Web 00ELB0012

(EURO 3)
Pub.No.00ELB0012, FEBRUARY 2013
Shop Manual
electrical
(EURO 3)
Shop Manual GROUP INDEX
electrical GENERAL ................................................

54-00A
SPECIFICATIONS .................................... 54-00B
STRUCTURE AND OPERATION.............
54-00C
FOREWORD
TROUBLESHOOTING ............................. 54-00D
POWER, CHARGE AND GROUND
CIRCUIT ................................................... 54-01
This Shop Manual is published for the information and
guidance of personnel responsible for maintenance of STARTING CIRCUIT ................................ 54-02
Mitsubishi Fuso ROSA series buses, and includes proce-
dures for adjustment and maintenance services. LIGHTING CIRCUIT ................................. 54-03
We earnestly look forward to seeing that this manual is
made full use of in order to perform correct services with METER CIRCUIT...................................... 54-04
no wastage. INDICATOR AND WARNING
LAMP CIRCUIT ........................................ 54-05
For more details, please consult your nearest authorized
Mitsubishi Fuso dealer or distributors. BODY SIDE ELECTRICAL CIRCUIT....... 54-06
Kindly note that the specifications and maintenance ser- CHASSIS SIDE ELECTRICAL
vice figures are subject to change without prior notice in CIRCUIT ................................................... 54-07
line with improvement which will be effected from time to
time in the future. OTHER CIRCUIT...................................... 54-09
ELECTRICAL EQUIPMENT
INSTALLATION POSITIONS ................... 54-10
FEBRUARY 2013 INSPECTION OF ELECTRICAL
EQUIPMENT ............................................ 54-11
Applicable models
BE
STARTER AND ALTERNATOR ............... 54-11
54-12
ON-VEHICLE INSPECTION AND
ADJUSTMENT ......................................... 54-13
CONNECTOR CONFIGURATION
CHART ..................................................... 54-14
©2013 Mitsubishi Fuso Truck & Bus Corporation Printed in Japan

This Shop Manual contains the information classified into the following groups.
If any system or equipment has two or more variations with significantly different construction, the variations are
handled as different groups. These groups are identified by different alphabets preceded by the same number.
1. ENGINE volume (Pub.No.00ELB0010)
Group No. Group subject

00 GENERAL
11 ENGINE
12 LUBRICATION
13 FUEL AND ENGINE CONTROL
13E ELECTRONICALLY CONTROLLED FUEL SYSTEM
14 COOLING
15 INTAKE AND EXHAUST
17 EMISSION CONTROL
2. CHASSIS volume (Pub.No.00ELB0011)

00 GENERAL
21 CLUTCH
22 MANUAL TRANSMISSION
25 PROPELLER SHAFT
26 FRONT AXLE
27 REAR AXLE
31 WHEEL, TIRE
33 FRONT SUSPENSION
34 REAR SUSPENSION
35 BRAKE
36 PARKING BRAKE
37 STEERING
41 FRAME
55 HEATER, AIR-CONDITIONER, VENTILATION
63 BODY
3. ELECTRICAL volume (Pub.No.00ELB0012)

54 ELECTRICAL
CONTENTS
54-00A GENERAL 54-00D TROUBLESHOOTING
VEHICLE MODEL CODING TROUBLESHOOTING .......................... 54-00D-2
SYSTEM................................................ 54-00A-2
EQUIPMENT TYPE CODES LIST ........ 54-00A-3 54-01 POWER, CHARGE AND
POWER TRAIN TABLE ........................ 54-00A-4 GROUND CIRCUIT
HOW TO READ THIS MANUAL........... 54-00A-6
FUSE BOX ............................................... 54-01-2
CHASSIS NUMBER, ENGINE
110 POWER SUPPLY CIRCUIT............ 54-01-4
NUMBER AND NAME PLATE............ 54-00A-14
115 RESERVE POWER CIRCUIT....... 54-01-12
PRECAUTIONS FOR
MAINTENANCE OPERATION 125 BATTERY CHARGING
1. General Precautions ........................ 54-00A-16
CIRCUIT........................................ 54-01-13
2. Handling of Battery ......................... 54-00A-19 130 GROUND ...................................... 54-01-14
3. Handling of Sensors, Relays and
Electronic Control Units................... 54-00A-19
4. Handling Precautions for Electric 54-02 ENGINE STARTING,
Circuits ......................................... 54-00A-20 STOPPING AND
5. Service Precautions for Alternators ... 54-00A-23
6. Intermittent Faults........................... 54-00A-24 PREHEATING CIRCUIT
7. Precautions for Arc Welding ............. 54-00A-25 210 ENGINE STARTING CIRCUIT ....... 54-02-2
8. Precautions When Repainting........... 54-00A-25
220 ENGINE PREHEATING
JACKING UP THE VEHICLE.............. 54-00A-26 CIRCUIT.......................................... 54-02-3
DIAGNOSIS CODES
1. Diagnosis Codes ............................ 54-00A-28
2. Access and Clearing of Stored
54-03 LIGHTING CIRCUIT
Diagnosis Code .............................. 54-00A-28 310 HEADLAMP CIRCUIT .................... 54-03-2
TABLE OF STANDARD TIGHTENING 315 FOG LAMP CIRCUIT...................... 54-03-3
TORQUES 320 TAIL LAMP, CLEARANCE LAMP
1. Tightening Torques ......................... 54-00A-34 AND LICENSE PLATE LAMP
2. Table of Standard Tightening CIRCUIT.......................................... 54-03-4
Torque .......................................... 54-00A-34
325 STOP LAMP CIRCUIT.................... 54-03-5
330 TURN SIGNAL AND HAZARD
54-00B SPECIFICATIONS LAMP CIRCUIT .............................. 54-03-6
SPECIFICATIONS ................................ 54-00B-2 340 BACKUP LAMP CIRCUIT .............. 54-03-7
345 ROOM LAMP CIRCUIT .................. 54-03-8
54-00C STRUCTURE AND 348 ILLUMINATION LAMP CIRCUIT.... 54-03-9
OPERATION 378 STEP LAMP CIRCUIT .................. 54-03-10
1. Starter ............................................. 54-00C-2
2. Alternator ........................................ 54-00C-3
3. Wiper Control ................................... 54-00C-6
4. Starter Continuous Energizing Preventing
Function and Preheating Function ...... 54-00C-8
54-04 METER CIRCUIT 54-07 CHASSIS SIDE
401 METER CLUSTER INTERNAL ELECTRICAL CIRCUIT
CIRCUIT.......................................... 54-04-2 710 EXHAUST BRAKE CIRCUIT.......... 54-07-2
410 TACHOMETER CIRCUIT ............... 54-04-3
412 SPEEDOMETER CIRCUIT ............. 54-04-4 54-09 OTHER CIRCUIT
420 FUEL GAUGE CIRCUIT ................. 54-04-5
907 DIAGNOSIS SWITCH AND MEMORY
425 WATER TEMPERATURE GAUGE CLEAR SWITCH CIRCUIT ............. 54-09-2
CIRCUIT.......................................... 54-04-6
54-10 ELECTRICAL EQUIP-

54-05 INDICATOR AND
MENT INSTALLATION
WARNING LAMP
POSITIONS
CIRCUIT
Body side
510 PARKING BRAKE INDICATOR
CIRCUIT.......................................... 54-05-2 A SWITCH AND SENSOR..................... 54-10-2
515 BRAKE WARNING CIRCUIT ......... 54-05-3 B RELAY AND ELECTRONIC
CONTROL UNIT................................. 54-10-4
536 ENGINE OIL PRESSURE
WARNING CIRCUIT ....................... 54-05-4 C FUSE, METER, SENSOR, MOTOR
AND BUZZER .................................... 54-10-6
540 BRAKE PAD WARNING
CIRCUIT.......................................... 54-05-5 D HEATER AND
AIR-CONDITIONER ........................... 54-10-7
566 FUEL FILTER WARNING
CIRCUIT.......................................... 54-05-6 F ROOF ................................................. 54-10-7
576 DOOR INDICATOR CIRCUIT ......... 54-05-7 J JOINTS OF MAIN HARNESS
CONNECTORS .................................. 54-10-8
P OTHER ............................................. 54-10-10
54-06 BODY SIDE
Engine and transmission
ELECTRICAL CIRCUIT
R ENGINE ............................................ 54-10-11
610 CIGARETTE LIGHTER CIRCUIT ... 54-06-2
S TRANSMISSION .............................. 54-10-12
612 AUDIO CIRCUIT ............................. 54-06-4
Chassis side
614 WIPER AND WASHER CIRCUIT ... 54-06-6
T SWITCH AND SENSOR................... 54-10-13
616 HORN CIRCUIT .............................. 54-06-7
U BATTERY ......................................... 54-10-13
618 HEATER CIRCUIT .......................... 54-06-8
V MAGNETIC VALVE.......................... 54-10-13
620 AIR-CONDITIONER CIRCUIT ...... 54-06-10
W BUZZER, LAMP ............................... 54-10-14
625 AUTOMATIC DOOR CIRCUIT ..... 54-06-13
X OTHER ............................................. 54-10-14
675 CLOCK CIRCUIT .......................... 54-06-16
676 BOTTLE COOLER CIRCUIT ........ 54-06-17
682 REAR WIPER AND WASHER
CIRCUIT........................................ 54-06-18
54-11 INSPECTION OF ELEC-
TRICAL EQUIPMENT
#001 to #179 SWITCH ............................. 54-11-2
#180 to #249 RELAY ............................... 54-11-7
#250 to #349 SENSOR ............................ 54-11-9
#350 to #409 CONTROL UNIT .............. 54-11-10
#410 to #509 MOTOR............................ 54-11-11
#510 to #559 ACTUATOR ..................... 54-11-12
#560 to #609 MAGNETIC VALVE ......... 54-11-13
#610 to #649 BUZZER, HORN .............. 54-11-14
#720 to #749 INTERIOR ........................ 54-11-16
#750 to #859 OTHERS .......................... 54-11-16
#860 BATTERY...................................... 54-11-18
#890 METER CLUSTER ........................ 54-11-21
54-12 STARTER AND

