BODY ELECTRICAL SYSTEM GENERAL ELECTRICAL COMPONENT LOCATION .. FUSIBLE LINKS AND FUSES INSTRUMENT AND WARNING SYSTEM .. MULTIFUNCTION SWITCH LIGHTING SYSTEM .. REAR WINDOW DEFOGGER (HEATED GLASS) . HORN CIGARETTE LIGHTER CLOCK. AUDIO .. WINDSHIELD WIPER AND WASHER ETACS..90-2 GENERAL GENERAL SERVICING THE ELECTRICAL SYSTEM 1. Prior to servicing the electrical system, be sure to turn off the ignition switch and disconnect the battery ground cable. 2. Secure the wiring harnesses by using clamps so that there is no slack, However, for any hamess which passes to the engine or other vibrating parts of the vehicle, allow some slack within @ range that does not allow the engine vibrations to cause the harness to come into contact with any of the surrounding parts, and then secure the hamess by using a clamp. 3. If any section of a wiring harness interferes with the edge of a part, or a comer, wrap the section of the harress with tape or ‘something similar in order to protect it from damage. 4, When installing any of the vehicle parts, be careful not to pinch or damage any of the wiring harnesses. 5. The sensors, relays, etc, must never be subjected to strong shocks. Do not allow them to fall and do not throw them when handling.GENERAL 90-3 6. The electronic parts are readily damaged by heat. If there is a need for service operations that may cause the temperature to 7. Loose connectors troubled. Make sure that the connectors are connected securely. | Li SCAN TNE 10. Connect connectors which have catches by inserting the connectors until a “snap” noise is heard.90-4 GENERAL 11. When using a circuit tester to perform continuity or voltage ‘checks on connector terminals, insert the test probe from the harness side. It the connector is a seales connector, insert the test probe in through the hole in the rubber cap forthe electrical wires, being careful not to damage the insulation of the wires; continue to insert the test probe until it contacts the terminal 12. In order to avoid overloading the wiring, take the electrical current load of the optional equipment into consideration, and determine the appropriate wire size. CHECKING CABLES AND WIRES 1. Check the terminal for tightness. 2. Check terminals and wires for corrosion by battery electrolyte, et. 3. Check terminals and wires for open circuit or impending open circuit. 4, Check wire insulation and coating for damege, cracks and degrading. 5. Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6. Check groundingpartsto verify thatthere is completecontinuity between attaching bol(s) and vehicle body. 7. Check for incorrect wiring 8. Check that wirings are so clamped as to prevent contact with sharp comers of the vehicle body, ete. or hot parts exhaust manifold, pipe, etc.). 9. Check that wirings are clamped firmly to secure enough clearance from the fan pulley, fan belt and other rotating or moving parts 10. Check that the wirings between the fixed parts such as the vehicle body and the vibrating parts such as the engine are made with adequate allowance for vibrations. cae | Parse corer Nominal | gauge [in engine | Other No _|ammatren | ses Tana? Tawea] YBa osm | awe so | 7a | aa Gasmm| awe is | oa | A t2smm | awe is | aa | 0a Zomm | await | tea | Son Somme | awa iz | 21a | aoa Somme Lawaio| 31a | seaELECTRICAL COMPONENT LOCATION 90-5 ELECTRICAL COMPONENT LOCATION RELAY AND CONTROL UNIT CJ) Name Symbol_[_Name Symbol Glow control unit A ‘Tail lamp relay D Starter relay | Rear fog amp relay D F Resistor with diode C__| Rasher unit D Head lamp relay c Power window relay D ETACS Cc Intermittent wiper relay E Front fog lamp relay D eri ined : paced gene ErolELECTRICAL COMPONENT LOCATIONFUSIBLE LINKS AND FUSES 90-7 FUSIBLE LINKS AND FUSES FUSIBLE LINKS SPECIFICATIONS lems ‘Specifications Main fusible link Type Screw up type Rated capacity 0A Housing color Black ‘Sub. fusible link Grreual Switch | Fuses | Defogger | Head lamp Item Rated capacity | 40A 0A 404 408 Wire color Green Red Green| Green Glow