5 A O D I I I O N A L CHARGE {Stt^d..d charg.)

'
Go ro "CAPACITY TEST
r 150 I 200

C h a r g ct o r 3 . 5 h o u r s Chargc lor 2.5 houri Ch.rgr ro. l Shou.t

e l r n r t i a lc h a r g , n g er Inrtr.l ch.rtrng

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

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

EL.l6
 BATTERY
BatteryTest and ChargingChart(Cont'd)
C OUICK CHAFGE
C U R R E N T S E T T I NAGN o
F r s .6 l N t T l A L C H A R G I N G
CHARGI G TIME lorick chrrg.)

1 BATTERY
\\ TYPE E
c! _t
\\-- (! iIC!
O a a r r h i n a r ^ r t . l c h a r g r n gc u r r ! . 1 l a t t r n 9 a n d \ cuR\
c h r r g r n gr r m c l r o m t p . c r f i c g . a v r l y , r l t l r r r n g coN. \ RENr cD oo 3?
ro Frg 6 V E R T E D\ A I
SPECTFTC
\
GRAVITY \ 1 0t A l 15lA) 20 (A) 30 (a) 40 (a)

1 1 0 0- 1 . 1 3 0 2.5 hour3

r .r 3 0. 1 .t 6 0 2.Ohour3

1 . 1 6 0- r . 1 9 0

1 . 1 9 0- 1 . 2 2 0

Above 1.220 O.75 houri (45 mi^.)

G o r o " C A P A C I T YT E S T "
C h . c k b a r t e r y t y p € a n d d e t c r m r n ? t h € s p e c i l j e dc u r r e n t u t r n g t h e l a b l e

a l r e r r r a r r ' n 9 c h a . g r h 9 ,a d t u r i h ? . t o l c h a r g r n gc u r r € ^ l r 3 n o r n a c a r g f v

CAUTION:
a. Oo not use quick charge method on a bdtery whose specific gravity is les.sthan 1.10O.
b. s€t initial charging curent to valr.p specified in Fig. 6. lf charger is not capable of producing spe
cified current value, set its charging current as close to that value as possible.
c. Keep battery away from open llame while it is being charged.
d. When connecting charger, connect leads tirst, then tum on charger. Do not turn on charger tirst, as
this may caus€ a spark.
e. 8e carefulof a rise in batterytemperaturebecausea largecurrentflow is requiredduring quick-
chargeoperation.
lf batterytemperaturcrisesabove6O"C(1.10"D, stop charging.Alwayschargebatterywhenits tem-
peratureis below6O"C(lrO'D.
f. Do not exceedthe chargin-g time speciliedin Fig.6, becausechargingbatteryoverthe chargingtime
can causedeteriorationof the battery.

ServiceDataand Specifications(S.D.S.)
Destination ForNorthEurope Exceplfor North Europe
Engine SR2ODE GA16DE LD20tl SR2ODE GA16DE LD20rl
Type 46824R 28819R 95D31R 80D26R 55D23R 11 5 D 3 R
1
CapacityV-AH 1245 12-30 '12-80 't245
12-60 12-aO

EL.17
 SYSTEM
STARTING

WiringDiagram

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

fi) e'..pt @

(cl0)[r n
@; [-r]
@
615)o E
/:;- ,\ 1l .:^r
!.&_r ! tr Ll

ii
ad) 6i
{pT
.)-l-
i

!@.,

_]
UNJ f E 5TAFI:Ii
F.]:I BLT LiNK AND/.i \,
|]c r0R
FUSE EOX !::]-/

EL-18
 STARTINGSYSTEM

Trouble-shooting
lf any abnormality is found, immediately disconnect battery negativeterminal.
- !
s3 !
lo h
b o
q 6 96 E I I
E
I
E
e
a
E
g>
q ih
H: :: ;r; q-_ eB
6 3+ b ;-9: qi" :;
-E
a 39 55; Ee io EO
9: F
d b; l Eis.E:
o(Ig
Coo.
E5 s =3 s L'l;ct

