Page 673 of 4264

ELECTRICAL-BODY AND CHASSIS 8A-15
Normal Blown
FUSE
Fuses are the most common form of circuit protection used in
vehicle wiring.
A fuse is a thin piece of wire or strip of metal encased in a
glass or plastic housing.
It is wired in series with the circuit it protects.
When there is an overload of current in a circuit, such as a
short of a ground, the wire or metal strip is designed to burn
out and interrupt the flow of current.
This prevents a surge of high current from reaching and
damaging other components in the circuit.
Determine the cause of the overloaded before replacing the
fuse.
Never replace a blown fuse with a fuse of a different amperage
specification.
Doing so can result in an electrical fire or other serious circuit
damage.
A blown fuse is easily identified.
Normal Blown
FUSIBLE LINK
The fusible link is primarily used to protect circuits where high
amounts of current flow and where is would not be practical to
use a fuse.
For example, the starter circuit.
When a current overload occurs, the fusible link melts open
and interrupts the flow of current so as to prevent the rest of
the wiring harness from burning.
Determine the cause of the overload before replacing the
fusible link.
The replacement fusible link must have the same amperage
specification as the original fusible link.
Never replace a blown fusible link with fusible link of a different
amperage specification.
Doing so can result in an electrical fire or other serious circuit
damage.
A blown fusible link is easily identified.
Fusible Link Specifications
Type Rating Case Color Maximum Circuit Current (A)
Connector 20A 10
Connector 30A Pink 15
Connector 40A Green 20
Bolted 50A Red 25
Bolted 60A Yellow 30
Bolted 80A Black 40
Page 674 of 4264
8A-16 ELECTRICAL-BODY AND CHASSIS
RELAY
Battery and load location may require that a switch be placed
some distance from either component.
This means a longer wire and a higher voltage drop
1. The
installation of a relay between the battery and the load reduces
the voltage drop
2.
Because the switch controls the relay, amperage through the
switch can be reduced.
Relay Specifications and Configurations
Name/
Color Rated
voltage/ Coil
resistance Internal circuit Name/
color Rated
Voltage/Coil
resistance Internal circuit
1T
(MICRO
ISO)
/Black 12V
Approx. 92
Minimum
operating
voltage: 7V at
20C (77F)
1M (MINI
ISO)
/Black 12V Approx.
94 Minimum
operating
voltage: 7V at
20C (77F)
1M
(MICRO
ISO)
/Black 12V
Approx. 132-3
Minimum
operating
voltage: 7V at
20C (77F)
1M
(power)/
Black 12V Approx.
94 Minimum
operating
voltage: 7V at
20C (77F)
* Relay contact shown in the wiring diagram indicates condition before actuation.
Page 675 of 4264
ELECTRICAL-BODY AND CHASSIS 8A-17
DIODE
Diode Specifications and Configurations
SHAPE
MARK/
COLOR
CONSTRUCTION CHECKING
THERE SHOULD BE CONTINUITY IN
EITHER A OR B WHEN A CIRCUIT
TESTER IS CONNECTED WITH
DIODE TERMINAL
BLACK
21
CONNECTION A+-
PATTERN B-+
TERMINAL NO.
BLACK
321
-+
CONNECTION+-
PATTERN+-
-+B A TERMINAL NO.
BLACK
321
-+
CONNECTION+-
PATTERN+-
-+B A TERMINAL NO.
BLACK
4321
+-
A-+
CONNECTION-+
PATTERN-+
B+-
+-
TERMINAL NO.
Maximum Rating (Temp.=25
C)
Items Rating Remarks
Peak reverse voltage 400V
Transient peak reverse voltage 500V
Average output current 1.5A Temp.=40C
Working ambient temperature -30C80C
Storage temperature -40C100ßC
Page 676 of 4264
8A-18 ELECTRICAL-BODY AND CHASSIS
CONNECTOR
The connector pin shape determines whether the connector is
male or female.
The connector housing configuration does not determine
whether a connector is male or female.
The symbol illustrated in the figure is used as connector in the
circuit this section.
Connector is identified with a number.