plug circuit Type Wire connecting type Location Between battery cable (+) and front wiring Wire color Black LOCATION ——__——5] rusiate|| || FusieLe UNKA NK FusieLe LINK rusete| | |_| rusieue LINK & NK D View "A"90-8 FUSIBLE LINKS AND FUSES a eae E EEE FUSES SPECIFICATIONS Power supply circuit Fuse No, Rated capacity Major load circuit 7 0A Room lamp 2 zy Hazard switch BATTERY (B+) 3 154 Horn, stop lamp _ 4 208, Rear defogger timer 5 15A, Fuel fiter relay 6 0A Back up switch IGN. SW (OST) 7 5A Head lamp 8 158, Head lamp 9 15A Door lock control relay BATTERY (B+) 10 108) Rear blower switch Rear fog lamp switch i 150, ‘Audio, DiClock, CiLighter INES ACCION) 12 108 ‘ABS, Head lamp relay 18, 15A WiperWasher motor IGN. Sw (ON) 4 208 Blower switch 15 15A Rear comb. lamp Tail lamp relay ON 7 70K 7 208 Power window switch (main) Piwincow reley ON 8 15A Power window switch (Sub) LOCATIONINSTRUMENTS AND WARNING SYSTEM INSTRUMENT AND WARNING SYSTEM ES EEUU UU EEE oe 90-9 SPECIFICATIONS Indicator and warning lamps Bulb wattage (W) tlumination color Battery charge 14 Red Oil pressure 14 Red Door ajar 14 Red Brake warming 14 Red Low fuel 34 ‘Amber Direction indicator (LH, FH) 30 Green High beam 3.0 Blue Rear heated 14 Amber Giow and starter indicator 14 Amber SERVICE SPECIFICATIONS tem ‘Specifications Speedometer Speed (Krrvh) 20 | 40 eo | 120 | 160 Tolerance (Kminy |" | +8 5 6 8 * +0 +0 +0 +0 Fuel gauge Fuel level F (Full) 1/2, E(Empty) Resistance (2) 7 325 5 Tolerance (°C) +18 ° 216 0 10 Temperature gauge Temperature (°C) 50 70 115 Resistance (Q) 228 104 238 Tolerance (°C) 5 8 * 10 Tachometer ENGINE RPM 750 | 1000 | 2000 3000 | 5000 | 6000 Tolerance (RPM) st00| 8 2125 2150 | +250 | =30090-10 INSTRUMENT AND WARNING SYSTEM INSTRUMENT CLUSTER [TRUCK] COMPONENTS 1. Inspection lid 2. Switch panel 3. Meter hood 4. Front hamess 5. Speedometer cable 6. Cluster REMOVAL AND INSTALLATION 1. Remove the switch panel from the meter hoody using special tool, 2. Remove screws (4€A) and meter hood from the instrument panel.INSTRUMENT AND WARNING SYSTEM 90-11 8, Removefourscrews retaining clusterandcarefully pullrearward ‘enough to disengage the speedometer cable and hamess. Carefully pull cluster away from the instrument panel 5. Installation is the reverse order of removal. METER CLUSTER CIRCUIT90-12 INSTRUMENT AND WARNING SYSTEM No_| Nomenciature } ‘At_| CHARGE A2_| DooR+ } ‘as_[ DooR- o 2 aa [ol o eur __ FF =i AS_| LOW FUEL Besos | a6_| FUEL UNIT oe SARTHBS—g | ar | wo o+ BD: ee | LG) co = RTOS 3 3 | Ate owe ® | ea | are ov = oma =, 85_| ABS - (pine J conan 3 Bé__| REED SWITCH eT it B7_| _WDEVICE =H s [aro cx STAPULSE — So | NTN al {5 —M B10 | ATR ec. oe | Bit | ATP eo aE | B12 | TURNL ce Me > ' ct_[ TuANR a c2_ | HLAMP ™ 2S MT j c3_ | HBEAM oo c4_| AT GROUND : see | 5_| ATOD/OFF 2 te | tt 6 _|_TACHO PULSE ss ABSCRE | 7_| CHOKE. HAZARD (+) 2 —_»,_@ | c8_| S/BELT- HAZARD (-) Sage || ce_| BRAKE () “un 999988 | cio [GROUND o wo 4 D1_| BRAKE () se fuser fg} ——-- b2_| _WISEPARATOR | o3_| RTD + MS 8 4 | b4_| pHTD- ss 0 > D5__|_STARTIABS] & Towsce — D6_| IGN (+) ~ fs o7_| cLow Gene) sovroes ba_| TEMP UNITINSTRUMENT AND WARNING SYSTM 90-13 REMOVAL AND INSTALLATION 1, Removal the screws (SEA) from meter hood and pullitforward with meter hood lifted by hand. 2. Remove the screw (4EA) restaining the cluster and carefully pull rearward enough to disengage the speedometer cable and hamess. Carefully pull out the cluster from the instrument panel Installation is the reverse order of remioval procedures. INSPECTION SPEEDOMETER 1. With a speedometer tester, check that any indication error is within tolerance limits. Speed (kvl) ‘Above 35 Tolerance (km/h) +15 - 10%, NOTE 1. Doas illustrated, so prevent a vehicle from shooting out. 2. It should be noted that the excessive tire wear and tire over or under-inflation will cause indication errors. 