= i 12-1 | | | | Chapter 12 Chassis electrical system Contos | tcton section setter enat ee a Somnus G Se ideee tecnica os 6 a ean -qanratiomcin Seen rat nonce chne oe Ce nen ee a 3 ecoseeetoataes oe eee camrenaces fe ee acento a ne es ofa ceo eens 3 STS: geome oe va eet ae ca Seeger ama eer eer = eaten reanenaa Seasons $ ot {Ree ortneara tee sected ano ; ao ree Plater 2 ee Oe a % Seaweeds. % 1 General information ‘The electrical system fsa 12-vol, noga~ tive earth type. Power forthe lights and all flectrcal accessories Is supplied by a lead/acid-type battery which is charged by the alternator. ‘This Chapter covers repair and service procedures for the various electrical compo- Fonts not associated with the engine. Infor- ‘mation on the battery, altemator, distributor land starter motor can be found in Chapter 5. Tt should be noted that when any portion cof the electrical systom is serviced, the cable ‘should be disconnected from the negative battery terminal to prevent electrical shorts andlor fre, 2. Electrical troubleshooting - general information Atypical electrical circuit consists of an ‘electrical component, any switches, relays, motors, fuses, fusible inks or cirult breakers Felated to that component and the wiring and ‘ectrcal connectors that link te component 10 both the battary and the chassis. To help you pinpoint an electrical cicult problem, Wiring dlagrams are included at the end of thie Chapter. Before tackling any troublesome elect- cal crcuit, frst study the appropriate wiring tlageams fo get & complete understanding of ‘what makes up that individual circuit Trouble spots, for instance, can often be narrowed down by noting f other components related ta the ocult are operating properly. f several ‘components or circuits fal at one time, Chances are the problom sin a fuse or earth Connection, because several circuits are ‘often routed through the same fuse and earth ‘connections. Electrical problems usually stom from simple causes, such as loose or corroded Connections, a blown fuse, a melted fusible link ora bad relay. Visually inspect the condi- tion of all fuses, wires and connections in a ‘probiom circuit before troubleshooting it. tasting instruments are going to be utilised, use the diagrams to plan ahead of ‘ime where you will make the necessary con- nections in order to accurately pinpoint the trouble spot.12-2 Chapter 12 Chassis electrical system The basic tools nesded for electrical troubleshooting include a circu tester or voltmeter (@ 12-volt bulb with a set of test loads can also be used), a continuity tester, which includes a bulb, battery and set of test leads, and a jumper wire, preferably with a circult breaker incorporated, which can be used to bypass electrical components. Before attempting to locate a problem with test instruments, use the wiring dlagramis) to decide where to make the connections Voltage checks Vattage cheeks shouldbe performed fa circuit isnot functioning propery. Connect one lead ofa crt tester fo ether the nega {te battery tamina ora known good earth Connect the other lead to a electrical con rector inthe cut being tatod, preferably Iearest o the battery of fuse. If the Bub of te tester lights, vollage is present, which means that he par ofthe cu betweon the tectical connector and the batty prob lem free. Continue checking the ret of the Cicutin the same fashion. When you reach Point at which no voltage Is presont, the problem les between thal point and ts last {est point with voltage. Most of the time the problem can Be traced toa loose connection. Note: Keep nmind tna ome cuts recat voltage only when the ignition key fn the Aacessory or Run poston. Finding a short ‘One metod offing shorts ina ckeut is to remove the fuse and connect atest ght or voltmeter ins piace. There shoul be no voltage present inthe crcl. Move the wiring hhamess ftom side to side while watching the test light. Ithe Bulb goes on, there isa short to earth somewhere in that area, probably where the insulation hs rubbed through. The same test can be performed on each compo- rent inthe circuit, even a sch Earth check Perform an earth test to check whether 3.4b 4. to access the fuses and rélays behind it. There is a spare fuse and a fuse puller on the cover 1 component Is properly earthed, Oisconnact the battery and connect one lead of a self Powered test light, known as a continuity tester, toa known good earth. Connect the other lsad to the wire or earth connection being teste. If the bulo goes on, the earth is good. Ifthe bulb does not go on, the sarth is not good, Continuity check ‘A continuity chack is done to determine it there are any breaks In a ckeuit =H itis passing electricity properly. With the circuit off (no power in the circuit), a se-powered Continuity tester can be used to check the circut. Connect the test leads to both ends of the crcut (or to the “power” and and a good ‘arth, and ifthe test light comes on the ei cuit is passing current property. Ifthe light ‘doesn't come on, there I a break someuwnere in the circu. The same procedure can be used to test a switch, by connecting the con- tinuty tester tothe power in and power out sides of the switch. With the switoh turned (On, the test ight should come on, Finding an open circuit ‘When diagnosing for possibie open cir cults, iis often cifficult fo locate them by sight because oxidation or terminal misalign- ‘ment are hidden by the