The applicable terminal number is shown for each connector.
Connector terminal numbers are clearly shown.
Male side connector terminal numbers are in sequence from
upper right to lower left.
Female side connector terminal numbers are in sequence from
upper left to lower right.
NOTE:
For those connectors on which specific terminal numbers
on symbols are shown, the terminal numbers or symbols
are used in the circuit diagram, irrespective of the above
rule.
Page 677 of 4264
ELECTRICAL-BODY AND CHASSIS 8A-19
Battery-1
BATTERY
Inspection
1. Check the battery terminals 1 for corrosion.
2. Check the battery cables
2 for looseness.
3. Check the battery case
3 for cracks and other damage.
4. Check the battery electrolyte level.
Battery-2
Battery Replacement
1. Disconnect the battery ground cable 1.
2. Disconnect the battery positive cable
2.
3. Remove the battery clamp
3.
4. Remove the battery
Caution:
It is important that the battery ground cable be removed
first.
Removing the battery positive cable first can result in a
short circuit.
Jump Starting the Engine with a Booster Battery
The following description assumes that you are using a booster
battery mounted on a second vehicle.
The listed steps (with some minor modifications) are also
applicable if you are using a naked booster battery or special
battery charging equipment.
Page 678 of 4264

8A-20 ELECTRICAL-BODY AND CHASSIS
Caution:
Never push or tow the vehicle in an attempt to start it.
Extensive damage to the emission system and other
vehicle parts will result.
(Only catalytic converter vehicle)
Treat both the discharged battery and the booster battery
with great care when using jumper cables.
Carefully follow the procedure outlined below.
Always be aware of the dangers of sparking.
Failure to follow the following procedure can result in:
a. Serious personal injury, specially to your eyes.
b. Extensive property damage from a battery explosion,
battery acid discharge, or electrical file.
c. Extensive damage to the electronic components o
f
both vehicles.
Do not use a 24 volt booster battery.
Serious damage to the vehicle's electrical system and
electronic components will result.
Jump Starting Procedure
1. Set the parking brake on both vehicles.
2. If one or both vehicles is equipped with a manual
transmission, place the gear shift in the "NEUTRAL"
position.
3. Turn off the ignition on both vehicles.
4. Turn off all vehicle lights and accessories.
5 Be sure that the two vehicles are not touching.
Attach the end of one jumper cable to the booster battery
positive terminal.
6
Attach the other end of the same cable to the discharged
battery positive terminal.
7. Once again, check that the booster battery has a 12 vol
t
rating.
8.
Attach one end of the remaining booster cable to the
booster battery negative terminal.
9.
Attach the other end of the booster cable to a solid ground
(such as the air conditioner compressor mounting bracke
t
or the alternator mounting bracket) in the engine room o
f
the vehicle with the discharged battery.
Be sure that the ground connection is at least 500 mm (20
in) from the discharged battery.
Page 679 of 4264
ELECTRICAL-BODY AND CHASSIS 8A-21
Caution:
Do not attach the booster cable to the discharged battery
negative terminal.
11. Start the engine of the vehicle with the booster battery.
Check that all unnecessary electrical accessories are off.
12. Start the engine of the vehicle with the discharged battery.
13. Remove the jumper cables in the reverse order to which
they were attached.
Caution:
Be absolutely sure to remove the negative jumper cable
from the vehicle with the discharged battery first.
Page 680 of 4264
8A-22 ELECTRICAL-BODY AND CHASSIS
READING THE CIRCUIT DIAGRAM
In this manual, each system has its own parts location illustration and circuit diagram.
And connector configurations used in the circuit diagram are shown at the end of this manual.
PARTS LOCATION: The parts location shows the location of the connectors
1 and the harnesses 2 used in the
each system.
CIRCUIT DIAGRAM: The circuit diagram shows the power supply
3, the load or loads 4 and the grounding
point(s)
5.
CONNECTOR LIST: The connector configuration shows each connector's number
6, configuration 7 and the pin
numbers
8, parts name 9 , connector color 10.
PARTS LOCATION
RTW38DMF000201