ALTERNATOR
#930 STARTER........................................ 54-12-2
#940 ALTERNATOR.............................. 54-12-16
54-13 ON-VEHICLE
INSPECTION AND
ADJUSTMENT
#950 INSPECTION OF ALTERNATOR... 54-13-2
#951 INSPECTION OF REGULATOR..... 54-13-3
#955 INSPECTION OF PREHEATING
SYSTEM.......................................... 54-13-4
#956 INSPECTION OF STARTER
CONTINUOUS ENERGIZING
PREVENTING FUNCTION ............. 54-13-9
#960 HEADLAMP AIMING .................... 54-13-12
#961 FOG LAMP AIMING...................... 54-13-14
54-14 CONNECTOR CONFIG-

URATION CHART
CONNECTOR CONFIGURATION
CHART ..................................................... 54-14-2
54-00A GENERAL
13A
13E
54-00A-1
VEHICLE MODEL CODING SYSTEM
1 2 3 4 5 6 7 8 9 10 11
B E 6 3 D J L M S H
1 Basic vehicle type B Front engine bus with frame

2 Drive system E 4 × 2 2WD Diesel
3 Development sequential number 6 Rosa
4 Suspension (front/rear) 3 Rigid leaf suspension/Rigid leaf suspension
5 Engine D 4M50T
E 3490
6 Wheelbase (mm) G 3995
J 4550
7 Steering position L Left-hand drive vehicle
M With air conditioner
8, 9,
Body arrangement S Standard
10
H High roof
11 Export specification
54-00A-2
EQUIPMENT TYPE CODES LIST 54-00A
Component Name plate marking Code description
Engine
4M50T7 4 M 5 0 T 7
Power version number

Turbocharged
Order of development within same series
Order of development among different series
Diesel engine
No. of cylinders (4)
Clutch
C5W33 C 5 W 33
Disc OD
Facing material (W: Woven)
Load carrying capacity of truck class (tonnage)
on which the clutch is primarily used
Initial letter of the clutch
Transmission
M036S6 M 036 S 6
Forward speeds
Type of mesh (S: Synchromesh)
Initial letter of the transmission
Propeller shaft
P3 P 3

Initial letter of the propeller shaft
Front axle
F020B F 020 B
Vehicle type (B: Bus)

Initial letter of the front axle
Rear axle
R033B R 03 3 B
Vehicle type (B: Bus)

Initial letter of the rear axle
Reduction and differential
D033H D 03 3 H
Tooth profile (H: Hypoid gear)

Initial letter of the reduction & differential
54-00A-3
POWER TRAIN TABLE
Propeller Reduction &
Vehicle model Engine Clutch Transmission Front axle Rear axle
shaft Differential
BE63DJLMSHNF 4M50-T7 C5W33 M036S6 P3 F020B R033B D033H
BE63DELSHGP 4M50-T7 C5W33 M036S6 P3 F020B R033B D033H
BE63DGLSHGP 4M50-T7 C5W33 M036S6 P3 F020B R033B D033H
BE63DJLMSHGP 4M50-T7 C5W33 M036S6 P3 F020B R033B D033H
54-00A-4
54-00A
M E M O
54-00A-5
HOW TO READ THIS MANUAL
This manual consists of the following parts:
• Specifications
• Structure and Operation
• Troubleshooting
• Circuits
• Electrical Equipment Installation Positions
• Inspection of Electrical Equipment
• On-vehicle Inspection and Adjustment
• Service procedures
• Connector configuration chart
On-vehicle Inspection and Adjustment

• Procedures for inspection and adjustment of individual parts and assemblies as mounted on the vehicle are de-
scribed including specific items to check and adjust. Specified or otherwise, inspection should be performed for
looseness, play, backlash, crack, damage, etc.
Service procedures
• Procedures for servicing components and parts off the vehicle are described centering on key points in their re-
moval, installation, disassembly, reassembly, inspection, etc.
Inspection
• Check items subject to “acceptable/unacceptable” judgement on the basis of service standards are all given.
• Some routine visual checks and cleaning of some reused parts are not described but must always be included in
actual service work.
Caution
• This service manual contains important cautionary instructions and supplementary information under the following
four headings which identify the nature of the instructions and information:
DANGER Precautions that should be taken in handling potentially dangerous substances

such as battery fluid and coolant additives.
WARNING Precautionary instructions, which, if not observed, could result in serious injury or
death.
CAUTION Precautionary instructions, which, if not observed, could result in damage to or de-
struction of equipment or parts.
Suggestions or supplementary information for more efficient use of equipment or

NOTE better understanding.
Terms and Units

• Front and rear
The forward running direction of the vehicle is referred to as the front and the reverse running direction is referred
to as the rear.
• Left and right

Left hand side and right hand side, when facing the forward running direction of the vehicle, are respectively left
and right.
Standard value
• Standard value dimensions in designs indicating: the design dimensions of individual parts, the standard clear-
ance between two parts when assembled, and the standard value for an assembly part, as the case may be.
Limit
• When the value of a part exceeds this, it is no longer serviceable in respect of performance and strength and must
be replaced or repaired.
54-00A-6
54-00A
Tightening torque
• Values are directly specified for out-of-standard tightening torques for bolts and nuts.
• Where there is no specified figure for tightening torque, follow the table covering standard tightening torques.
(Values for standard tightening torques are based on thread size and material.)
• When the item is to be tightened in a wet state, “wet” is indicated. Where there is no indication, read it as dry.
Units
• Tightening torques and other parameters are given in SI* units with metric units added in brackets { }.
*SI: Le Système International d’Unités
Example: 390 N·m {40 kgf·m}
Metric unit
SI unit
Unit SI unit {metric unit} Conversion factor

Force N {kgf} 9.80665 N {1 kgf}
Moment of force N·m {kgf·m} 9.80665 N·m {1 kgf·m}
Positive pressure kPa {kgf/cm2} 98.0665 kPa {1 kgf/cm2}
Pressure kPa {mmHg} 0.133322 kPa {1 mmHg}
Vacuum pressure
Pa {mmH2O} 9.80665 Pa {1 mmH2O}
Volume dm3 {L} 1 dm3 {1 L}
Heat quantity J {kcal} 4186.05 J {1 kcal}
Heat flow W {kcal/h} 1.16279 W {1 kcal/h}
Power kW {PS} 0.7355 kW {1 PS}
54-00A-7
Illustrated Parts Breakdown and Service Procedures
Symbol Denotation Application Remarks
Specified values shown in table
Parts not tightened to standard torques
See Table of Standard Tightening Torques for
Tightening torque (standard torques specified where neces-
parts for which no tightening torques are speci-
sary for servicing)
fied.
Locating pin Parts to be positioned for installation
Non-reusable parts Parts not to be reused
Lubricant and/or Parts to be coated with lubricant or sealant Necessary lubricant and/or sealant, quantity re-
sealant for assembly or installation quired, etc. are specified in table.
Parts for which special tools are required for Tool name/shape and part number are shown in
Special tool
service operation table.
Parts associated with those removed/disas-
*a Associated part
sembled for servicing
54-00A-8
54-00A
54-00A-9
How to Read Circuits (Electrical)
54-00A-10
54-00A
1.1 Index number: 100 to 999
• Index numbers are used as reference numbers for electrical circuits. Each electrical circuit has been assigned its
own index number.
1.2 Key number: A01 to Z99
• Key numbers indicate electrical equipment installation locations. The installation location of an electrical equip-
ment can be easily found using its key number shown in a circuit diagram.
All of the electrical equipment installation locations are listed in Gr54-10.
1.3 Part name
1.4 Connector type (type indication)
• A list of the connectors used is included in Gr54-14.
1.5 Connector terminal number
1.6 Major harness division

• Major harness divisions are shown.
1.7 Wiring variations between different specifications
• Variations in wiring/circuit between different vehicle specifications are clearly indicated as shown.
1.8 Circuit number, wire diameter, wire color
1.9 Code number: #001 to #999