electrical connectors. Merely wiggling an electrical connactor on ‘sensor or in the wiring hamess may correct the open circuit condition. Remember thie when an open circut is incated when trou- bleshooting @ circuit Intermittent probiems may also be caused by oxidised or loose ‘connections. Electrical troubleshooting Is simple if you ke9p in mina that al alectrica circuits are basically electricity running from the battery, ‘through the wires, switches, relays, fuses and fusible links to each electrical component (light bulb, moter, ete) and to earth, trom Which itis passed back to the battery. Any electrical problem ie an interruption in the flow of electricity to and trom the battery 3.ta Remove this cover panel 3 Fuses - general information eter to lustrations 9.18, 3.1b and 3.9 The electrical circuits of the vehicles are protected by a combination of fuses, crcut breakers and fusible links, Fuse blocks are focated in the right kick panel and in the engine compartment (see Mlustrations) Each ofthe fuses is designed to protoct a specific crcul, and the various circuits are identified onthe fuse panel cover. Miniaturised fuses are employed inthe fuse biocks. These compact fuses, wlth blade terminal design, allow fingertip removal and renewal. an electrical component falls, ‘always check tha fuse fst. A blowin fuse is caslly Identified through the clear plastic body. Visually inspect the element for evi- dence of damage (see illustration), Be sure to renew blown fuses with the correct amperage rating. Fuses of different ratings are physically interchangeable, but ‘only fuses ofthe proper rating should be used, Renewing a fuse with one of a higher or lower value than specified is not recommended. Each electrical crcut needs a speci amount eve 33 When fuse blows, th eloment betwen the terminals rns = the fuse on the lft is blown: the fuse on the rights goodChapter 12 Chassis electrical system 12-3 42 The fusible inks are connected to the positive terminal of the battery. Be sure to disconnect the negative terminal ‘before working on them of protection, The amperage value of each {use is moulded into th fuse body. If the replacement fuse immediately falls, don’t renew it again until the cause of the problem is Isolated and corrected. Fuses do not weer out, There is always another ‘component in the system which caused the fuse to blow, In most cases, tis will be a ‘shot circuit in the wiring caused by a broken (F deteriorated ire 4 Fusible links - general information Rofer to Mustation 4.2 Some circuits are protected by fusible links, Tha inks are used in orcuts which are ot ordinary fused, such as the ignition c= cut ‘There are several fusible links located adjacent to the battery in the engine com- partment, They can be easlly inspected for ‘melting (see illustration) Conventional type fusible tinks cannot be repaired, a naw link of the same gauge should be refite in its place. The procedure iss folows: {@) Disconnect the cable from the negative battery terminal ) Disconnect the fusible link from the wiring hamess. @) Cut the damaged fusible link out ofthe wiring just behind the connector. ) Strip the insulation back approximately 107mm. ) Position the connector on the new fusibie ink and crimo it into place. 1) Use rosin core solder at each and ofthe new lnkto obtain @ good solder joint. @) Use plenty of electrical tape around the soldered joint. No wires should be exposed. 1h) Connect the battery earth (negative) cable, Tast the circult for proper opera tion. 5 Circuit breakers - general information Circult breakers can protect compo- rents such a, power windows, power door locks and headlights. Not all models utlise ciroult breakers, ‘On some models, the circuit breaker resets itself automatically, so an electrical ‘overload ina cicult Breaker protected sys- tem will cause the circu to fll momentary, then come back on. ifthe circuit dossa't come back on, check it immediately. Once the condition is comractad, the cult breaker il resume its normal function. Some circuit breakers must be reset manually. 6 Relays - general information and testing. General information oer to ilustrations 6.18 and 6.16 1. Several electrical accessories in the Vehicle, such as the fuel injection system, hors, starter, and fog lamps use relays to transmit the electrical signal to the compo- nent. Relays use @ low-current circuit (the contol circuit) to open and ciose a high-cur- rent circuit the power circuit). If the relay is, defective, hat component will not operate propery. The various relays are mounted in ‘the engine compartment, atthe fuse box and In other locations throughout the vehicle (see ilustrations). I faulty relay is suspected, it ‘can be removed and tested using the proce- dure below or by a dealer senice department fra repair shop. Defective relays must be renewed as a unit Testing 2 It's best to refer tothe wing diagram ‘or the circu to determine the proper hook: tps for the relay you're testing. However, it you're not able to determine the correct hook-up trom the witing diagrams, you may be abla to determine the test hook-ups from the information that follows. 