2. Check the speedometer for pointer fluctuation and abnormal noise. NOTE Pointer fluctuations can be caused by a faulty speedom- eter cable. TACHOMETER With the engine started, check that engine speedometer and tachometer indicate as shown in the table below. Replace tachometer if difference is excessive RPM 7,000 3,000 5,000 TOLERANCE #100 #150 +250) NOTE Don't connect battery terminals reversely, or you can damage a diode or a transistor because the tachometer is negative earthed. es rare sreoanater inecton pipe | D | Us pRLY ~y | | os) fe ‘T Tachometer 490-14 INSTRUMENT AND CLUSTER INSTRUMENT CLUSTER [VAN & WAGON] COMPONENTS 1. Cluster glass & vessel 2. Meter hood 3. Printed circuit board 4. Fuel gauge 5. Speedomemter 6. Tachometer 7. Temp. gauge 8. Switeh 9. Clock 10.Facia panelINSTRUMENT AND WARNING LAMP 90-15 INSPECTION SPEEDOMETER 4. Usinga speedometer tester, ensure that any indication erroris, within tolerance limits. NOTE Itshould be noted thatthe excessivetire wear andtire over oF under-infiation will cause indication errors. ‘Speed (Km/h) 20 | 40 | 80 | 120 | 160 Tolerance (Kmvm) | 23 | +5 | +5 | +6 | +8 +0 | +0 | +0 | +0 2. Check the speedometer for pointer fluctuation and abnormal noise. NOTE Pointer fluctuations can be caused by a faulty speedom- eter cable. FUEL GAUGE AND FUEL SENDER 1. Remove connector from the fuel sender in the fuel tank. 2. Connect the test bulb (12V. 3.4W) between terminal 2 (Y) and. terminal 3 (B) on the wiring side. 3. Tum the ignition switch to the ON position. 4. Checktobe sure that the test bulb flashes andthat he indicator moves gradually to the “F* position. NOTE If the test bulb does not flash (and indicator does not move), check fuse for broken wire or resistance between gauge terminal, or break in harness. Replace or repair defective parts. ENGINE COOLANT TEMPERATURE (ECT) GAUGE 1. Remove connector from the ECT sender in the engine ‘compartment. 2. Ground wiring side connector via test bulb (12V. 3.4W) 3. Tum the ignition switch to the ON position. 4. Check to be sure that the test bulb flashes and the indicator moves. NOTE: 4. Ifthe test bulb flashes but the indicator does not move, replace ECT gauge. 2. It the test bulb does not flashes (and indicator does not move), check fuse for broken wire or resistance between gauge terminal (Refer to step 5), or break in harness. Replace or repair defective parts.90-16 MULTIFUNCTION SWITCH MULTIFUNCTION SWITCH COMPONENTS 1. Horn cover 2. Steering wheel 3. Steering colum shroud 4, Cable strap 5. Multifunction switchMULTIFUNCTION SWITCH 90-17 REMOVAL AND INSTALLATION 1. Remove the horn cover. Remove the steering wheel mounting nut. 3. Remove the steering wheel. Remove the steering column shroud. Disconnect the hamess connetors. Remove straps. poe 7. Remove the multifunction switch assembly by loosening 2 screws. 8. Installation is the reverse order of the removal procedure. INSPECTION With the multifunction switch in each position, make sure the continuity exists between terminals below. Lighting switch Terminal Position ts Hatt) Es OFF H —— couriso U —— fen90-18 MULTIFUNCTION SWITCH Dimmer and passing switch Terminal Hl a eb L HU | Hs(2) HU ——<<———o HL ——o PASSING ——_— 7) Wiper switch Tema Tig Ta |e ] ew | wr Position OFF —— INT ——a —J LO ———$——<—=o HI —_ Washer switch Terminal Position ce He(t) OFF ‘ON — Tum signal switch Terminal | 1 TA Position L ——" N R —————" Parking switch Terminal Position GS GS Gar OFF _————-> ‘ON —. (Om: indicates that there is continuity between terminals.LIGHTING SYSTEM a LIGHTING SYSTEM [VAN & WAGON] SPECIFICATIONS Exterior lamps Headlamp Front combination lamp Turn signal lamp Position and parking lamp Side turn signal lamp Rear combination lamp ‘Turn signal lamp Back-up lamp ‘Stop and tail lamp Rear side marker lamp Licence plate lamp Interior lamps Step lamp Front room lamp Rear room lamp (Lens slid type) Rear room and map lamp Tail Gate lamp Flasher unit Tum signal blinking frequency Hazard waming blinking frequency Styled serisealed lamp 21w SW sw 21w 21W 2/5W 3.4W tow sw 10w 10W aw sw 85215 Cycle/Min 80210 Cycle/Min90-20 LIGHTING SYSTEM TROUBLESHOOTING