• Code numbers are reference numbers to find individual electrical equipment inspection procedures. The inspec-
tion procedure for an electrical equipment can be found using its code number shown in a circuit diagram.
1.10Grounding point: [1] to [99]
• Locations where wires are grounded to the vehicle. All of the grounding points are listed in 130 .
1.11 Harness connection
• The arrow in the wiring diagram indicates where harnesses are connected, and NOT the flow of electricity.
54-00A-11
Wire color
Wire color Base color + tracer
Black/ Black/ Black/ Black/ Black/
BW BY BR Black/red BG BL BO
white yellow green blue orange
B Black
Black/ Black/ Black/
BP BV B Br
pink violet brown
Brown/ Brown/ Brown/ Brown/ Brown/ Brown/
BrW BrB BrY BrR BrG BrL
white black yellow red green blue
Br Brown
Brown/ Brown/
BrGr BrV
gray Violet
Green/ Green/ Green/ Green/ Green/ Green/
GW GR GY GB GL GO
white red yellow black blue orange
G Green
Green/ Green/ Green/
GGr GBr GV
gray brown violet
GrL, Gray/ GrR, Gray/ GrB, Gray/ GrG, Gray/ GrW, Gray/ Gray/
GrY
Gr, GyL blue GyR red GyB black GyG green GyW white yellow
Gray
Gy Gray/ Gray/
GrG GrBr
green brown
Blue/ Blue/ Blue/ Blue/ Blue/
LW LR Blue/red LY LB LO LG
white yellow black orange green
L Blue
Blue/
LGr Blue/gray LBr
brown
Light Light Light Light
Light
Lg LgR green/ LgY green/ LgB green/ LgW green/
green
red yellow black white
Orange/ Orange/ Orange/
O Orange OL OB OG
blue black green
Pink/ Pink/ Pink/ Pink/ Pink/
P Pink PB PG PL PW PGr Pink/gray PV
black green blue white violet
Pu Purple
Red/ Red/ Red/ Red/ Red/
RW RB RY RG RL Red/blue RO
white black yellow green orange
R Red
Red/ Red/
RBr Rgr
brown Gray
Sb Sky blue
Violet/yel- Violet/ Violet/ Violet/ Violet/
V Violet VY VW VR Violet/red VG VGr VB
low white green gray black
White/ White/ White/ White/ White/ White/
WR WB WL WG WO WV
red black blue green orange violet
W White
White/ White/
WBr WY
brown yellow
Yellow/ Yellow/ Yellow/ Yellow/ Yellow/ Yellow/
YR YB YG YL YW YO
red black green blue white orange
Y Yellow
Yellow/ Yellow/ Yellow/ Yellow/
YP YV YGr YBr
pink violet gray brown
54-00A-12
54-00A
M E M O
54-00A-13
CHASSIS NUMBER, ENGINE NUMBER AND NAME PLATE
• Serial chassis (vehicle identification) and engine numbers are assigned to the vehicles and engines in manufac-
turing sequence. Every vehicle and engine has its own number. These numbers are required for registration and
related inspection of the vehicle.
• Chassis number <Type A>
• Vehicle identification number (VIN) <Type B>
J L B B E 6 3 D J C R
(1) (2) (3) (4) (5) (6) (7)
(1) Geographic area

J: Japan
(2) Manufacturer
L: Mitsubishi Fuso Truck & Bus
(3) Country
B: Peru
(4) Model Code
(5) Model year
C: 12M/Y
D: 13M/Y
E: 14M/Y
F: 15M/Y
(6) Plant
K: Kawasaki
R: Toyama
(7) Plant Sequential Number
54-00A-14
54-00A
• Name plate contains the following information.
• MODEL
• CHASSIS No. <Type A>
• Engine model
• Vehicle identification number (VIN) <Type B>
• An engine name plate indicates the following item.

• Engine model
54-00A-15
PRECAUTIONS FOR MAINTENANCE OPERATION
1. General Precautions
• Before performing service operations, inquire into the customer’s complaints and ascertain the condition by
checking the total distance traveled, the conditions under which the vehicle is operated, and other relevant factors
on the vehicle. And note the necessary information. This information will help you to service the vehicle efficiently.
• Check the location of the fault, and identify its cause. Based on
your findings, determine whether parts must be removed or dis-
assembled. Then, follow the service procedure given in this
manual.
• Perform service operations on a level surface. Before starting,

take the following preparatory steps:
• To prevent soiling and damage, place covers over the seats,
trim, floor and over the paintwork of the body.
• Prepare all the general and special tools necessary for the job.
WARNING
• Special tools must be used wherever specified in this man-
ual. Do not attempt to use other tools since they could
cause injuries and/or vehicle damage.
• Take extreme care when removing/installing heavy items such

as engine, transmission and axle. When lifting heavy items using
a cable etc., observe the following precautions.
• Identify the weight of the item being lifted. Use the cable that
is strong enough to support the weight.
• If lifting eyes are not provided on the item being lifted, tie a ca-
ble around the item taking into account the item’s center of
gravity.
54-00A-16
54-00A
• Do not allow anyone to pass or stay under a lifted item which
may possibly fall.
• Never work in shoes that have oily soles.

When working with a partner or in a group, use pre-arranged sig-
nals and pay constant attention to safety. Be careful not to touch
switches and levers unintentionally.
• Inspect for oil leakage etc. before washing the vehicle. If the or-
der is reversed, any oil leakage or fault that may exist could go
unnoticed during inspection.
• Prepare replacement parts ready for installation.
• Oil seals, packings, O-rings and other rubber parts, gaskets, and
split pins must be replaced with new ones after removal. Use
only genuine MITSUBISHI replacement parts.
54-00A-17
• When disassembling parts, visually check them for wear, cracks,
damage, deformation, deterioration, rust, corrosion, defective ro-
tation, fatigue, clogging and any other possible defect.
• To facilitate correct reassembly of parts, make alignment marks

on them before disassembly and arrange disassembled parts
neatly. Make punch marks and other alignment marks where
they will not detract from parts’ functionality and appearance.
• After removing parts from the vehicle, cover the area to keep it
free of dust.
CAUTION
• Be careful not to mix up identical parts, similar parts and
parts that have left/right alignments.
• Keep new replacement parts and original (removed) parts
separately.
• Apply the specified oil or grease to U-seals, oil seals, dust seals
and bearings before reassembly.
• Always use the specified oils and greases when performing in-
spection or replacement. Immediately wipe away any excess oil
or grease with a rag.
• Wear safety goggles when using a grinder or welder. Wear

gloves when necessary, and watch out for sharp edges and oth-
er items that might wound your hands.
54-00A-18
54-00A
2. Handling of Battery
2.1 Handling of battery cable
• Before working on the electrical system, disconnect the (–) bat-
tery cable to prevent short circuits.
CAUTION
• Make sure that the starter switch and lighting switches are
OFF before disconnecting or connecting battery cable.
(Semiconductor components may otherwise be damaged.)
• Disconnect the (–) battery cable, then insulate the (–) termi-
nal of the battery and (–) battery cable with insulating tape
or the like.
• If the (–) battery cable is not disconnected, battery voltage
will remain constantly applied to the B terminal, inviting
danger of electric shock.
3. Handling of Sensors, Relays and Electronic Control Units

• Carefully handle sensors relays, and other items that are sensi-
tive to shock and heat. Do not remove or paint the cover of any
control unit.
• When separating connectors, grasp the connectors themselves

rather than the harnesses.
• To separate locking connectors, first push them in the direction
of the arrows. To reconnect locking connectors, push them to-
gether until they click.
• Before washing the vehicle, cover electrical parts to keep them

dry. (Use plastic sheets or equivalent.) Keep water away from
harness connectors and sensors and immediately wipe off any
water that gets on them.
54-00A-19
• When applying a voltage to a part for inspection purposes,
check that the (+) and (–) cables are connected properly then
gradually increase the voltage from zero. Do not exceed the
specified voltage.
Remember that control units and sensors do not necessarily op-
erate on the battery voltage.
4. Handling Precautions for Electric Circuits

CAUTION
• Do not pierce wire insulation with test probes or alligator
clips when performing electrical inspections. Doing so can,
particularly with the chassis harness, hasten corrosion.
4.1 Inspection of harnesses

(1) Inspections with connectors fitted together
(1.1) Waterproof connectors
• Connect an inspection harness and connector A between the
connectors B of the circuit to be inspected. Perform the inspec-
tion by applying a test probe C to the connectors of the inspec-
tion harness. Do not insert the test probe C into the wire-entry
sides of the waterproof connectors since this would damage
their waterproof seals and lead to rust.
(1.2) Non-waterproof connectors

• Perform the inspection by inserting a test probe C into the wire-
entry sides of the connectors. An extra-narrow probe is required
for control unit connectors, which are smaller than other types of
connector. Do not force a regular-size probe into control unit
connectors since this would cause damage.
(2) Inspections with connectors separated