3. On most relays, two ofthe terminals aro the relay’s control crcut (hey connect tothe relay coll which, when energised, closes the large contacts to complete the circu). The other terminals ae the power cut (they are ‘connected together within the relay when the Ccontrol-ccult cals energie) 4 The relays aro usually marked as an aid tohelp you determine which terminals are the ‘control citcult and which are the power cir cuit 5 Connect a fused jumper wire between fone of the two control circut terminals and the positive battery terminal. Connect ‘another jumper wire between the other con {10l circu terminal and earth, When the con- nections are made, the relay should click. On ‘some roays, polarty may be crical, so, if the relay doesn't click, try swapping the jumper ‘wires on the contro crcl terminals, 6 With the jumper wires connected, check for continutty between the power circuit ter- rminals as indicated by the markings on the regy. 7. Ifthe relay falls any of the above test, ‘6:1b The relays are olearly labeled. As they operate, ‘they emit a clicking which can be heard and felt'84 Disconnect the wiring from the rear of the combination ‘switch before loosening the retaining screw 8:7b . .. then simply lift the switch off 7 Tur signal and hazard flasher - check and renewal 1 The turn signav/hazard flasher Is con: tained (r most models) in a single small uit Ipcated in the wing harness under the dash te the left of the steering column, 2 When the flasher unit is functioning properly; an audible cick can be heard during its operation, Ifthe tur signals fll onone 5180 oF the other andthe fasherurit dose not ‘make tg characteristic clicking sound, & faulty tun signal bubs inciated, 3». It both tum signal fal to bli the prob Toni may be-due to a Blown fuse, a faulty flasher Unt, a broken switch ora Joose or ‘open connection. if quick check ofthe fuse box indleates that the turn signal fuse has blown, check the wiing for a short before refiting new fuse. — 4 Tolrenew the flasher, Simply bulk out of the socket. 5 Maks sure thatthe new unit i'identical to the original. Compare the old ofe to the 9.5 The ignition switch is secured by a single screw ‘ew one before reiting Ht 6 Rating Is the reverse of ramoval 8 Combination switch - removal and refitting Feter to itstrations 8.4, 8.7a and 8.7 1. Disconnect the cable from the negative ‘terninal of the battery 2. Flemove the steering wheel (s8e Chap- ter 10), 3 Remove the steering column covers (00 Chapter 11), 4 Unplug the electrical connectors trom ‘the combination switch (see ilustration), 5 Remove the retaining screw. 6 Push in on the switch and tum it clock- wise. Pull the combination aultch trom the shat 7 Riting isthe revetee oF removal Ths Combination switch must seat correctly with its tab in the hole in tha steering column, Note:-The wiper/washer switch and the ight ‘87a The Individual ewitches can be removed from the ‘combination switch by removing the mounting screws. 9.9 The two shear screws (arrow) must be drilled out in order to remove the tentre housing ‘switch can both be removed trom the suttch ‘base and renewed independent (see ius ‘rations). 9 Ignition switch and lock cylinder = removal and refitting Ignition switch eter to jtustration 9:5. + Disconnect the cable terminal ofthe battery 2 Remove the. lower steering column ‘cover (se0 Chapter 1) 3 Remove the switch retaining serew. 4 Disconnect the witing hamess from the switch. 5 Remove the switch (S00 illustration). 6 Rofiting isthe reverse of removal om the negative Lock eylinder Fofer to lustration 9.9 7. Remove the steering column covers (ofr to Chapter 11,11.2 The bezel lower screws are removed next 41.3 Pull the bezel off. Some components are removed here for Clarity - be careful to avoid scratching the upper @ Using a small nail or punch to depress the lock eylinder retaining pin, pul straight ‘out onthe lack eynder assembly to remove Ie from the vehicle. 9 To raft the lock cylinder, depress the retaining pin and guide the lock eylindar into the steering column housing until the retain- ing pin extends back into the locating hole in the steering column housing. Note: The lock cylinder housing 's secured to the steering Shaft with two shear bots (800 Mustration). Thase wil have to be dil out ifthe entre ‘assombiy isto be renewed. 10 The remainder of the reiting is the reverse of removal 40 Instrument panel gauges - check Fuel, oil and temperature gauges 1 All tests below require the ignition switeh to bp turned to ON postion when test in 2 Ifthe gauge pointer does not move from the empty, low or cold positions, check the ‘steering column cover when its in place ‘use Ifthe fuse s good, locate the particular ‘sending uni for the excult you're working on {e20 Chapter 4 for fuel ending unt location, Chapter 2 for the oll sending unit location or Ghapter $ for the temperature sending unit location). Connect the sending unit connector to earth. the pointer goes tothe ful high or hot position renew the sending unit. f the pointer stays In same poston, use a jumper Wie fo aarth the sending unt ferminal onthe back of the gauge, i necessary, refer to the wiring diagrams at the end ofthis Chapter. ‘the pointer moves, the problem lies in the wire between the gauge and the sending unt. Ifthe pointer does not move wit the sending unit terminal on the back of the gauge tearthed, check for voltage atthe other term nal ofthe gauge. If voltage is present, renew the gauge. 11. Instrument cluster - removal and refitting Rotor to ilustrations 11.24, 11.2b, 11.3, 11a, 11.db and 11.5 41 Disconnect the negative battary cable. 11.4b Lift the cluster out only slightly -.