Problem Possible cause Remedy ‘One lamp only does not light Bulb bumt out Replace bulb Socket, wire or ground faulty Repair as necessary No headlamps light Sub-fusible link blown Replace sub-fusible link headlamp relay faulty Check relay Lighting switch faulty Check switch Wiring of ground faulty Repair as necessary Tail, parking and license lamp do | Tail fuse blow (No.3) Replace fuse and check for short not light, Fusible link blown Replace fusible link Taillamp relay faulty Check relay Lighting switch faulty Check switch Wiring or ground faulty Repair as necessary ‘Stop lamps do not ight ‘Stop fuse (No.2) blown Replace fuse and check for short Stop lamp switch faulty Adjust or replace switch Wiring or ground faulty Repair as necessary Stop lamps stay on Stop lamp switch faulty ‘Adjust or replace switch Instrument lamps do not light Lamp control rheostat faulty Check theostat (taillamps tight) Wiring or ground faulty Repair as necessary Tum signal does not flash on one | Bulb bumt-out Replace bulb side Tum signal switch faulty Check switch Wiring or ground faulty Repair as necessary Tum signals do not operate ‘Sub-fusible ink blown Replace fusible link ‘Tum fuse (No.17) blown Replace fuse and check for short ‘Tum signal flasher faulty Check flasher Tum signal switch faulty Check switch Wiring or ground faulty Repair as necessary Hazard warning lamps do not Hazard fuse (No.6) blown Replace fuse and check for short operate ‘Tum signal flasher faulty Check flasher Hazard switch faulty Check switch Wiring or ground faulty Repair as necessary Flasher rate too slow or too fast | Lamps are of a wattage smaller or | Replace lamps larger than is specified for use Defective flasher unit Replace unit Backup lamps do not light Back up fuse (No.6) blown Check for shor, replace fuse Back up lamp switch faulty Check switch Damaged wiring or poor grounding | Repair as necessaryLIGHTING SYSTEM 90-21 ——— HEADLAMP AIMING WITH SCREEN Headlamp aiming preparation Place the vehicle on a level floor, 3m (9.84 feet) from the aiming screen ora light-colored wall. i: Height from earth to headlamp V: Vertical center line Y: Distance between center of headlamps X: Cut off line v v :Allowable adjustment rance ‘Intersection of cut off line 1. Position a vertical place of tape so that it is aligned with the vehicle center line. 2. Position a horizontal tape with reference to the centerline of the headlamp. 3. Position a vertical piece of tape on the screw for vertical adjustment, adjust side screw for horizontal adjustment, Visual headlamp adjustment 1. A property aimed low beam will appear on the aiming screen ‘3m (9.84 feet) in frontofthe vehicle. The shaded areaas shown in the illustration indicates a high intensity zone. 2. Adjust the low beam headlamps to match the low beam pattern of the right and left headlamps. NOTE If the visual headlamp adjustment at low beam is made, the adjustment at high beam is not necessary.90-22 LIGHTING SYSTEM Horizontal asusing bot 7 ‘eel ajusing bok / fea View from "B* View from “A HEADLAMP Replacement of bulb 1. Remove the headlamp assembly by loosening the screws. 2. Remove the dust cover on the lamp body reer. ‘3. Remove socket holder and remove the socket assembly trom lamp body. 4, Assembly is the reverse order of the removal. CAUTION 1. Never hold the halogen lamp bulb with a bare hand, dirty glove, etc. ifthe glass surface is dirty, be sure to clean and install it after drying it thoroughly. 