Page 1334 of 1659

Trouble Diagnoses
Before conducting an alternator test, make sure that the battery is fully charged. A 30-volt voltmeter and
suitable test probes are necessary for the test. The alternator can be checked easily by referring to the
Inspection Table.
lBefore starting, inspect the fusible link.
lUse fully charged battery.
GASOLINE ENGINE MODELS
Check the fol-
lowing:
lWarning
lamp bulb
lFuse for
warning lamp
Ignition switch
``ON''Warning lamp
``OFF''Disconnect connector (S, L) and
ground L harness side.Warning lamp
``OFF''
Warning lamp
``ON''Damaged IC
regulator.
Replace.
Warning lamp
``ON''
Engine start.
Engine speed:
1,500 rpmWarning lamp
``ON''Check the following:lDrive beltlFuse for S terminallConnector (S, L terminal) con-
nection
Engine idlingWarning lamp
``OFF''OK
Warning lamp
``ON''
Warning lamp
``OFF''OKEngine speed:
1,500 rpm
(Measure B
terminal volt-
age)More than
15.5VDamaged IC
regulator.
Replace.
No generationField circuit is
open.
Warning lamp: ``CHARGE'' warning lamp in combination meter
Note:
lIf the inspection result is OK even though the charging system is malfunctioning, check the B
terminal connection. (Check the tightening torque.)
lWhen field circuit is open, check condition of rotor coil, rotor slip ring and brush. If necessary,
replace faulty parts with new ones.
Malfunction indicator
The IC regulator warning function activates to illuminate ``CHARGE'' warning lamp, if any of the following
symptoms occur while alternator is operating:
lField circuit is open.
lExcessive voltage is produced.
CHARGING SYSTEM
EL-36
Page 1335 of 1659
DIESEL ENGINE MODELS
Check the fol-
lowing:
lWarning
lamp bulb
lFuse for
warning lamp
Ignition switch
``ON''Warning lamp
``OFF''Disconnect connector (S, L) and
ground L harness side.Warning lamp
``OFF''
Warning lamp
``ON''Damaged IC
regulator.
Replace.
Warning lamp
``ON''
Engine idlingWarning lamp
``ON''Check the fol-
lowing:
lDrive beltlField circuit
Check the fol-
lowing:
lFuse for S
terminal
lOpen circuit
for S terminal
lIC regulator
Warning lamp
``OFF''Engine speed: 1,500 rpm
(Measure B terminal voltage)More than
15.5V
13 - 15VOK
Warning lamp: ``CHARGE'' warning lamp in combination meter
Note:
lIf the inspection result is OK even though the charging system is malfunctioning, check the B
terminal connection (check the tightening torque).
lWhen field circuit is open, check condition of rotor coil, rotor slip ring and brush. If necessary,
replace faulty parts with new ones.
CHARGING SYSTEM
Trouble Diagnoses (Cont'd)
EL-37
Page 1347 of 1659

Bulb Replacement
The headlamp is a semi-sealed beam type which uses a replace-
able halogen bulb. The bulb can be replaced from the engine
compartment side without removing the headlamp body.
lGrasp only the plastic base when handling the bulb.
Never touch the glass envelope.
1. Disconnect the battery cable.
2. Disconnect the harness connector from the back side of the
bulb.
3. Pull off the rubber cap.
4. Push and raise retaining pin to loosen it.
5. Remove the headlamp bulb carefully. Do not shake or rotate
the bulb when removing it.
6. Install in the reverse order of removal.
CAUTION:
Do not leave headlamp reflector without bulb for a long
period of time. Dust, moisture, smoke, etc. entering head-
lamp body may affect the performance of the headlamp.
Remove headlamp bulb from the headlamp reflector just
before a replacement bulb is installed.
Aiming Adjustment
When performing headlamp aiming adjustment, use an aiming
machine, aiming wall screen or headlamp tester. Aimers should
be in good repair, calibrated and operated in accordance with
respective operation manuals.
If any aimer is not available, aiming adjustment can be done as
follows:
For details, refer to the regulations in your own country.
a. Keep all tires inflated to correct pressures.
b. Place vehicle and tester on one and same flat surface.
c. See that there is no-load in vehicle (coolant, engine oil
filled up to correct level and full fuel 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
adjustment on vehicles equipped with headlamp aiming
control.
GEL187
SEL226P
HEADLAMP Ð Conventional Type Ð
EL-49
Page 1349 of 1659