-
E a !
>E f
69
6 . EEE !
€9
i 9
1 e =F
;9 I .p6.
=2 !. 6 9
iq 9 9

3 s
i
e!;9.
;> ;i i;
E
O9 Oo 99dgP E

E E

-
E
E :
2 qF; 9; P
-9

6
I
E E
o I o
q
I cr
d
O 5(!

-9

-
o
2 j

q
6
og

o-

EL-l9
 STARTINGSYSTEM- Starter-

Construction(Mitsubishimake)
M1T6681(SR2oDEengine)

O Rear cover O Pack @ Gear

O Metal rear cover @ Magneticswitch 'rt Hrnron
O Brushspring @ Shittlever @ Bearing
O Brush @ Gearcase @ Housing
@ Brushholder @ Stopperprnion (} Startermotorassembly
@ Fieldcoil Pinionshalt (t Gear case metal
@
O Armature

EL-20
 STARTINGSYSTEM- Stader-

Construction(Cont'd)(BOSCHmake)
9q)0.3.31424 (LlI2Ollengine)

wk
w$
FF.-, I@----.
@ /K:b@;-"
O Bearing O Armatureassembly @ Dust cap
O Gearcass @ Armaturelrame Rear cover
@
O Bushing @ Solenoid Fieldcoil
@
O Pinionass€mbty @ shitt tever
@ Brushspring
@ wheelcrown O Pinionshatt
O Brushspring guide
O Plate @ Brush

EL.21
 STARTINGSYSTEM_ StArtEr_

Bemovaland Installation
SR2ODEENGINE

ENGINE
GA16DE

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

LD2OIIENGINE

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

BEMOVING THE REAR COVER

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

EL-22
 STARTINGSYSTEM_ Starter_
GA16DE)(Cont'd)
Dismantling(SR20DE,
REMOVE THE BRUSH PLATE
o By meansof a pliers,move the end @ of the brushsprings
Irom the rearlo the left side of the brush.This is to release
the brushesfrom pressure.
Repeatthe same operationfor the rest of brushes.
o Take out the brush plate assembly.

REMOVING
THEFIELDCOILANDTHEARMATURE
o Withdrawboth the field coil and the armatureat the same
time.

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

SR20DEengine
Dismantlinggearcase

EL-23
STARTINGSYSTEM_ Starter_

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

Continuilybetween Continurty Action

"S" lerminaland switch Yes o.K.
DOOy No Replace
"S" terminaland "l\,t" Yes o.K.
terminal No Replace

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

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

EL.24
 STARTINGSYSTEM_ Starter_

BrushCheck
BRUSH
Checkwearof brush.
Wearlimit length:
Referto S.D.S.
o Excessivewear...Replace.

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

BRUSHHOLDER
1. Performinsulation
testbetweenbrushholder(positive
side)
and its base (negativeside).
Continuity exists.... Replace.
2 . Check brush to see if il moves smoothlv.
lf brush holderis bent. replaceit: if slidingsurfaceis dirty.
ctean.

ilv betweenbrush holderand....

Negative
brush
rsolat
Positivebrush

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

EL-25
 STARTINGSYSTEM_ StaTteT_
ArmatureCheck(Cont'd)
2. Insulatrontest (betweeneach commutatorbar and shafl).
o Continuity exrsts.... Replace.

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

Check diameterol commutator.

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

Undercutprocedures 5. Check depth of insulatingmold irom commutatorsuriace.