- 2 Remove the cluster bezel lustrations) 3. Remove the instrument cluster bezs! {Goo ilustration). 4 Remove the eluster mounting serous (see illustrations) and pull the instrument fous (S00 4212.14a Prise up the cover from the Fear ‘wiper arm nut and then remove It cluster towards the steering wheel 5 Disconnect ary electrical connectors that would interfere with removal (eee tus tration) 8 Cover the steering column with a cloth to protect the trim covers then remove the Ingrument cluster from the vehicle. 7 fitting is the reverse of removal, 12 Wiper motor - removal and refitting Wiper motor circuit check Noto: eter to the wiring clagrame for wire colours and locations inthe following checks. ego in mind hat power wires are ganwaly legerinclamoter and tighter colour, where earth wires are usually Smaller in clamoter and darker coeur. When checking for va ‘ge, probe an earthed 12-volt tot light fo tach terminal ta connector unt ght is Yerfesvotage power atthe trina 1h ifthe wipere work sly, make sure the ‘Battery Is in good condition and has a.strong charge (eee Chapter 1). the battery isn 920d eondon, remove the wiper motor (20 Selon) and operate the wiper ams by hand. can © 42:10 Remove the mounting bots (arrows) 12:14b Unsorew the retaining nut. CCheck for binding linkage an pivots, Lub ‘cate or repair the linkage or pivots as naces- sary. Poft the wiper motor. Ifthe wipers stil ‘operate slowly, check for loose or corroded connections, especialy the earth connection, If all connections look correct, renew the motor 2 I the wipers fall to operate when act- vated, check the fuse. 1 the fuse is good, Connect a jumper wire between the Wiper motor and earth, then retest. If the motor works now, repair the earth connection. the ‘motor stil doesn’t work, turn on the wipers land check for voltage at the mato. I there's ‘no voltage at the motor, remove the motor and check I off the vehicle wit fused Jumper wires from the battery. 1 the motor now works, check for binding inkage (see Stop 1 above). ifthe motor stil dosent work, renew I. If there's no voltage atthe motor, tack for voltage at the switch. If there's no voltage at the switch, check the wiring between the ‘witch and fuse panel for continuity. If the iting is good, the switch is probably bad. 3 It the wipers only work on one speed, ‘check the contnulty of the wires between the switel"and motor. If the wires ar@ good, reniow the suitch 4 Ifthe interval (delay) function is inop- erative, check the continuity ofall the wiring remove the nut betwen the switch and motor. the wing le 900d, renew the interval module. 5 it the wipers stop at the position they/re in when the switch is tumed of (all to.park), check for voltage atthe wiper motor when the wiper suite is OFF but the ignition |S ON. If voltage is present, the iit swith in ‘the motor is malfunctioning. Renew the wiper motor. If no voltage is present, trace and repair the mit svitch witing betwoen the fuse panel and wiper moto. 6 Ifthe wipers won't shut of unless the ignition is OFF, disconnect the wiring from the wiper control switch. If the wipers stop, renew the switch. Ifthe wipers keep running there's a defective limit sultch in the motor renew the motor. 7 Ifthe wipers won't retract below the bonnet line, check for mechanical obstruc- tions in the wiper linkage or on the vehicle's body which would prevent the wipers from parking. If there are no obstructions, chack the wiring between the switch and motor for Continuity. If the wiring is good, renew the wiper mater. Wiper motor renewal Front Roter to istration 12:10 8 Disconnect the negative battery cable.Chapter 12 Chassis electrical system a and lft off the washer 9 Disconnect the wiring from the motor. 10 Remove the mounting bolts and pul the ‘motor out slightly (2ee llustration) 11 Disconnect the wiper transmission from the motor, Remove the motor 12 Rating is the roverse of removal Rear Refer to lustrations 12.14a, 12.14, 12.146, 12.14d and 12.17 48 Disconnect the negative battery cable. +14 Remove the wiper arm (refer to Chap~ ter). Itmay be necessary to fst remove the spare tyre, Remove the nut and bezel trom the wiper shaft (see illustrations). 18 Remove the inner door panel (refer to Chapter 11) 16 Disconnect the wing from the motor. 47 _Unbolt the motor and remove it (see ilustration). 18» Refiting is the reverse of removal 48. Radio and speakers - removal and refitting 1. Disconnect the negative battery cable Radio 2 Remove the centre dash bezel (refer to 418.7 Disconnect the speakor wiring after removing it from the ‘door frame Chapter 11. 2 Remove the screws and pul the radio ‘ut far enough to access the rear ot. 4 Disconnect the aerial and the wing har- ness trom the rear of the rado, then ramove the radio, 5 Rofiting is the reverse of removal Speakers oer to ilustration 13.7 {8 Remove the door trim panel (688 Chap- ter 1). 7. Remove the speaker retaining screws. Disconnect the electrical connector and remove ine speaker from the vehicle (see Mlustrtion), 18 Rafting Is the raverse of removal 44 Aerial - removal and refitting 1. Detach the radio and disconnect the aerial sad from the rear side of the radio (s0= Section 13) Attach a piece of stiff wir to the fend of the acral lead, then remove any ‘retaining clips under the instrument panel ‘securing the aerial lead, 2 On vehicles equipped with fixed type antennas, use a small spanner and remove the aerial mast retaining nut 1217 The rear wiper motor withthe harness disconnected. Do not disconnect the wires shown 8 Using pair of anap rng pliers or sirilar too, remove the aerial base retaining nut. 4 ‘On vehicles equipped with a power ‘aerial, remove the aerial motor mounting ‘raw from the inner fender wel '5 Pull the aerial up and out to remove it luni you can 990 the wire. then remove the ‘ld aarial lead from the wire and renew it with the now arial lad. 6 Working in he passenger compartment, pull the wire and the aerial lead rearward into the passenger compartment. 