System Description
OPERATION
Headlamp system on vehicles for North Europe contains a daytime light system. The unit operates to illu-
minate headlamps low beam, parking, tail, license lamps and illuminations automatically in the following
conditions.
lThe engine is running with lighting switch in OFF position.
When the any of following conditions exists, the daytime light operation will be canceled.
lIgnition switch is in any position other than ON
lEngine is stopped
lLighting switch is turned to 1st or 2nd position.
If the daytime light system is canceled, lighting switch operations are the same as for conventional light sys-
tem.
DAYTIME LIGHT IS OPERATING
(With engine running and lighting switch in OFF position)
With engine running, power is supplied
lfrom alternator terminal L
lthrough daytime light control unit terminalV8
lto base of transistor-2 in the daytime light control unit.
The transistor-2 supplies ground path to all relays. Then the relays energize to illuminate lamps.
SEL667V
HEADLAMP Ð Daytime Light System Ð
EL-51
Page 1355 of 1659
Trouble Diagnoses
DAYTIME LIGHT CONTROL UNIT INSPECTION TABLE
Terminal No. ConnectionsINPUT (I)/
OUTPUT (O)Operated conditionVoltage (V)
(Approximate
values)
1Power source for illumi-
nation & tail lampÐÐ12
2Power source for head-
lamp LHÐÐ12
3Power source for head-
lamp RHÐÐ12
4 Headlamp RH OON (daytime light operating*) 12
OFF 0
5 Headlamp LH OON (daytime light operating*) 12
OFF 0
6 Start signal I Ignition switchSTART 12
ON, ACC or OFF 0
7 Power source Ð Ignition switchON or START 12
ACC or OFF 0
8 Alternator ``L'' terminal I EngineRunning 12
Stopped 0
9 Ground Ð Ð Ð
10 Illumination & tail lamp OON (daytime light operating*) 12
OFF 0
11 Lighting switch I1STz2ND position 12
OFF 0
*: Daytime light operating: Lighting switch in ``OFF'' position with engine running.
Bulb Replacement
Refer to ``HEADLAMP'' (EL-49).
Aiming Adjustment
Refer to ``HEADLAMP'' (EL-49).
HEADLAMP Ð Daytime Light System Ð
EL-57
Page 1397 of 1659