(2.1) Inspections on female terminals
• Perform the inspection by carefully inserting a test probe into the
terminals. Do not force the test probe into the terminals since
this could deform them and cause poor connections.
54-00A-20
54-00A
(2.2) Inspections on male terminals
• Perform the inspection by applying test probes directly to the
pins.
.
CAUTION
• Be careful not to short-circuit pins together with the test
probes. With control unit connectors, short-circuiting of
pins can cause damage to the control unit’s internal circuit-
ry.
• When using a multimeter to check continuity, do not allow the

test probes to touch the wrong terminals.
4.2 Inspection of connectors

(1) Visual inspection
• Check that the connectors are fitted together securely.
• Check whether wires have been separated from their terminals

due to pulling of the harness.
• Check that male and female terminals fit together tightly.
54-00A-21
• Check for defective connections caused by loose terminals, by
rust on terminals, or by contamination of terminals by foreign
substances.
(2) Checking for loose terminals

• If connector terminal retainers become damaged, male and fe-
male terminals may not mate with each other when the connec-
tor bodies are fitted together. To check for such terminals, gently
pull each wire and see whether any terminals slip out of their
connector housings.
4.3 Inspections when a fuse blows

• Remove the fuse, then measure the resistance between ground
and the fuse’s load side.
Next, close the switch of each circuit connected to the fuse. If
the resistance measurement between any switch and ground is
zero, there is a short circuit between the switch and the load. If
the resistance measurement is not zero, the circuit is not cur-
rently short-circuited; the fuse probably blew due to a momen-
tary short circuit.
• The main causes of short circuits are as follows:

• Harnesses trapped between chassis parts
• Harness insulation damage due to friction or heat
• Moisture in connectors or circuitry
• Human error (accidental short-circuiting of components)
4.4 Inspection of chassis ground

• A special ground bolt is used to tighten a ground terminal. When
servicing the ground point, be sure to follow the procedures de-
scribed below:
• When reinstalling the ground bolt
Tighten the ground bolt to the specified torque.
• When relocating the ground point
A special ground bolt must be used. Spot-weld a nut to a
frame and tighten the ground bolt to the specified torque. Be
sure to apply touch-up paint to the welded point.
54-00A-22
54-00A
5. Service Precautions for Alternators
• When servicing alternators, observe the following precautions:
• Never reverse the polarity of battery connections.
If the polarity of the battery connections were to be reversed,
a large current would flow from the battery to the alternator,
damaging the diodes and regulator.
• Never disconnect the battery cables with the engine running.

Disconnection of the battery cables during engine operation
would cause a surge voltage, leading to deterioration of the di-
odes and regulator.
• Never perform inspections using a high-voltage multimeter.

The use of a high-voltage multimeter could damage the diodes
and regulator.
• Keep alternators dry.

Water on alternators can cause internal short circuits and dam-
age.
• Never operate an alternator with the B and L terminals short-cir-

cuited. Operation with the B and L terminals connected together
would damage the diode trio.
54-00A-23
• Disconnect the battery cables before quick-charging the battery
with a quick charger.
Unless the battery cables are disconnected, quick-charging can
damage the diodes and regulator.
6. Intermittent Faults
• An intermittent fault typically occurs only under certain operating
conditions. Once these conditions have been identified, the
cause of the intermittent fault can be ascertained easily. First,
ask the customer about the vehicle operating conditions and
weather conditions under which the fault occurs. Also ask about
the frequency with which the fault occurs and about the fault
symptoms. Then, reproduce the fault based on this information.
In accordance with the conditions under which the fault occurs,
determine whether the fault is caused by vibration, heat or other
factors. if vibration is a possible factor, see if the fault can be re-
produced by performing the following checks on individual con-
nectors and other parts:
• Gently move connectors up and down and to left and right.
• Gently move wiring harnesses up and down and to left and
right.
• Gently wiggle sensors and other devices by hand.
• Gently wiggle wiring harnesses on suspension systems and
other moving parts.
• Connectors and other parts to be checked are those included or

given as likely fault locations in inspection procedures corre-
sponding to diagnosis codes and/or fault symptoms.
54-00A-24
54-00A
7. Precautions for Arc Welding
• When arc welding is performed, current from the welder flows to ground via the vehicle’s metal parts. Unless ap-
propriate steps are taken, this current can damage control units, other electrical devices and wiring harnesses.
And any electrical device near the point on the vehicle to which the (–) cable of the welder is connected, might be
largely damaged.
• Current flows backward as shown below.

7.1 From battery (–) cable
To prevent damage to the battery and to electrical devices that are
connected directly to the battery, it is essential to disconnect the
battery’s (–) cable.
7.2 Procedure
• Turn the starter switch to the LOCK position.
• Disconnect the battery’s (–) cable.
• Cover all parts of the vehicle that may be damaged by welding
sparks.
• Connect the welder’s (–) cable to the vehicle as close as possi-
ble to the area being welded. Do not connect the welder’s (–) ca-
ble to the cab if the frame is being welded, and vice versa.
• Set the welding current in accordance with the part being weld-
ed.
8. Precautions When Repainting
• When repainting, cover the following electronic control components with a masking material. If paint get on these
components, functional reliability could be deteriorated as a result of the poor connection of connectors, internal
circuit failure caused by heat build-up due to poor heat dissipation, erroneous sensor values due to clogged venti-
lation holes.
• Engine electronic control unit and other electronic control units
• Sensors
54-00A-25
JACKING UP THE VEHICLE
<Front of Vehicle>
Jacking up procedure
1 Place chocks against the rear wheels.
2 Jack up the front of the vehicle with a bottle jack or garage jack.
3 Support the front of the vehicle frame on jack stands.
WARNING
• Chock the wheels firmly to prevent the vehicle from rolling away.
• Do not attempt to remove the chocks until the operation is completed.
• It is extremely dangerous to support the vehicle with only bottle jack or garage jack. Be sure to addition-
ally support the front of the vehicle frame on jack stands.
• Never attempt to remove the bottle jack, garage jack, or jack stands until the operation is completed.
54-00A-26
54-00A
<Rear of Vehicle>
Jacking up procedure
1 Place chocks against the rear wheels.
2 Jack up the rear of the vehicle using a bottle jack or garage jack as illustrated above.
3 Support the vehicle frame on jack stands on both sides.
WARNING
• Chock the wheels firmly to prevent the vehicle from rolling away.
• Do not attempt to remove the chocks until the operation is completed.
• It is extremely dangerous to support the vehicle with only bottle jack or garage jack. Be sure to addition-
ally support the vehicle frame on jack stands on both sides.
• Never attempt to remove the bottle jack, garage jack, or jack stands until the operation is completed.
54-00A-27
DIAGNOSIS CODES
1. Diagnosis Codes
• The diagnosis code indicates the faulty location(s) of the vehicle.
• Reading the diagnosis code(s) and performing the corresponding remedy (troubleshooting) repairs the faulty lo-
cation(s).
• Diagnosis codes can be displayed in the following two methods. Select either of them according to the system to
be diagnosed.
• Using a Multi-Use Tester
• Flashing of warning on meter cluster
• The table below indicates the systems for which diagnosis codes can be displayed and the methods usable for in-
dividual systems.
1.1 Systems and diagnosis code displaying methods

Diagnosis code displaying
Warning methods
System Reference Gr
lamp Warning
Multi-Use Tester
display
Common rail 13E
Exhaust gas recirculation O O 17
Starter continuous energizing preventing function 54
1.2 Types of diagnosis codes

(1) Present diagnosis code
• Fault developed in the vehicle after the starter switch is set to ON is indicated by corresponding diagnosis code.
• The fault warning is displayed at the same time.
(2) Past diagnosis code

• Past fault developed in the vehicle is indicated by corresponding diagnosis code stored in the memory of the elec-
tronic control unit.
• With the vehicle restored to its normal condition or the starter switch turned from OFF to ON after inspection or re-
pair against present diagnosis codes, the present diagnosis code is stored as past diagnosis codes in the memory
of the electronic control unit.
• The warning is not displayed because the indicated fault is not present one.
2. Access and Clearing of Stored Diagnosis Code

2.1 Using Multi-Use Tester
(1) Connecting Multi-Use Tester
Special tools
Mark Tool name and shape Part No. Application
FMS-E12-3 or
higher (Multi- Data transmission between V.C.I. and
PC
Use Tester-III PC
version)
Data transmission between electronic

V.C.I. MH062927
control unit and PC
54-00A-28
54-00A
Multi-Use Tester test
harness E
MH063659
A: For inspection and
A: MH063661
drive recorder Power supply to V.C.I. and communi-
B: MH063663
B: For drive recorder cation with electronic control unit
C: MH063665
C: Drive recorder har-
D: MH063666
ness
D: Cigar plug harness
Multi-Use Tester test

Multi-Use Tester test harness A and B
harness D MH062951
extension
(used for extension)
Communication between V.C.I. and