7. The remainder of reiting isthe reverse of removal 15 Rear window defogger - check and repair ‘Refer to ilustation 15.1 1 The rear window defogger consists of a ‘number of horizontal elements laminated ‘onto the glase eurface(s9e illustration). 2. Small breaks in the element can be repaired without removing the rear window. Check Retr to ilustrations 15.4, 15.8 and 16.7 3. Turn the ignition switch and defogger ‘system switches tothe ON pasion. 181 The defogger circult consists of a 12 volt input (arrow) and ‘an earth atthe other endl of the grid15.4 When measuring the voltage at the rear window defroster ord, wrap a piece of aluminium fol around he negative probe and press the fol against the wire with your finger 4 When measuring voltage during the next two tests, wrap a piece of aluminium fol ‘around the tip of the voltmeter negative probe and press the fll against the heating flement with your finger (S00 illustration). 5 Check the voltage atthe centre of each heating element (g8e tlustration. If the vot. age is 6-volts, the elamant is okay (here fs no break) f the voltage Is 12-vols, the element 's broken between the corire ofthe element land the postive end. I the voltage le Ovolte the element is broken between the centre of the elament and earth 6 Connect the negative lead to a good cearthing pol. The reading should stay the 7 To find the break, place the voltmeter postive lead against the defogger positive terminal. Place the voltmeter negative lead with the fl stip against the heating element t the positive terminal end and slide it toward the negative terminal end. The point at which the voltmeter deflects from zero to Es 15.49 To use defogger repair Ki, ably masking tape to the Inldo ofthe window at the damaged area, then brush on the special conductive coating 155 To determine ita heating element hhas broken, check the voltage at the ‘contro of each element - I the voltage i 6-volts, the element is unbroken - i the voltage is 12-volts, the element is broken botwoan the centre and the positive end - if there is no voltage, the element is broken between the centre and the earth ‘several volts isthe point at which the heating tlements broken (see illustration) Repair eter to stration 15.19 8 Repair the break in the eloment using @ repair kit specifically recommended for this purpose, such as Dupont paste No. 4817 (or ‘suivant Included in his rs platc eon. ductive epony. 8 Prior to repairing a break, tur off the system and alow ito cool off fora fow min utes, 410 Lightly butt the element area with fie stee! wool, then clean i thoroughly with iso propyl alcoho 41 Use masking tape to mask off the area being repaired. 42 "Thoroughiy mix the epony, flowing the iistuctions provided withthe repair kt 18.7 To find the break, place the ‘voltmeter positive probe against the {defogger positive terminal, place the voltmeter negative probe withthe fol strip against the heating element at the positive ‘terminal and slide it toward the negative terminal - the point at which the voltmeter roading changes abruptly Is the point at Which the element ls broken 18 Apply the epoxy material tothe sit in the masking tape, overlapping the undamaged {area about 20 mm on each end (see illustra- tion). 14. Allow the repair to cure for 24 houre before removing the tape and using the sys- tem, 16 Headlights - removal and refitting 1. Disconnect the negative cable from the battery Sealed beam type Fer to itustation 16.4 2 Romove the grile/headlight trim bezel on utlty and cab chassis models (refer to ‘Chapter 11), 164 These are the three screws which retain the headlight. The ‘other screws should net be touchedavait a An 17A There are two adjustment screws for ‘each headlight. This (arrow) is an upper ‘one forthe vertical adjustment 3 Whenever renewing a headlight, be ‘careful not fo tum the spring-loaded adjust- ing screws of the headlight, a this wil ater the aim, 4. Remove the screws which secure the retaining ring and withcraw the ring. Support the light as this is done (see ilustraton). 5. Pull the headlight out slightly and ais- ‘connect the electrical connector rom the rear ‘of the light. Remove the light from the vehi- le. Position the new unit close enough to Cconnoct the electrical connector. Make sure thatthe numbers moulded into the lens are at thetop. 7° Refit the retaining ring with ts mounting serews and spring. 18 Check the headlights for proper opera- ‘ton and adjustment. If the adjusting screws ‘were not altered, the new headlight will not ‘need to have its aim adjusted. 9 Rell the radiator grlle If necessary Halogen bulb-type ‘Waring: Helogen gas filed bulbs are under pressure and may shatter if the surface is ‘Scratched or the Bulb is dropped. Wear eye protection and handle the bulbs carefully, Grasping only the base whenever possible. ‘Do not touch the surface ofthe bulb with your fingers because the ol frm your skin could ‘cause It fo overheat and fall prematurely. If ‘you do touch the bulb surface, clean It with |sopropy| alcohol. 