Before starting trouble diagnoses below, perform PRELIMINARY CHECK, EL-98.
SYMPTOM CHART 1 (MALFUNCTION IS INDICATED IN DIAGNOSIS MODE)
Symptom Possible causes Repair order
Speedometer and/or odo/trip
meter indicate(s) malfunction
in Diagnosis mode.
lSpeedometer (Unified meter control unit)lReplace speedometer (unified meter control unit).
Multiple meter/gauge indicate
malfunction in Diagnosis
mode.
One of tachometer/fuel gauge/
water temp. gauge indicates
malfunction in Diagnosis
mode.
lMeter/GaugelSpeedometer (Unified meter control unit)1. Check resistance of meter/gauge indicating malfunction. If
the resistance is NG, replace the meter/gauge. Refer to
``METER/GAUGE RESISTANCE CHECK'', EL-103.
2. If the resistance is OK, replace speedometer (unified meter
control unit).
SYMPTOM CHART 2 (NO MALFUNCTION IS INDICATED IN DIAGNOSIS MODE)
Symptom Possible causes Repair order
Speedometer and odo/trip
meter are malfunctioning.1. Sensor
- Speedometer, Odo/Trip meter
2. FPC connector
3. Speedometer (Unified meter control unit)1. Check vehicle speed sensor.
INSPECTION/VEHICLE SPEED SENSOR (Refer to EL-101.)
2. Check FPC connector. Refer to ``FLEXIBLE PRINT CIRCUIT
(FPC)'', EL-97.
3. Replace speedometer (unified meter control unit).
Multiple meter/gauge are mal-
functioning. (except
speedometer, odo/trip meter)1. FPC connector
2. Speedometer (Unified meter control unit)1. Check FPC connector. Refer to ``FLEXIBLE PRINT CIRCUIT
(FPC)'', EL-97.
2. Replace speedometer (unified meter control unit).
One of tachometer/fuel gauge/
water temp. gauge is malfunc-
tioning.1. Sensor/Engine revolution signal
- Tachometer
- Fuel gauge
- Water temp. gauge
2. FPC connector
3. Speedometer (Unified meter control unit)1. Check the sensor for malfunctioning meter/gauge.
INSPECTION/ENGINE REVOLUTION SIGNAL (Refer to
EL-101.)
INSPECTION/FUEL TANK GAUGE (Refer to EL-102.)
INSPECTION/THERMAL TRANSMITTER (Refer to EL-102.)
2. Check FPC connector. Refer to ``FLEXIBLE PRINT CIRCUIT
(FPC)'', EL-97.
3. Replace speedometer (unified meter control unit).
INTERIOR AND SPOT LAMPS
Trouble Diagnoses (Cont'd)
EL-99
Page 1399 of 1659

INSPECTION/VEHICLE SPEED SENSOR
CHECK VEHICLE SPEED SENSOR
OUTPUT.
1. Remove vehicle speed sensor from
transmission.
2. Check voltage between combination
meter terminals
V8andV10while
quickly turning speed sensor pinion.
Voltage: Approx. 0.5V
NG
cOK
Vehicle speed sensor is
OK.
CHECK VEHICLE SPEED SENSOR.
Check resistance between vehicle speed
sensor terminals
V1andV2.
Resistance: Approx. 250W
OK
cNG
Replace vehicle speed
sensor.
Check harness or connector between
speedometer and vehicle speed sensor.
INSPECTION/ENGINE REVOLUTION SIGNAL
(Models with tachometer)
Engine Check itemTerminals
ExplanationÅ@
Injection
DC voltage
V9V26
Higher rpm = Higher voltage
Lower rpm = Lower voltage
Voltage should change with
rpm. Diesel
(TD25)
Carburetor AC voltage
If NG, check the following.
Engine Check item
Injection
lHarness for open or short and connection
Carburetor
lHarness for open or short and connection
lResistor etc.
Diesel
lHarness for open or short and connection
lEngine revolution sensor etc.
SEL167V
SEL118V
SEL168V
.
.
INTERIOR AND SPOT LAMPS
Trouble Diagnoses (Cont'd)
EL-101
Page 1414 of 1659
Electrical Components Inspection
FUEL WARNING LAMP SENSOR CHECK
lIt will take a short time for the bulb to light.
OIL PRESSURE SWITCH CHECK
Oil pressure
kPa (bar, kg/cm2, psi)Continuity
Engine startMore than 10 - 20
(0.10 - 0.20, 0.1 - 0.2,1-3)NO
Engine stopLess than 10 - 20
(0.10 - 0.20, 0.1 - 0.2,1-3)YES
Check the continuity between the terminals of oil pressure switch
and body ground.
DIODE CHECK
lCheck continuity using an ohmmeter.
lDiode is functioning properly if test results are as shown in
the figure at left.
NOTE: Specification may vary depending on the type of
tester. Before performing this inspection, be sure to
refer to the instruction manual for the tester to be
used.
lDiodes for warning lamps are built into the combination meter
printed circuit.
GEL191
MEL425F
SEL901F
GEL192
WARNING LAMPS
EL-116