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

Round O.
IO.O2O.
-->-
^/

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

Sr F ,t e

rF:=

E1.26
STARTINGSYSTEM- Starter-

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

(S.D.S.)
ServiceDataand Specifications
M TSUBISHI BOSCH
Type
t\.rf
1T6 058 I M002T25481 9000.3
31424
Engineapplied SR20DE GA16DE LD20rl
Systemvoltage V 12
No load
Terrnrnavoltage V t1 115
Current A [ra.x 88 50 [,,lorelhan 150
tulorethan Less than
Bevolubon rpm 5.600
3 000 4,500
Minimumdiameterof comrnula-
288 28 8 (1 134) 2 8 . 9( 1 . 1 3 8 )
lor mm (rn)
Mrnimumlenglhof brush mm (in) 12.0 1 20 ( 4 . 4 7 2 ) 7 (0 028)
13.7 25.5 137 16.5 32.0
Brushspringtenson N (kg, lb) (1.4 26 ( 1. 4 - 2 . 6 ( 1 . 7- 3 . 3
3 . 1- 5 7 ) 3.1 3.7- 7.3)

EL.27
 CHARGING
SYSTEM

WiringDiagram

ffi
I
dd
'HEE
.<

-Fr
Fl-1 t
Etr
o
F
t44
z

@ E
o

-H
t-.t-.]

t-f1
t-t-1
H
t:]-

F;
rr, (E/
8sF
E
3 A
c ll r-. ,,!
@
^l
9t I "Ll z
f_

taA. @+ t9E[!J0 v)Z

o
o
.
r?r r A.r- .6\F tr cD
€_llD \sl'-Y tsF r.g? o f)

," fsl
EF+
ai_

!!
9! o
3 6; .9
;;p !F
;; '; ;: : v : l P F 9
6 i, ofo)to6 -
n
HHI'::IP:
ooo(,

@# ra$d@ SoS *@ 0a<ox

v1 0 )u urr! it:
*- : |r
-l
At-- -------r 'l @@@@@@ec
lln 6
frt6 lEt
il' a I
-l -:? J -=:'

EL.28
 CHARGING
SYSTEM

Troubleshooting
Beforeconductingan alternatortest, make sure that the batteryis fullycharged.A 3o-voltvoltmeterand
suitabletest probesare necessaryfor the test. The alternatorcan be checkedeasilyby relerringto the
InsoectionTable.
Betore starting troubleshooting, inspec,t the fusible link.

WITH IC REGULATOR
l/Vrrh.lt.rn.to. iid. L r.rm;nel
g r o u n d a d , I n t c r n a l 3 h o 7 to c c u r i
whln + diod. ri 3hoit-crrcurtod.
|;;;;-l
I burb Repl.ceI
I end Proceed I
- -l'."r-" I
' S G e4 l l o r g r o u n d i n g F t e r m r n e l .

\--6;;"*;l
,/
lRepleco. I
( H I T A C HI

) F"-"r"""c;:l
E."*;;I
- -lo, a.c.c
I
- F;"d"-l
--F* _-l

-@
Morethan 15.5V D-|;;;d'cnc'l
/

1 3r o l 5 V
__l
I
lR6elacs.
---l;*
1 ) Ur lully dr.n d brtr.ty.
2l Light : Cbrgt wrming light Make suro connodor
A.C.G. : Alt.nrator p.rtr ax6pt lC lrguhtot (S, L) is connocted
IC.RG : lC r.!ul or
O.K. : lC-rhrrtt.tor it in good @ndhbn.
3) Wbn r.aafiing "O.nrqad A.C.G.", rar|oy!
allarnatc tron r.lrida ||td ditaaxmbla, intpasr
|rrd corrrct or aapLc. fasltY prn!.
4) 'Mrthod of ero{Ddirt F t.rmin.l {HITACHI mrkc
onlyl

EL-29
 SYSTEM_ Alternator_
CHARGING

Removaland lnstallation

SR2ODEENGINE pl ro :r t.6-p1 12 i,,i

."-"'-E

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

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

GA16DEENGINE

--'-.!