40. Reach behind the headlight assembly ‘and unplug the elecvcal connector. SH Grasp the bulb holder securely and rotate It counterclockwise to remove it trom the housing 412. Remove the rubber cover fom the rear cof the headlight. 43. Tum the bulb counter-clockwise to remove it from the bulb holder. Without touching the glass with your bare fingers, inser the new bub assemoiy into the head light housing, Pianta pe aes Cents Jf dade ten os = feet te 47.2 Headlight adjustment details 44 Plug In the electrical connector. Test heecight operation, then clogs the bonnet. 17 Headlights - adjustment Refer to ilustrations 17.1 and 17.3 Note: The headlights must be slmed cor- rcty. H adusted incorecty they coutd blind the driver af an oncoming vehicle and cause a ‘serious accident or seriously reduce your billy to 986 the road. The headlights should bbe checked for proper aim every 12 months and any time a now headlight is refitted or front end body work i performed. it should 'bo emphasised thatthe folowing procedure Is only an interim step which wil provide tem= porary adjustment untl the headlights can be ‘adjusted by @ propery equipped shop. +All headlights have two spring loaded adjusting serews, one on the top or bottom ‘controling up-and-down movement and one on the side controling let-and-right move- ‘ment (see lustration). 2. There are several methods of adjusting the headlights. The simplest method requires, fa blank wall 8 meter infront of the vehicle land leva floor. 3. Position masking tape vertically on the \wal in reference tothe vehiie care line and the centre lines of both headlights (see illus- ‘ration). 4 Position a horizontal tape line in refer- fence to the centre line ofall the headlights. Note: it may be easier fo poston the tape on the wall withthe vehicle parked close to the wall 5. Adjustment should be made with the Vehicle sting love, the fuel tank half-full and ‘no unsualy heavy loadin the vehicle 6 Starting with the low beam adjustment, pasiton the righ intensity zone so itis § cen fimetres below the horizontal ine and 5 cen timetres to the side of the headlight vertical line away from oncoming trafic. Adjustment fg made by turing the top or bottom adjust- ing serew to raise or lower the beam. The Aacjusting sore on the side should be used in the same manner to move the beam let or right. 5 7. With the high beams on, the high inten- ‘ity zane should be vertically Contved with the18.9 The hom is secured by a single bol. ‘the horn ifthe gril 18.2 The bulb holder cah be removed by turning it counter-clockwise ‘exact centre just Below the horlzontal line. Note: it may not be possible to position the headlight aim exactly tor both high and low ‘beams. if compromise must be made, keep Inmind that the low beams are the most used and have the groatst affect on driver sarey. 8 Have the headlights adjusted by a dealer service department or sanvice station atthe earfest opportunity. 18 Horn - check and renewal Check Note: Cheak the fuses before beginning elec- trical agnosis. 1. Remove the gle, f necessary and dis- connect the electrical connector from the hom, 2 To test the hom, connect battery vot- age to the two terminals (or to the terminal ‘and earth) with a pair of jumper wires. If the hom oser‘t sound, renew 8 Ifthe hora doss sound, check for vot ‘age atthe terminal when the horn button fe depressed. If there's voltage atthe terminal, ‘check fora bad earthing point atthe horn, is removed completely Itis easiest toremove 198a Both styles of rear lights are removed with a Philips screwdriver... 4 If there's no voltage atthe horn, chack the relay (600 Section 6). Note that mst horn relays are either the four-terminal or exter rally earthed three-terinal type. 5 ifthe way is good, check for voltage to the relay power and contro cout. f ether Cf the circuits is not receving vottage, nso the wiring between the relay and the fuse panel 5 If both relay circuits are receiving vot age, depress the hom button and check the Circuit from the relay to the horn button for Continuity to earth. If there's no continulty, check the circuit for an open. If there's no ‘open circu, renew the horn button, 7. Af there's contnulty o earth through the horn button, chock for an open or short in the Creu trom the rlay to the horn, Renewal Refer to ilustration 18.3 8 Remove the radiator grille ter 1) '8—--To:renew the hor(s), elsconnect the ‘lectrical connector and remove the brackst Dott (see ilustration) 10. Fefiting isthe reverse of removal Chap- 19.1 Most exterior lights are serviced lke this tu signal ‘assembly - remove the Philips head screws and pull t out ‘some units.are located in ‘the bumper 19.80 49.8c Pull the assembly out... 19 Bulb renewal Front combination or turn signal light Hardtop and wagon models eter fo ustations 19.1 andl 19.2 1 Remeve the light assembly ( tration),Chapter 12 Chassis electrical system 12-11 ‘then remove the bulb holder 49.16 The bull Is then accessible 2 Turn the bulb holder one quarter turn ‘counter-clockwise and remove it from the tear ofthe light (2ee ilustration). 3 For parking ight bul pull the bulb from ‘the socket. For tur signal bulbs, push the bulb inward and tun it countor-clockwise to 4 Rain i the reverse of removal Early utility and cab chassis models 5 Remove the lens and gasket from the light. 