USB cable MH063668
PC
(1.1) System inspection

• Move the starter switch to the LOCK position.
• Connect installed PC, , -A and as illustrat-
ed.
• Connect the Multi-Use Tester connector on the vehicle with the
connector of -A.
54-00A-29
DIAGNOSIS CODES
(1.2) Inspection using the drive recorder function
• Move the starter switch to the LOCK position.
• Connect installed PC, , -A, -B and as
illustrated.
• Connect the cigarette lighter plug of -C with the cigarette
lighter socket.
• Connect the Multi-Use Tester connector with the connector of
-B.
(1.3) To extend the cable

• Use to extend the cable if -A is not long enough such
as when using Multi-Use Tester outside the vehicle.
(2) Access of diagnosis code

• Set the starter switch to ON.
• Operate the Multi-Use Tester for a display of necessary diagnosis code stored in the memory of the electronic
control unit and identify the location of the fault.
(3) Clearing of diagnosis code

• Set the starter switch to ON (the engine not to be started).
• Operate the Multi-Use Tester to delete all the diagnosis codes stored in the memory of the electronic control unit.
54-00A-30
54-00A
2.2 Use of Warning Display for Diagnosis Code
(1) Engine control
• Using the diagnosis and memory clear switches, display diagnosis codes.
CAUTION
• Opening the memory clear switch followed by its reconnection will erase the stored diagnosis codes from
the memory. To avoid inadvertently erasing necessary codes, be sure to read well the procedure de-
scribed below before handling diagnosis codes.
(1.1) Reading diagnosis codes

• To read a diagnosis code, observe how may times the warning
flashes and how long each illumination lasts.
• The duration of illumination differs between the first and second
digits.
• Second digit: 1.2 sec.
• First digit: 0.4 sec.
• A diagnosis code consists of the flashing of second digit and the
flashing of first digit in that order. If a diagnosis code has “0” in
the second digit, only the first digit will be displayed.
• The diagnosis code 01 will be displayed if the system is normal.
• The same diagnosis code will be displayed 3 times in a row be-
fore moving to the display of the next code.
• After the last diagnosis code is displayed, the first code will be
displayed again 3 times in a row and then the subsequent
codes. This will be repeated.
54-00A-31
DIAGNOSIS CODES
(1.2) Present diagnosis codes
• Turn the starter switch ON.
• Open the diagnosis switch.
• Present diagnosis codes will be displayed by flashing of the
warning.
• When the diagnosis switch is connected, electronic control unit
will stop (terminate) displaying diagnosis codes.
(1.3) Present and past diagnosis codes

• Turn the starter switch to the ON position.
• Open the diagnosis switch.
• Present diagnosis codes will be displayed by flashing of the
warning.
• Open the memory clear switch.
• Present and past diagnosis codes will be displayed by flashing
of the warning.
• Turn the starter switch to the OFF position and connect the
memory clear switch and diagnosis switch to terminate the diag-
nosis code displaying mode.
(1.4) Erasing diagnosis codes

• Turn the starter switch to the ON position (do not start the en-
gine).
• Open the memory clear switch and reconnect it; all diagnosis
codes stored in electronic control unit memory will be erased.
To cancel diagnosis code erasure after opening the memory
clear switch, turn the starter switch to the OFF position and then
reconnect the memory clear switch.
54-00A-32
54-00A
M E M O
54-00A-33
TABLE OF STANDARD TIGHTENING TORQUES
1. Tightening Torques
• Tightening torques are roughly classified into the following two categories:
Availability of
How to determine tightening
Tightening torque Definition torque specifica-
torque
tions in text
Locate a bolt or nut correspond-
Standard tightening Tightening torque determined according to thread
None ing to actual part in the following
torque size and material of bolts and nuts
standard tightening torque table.
Tightening torque of bolts and nuts other than those
Specified tightening Tightening torque is shown in
defined in “Standard tightening torque”, or that of Provided
torque the text.
bolts and nuts not identified in the following tables
• Fasteners used in a location denoted by “wet” should always be tightened in a wet condition (lubricated with en-
gine oil or grease). Any other fasteners than those so specified should be tightened in a dry condition.
2. Table of Standard Tightening Torque

• Threads and bearing surfaces shall be dry (tightened in a dry condition).
• If the mating nut and bolt (or stud bolt) are different in level of strength, tighten them to the torque specified for the
bolt.
• Automotive screws refer to coarse screw thread with nominal diameter of 3 to 8 mm or fine screw thread with
nominal diameter of 10 mm or larger.
(1) Hexagon head bolts and stud bolts (Unit: N·m {kgf·m})
Strength
4T 7T 8T
(stud) (stud) (stud)

Automotive Coarse screw Automotive Coarse screw Automotive Coarse screw
screw thread thread screw thread thread screw thread thread
2 to 3 4 to 6 5 to 7
M5 – – –
{0.2 to 0.3} {0.4 to 0.6} {0.5 to 0.7}
4 to 6 7 to 10 8 to 12
M6 – – –
{0.4 to 0.6} {0.7 to 1.0} {0.8 to 1.2}
9 to 13 16 to 24 19 to 28
M8 – – –
{0.9 to 1.3} {1.6 to 2.4} {1.9 to 2.9}
18 to 27 17 to 25 34 to 50 32 to 48 45 to 60 37 to 55
M10
{1.8 to 2.8} {1.7 to 2.5} {3.5 to 5.1} {3.3 to 4.9} {4.6 to 6.1} {3.8 to 5.6}
34 to 50 31 to 45 70 to 90 65 to 85 80 to 105 75 to 95
M12
{3.5 to 5.1} {3.2 to 4.6} {7.1 to 9.2} {6.6 to 8.7} {8.2 to 11} {7.6 to 9.7}
Nominal
60 to 80 55 to 75 110 to 150 100 to 140 130 to 170 120 to 160
diameter M14
{6.1 to 8.2} {5.6 to 7.6} {11 to 15} {10 to 14} {13 to 17} {12 to 16}
mm
90 to 120 90 to 110 170 to 220 160 to 210 200 to 260 190 to 240
M16
{9.2 to 12} {9 to 11} {17 to 22} {16 to 21} {20 to 27} {19 to 24}
130 to 170 120 to 150 250 to 330 220 to 290 290 to 380 250 to 340
M18
{13 to 17} {12 to 15} {25 to 34} {22 to 30} {30 to 39} {25 to 35}
180 to 240 170 to 220 340 to 460 310 to 410 400 to 530 360 to 480
M20
{18 to 24} {17 to 22} {35 to 47} {32 to 42} {41 to 54} {37 to 49}
250 to 330 230 to 300 460 to 620 420 to 560 540 to 720 490 to 650
M22
{25 to 34} {23 to 31} {47 to 63} {43 to 57} {55 to 73} {50 to 66}
320 to 430 290 to 380 600 to 810 540 to 720 700 to 940 620 to 830
M24
{33 to 44} {30 to 39} {61 to 83} {55 to 73} {71 to 96} {63 to 85}
54-00A-34
54-00A
Strength
8.8 (Nut 4T) 8.8 (Nut 6T)
Automotive screw thread

18 to 27 45 to 60
M10
{1.8 to 2.8} {4.6 to 6.1}
Nominal
34 to 50 80 to 105
diameter M12
{3.5. to 5.1} {8.2 to 11}
mm
60 to 80 130 to 170
M14
{6.1 to 8.2} {13 to 17}
(2) Hexagon flange bolts (Unit: N·m {kgf·m})

Strength
4T 7T 8T

4 to 6 8 to 12 10 to 14
M6 – – –
{0.4 to 0.6} {0.8 to 1.2} {1.0 to 1.4}
10 to 15 19 to 28 22 to 33
Nominal M8 – – –
{1.0 to 1.5} {1.9 to 2.9} {2.2 to 3.4}
diameter
mm 21 to 31 20 to 29 45 to 55 37 to 54 50 to 65 50 to 60
M10
{2.1 to 3.2} {2.0 to 3.0} {4.6 to 5.6} {3.8 to 5.5} {5.1 to 6.6} {5.1 to 6.1}
38 to 56 35 to 51 80 to 105 70 to 95 90 to 120 85 to 110
M12
{3.9 to 5.7} {3.6 to 5.2} {8.2 to 11} {7.1 to 9.7} {9.2 to 12} {8.7 to 11}
Strength
8.8 (Nut 4T) 8.8
Automotive screw thread

21 to 31 50 to 65
Nominal M10
{2.1 to 3.2} {5.1 to 6.6}
diameter
mm 38 to 56 90 to 120
M12
{3.9 to 5.7} {9.2 to 12}
54-00A-35
TABLE OF STANDARD TIGHTENING TORQUES
(3) Hexagon nuts (Unit: N·m {kgf·m})
Strength
4T 6T (Bolt 7T) 6T (Bolt 8T)