Q r e - z r t 16 21 1p,i5t
//

t) N m r r . t j ma , b ) rz so(38 s r 27 37r
f) EEL0]3

EL-30
 SYSTEM_ Alternator_
CHARGING
Removaland Installation(Cont'd)

EL-31
 SYSTEM- Alternator-
CHARGING

Construction
SF2ODEENGINE _ LR.19O-719
GA16DE ENGINE_ LR-18G735

*>d0
(n @shM*
.eu'r6 (v\
" .\ Y
. \ .' .i,
,"d
,9

LII20[ ENGINE- 9120.335.000

O Vacuum pump .9 Pulley

@ Rearcover
O Rotor O stator O Voltageregulator
(D Frontcover O Diodeplateassy. f,Q Brush
@ Fan

EL.32
 SYSTEM- Alternator-
CHARGING

Disassembly
BEAR COVER REMOVAL
CAUTION:
S o l d e r i n ga r o n Rear cover may be hard to remove because a ring is used to
{200W capacirv, lock outer race of rear bearing. To facilitate removal of rear
cover, heat iust bearing box section with a 2oGwatt soldering
iron.
Do not use a heat gun, as it can damage diode assembly.

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

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

Erushwoar limiting line

BrushCheck
'L Check smoothmovement
of brush.
. Not smooth... Checkbrushholderand clean.
2. Checkbrushfor wear.
o Replacebrushif it is worndown to the limitline.

3. Check brush lead wire for damage.

2 mm (0.O8in)
o Damaged...Replace.
4. Check brush spring pressure.
Measure brush spring pressure with brush projected
approximately 2 mm (0.08in) from brushholder.
Spring pressure:
Refer to S.D.S.
o Not withinthe specifiedvalues... Replace.

EL.33
 SYSTEM- Alternator-
CHARGING

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

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

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

MAINDIODES
r Use an ohmmeterto checkconditionof diodesas indicated
in chart below.
o lf any of the test resultsis not satisfactory,replacediode
assembly.
probes
Ohmmeter
Continuity
PositiveO NegativeO
Positivediode plale Diodeterminals Yes
Diodelerminals Positivediode plate No
Negalivediode plate Oiodeterminals No
Oiodeterminals Negativediode plate Yes

EL-34
 CHARGING - Altemator-
SYSTEM
StatorCheck(Gont'd)
SUB-DIODES
o Attach ohmmeter's orobe to €ach end of diode to check for
continuity.
o Continuityis N.G. ... Replacediode assembly.

Assembly
Carefullyobservethe followinginstructions.
o Whensoldering eachstatorcoilleadwireto diodeassem-
bly terminal,carryoul lhe operationas fastas possible.

Crolin .nia|| ,Dod.l REARCOVERINSTALLATION

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

EL€5
 SYSTEM- Alternator-
CHARGING

(S.D.S.)
ServiceDataand Specifications
ALTERNATOR

LR190-719 1 R 1 8 0 - 7 3 5 I 120.335.000
Type
HITACHI BOSCH
Engine SR2ODE GAl6DE LD20rl
Nomina rating V-A 12-90 12- 80 12-90
Groundpolarity Negalrve
l\,4inimum
revolutionunderno-load
10500
(When13 5 voltsis applred) rpm
234300 2311300 16.5/1300
Hotoutputcurrent A./rpm 63/2500 63/2500 68.5/2500
87/5000 77l5000 B3/5000
Regulatedoulpulvollage V 1 4 . 1 14.7

Minimumlengthot brush mm (in) 6 0 (0 236) t 010.276) 1 00 { 0 . 3 9 )

1.0003.432 1.8633.040
1 . 9( 1 9 4 ,
Brushspringpressure N (9,oz) (102 350, ( 1 S 0- 3 1 0 ,
6 84)
3 . 6 0- 1 2 . 3 4 ) 6 7 0 - 1 0 . 9 3 )
Slip nng minimumouter 26.0
306 (1.20s) 1 s . 3( 0 6 0 2 )
orameler mm (1n) ( 10 2 4 )