6 Push the bulb inward and tum it Counter-elackwise to remove it from the socket 7. Clean the socket If necessary. Refiting isthe reverse of removal Rear combination or turn signal light Hardtop and wagon models Refer to ilustrations 19.8, 19.86, 19.8¢ and 19.9 {8 Remove the light from the rear of the vehicle (ge llustrations 3 Tum the bulb holder one quarter turn Ccounter-clockwise and remove it from the ‘a ofthe light (88 Mlustration). 49,162 The number plate light should be ‘checked periodically o avoid a citation. It itis defective, remove the screws: 1918 A typical side marker light can be pried off with a 30 Push the bulb Inward and tum it ‘counter-clockwise to remove It 11 Rotting is the reverse of removal Utility and cab chassis models 42. Remove the lens and gasket from the light 18 Push the bulb inward and tum it counter-clockwise to remove it from the socket 414 Clean the socket it necessary. Rfiting Is the reverse of removal Number plate light efor to lustrations 19.154, 19.160 and 19.16 15 Remove the sorows and detach the lens ‘and gasket (see illustrations). 46 Remove the bulb from the socket by pushing inwards and turning it counter-clock- Wise (see ilustration). 47 iting is the roverse of eamoval Side marker light Refer to ilustrations 19.18 and 19.19 48 Remove the eide marker light from the vehicle (see tustration) 49. Turn the bulb holder one quarter turn counter-clackwise and remove it from the screwdriver. A card si ed between tho blade ‘and the paint 19:19 Twist the bulb holder to get at the lb inside light (se ilustration). 20° Push the bulb’ inward and tun it ‘counter-clockiise to remove it. Bt Refiting Is the reverse of removal Instrument cluster lights Refer oiustration 19.29 22 To gain access tothe Instrument clusterChapter 12' Chassis electrical system 19.23 Each bulb holder in the rear of the Instrument panel can be twisted ‘and then removed lumination bulbe, the Instrument cluster wi have to be removed (s9@ Section 11). The ‘bulbs'can then be renewed from the rear of the cluster. 23 Rotate the holders counterclockwise to remove them (see illustration). Pul the bubs out 24 Refiting is the reverse of removal Interior light Hardtop and wagon models 25. Prise the Interior lens off the interior ight housing. 26 Pull he bulb directly out ofthe socket. 27 Refiting isthe reverse of removal Utility and ¢ab chassis models 28 Rotate the round lens Fused) counter- lockise te remove it ‘ 29. Use a screwdriver to carefuly prise off the square lens (used) 30. Pull the bulb directly out. Ii is dificult to remove, prise downward en one end with fa small screwdriver. Do not prise on the glass. 31 Refiting isthe reverse of removal ‘Map light 82 Use a small screwdriver to cafefully pig the lans from the lemp. 88. Remove the bulb by pushing It inward hile turning it counterclockwise 34 Refiting is the reverse of removal, 20 Electric side view mirrors - description and check 1. Most electic rearview mirrors use two motors:to-move the glass; one-for up and down adjustments and one for left-right adjustments. 2.” Tha control switch has a selector por- tion which sends voltage tothe left or right side mirof, With:the: Ignition. ON. but the engine OFF, oll down the windows and opor- ate the miror contol swrtch trough all une- ‘ions (leigh ard up-down) for both the left and right side miro. 3_Listen: carefully for the sound. of the ‘lecric motors runnin the mirors 4 the motors can be heard bit tha miror lass dosen't move, there's probabiy @ prob- lem with the drive mecharism inside the mi- ror. Remove and disassemble the.mirror to locate the problem, 5 If the mirrors don't operate and no ‘sound comes.from the mirrors, check the fuse (988 Chapter 1). 6 Ifthe fuse Is good, remove the mieror Control switch from its mounting without dis- connecting the wires attached to it. Tur the ignition ON and check for voltage at the ‘Switch. There shouldbe voltage atone termi ‘al there's no vltage atthe switch, check {or an open or short in the circut between the {use panel and the switch 7 If there's voltage at the switch; discon rect it. Check the switch for continuity In all Its operating postions. ithe suftch doss not have continuity, renew 8 Re-connect the switch. Locate the wire golig from the switch to earth, Leaving the Switch connected, connect a jumper wire between this wire and earth. If the mitror ‘works normally with this wire In pace, repair the faulty earth connection. 8 If the micor stil doesn't work, remove the miror and check the wires at the miror {or voltage. Chack with ignition ON and the imirror seleétor switch on the appropriate ‘Side. Operate the mirror switch in alts pos tions. There should be voltage at one of the ‘sultch-to-miror wires in each switeh postion {except the neutral “of” poston 10 If there's not voltage in each switch position, check the circuit between the miror land control switch for opens and shorts, 11. If there's voltage, remove the miror and test it off the vehicle with jumper wires. Flonew the mirorif it falls tis test. 21. Cruise control system - description and check 1. The cruise control system maintains Vehicle speed with an electrically operated ‘motor located in the engine compartment, \which is connected to the accelerator pedal by a cable. The system consists ofthe cruise Control unit, brake switch, contro! switches ‘and vehicle speed sensor. Some features of ‘the system require special testers and diag- nostic procedures which are beyond the scope ofthis manual. Listed below are some ‘general procedures that may be used to locate common problems, 2 Locate and check the fuse (Section 3). 