2 to 3 4 to 6 5 to 7
M5 – – –
{0.2 to 0.3} {0.4 to 0.6} {0.5 to 0.7}
4 to 6 7 to 10 8 to 12
M6 – – –
{0.4 to 0.6} {0.7 to 1.0} {0.8 to 1.2}
9 to 13 16 to 24 19 to 28
M8 – – –
{0.9 to 1.3} {1.6 to 2.4} {1.9 to 2.9}
18 to 27 17 to 25 34 to 50 32 to 48 45 to 60 37 to 55
M10
{1.8 to 2.8} {1.7 to 2.5} {3.5 to 5.1} {3.3 to 4.9} {4.6 to 6.1} {3.8 to 5.6}
34 to 50 31 to 45 70 to 90 65 to 85 80 to 105 75 to 95
M12
{3.5 to 5.1} {3.2 to 4.6} {7.1 to 9.2} {6.6 to 8.7} {8.2 to 11} {7.6 to 9.7}
Nominal
60 to 80 55 to 75 110 to 150 100 to 140 130 to 170 120 to 160
diameter M14
{6.1 to 8.2} {5.6 to 7.6} {11 to 15} {10 to 14} {13 to 17} {12 to 16}
mm
90 to 120 90 to 110 170 to 220 160 to 210 200 to 260 190 to 240
M16
{9.2 to 12} {9 to 11} {17 to 22} {16 to 21} {20 to 27} {19 to 24}
130 to 170 120 to 150 250 to 330 220 to 290 290 to 380 250 to 340
M18
{13 to 17} {12 to 15} {25 to 34} {22 to 30} {30 to 39} {25 to 35}
180 to 240 170 to 220 340 to 460 310 to 410 400 to 530 360 to 480
M20
{18 to 24} {17 to 22} {35 to 47} {32 to 42} {41 to 54} {37 to 49}
250 to 330 230 to 300 460 to 620 420 to 560 540 to 720 490 to 650
M22
{25 to 34} {23 to 31} {47 to 63} {43 to 57} {55 to 73} {50 to 66}
320 to 430 290 to 380 600 to 810 540 to 720 700 to 940 620 to 830
M24
{33 to 44} {30 to 39} {61 to 83} {55 to 73} {71 to 96} {63 to 85}
(4) Hexagon flange nuts (Unit: N·m {kgf·m})

Strength
4T
Automotive Coarse screw

screw thread thread
4 to 6
M6 –
{0.4 to 0.6}
10 to 15
Nominal M8 –
{1.0 to 1.5}
diameter
mm 21 to 31 20 to 29
M10
{2.1 to 3.2} {2.0 to 3.0}
38 to 56 35 to 51
M12
{3.9 to 5.7} {3.6 to 5.2}
(5) Tightening torques of general flare nuts (Unit: N·m {kgf·m})

Pipe diameter mm φ4.76 φ6.35 φ8 φ10 φ12 φ15
Tightening torque 17 {1.7} 25 {2.6} 39 {4.0} 59 {6.0} 88 {9.0} 98 {10}
54-00A-36
54-00A
(6) Tightening torques of nylon tubes for general air piping (DIN) (Unit: N·m {kgf·m})
Nominal diameter
6×1 10 × 1.25 12 × 1.5 15 × 1.5
× wall thickness mm
+6 +0.6 +10 +1.0 +10 +1.0 +5 +0.5
Tightening torque 20 0 {2.0 0 } 34 0 {3.5 0 } 49 0 {5.0 0 } 54 0 {5.5 0 }
(7) Tightening torques of nylon tubes for general air piping (SAE) (Unit: N·m {kgf·m})
Nominal diameter in. 1/4 3/8 1/2 5/8
+4 +0.4 +5 +0.5 +5 +0.5 +5 +0.5
Tightening torque 13 0 {1.3 0 } 29 0 {3.0 0 } 49 0 {5.0 0 } 64 0 {6.5 0 }
54-00A-37
54-00B SPECIFICATIONS
54-00B-1
SPECIFICATIONS
Battery
Item Specifications
Model 75D26R
Voltage × Quantity V 12 × 2
Capacity (5-hour rating) Ah 52
Alternator
Item Specifications
Manufacturer MITSUBISHI ELECTRIC
Alternator with built-in regulator
Type Without brush
External fan
Model A4TU6981D
Output V–A 24–80
Starter and Preheat System

Item Specifications
Starter Manufacturer MITSUBISHI ELECTRIC
Model M008T85771
Output V–kW 24–3.7
Magnetic switch operating
16 or less
voltage V
Starter relay Model U001X33173
Excitation current V–A 24–2.3
Closing voltage V 16 or less
Opening voltage V 4 or less
Allowable cutoff current A 200
Glow plug Model Sheathed type
Rated voltage and current V–A 23–3 (reference)
Glow relay Model U001T41372
Excitation current V–A 24–2.3
Closing voltage V 16 or less
Opening voltage V 4 or less
Allowable cutoff capacity A 200
Temperature fuse capacity A 127
54-00B-2
54-00B
Lighting
Item Specifications
Headlamp Model Round 4-lamp type headlamp
Main beam (high) W 70 (H1)*
Main/Dipped beam
75/70 (H4)*
(high/low) W
Fog lamp W 70 (H3)*
Clearance lamp/turn signal
Front combi-
lamp (serving also as 5/21 (W5W/P21W)*
nation lamp
hazard warning lamp) W
Front side turn signal lamp
12
(serving also as hazard warning lamp) W
Stop and tail lamp W 25/10
Rear combi- Turn signal lamp
nation lamp (serving also as hazard 25
warning lamp) W
Backup lamp W 21
Step lamp W 6
Room lamp Incandescent lamp W 12
License plate lamp W 5
All bulbs in the lamps shown above have voltage rating of 24 volts.
*: The types of bulbs are shown in parentheses.
Meter
Item Specifications
Manufacturer Continental
Rated voltage V 24
Speedometer indicating range km/h 0 to 160 ( +30 at 40 km/h)
Tachometer indicating range rpm 0 to 4000 (± 50 at 2000 rpm)
Meter
cluster
Water temperature gauge
indicating range
Meter warning buzzer dB 60 ± 3 (at 1 m)
54-00B-3
SPECIFICATIONS
Relay, Audio, Motor, Horn, Buzzer
Item Specifications
Rated voltage V 24
Relay Minimum operating
16 or less
voltage V
Manufacturer MITSUBISHI ELECTRIC
AM radio
Model AR-2XS0C-3
AM/FM radio Manufacturer Clarion

(with CD player) Model PM2893DA
Type One way
Rated input W 5
Speaker
Maximum input W 7
Impedance Ω 8 ± 1.2
Rated voltage V 24
Electric horn Current consumption A 2
Sound pressure dB 110 ± 5 (at 2 m)
Rated voltage V 24
Rated current mA 50 or less
Back buzzer Sound pressure dB 85 ± 10 (at 1 m)
times
Intermittence 85 ± 15
/min
Wiper motor Rated voltage V 24
(front) No-load current A 2.3 or less (at low speed), 2.8 or less (at high speed)
Wiper motor Rated voltage V 24
(rear) No-load current A 1 or less
Rated voltage V 24
Washer motor
Rated current A 2 or less (front), 1.5 or less (rear)
Manufacturer Rhythm Watch Co.,Ltd.
Clock
Model 8AD854-B
Rated input W 27
Bottle cooler Rated voltage V 15
Model MD45F-KB
54-00B-4
54-00C STRUCTURE AND OPERATION
54-00C-1
STRUCTURE AND OPERATION
1. Starter
• This starter uses planetary gears as its reduction gearing mech-

anism.
54-00C-2
54-00C
2. Alternator
54-00C-3
2.1 Alternator with neutral diodes
(1) Features
• The alternator is the same as the cur-
rent alternator except that neutral di-
odes have been added.
• These neutral diodes enable this alter-
nator to provide higher DC output dur-
ing operation at high speeds than the
alternator without neutral diodes.
(2) Variations of voltage at neutral

point and operation of neutral di-
odes
• The potential at the neutral point var-
ies up and down with the neutral point
DC voltage (1/2 of output voltage) as a
center as shown.
• When the alternator is operated at
high speeds, the voltage at the neutral
point can increase to exceed the out-
put voltage (28 V) and decrease to be-
come lower than the ground voltage (0
V). To adjust these over-voltage and
under-voltage (shaded portions of dia-
gram) the current from the excess volt-
ages is taken by neutral diodes and
added to the DC output.
The operation of neutral diodes for each

voltage and potential is as follows.
• When the voltage at neutral point is in

the range from 0 to 28 V, the other six
diodes are operated. Neutral diodes
are not operated.
54-00C-4
54-00C
(3) When the voltage at neutral point
exceeds 28 V
• The positive diode (+) adds extra out-
put to the DC output for supply to each
electric equipment.
(4) When the voltage at neutral point

drops below 0 V
• The negative diode (–) supplies the
output from neutral point through other
three diodes.
54-00C-5
3. Wiper Control
3.1 Outline
• This wiper electronic control unit is an integrated control unit controlling the following functions.
• Windshield washer interlocking wiper-operating function.
• Intermittent wiper activation function.
(1) System function schematic
3.2 Windshield washer interlocking wiper-operating function