2. When installing socket cover, install with its top mark upwards. Socket cover should snug fit lamp body rear and valve socket. =»LIGHTING SYSTEM HEADLAMP RELAY Inspection 4. Remove headlamp relay from relay box. 2. Connect the battery to terminal 1 and 3 and check continuity between terminals, Poweris supplied | 1-3terminals [ Continuity Poweris not supplied | 1-3terminals | No Continuity a 3 2-4terminals | Continuity sure HAZARD SWITCH Inspection 1. Remove the hazard switch 2. Check the continuity between the terminals. Terminal Switch sl2|1isjel7|s/4}o OFF olo ‘ON. One | OnpOrposho [0 [TO NOTE: OmeO indicates that there is a continuity between the terminals.90-24 LIGHTING SYSTEM LIGHTING SYSTEM [1TON & 1.25TON TRUCK] ‘SPECIFICATIONS Exterior lamps Headlamp eolssw Front combination lamp Tum signal lamp 21w Position and parking lamp sw Rear combination lamp Tum signal almp 21w Back-uplamp zw ‘Stop and tail lamp 21/5W Licence plate lamp 10w Interior lamps Front room lamp. ow Rear room lamp owLIGHTING SYSTEM 90-25 neta HEADLAMP AIMING WITH SCREEN Headlamp aiming preparation GROUND Headlamp lower bulb center insane mesa oo headlamp pee way (Empty venice) cutot ine rH 652.5 (th diver), HEADLAMP Replacement of bulb - 1. Remove the headlamp assembly after loosening the screws. 2. Remove a spring fy ( 3. Remove a condenser. \ S 4. Remove the dust cover on the lamp body. y Replace bulb. “7 NOTE 1. Never hold the halogen lamp bulb with a bare hand dirty sonra glove. If the glass surface is dirty, be sure to clean and install it after drying it throughly. 2. Assembling the dust cover, install with its top mark upwards.90-26 REAR WINDOW DEFOGGER (HEATED GLASS) SS REAR WINDOW DEFOGGER (HEATED GLASS) SPECIFICATIONS Items Specifications Rear window defogger switch Rated load DC 12V, 1A Operating force 0.3-1.0kg Insulating resistance Rear window defogger timer Rated voltage Operating votage range Operating temperature range Operating time Rear window defogger relay Rated load Exciting current Insulating resistance MIN. 5MO. (DC 500V megger) De. 12v Dc 10 ~ 1sv ~40 ~ 480°C 101 Minutes De 12V, 200 MAX. 150 mA at 24° MIN. 10M9. (DC 500V megger) COMPONENTS: Rear heated glassREAR WINDOW DEFOGGER (HEATED GLASS) REAR WINDOW DEFOGGER SWITCH INSPECTION Remove the defogger switch connector from the wiring hamess. Operate the switch, and check the continuity between the terminals. If continuity is not as specified, replace the switch. REAR WINDOW HEATED TIMER Terminal a) | Le) Position ae |e ec w OFF e ON =) ——" CIRCUIT DIAGRAM ALTA (ENG. RUNNING) 71 a + ien.sw ON. j * 5 ale =~ morwossee [— on ' DeF.sw Gye—J LiLSLi_ oH or - ps i | j | TIMER OUTPUT Oye } | ee | | DEFOSGER 1oMin —ToMin 70 in | I ] eRUNT) | | | IND. LAMP Lik INSPECTION Ifthe heated switch is depressed while the ignition switch in ON, the o) {teil sae defogger timer operates for 10+1 minutes. Even while the defogger _fial s noe timer is in operation, depressing the defogger switch again or Pra Ty tuning the igntion sutel OFF, ne defogger mer operation wil | CE | stop. After tracing the problem tothe defogger timer, replaceit with anew ‘one, check for proper operation. If the system operates properly, the original defogger timer is fautty.90-28 REAR WINDOW DEFOGGER (HEATED GLASS) ee EEE ee EEE PRINTED HEATER LINE CHECK CAUTION Finger pressure Wrap tin foil around the end of the voltmeter test lead to prevent damaging the heater line. Apply finger pressure on ee the tin foil, moving the tin foil along the grid line to check for open circuits. 1 Tot Printed neater 1. Tum on the defogger switch and use a voltmeter to measure the voltage of each heater line at the glass center point. If a voltage of approximately 6V is indicated by the voltmeter, the heater line of the rear window is considered satisfactory. 2. Bumredoutbetween the centerpointand(+) terminal, voltmeter indicates 12 volts RV] ovens SP server 3. Ifa heater tine is burned out between the center point and (-) Barmed ou pane terminal, the voltmeter indicates 0 volt. 4. To check for open circuits, slowly move the test lead in the ‘Vatiage changes botore and direction that the open circuit seems to exist. Try to find a point, ater pen exeuted pont where avoltageis generatedorchangestoOV. Thepointwhere the voltage has changed is the open-circuited point Here a votage OV |= termina o D.REAR WINDOW DEFOGGER (HEATED GLASS) 90-29 Defogger OFF Use an ohmmeter to measure the resistance of each heater line between a terminal and the center of a grid line and between the same terminal and the center of one adjacent heater line after another. The section involving a broken heater line indicates resistance twice as that in other section. In the affected section, move the test lead to a position where resistance sharply changes. Repair Provide the following items. 