E1.36
 COMBINATION
SWITCH

CombinationSwitch/Check

REARWIPER
AND WASHER
-wrpEa
TURN
a; --r o"fr WASH& WIPE
OFF

u Lf t
e
INT
1ST
t
^
t\ in,A ll ,
LO

OFF
tl {
-r-\
\\1t F
L I
LIGHT \-:=/// Ht /
;*-a o a-Lj F N O N TW I P E R
AND WASHEF

a] til l-l
Iii ,6iGT,
.td
tq-Tfll l , L 6 l eL , r tIr
L r g h t r n ga n d
rurn srgnal

FRONTWIPERAND REARWIPERAND
WASHERSWITCH WASHERSWITCH
PER
WIPE O F F WIPE
\ OFF I NT I]I GH
LIGHTING SWITCH

HORN SWITCH
TURN
SIGNAL
swtTcH
NmNn
llo ol
f2TdTm
ETT r0l

I
l-1
tGt
INTERMITTENT
wlPEF VOLUME

EL-37
 COMBINATION
SWTCH

Replacement
o Each switch can be replacedwithout removingcombination
switch base.

r To removecombinationswitchbase,removebase anach-
ing screwand turnafterpushingon rt.

SEL39OL

EL.38
HEADLAMP- Without DaytimeLight Systemand Dim-dipLamp System-

WiringDiagram

ttf
ffi
T.-l
m

=
ffii
ff-l

E
L

t=

t-:J!.ll= rT_-

m q4+
L

[-/

z
=
o
ztx

/-, -
lEl z
aolr,?
a
.o11'A
@E
I /-:\
qtrLdl
al
tP q+
1+ +
rf rJl
6i rA r-l 6\ " --1-tf- '
!-rtrr"" 9( t.A.r ) g(--.1-t+.
ur )
;\ \-r-{-/ / ;\ \ll, ,/
'\-,--l
3 v d
fI Ii f f

EL.39
 - DaytimeLight System-
HEADLAMP

Operation
After startingthe engine with lhe lightingswitch in the "OFF"
position,the headlamplow beam and clearance,tail, license
and instrumenlillumination lampsautomatically turn on. Light-
ing switch operationsother than the above are the same as
conventionallight systems.
Engine Wjth enginestopped Wrthenginerunning
OFF 1ST 2ND OFF 1ST 2ND
Lightingswitch
B c B c B c B c B c B c
High beam X X o X X o o X o X X o X X o o X o
Headlamp
LOWDeam X X X X x X X o X o o o X X X X o X
Clearanceand tail lamp X X X o o o o o o o o o o o o o o o
Licenseand instrument
illumination
lamp
X X X o o o o o o o o o o o o o o o

O: Lamp"ON"
X: Lamp"OFF"
El: Added functions
Schematic
] GNI TI ON SWI ICIl JGN] T] ON SW] ICI
ON o. START SIART BATTERY

L]GNTING SW]TCH

a 7 9 5 tt I
)? 3
OAYIIIlE L] GII
C O NI R O L U N ] T

HEAO. H] GH AEAM
] NDI CAIOR
Rf.

LO20 ensine mode s

ALIERNAIOR Exccpt LDz0 eng ine node s

MEL675A

EL4O
 - DaytimeLightSystem-
HEADLAMP

WiringDiagram
ffi
zu
t -n To. ea^an. e amF+

4c)
ffi
q
H
E -..
iY
C E
i ir F
ril trTT -.- qr
E,i )
FE rq
Y !4

-u \Y/ ffi Z
tTt t,t -F -
l-.l H{
z
o r-
z
ffi trTl B!0!]

A
E
? FF ffi
H fl
--J -T-t F?r
Tt l
o-"