• This function causes the windshield
wipers to operate a few times at low
speed when the windshield washer
switch is turned ON.
• As shown in the drawing, the wiper
electronic control unit introduces a
short delay between detecting the ON
condition of the wiper and washer
switch (washer switch) and activating
the wiper relay.
3.3 Intermittent wiper activation function

• Wiper electronic control unit causes
intermittent wiper operation to take
place as shown in the drawing.
54-00C-6
54-00C
3.4 Wiper electronic control unit connection diagram
54-00C-7
4. Starter Continuous Energizing Preventing Function and Preheating Function
4.1 Outline
• These functions are controlled by the engine electronic control unit.
(1) System function schematic
Parts name Major function and operation

Water temperature sensor Engine water temperature detection
Starter switch Start position detection
Engine speed sensor Engine speed detection
Diagnosis switch Output of diagnosis code
Engine warning lamp Abnormality of each function
Safety relay Release of starter continuous energizing
4.2 Starter continuous energizing preventing function

• This function is provided to prevent
starter over-run.
• If the starter operates for longer than a
predetermined period following engine
startup, the Engine electronic control
unit deems that it has been energized
continuously for too long. The Engine
electronic control unit then stops the
flow of current to the starter and starter
relay, thereby preventing the starter
from seizing.
54-00C-8
54-00C
• If the engine electronic control unit de-
termines, based on the engine speed
signal it receives, that the engine has
run at or above the specified speed for
longer than the specified time period
after start-up, the unit trips the safety
relay open.
4.3 Preheating function

• This preheating function aims to enhance the engine start up when the engine coolant is low in cold weather or
temperature.
Engine electronic control unit the entire function as follows:
(1) Pre-glow and After-glow
The preheating is operated with a pre-
glow before the engine starts and an af-
ter-glow after the engine starts. They are
controlled by the starter switch (S termi-
nal) signal, engine water temperature
signal and the engine speed signal.
(2) Operation mode

• When the engine coolant temperature
is 60°C or more.

is 0 to 60°C.
54-00C-9
is 0°C or less.
4.4 Fault diagnosis function

• While the starter switch is in the ON position, the sensors and other components are continuously monitored for
faults. In the event that a component is found faulty, an indication is made in the meter cluster to alert the driver,
the fault location is memorized in the form of a diagnosis code, and backup control necessitated by the fault is ini-
tiated.
• While the backup control is taking place, the system’s functionality is limited to ensure vehicle and driver safety. It
is possible to read the memorized diagnosis code using a Multi-Use Tester or from flashing of the warning lamp.
NOTE
• Diagnosis codes shown by the Multi-Use Tester and those indicated by flashing of the warning lamp are
different.
• The Multi-Use Tester is capable of showing more detailed diagnosis codes.
54-00C-10
54-00C
4.5 Engine electronic control unit connection diagram
54-00C-11
54-00D TROUBLESHOOTING
54-00D-1
TROUBLESHOOTING
1. Power and Charging
Symptoms
Battery electrolyte decreases too early.
Battery is normal but over-discharged.

Charge warning lamp does not light
when starter switch is turned ON,
Alternator is normal but battery

Reference Gr
with engine stopped.

Battery overheating.
over-discharged.
Possible causes
Connector connection faulty, harness broken, grounding faulty O O
Fuse blown O O O
Belts loose O O Gr14
Belts damaged O O Gr14
Battery faulty O O
Stator coil broken O
Stator coil short-circuited with core O
Field coil broken O
Alternator Rectifier faulty O
Regulator faulty O O O
Wiring faulty O
Pulley faulty O
Meter cluster faulty O
54-00D-2
54-00D
2. Engine Starting, Preheating and Stopping
Symptoms Starter operates
but engine does
not start.
Pinion engages with ring gear
Engine cannot be preheated.

Flywheel rotates but engine
Starter does not operate.
Pinion does not engage
Engine is hard to start.

Engine does not stop.
Reference Gr
but does not rotate.
does not start.

with ring gear.
Possible causes
Connector connection faulty, harness broken, grounding faulty O O O O O
High-current fuse blown O
Fuse blown O O
Battery insufficiently charged O O
Magnetic switch contacts stuck or
O
fused together
Starter Open circuit in magnetic switch coil O
Overrunning clutch malfunctioning O
Pinion worn or damaged O
Starter relay faulty O
Starter switch faulty O O
Flywheel ring gear worn or damaged O Gr11
Engine electronic control unit faulty O O O Gr13E
Water temperature sensor faulty O
Connecting plate connection faulty O
Exhaust brake system faulty O Gr35
Glow plugs faulty O O
Glow relay faulty O O
Glow drive relay faulty O O
Safety relay faulty O
54-00D-3
TROUBLESHOOTING
3. Lighting
Symptoms Headlamp
License plate lamp does not light.

Does not switch to dipped beam.
Does not switch to main beam.
Clearance lamp does not light.

Fog lamp does not light.
Tail lamp does not light.
Reference Gr
Does not light.

Dim.
Possible causes
Connector connection faulty, harness broken, grounding
O O O O O
faulty
Fuse blown O O O O O
Battery capacity insufficient O
Alternator output insufficient O
Bulb burnt-out O O O O O
Lighting switch faulty O O O O
Combination switch
Dimmer switch faulty O O
Headlamp relay
O O O
Relay box (HIGH, LOW) faulty
Tail lamp relay faulty O O O
Fog lamp switch faulty O
54-00D-4
54-00D
Symptoms Turn signal lamp
Back buzzer does not sound.

Backup lamp does not light.
(serving also as
Stop lamp does not light.

hazard warning
lamp)
Blinks too quickly.

Blinks too slowly.
Blinks irregularly.
Reference Gr
Does not light.

Stay ON.
Possible causes
Connector connection faulty, harness broken, grounding faulty O O O O
Fuse blown O O O O
Battery capacity insufficient O
Alternator output insufficient O
Bulb burnt-out O O O O
Power (wattage) of bulb is lower than specified value O
Power (wattage) of bulb is higher than specified value O
Lighting switch faulty
Combination switch Turn signal lamp switch faulty O
Hazard switch faulty O
Tail lamp relay faulty
Relay box
Stop lamp relay faulty O
Stop lamp switch faulty O
Flasher relay faulty O O O O O
Backup lamp switch faulty O O
Back buzzer faulty O
54-00D-5
TROUBLESHOOTING
Symptoms
Night illumination for meters and switches do not light.

Reference Gr
Room lamp does not light.

Step lamp does not light.
Possible causes
Connector connection faulty, harness broken, grounding faulty O O O
Fuse blown O O
Bulb burnt-out O O O
Room lamp faulty O
Room lamp switch faulty O
Starter switch faulty O
Step lamp switch faulty O
54-00D-6
54-00D
4. Meter
Symptoms
Pointer movement unstable.

Pointer does not move.
Reference Gr
Indication error large.

Possible causes
Connector connection faulty, harness broken, grounding faulty O O
Fuse blown O
Internal circuits of meter cluster faulty O O O
Printed wiring board of meter cluster faulty O
Engine speed sensor coil open-circuited O
Engine speed sensor improperly mounted O O Gr22
Tachometer
Tachometer faulty O O O
Engine electronic control unit faulty O O O Gr13E
Specified tires not used O
Gr31
Tires worn or inflation pressure incorrect O
Speedometer Vehicle speed sensor faulty O
Vehicle speed sensor improperly mounted O Gr22
Speedometer faulty O O O
Water temperature sensor faulty O O
Water temperature gauge Water temperature gauge faulty O O
Thermostat does not close O Gr14
Fuel level sensor faulty O O
Fuel gauge
Fuel gauge faulty O O
54-00D-7
TROUBLESHOOTING
5. Cigarette Lighter and Audio
Symptoms Ciga-
rette Audio
lighter
CD player does not work when CD inserted.

Specific frequency band does not work.
Left and right volume different.
CD jumps at the same point.

Reference Gr
Spurious noise generated.
Sound from one side only.
CD cannot be inserted.
Radio reception poor.
Radio does not work.
Sound quality poor.