1. Conductive paint 2. Paint thinner 3. Masking tape 4. Silicone remove 5. Thin brush Wipe the glass adjacent to the broken heater line, clean with silicone remover and attach the masking tape as shown. Shake the conductive paint container well, and apply three coats with a brush at intervals of about 15 minutes apart. Remove the tape and allow sufficient time for drying before applying power. For a better finish, scrape away excess deposits with a knife after completely dried. (allow 24 hours) CAUTION After repairing, clean the glass witha soft dry cloth or wipe along the grid line with a slightly moistened cloth. Saree Grane, f\G comet “Tester Bread restance nce alae as tsar Masking tape90-30 EE HORN SPECIFICATIONS items Specifications Type Flat Rated voltage De. 12v Consumption current MAX. 3.58 ‘Sound level 1.5-115 4B (at 2M) Fundmental frequency Low pitch 350220 Hz High pitch 415220 Hz TROUBLESHOOTING ‘Symptom Homn does not sound Horn will not stop sounding Inspection items Hom switch ° ° Horn ° Wiring hamess and connector connection ° ° Ground ° Other inspection items Hom contact plate NOTE Circle indicates inspection items.HORN HORN COMPONENTS 90-31 Hom bracket a Attaching bot Disconnect the negative cable of battery. Remove the horn attaching volt. Disconnect the wires from the horn. Remove the horn. NOTE ‘Check horn adjusting screw for looseness. pepe ADJUSTMENT Operate the horn and adjust the tone to a suitable level. By tuning the adjusting screw as belows. Volume Direction Too Low In the “UP” direction Too Loud In the ‘DOWN’ direction If satisfactory volume cannot be obtained, replace it. CAUTION: After the adjustment, apply a small amount paint around the screw head to avoid the possibility of loosening.90-32 CIGARETTE LIGHTER CIGARETTE LIGHTER SPECIFICATIONS tems Specifications Max. input 20W Reset time 19 +5 sec. “Thermal fuse fusion temperature 180-250°C (356-482°F) INSTRUMENT PANEL CIGARETTE LIGHTER COMPONENTS Center pane!CIGARETTE LIGHTER 90-33 REAR SIDE TRIM CIGARETTE LIGHTER COMPONENTS Ashtray Pocket Plug ‘Socket ~ _ fat Outer case INSPECTION 1. Take out the plug. 2. Examine the element spot connection for remnants of tobacco and other materials. 3. Using an ohmmeter, check for the continuity of the element.cLock 90-34 a CLOCK SPECIFICATIONS tems Specifications Type Crystal oscilating type Rated voltage Dc. 12v Operating voltage range DC. 6 ~16V Display type Fluorescent cigital display COMPONENTS (TRUCK) (VAN & WAGON) ] Heater control lever khob Center panel 1. First remove the glove compartment, heater control lever and the ashtray. 2. After removing the center panel, take off the radio. 3. Hold spring on clock side and press instrument panel forward as figure,AUDIO 90-35 Cty AUDIO SPECIFICATIONS Items ELECTRONIC TUNING RADIO Radio| Receiving band ANIM Tuning method ELECTRONIC Frequency range AM 510 ~ 1650 KHz FM 88 ~ 108 MHz Current consumption acc Sorless A wu 140 mA Tape player Deck type Mechanical Reproducing type Auto reverse Eject type Key of release Permissible tape Compact tape Tape speed 4.78 cmisec. SPEAKER items Specifications Front speaker Type Dual cone Size 40.em (4 in.) Input power NOM. 1SW/MAX. 20W Rated impedence 8a Rear speaker Type 2 way coaxial Size 160m (6.5 in) Input power NOM. 15WIMAX. 40W Rated impedence 8a90-36 AUDIO RADIO AND TAPE PLAYER COMPONENTSFRONT SPEAKER COMPONENTS90-38 AUDIO REAR SPEAKER Quarter trim SERVICE ADJUSTMENT PROCEDURES TAPE HEAD AND CAPSTAN CLEANING 1. To obtain optimum performance, clean the head and capstan as often as necessary, depending upon frequency of use and tape cleanliness. 