3 Have an assistant operate the brake lights while you check ther operation (voltage {rom the brake light switch deactivates the cruise contra, 4 Ifthe brake lights don’t come:on or don't shut of, comect the problem and retest the cruise control. 5 Visually “inspect “the control cable between cruise contr! motor and the throttle linkage for free movement, renew if neces. ‘ary 8 The cruise control system uses @ speed sensing device. The speed sensor is located in the speedometer. To test the speed sensor ‘866 Chapter 6 7. Test crive the vahicie to determine if the Cruse controls now working. Hit st, take it toa dealer service deparment or an autorno- tive electrical specials for further agnosis, 22 Power window system - description and check 1. The power window system operates electric motors, mounted in the doars, which lower and raise the windows, The system Consists ofthe contro switches, relays, the motors, regulators, glass mechanisms and associated wiring. 2. The power windois can be lowered and falsed from the mastor control switch by the driver or by-remote switches located at the Indlvidual windows. Each window has a sep- ‘arate motor which is reversible. The position ‘of the conttbl switch determines the polarity ‘and therefore the direction of operation 3 The circuit is protected by a fuse and a Circuit breaker. Each motor le also equipped ith an internal circuit breaker, this prevents fone stuck window from elsabilng the whole system. 4 The power window system will only ‘operate when the ignition switch Is ON. In addition, many models have @ window lock- out switch at the master control switch ‘which, when activated, disables the switches at the rear windows and, sometimes, the switch at the passenger's window also, Always check these items before trou- bleshooting a window probiem. 5 These procedures are general in nature, {80 if you cant find the problem using them, take the vehicle to a dealer service depart tan or other propery equipped repair faci y. 6 It the power windows won't operate, always check the fuse frst. 7. If only the rear windows are inoperative, ‘orf the windows only operate from the mac ter control switch, check the rear window lockout switch for Continuity in the unlocked position. Renew i i t doesn't have continu fy. 8 Check the wiring between the switches land fuse panel for continu. Repair the virng, if necessary, 8 If only one window is inoperative trom the master control switch, ty the other con ‘rol switch atthe window. Note: This doesn't apply to tho driver's coor window. 40 If the same window works trom one ‘witch, but not the other, check the switchChapter 12 Chassis electrical system 12-13 EO {or continuity. the continuity s not as spect- fied renew te switch. 11 Ifthe sulteh tests valid, check for a short or open in the circuit between the affected sutch and the window motor. 412. Hone window is inoperative from both switchas, remove the ‘rim panel from the affected door and check for voltage at the ‘ewiteh and at the motor while the switch is operated. 13 if yoitage is reaching the motor, dscon- rect the glass from the regulator (see Chap ter 11), Move the window up and down by hand while checking for binding and damage. ‘Aigo cheok for binding and damage to the regulator. If the regulator isnot damaged and the window moves up and down smoothly, renew the motor. If there's binding or dam ‘age, lubrieat, repair or renew parts, 28 nec- essary. 44. If voltage isn't reaching the motor, ‘check the wiring in the cicult for continuity between the switches and motors. You'l reed to consult the wiring diagram for the vehicle, i the circuit is equipped with a relay, ‘check that the relay Is earthed propery and ‘eceiving voltage. 416 Test the windows after you are done to ‘confirm proper repairs 23. Power door lock system = description and check Fler to ilustration 23.2 ‘The power door lock system operates the door lock actuators mounted in each door. The aystem consists ofthe switches, ‘actuators, a control unit and associated ‘wiring. Diagnosis can usually be limited to ‘simple chooks of the whing connections anc ‘actuators for minor fats which can be easly Tepalre. In-depth dlagnosis should be left to ‘a dealorshp sence department. Power door lock systems are operated 28.2 The door lock solenoid is at ‘the base of the door by bi-directional solenoids located in the coors (808 illustration). The lock switches have two operating positions: Lock and Unlock. When activated, the switch sends an tearth signal to the door lock control unit to lock or unlock the doors. Depending on which way the switch is activated, the control Unit reverses polarty to the solenoids, allow- ing the two sides of the circu to be used alternately as the feed (positive) and earth side, ‘Some vehicles may have an antl-thett systems incorporated into the power locks. i {you are unable to locate the trouble using the following general Steps, consult your a dealer service department. 1 Always check the clout protection frst ‘Soma vohisles use a combination of circuit breakers and fuses. 2. 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