!:l:l E a
l
.a .a
;
:
i -l-
9

ttr
fT_
-T-
: 6lr6 G ra , -
-----1 c
o
o
5
3- rR."i al E
t, til
- /:\
t

/:\ o =l ;;
---D L€/
n o rldadd dd

I A -
;
F:u /-L I .G+
; DLi
/a a.n :
trT-l .4 h:i
!:r
I L= €/ 2
rEl
5 Frl

6), - t-,
reJc

eml -

= +so qF,3l eH
-n
zu ffi' rtr
-i
I
fl
i ,--]---.:
. .r c- je-T"
- t I t-*,-'
.tr' ,i'j A
,-D', [r_] ." T

t!.4E16744

EL.41
 HEADLAMP- Dimdip lamp System-

Operation
When ignitionswitch is in the "ON" positionwith the lighting
switchin the "1ST" oosition.the headlamolow beam comeson
dimly to functionas a clearancelamp. Lightingswitch opera-
tions other than the above are the same as conventionalfioht
svstems.
lgnitionswitch OFF or ACC ON
OFF 1ST 2ND OFF 1ST 2ND
Lighting switch
B c B B c B c B (. B c
High beam X X o X x o X o X X X X o X

Headlamp
Low beam X X X X X X X o X X X X X X X x o X
Dimp-dip
(Low b€am)
X x X X X X X X X X x X x X X X

Clearanceand tail lamo X x X o o X X X o o o

Licenseand instrument
illumination
lamp
X X x o o X X X o o o

O: Lamo "ON"
X: Lamo "OFF"
Cl Added functions
Schematic
I G N JI ] O N S W JI C H AAITERY
0N o. START

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

To c €a.ance, ta i I
I iccnse amps

5 O]I1'O]P LJGHT 9
C O NI R O L U N I I
?

it
]?

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

MEL6/78

EL42
 HEADLAMP- Dimdip lamp System-

Wiring Diagram
(€J :
6,3
r_re'jt =
Tr]
Tr"l

rn
ffi
T5-1
\y
-T-.1-.1|
m !'t-

E
LG,S_
F. s -Gll
H +fm LZ
:J^-r OO

:}<

R |l |] tl
6- euJJ'g@ tq
d );)))d)d;,i /l
p6 ,', i' 'i tvr l
u or----f-t-l-t-t-
a66l
-L _- ol :l:9dc9{,!
-;:+H++++H+a
i - -
| r r 4 - - - t

^l
-----6-d-:',P
/ax\ I
bl tr<<:ir"li(7 Lti19 co

dc rrrrrlrrri f$a
t?T
/'\
\9
EEE tffi-
mJ r+Ft
ffi llE
L::

c
E

6\-
cc
I!r
6t,'F
@ll,:
OE
9a ;)j (9 co
t_i.Iri ttl_\
tu..r,!
ta i lm aj
6t,

-
tcn
|i -
tcD
l|
;;
; Til : t.rl
(t tt t.frh
6\ U' ,/
t.trh
6\ U-,l ,/
II

MEL676A
 - Headlamp
HEADLAMP AimingControl-

Description
o The verticaldirectionof the headlampprolection
can be adjustedlrom insidethe vehicleto prevent
lhe headlightbeam axis from facingupwarddue to a changein the numberof occupantsand load
conditionsin the vehicle.
Battot^y

R c v cn a I n 9
t cIlv

Fon /ard
.e lay
No cont Inu lty Almlno
ContInu lty (Whltc po.t I or, gw I tc6

S E N S O R( R o t E t I n a
por-t I od
I Thoi. trto.
AI I1ING I1OTORUNI T (R. I-t )

Rcve.aIno
rc l!y

EnI a.ocd
gont l6n A
No cont Inu lty
Contlnu lty ( W hl t 6 p o . t l o r ,

SENS0R (Rotat Ino

po.t I od
Jhcnn I ator

AI MI NG I'IOTORUNI T (L. I{ )

EL-44
 - Headlamp
HEADLAMP AimingControl-
Description(Cont'd)
l J p a n d d o w n a d j u s t r n gs c r e w

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

CIRCUIT
OPERATION
IExample]
Aimingswitch"0"
o Whenthe aimingswitchrs set to "0", the motorwillnot start
becausethe powerterminalsare positioned at the noncon-
ductivesectionol lhe sensor'srotarvunit.