2. Tocleanthe tape head and capstan, use cotton swab dipped inordinary rubbing alcohol. Wipe the head and capstan SPEAKER CHECKING 1. Check the speaker by using an chmmeter. fan ohmmeter indicates the impedance of the speaker when checking between speaker (+) and speaker (-) of the same channel, the speaker is OK. 2. Ifclicking soundis emittedromthe speaker when the ohmmeter plugs touch the speaker terminals, the speaker is OK. ‘Obmmeter NOISE SUPPRESION Noise interfering with radio reception may be roughly classified as follows: 1. Noise produced by the vehicle itself Noise from the ignition circuit, alternator circuit, ete. 2. Noise generated in the radio itself. ‘Thermal noise from transistors, IC, resistors, etc. 3. Atmospheric noise Noise from other vehicles, neon signs, tec.AUDIO 90-39 iy The radio has devices to suppress noise of the radio itself and atmospheric noise, but itis difficult to eliminate them completely. Noise produced by the vehicle includes whining from the alternator system, and a strong, impulsive, fast popping noise from the ignition system, (1) Adjust the antenna trimmer completely. (2) Set the push buttons (tuning) properly (G) Extend the antenna all the way. PREVENTION OF IGNITION CIRCUIT NOISE Aresistance-equipped cable is used for the high-tension cable in orderto preventnoise; however, ifany noise fromthe ignition circuit does occur, check the tighteness and ground connection of the Position (+) terminal of the noise filter and if necessary, check the noise filter. Caution Be careful not to connect the noise filter to the high-tension cable, or it could damage the noise filter. PREVENTION OF OTHER CIRCUIT NOISE For other noise, take necessary corrective actions in accordance with the following items and the NOISE SUPPRESSION CHART. Polish the grounding cable terminal, and connect it properly. Polish the pillar antenna grounding terminal, and connect it property. Ground electric parts completely. Keep the antenna cable and speaker lead wire away trom other electric wiring,90-40 AUDIO NOISE SUPPERSSION CHART flashing of turn-signal lights, ‘Symptom Noise source Remedy Unusual noise related to engine | Engine ‘Securely earth the engine, frame and/or body and speed engine hood. Engine SN ~ Earth wire “Giatter noise related fo the Turr-signals Connect a 0.5 uF noise-suppression capacitor to the B terminal of the flasher unit. Flash unit -— 05 pF noise suppression capacitor ‘Abnormal noise when the hom is | Hom operated 1. Connect a 0.5 iF noise-suppression capacitor to the +B terminal of the horn. 2. Foran FM radio, connect an LC filter to the horn terminals. Lc finer Gtr | Noise when the windshield washer | Washer motor operates Connect an LC filter between the terminals of the washer motor and the power source wire, Unusual noise when the engine is] Water temperature started ‘gauge unit ‘Connect a 0.1 \F noise-suppression capacitor to the| terminal of the water temperature gauge unit. ' L 0.1 pF noise PEE | smentoncaratorAUDIO 90-41 ANTENNA COMPONENTS 1. Antenna feeder cable clip 2. Antenna feeder cable jack 3. Pillar antenna 4, Waterproof cap90-42 WINDSHIELD WIPER AND WASHER Se WINDSHIELD WIPER SPECIFICATIONS ems Specifications Wiper motor Rated voltage De 12v Testing voltage 1.5V (terminal voltage) Starting voltage (no load minimum) av Operating voltage range DC 10~ 15v Insulating resistance MIN. 1MQ. Revolution (under load) pm Low speed 44-52 High speed 63-7 Wiper blade Wiper blade length (when flat) 425 mm TROUBLESHOOTING Problem Possible cause Remedy ‘Wipers do not operate or return Wiper fuse blown Replace fuse and check for short to off position Wiper motor faulty ‘Check motor Wiper switch faulty Check switch Wiring or ground faulty Repair as necessary Wipers do not operate in INT Intermittent relay faulty Check intermittent relay position Wiper switch faulty Check switch Wiper motor faulty Cheek motor Wiring 0 ground faulty Repair as necessary SERVICE SPECIFICATIONS Ttems ‘Specifications Windshield wiper biade stopping position (distance between blade 35-45 mm tip and weatherstrip) Rear wiper blade stopping position (distance between blade tip and 25-35 mm weatherstrip) TORQUE SPECIFICATIONS Items Nm Itt Windshield wiper pivot shaft installing nut 10-16 7212 Windshield wiper arm locking nut 10-16 7212 Rear wiper arm locking nut 69 43-58WINDSHIELD WIPER AND WASHER 90-43 FRONT WIPER COMPONENTS Wiper biade arm assembly Wiper blades Wiper arm . Instrument panel >. Wiper motor assembly Cap . Wiper pivot nut Washer with packing ). Wiper link assembly 10. Holder 11, Washer nozzle 12, Washer tube 1. Washer tank assembly OeNOMAePe90-44 WINDSHIELD WIPER AND WASHER SERVICE POINTS OF REMOVAL REMOVAL OF WIPER MOTOR ASSEMBLY 1. Remove the wiper motor assembly installation bolt. 2. Uncouple the connection of the wiper motor assembly and wiper linkage assembly, and then take out the wiper motor assembly. CAUTION Regarding the installation point of the crankshaftarm and wiper motor, the automatic stop angle is set. So do not remove crankshaft arm from wiper motor. Removing it, mark both for identification. REMOVAL OF WASHER NOZZLE 1. Remove the holder from inside the vehicle, and then take out the washer nozzle. INSPECTION WIPER MOTOR Disconnect the wiring connector from the wiper and connect battery to the wiper motor connector to check that the wiper motor runs. 1. LOW SPEED OPERATION CHECK To wiper Connect battery (+) to terminal 2 and battery (-) to the wiper smote bracket motor bracket and check that the motor runs at low speed. {SZ of \[ée4 L4]3 wees 2. HIGH SPEED OPERATION CHECK aaaoe Connect battery (+) to terminal 1 and battery (-) to the wiper ‘motor bracket motor bracket land check that the motor runs at high speed.WINDSHIELD WIPER AND WASHER 90-45 3. AUTOMATIC STOP OPERATION CHECK 4) Connect battery (+) to terminal 2 and battery (-) tothe wiper motor bracket to run the motor at low speed. 2) Disconnect terminal 2 during operation to stop the motor. 3) Connect terminal 2to terminal 3 and connect battery (+) to terminal 4 and battery (-) to the wiper motor bracket to check that the motor starts to run at low speed and then stops. SERVICE POINTS OF INSTALLATION INSTALLATION OF WIPER LINKAGE ASSEMBLY ‘Align the lock base concave parts of wiper linkage assembly with the projection of the body, and then install the wiper linkage assembly INSTALLATION OF WIPER MOTOR ASSEMBLY Ifthe wiper motor assembly is removed, be sure to confirm that it is securely grounded when itis installed. INSTALLATION OF WIPER BLADE ARM ASSEMBLY Install the wiper blade arm assembly so that the wiper blade is the standard value. Standard value: 35-45 mm (1.4-1.8 in.) 4 We, moto racket \fed a [4a a} | a4) WINDSHIELD WASHER ‘SPECIFICATIONS tems Specifications jasher motor and pump Power consumption 30orless A Nozzle jet pressure 70 or more kpa Tank capacity 15 or more lit Allowable period of continuous use with washer fluid MAX. 20 sec.90-46 WINDSHIELD WIPER AND WASHER WASHER MOTOR AND PUMP Make the check while the motor is installed to the washer tank. 1. Check to be sure that there is washer fluid in the washer tank 2. Check to be sure that the washer motor operates and the fluid is forced out under pressure when the battery's positive (+) terminalis connectedto terminal 2 and the negative (-) terminal is connected to terminal 1WINDSHIELD WIPER AND WASHER 90-47 ES WINDSHIELD WIPER [1TON & 1.25TON TRUCK] ‘SPECIFICATIONS tem Specifications Wiper motor Rated voltage Dc 1av Testing voltage 18.54 (terminal vitage) Revolution (under load) Low speed 4825 RPM High speed 6828 RPM Wiper blade Wiper biade length 450mm Wiping angle Right 85.5%2 Left 107522 TROUBLESHOOTING Problem Possible cause Remey Wipers do not operate or retum | Wiper fuse blown Replace fuse and check for short to of position Wiper motor faulty Check motor Wiper switch faulty Check switch Wiring or ground faulty Repair as necessary Wipers do not operate in INT Intermittent relay faulty Check intermittent relay position Wiper switch faulty Check switch Wiper motor faulty ‘Check motor Wiring or ground faulty Repair as necessary