Aiming switch "O" -- "1"

o When the aimingswitchismovedfrom "0" to "1", poweris
0 appliedto the motor throughthe relay operatedby the
l
2
sensor'sconductivesecton.The headlamps willthenmove
3 in lhe "DOWN"direction.
o The motor continueslo rotate while the rotary unit of the
sensorsmovesfrom pointA to pointB.
o The powerterminalswilllhen be positioned at the noncon-
ductiveseclion,disconnectingthe power tothe motor.The
motorlhen slops.

Aimingswitch"1" - "0"
o Whenthe aimingswitchis movedfrom "1" to "0", powerts
applied to the motor through the relay operated by the
conductivesectionof the sensor.The motor will rotateto
movethe headlampsin the "UP" direction.
o When the rotaryunit of the sensor moves from point B to
pointA, the motorwill stop.

EL-rts
 - HeadlampAimingControl-
HEADLAMP

EL.45
 - HeadlampAimingControl-
HEADLAMP

WiringDiagram

/:\
6

o *#l
e -{-rl

---t-
^/A

c
E^

f oc

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

n €l
!
: o
.
a Lrn
-Ll
6 o
=
i; L-l zu
! tr
- o

EL47
 - Headlamp
HEADLAMP AimingControl-

A Troublediagnoses
5rCil E
SYMPTOM:Headlampaiming does not operate.

P O W E RS U P P L YC I R C U I T Check 10Afse al luse block.

Lightingswrlch lsl CHECK(For aimingswitch) (Referto "POWERSUPPLY
Check if 12 voltsexistbetween ROUTING.")
t e r m i n a l sO a n d a O .

ts
EI
'H) A I M I N GS W I T C HC H E C K
Checkcontinuitybetweentermi-
nals at each switchposition.

mtri
G R O U N DC I R C U I TC H E C K Bepairharnessbetweenaiming
F O RA I M I N GM O T O R motorand body ground.
Checkcontinuitybetweentermi-
nals rj) and body grround.
Continuity exists ... O.K.

P O W E RS U P P L YC I R C U I T Check harnessbetweenaimjng

mti CHECK
(For aimingmotor unit)
Check il 12 volts existbetween
switchand aimingmotor unit.

t e r m i n a t s' O , @ , @ , @ a n d
o
Volt-
Aiming
meter
Voltage [V] switch
termina
posrtron

Approx.12 "0"
o o "0"
.;\ Approx1.2 "1"
0 "1"
Approx.12
o 0
A p p r o x .1 2 ,.3,,
o 0 "3"

EL.48
 HEADLAMP

Bulb Replacement
The headlamp is a semi-sealedbeam type which uses a
replaceablehalogenbulb. The bulb can be replacedfrom the
PUSHIo f ront compartmentside withoutremovingthe headlampbody.
r Grasp only the plastic base when handling the bulb. Never
touch the glass envelope.
1. Disconnectthe batterycable.
2. Disconnectthe harnessconnectorfrom the back side ol the
bulb.
3. Pulloff the rubbercap.
4. Remove the headlampbulb carefully.Do not shake or
rotatethe bulb when removingit.
5. Installin the reverseorderof removal.
CAUTION:
o Do not leave the bulb out of the headlamp reflector for a
\ long period of time as dust, moisture, smoke, etc. may
enter the headlampbody and aflect the pedormance of the

_@. PUSH
lo
headlamp. Thus, the headlamp bulb should not be
removed from the headlamp reflector until just before a
replac€mentbulb is to be installed.

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

CAUTION:
Be sure aiming switch is set to "0" when performing aiming
lF-bl
l3 2 I 0l
adiustment on vehicles equipped with headlamp aiming con-
trol.

,n
L,\_-! Sl l

[)
\/

EL-49
 HEADLAMP
AimingAdjustment(Cont'd)
LOWBEAM
1. Turn headlamplow beam on.
2. Use adjustingscrewslo performaiming adjustment.
o First tighten the adiusting screw all the way and then make
adiustment by loosening the screw.

lJp and down adlustrng

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

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

q$ = acceenerenrruce

EL-50