Does not return.
Does not glow.
Possible causes
Connector connection faulty, harness broken,
O O O O O
grounding faulty
Fuse blown O O O
Cigarette lighter faulty O O
Antenna and antenna cable connection faulty O O O
Radio amplifier faulty O O O O O
Radio tuner faulty O O O O
Speaker faulty O O O O O O O O
Left and right speaker impedance different O
CD already in slot O
CD scratched or dirty O
CD scratched or dirty
O
Unsupported CD is inserted
CD player faulty O O
Accessory Noise Generation Source

Accessory Noise Symptoms
High pitch sound when accelerator pedal suddenly depressed
Alternator Whistling
(stops soon after engine stopped)
Occurs when engine running (continues for a while after en-
Water temperature gauge Scratching
gine stops)
Engine oil pressure switch Rattling Depends on engine speed (does not occur during idling)
Occurs when engine suddenly revved, while running on rough
Fuel level sensor Scratching
roads, or starter switch turned ON
Flasher relay Banging When turn signal blinks
Horn Hissing Occurs when horn button pressed or released
Wiper motor Whining Depends on windshield wiper speed
Washer motor Whining When windshield washer operates
54-00D-8
54-00D
6. Horn
Symptoms Horn
Sound quality poor

Continuous sound
Reference Gr
Small sound
No sound
Possible causes
Connector connection faulty, harness broken, grounding faulty O
Fuse blown O
Horn switch faulty O O
Horn faulty O O O
Horn stay warped O O
Battery voltage insufficient O O
7. Starter Continuous Energizing Preventing Function (See #956.)
54-00D-9
54-01 POWER, CHARGE AND GROUND
CIRCUIT
54-01-1
FUSE BOX
WARNING
To prevent possible injury, be sure to disconnect the negative (-) cable of the battery and insulate it with
tape before removing fuses.
CAUTION
With the negative (-) cable of the battery connected, some fuses are always under battery voltage.
An arc will be generated when any of these fuses is replaced without disconnecting the battery
negative cable, and this could cause the related electric devices to be damaged.
If a fuse blows out, identify and remedy the cause, then replace the fuse.
Be sure to use the fuse with the specified ampere.
54-01-2
54-01
54-01-3
110 POWER SUPPLY CIRCUIT
54-01-4
54-01
54-01-5
54-01-6
54-01
54-01-7
54-01-8
54-01
54-01-9
54-01-10
54-01
54-01-11
115 RESERVE POWER CIRCUIT
54-01-12
125 BATTERY CHARGING CIRCUIT 54-01
54-01-13
130 GROUND
54-01-14
54-01
54-01-15
130 GROUND
54-01-16
54-01
54-01-17
130 GROUND
54-01-18
54-01
54-01-19
130 GROUND
54-01-20
54-01
54-01-21
130 GROUND
54-01-22
54-01
54-01-23
54-02 ENGINE STARTING, STOPPING AND
PREHEATING CIRCUIT
54-02-1
210 ENGINE STARTING CIRCUIT
54-02-2
220 ENGINE PREHEATING CIRCUIT 54-02
54-02-3
54-03 LIGHTING CIRCUIT
54-03-1
310 HEADLAMP CIRCUIT
54-03-2
315 FOG LAMP CIRCUIT 54-03
54-03-3
320 TAIL LAMP, CLEARANCE LAMP AND LICENSE PLATE LAMP CIRCUIT
54-03-4
325 STOP LAMP CIRCUIT 54-03
54-03-5
330 TURN SIGNAL AND HAZARD LAMP CIRCUIT
54-03-6
340 BACKUP LAMP CIRCUIT 54-03
54-03-7
345 ROOM LAMP CIRCUIT
54-03-8
348 ILLUMINATION LAMP CIRCUIT 54-03
54-03-9
378 STEP LAMP CIRCUIT
54-03-10
54-04 METER CIRCUIT
54-04-1
401 METER CLUSTER INTERNAL CIRCUIT
54-04-2
410 TACHOMETER CIRCUIT 54-04
54-04-3
412 SPEEDOMETER CIRCUIT
54-04-4
420 FUEL GAUGE CIRCUIT 54-04
54-04-5
425 WATER TEMPERATURE GAUGE CIRCUIT
54-04-6
54-05 INDICATOR AND WARNING LAMP
CIRCUIT
54-05-1
510 PARKING BRAKE INDICATOR CIRCUIT
54-05-2
515 BRAKE WARNING CIRCUIT 54-05
54-05-3
536 ENGINE OIL PRESSURE WARNING CIRCUIT
54-05-4
540 BRAKE PAD WARNING CIRCUIT 54-05
54-05-5
566 FUEL FILTER WARNING CIRCUIT
54-05-6
576 DOOR INDICATOR CIRCUIT 54-05
54-05-7
54-06 BODY SIDE ELECTRICAL CIRCUIT
54-06-1
610 CIGARETTE LIGHTER CIRCUIT
54-06-2
54-06
M E M O
54-06-3
612 AUDIO CIRCUIT
54-06-4
54-06
54-06-5
614 WIPER AND WASHER CIRCUIT
54-06-6
616 HORN CIRCUIT 54-06
54-06-7
618 HEATER CIRCUIT
54-06-8
54-06
M E M O
54-06-9
620 AIR-CONDITIONER CIRCUIT
54-06-10
54-06
54-06-11
620 AIR-CONDITIONER CIRCUIT
54-06-12
625 AUTOMATIC DOOR CIRCUIT 54-06
54-06-13
625 AUTOMATIC DOOR CIRCUIT
54-06-14
54-06
54-06-15
675 CLOCK CIRCUIT
54-06-16
676 BOTTLE COOLER CIRCUIT 54-06
54-06-17
682 REAR WIPER AND WASHER CIRCUIT
54-06-18
54-07 CHASSIS SIDE ELECTRICAL
CIRCUIT
54-07-1
710 EXHAUST BRAKE CIRCUIT
54-07-2
54-09 OTHER CIRCUIT
54-09-1
907 DIAGNOSIS SWITCH AND MEMORY CLEAR SWITCH CIRCUIT
54-09-2
54-10 ELECTRICAL EQUIPMENT
INSTALLATION POSITIONS
54-10-1
A SWITCH AND SENSOR
Body side
54-10-2
54-10
M E M O
54-10-3
B RELAY AND ELECTRONIC CONTROL UNIT
54-10-4
54-10
54-10-5
C FUSE, METER, SENSOR, MOTOR AND BUZZER
54-10-6
D HEATER AND AIR-CONDITIONER, F ROOF 54-10
54-10-7
J JOINTS OF MAIN HARNESS CONNECTORS
54-10-8
54-10
54-10-9
P OTHER
54-10-10
R ENGINE 54-10
Engine and transmission
54-10-11
S TRANSMISSION
54-10-12
T SWITCH AND SENSOR, U BATTERY, V MAGNETIC VALVE 54-10
Chassis side
54-10-13
W BUZZER, LAMP, X OTHER
54-10-14
54-11 INSPECTION OF ELECTRICAL
EQUIPMENT
54-11-1
#001 to #179 SWITCH
#001 Inspection of combination switch
DD13A connector connection table
Switch position Continuity terminal
OFF –
I 1–10
Lighting switch
1–10–11 *1,
II
1–9 –10 *2
Main 1–9, 9 –10 *3
Dimmer switch Dimmer 1–11, 10–11 *3
Passing 1–9
LH 3–7
Turn signal lamp
N (neutral) –
switch
RH 3–8
OFF –
Horn switch
ON 2 – Body ground
*1 When dimmer switch is in dimmer position
*2 When dimmer switch is in main position
*3 When lighting switch is in II position
DD15B connector connection table

OFF –
INT (interval) 3–15
Wiper and washer LO (low) 2–15
switch
HI (high) 1–2–15
WASH
14–15
(washer)
OFF –
Hazard switch
ON 7–8–9
OFF –
Exhaust brake switch
ON 5–6
• If any fault is found, replace the switch.
#002 Inspection of starter switch

AP2A, AN6A connector connection table
LOCK –
ACC (2)–3
ON (2)–3–(1)–4
START (2)–3–(1)–4–2
• Terminal numbers within parentheses ( ) show terminals of
AP2A.
54-11-2
54-11
#023 Inspection of vacuum switch
• Perform the following checks, and if any fault is found, replace
the switch.
(1) Inspection without applying negative pressure

• Make sure that there is continuity between terminals 1 and body.
(2) Inspection by applying negative pressure
• Gradually apply negative pressure to the switch starting from 0
kPa {0 mmHg}.
• Measure the degree of air pressure at the moment when conti-
nuity is not detected between terminals 1 and body, and make
sure to confirm if the value meets the standard.
Standard value –(47 +3.3 +25
–4 ) kPa {–(350 –30 ) mmHg}
#028 Inspection of low air pressure switch

• Perform the following inspection and if any fault is found, replace
the switch.
(1) Inspection without applying vacuum

• Check that there is continuity between terminals 1 and 2.
(2) Inspection with vacuum applied
• Gradually apply vacuum, starting from 0 kPa {0 kgf/cm2}.
• Measure the vacuum when the continuity between terminals 1
and 2 is lost and confirm that it is within the standard value.
Standard value (ON→OFF) 50 kPa {380 mmHg}
• Gradually decrease the vacuum.
• Measure the vacuum when the continuity between terminals 1
and 2 returns and confirm that it is within the standard value.
Standard value (OFF→ON) 140 kPa {1050 mmHg}
#031 Inspection of clutch switch

A 1–4
B 2–3
• If any fault is found, replace the switch. (See Gr21.)
#035 Inspection of door switch

<Swing door and driver side door>
OFF –
ON 1–body, 2–body
54-11-3
#001 to #179 SWITCH
<Swing door>
OFF –
ON 2–3
#038 Inspection of parking brake switch

OFF –
ON 1–2
#041 Inspection of brake fluid level switch

• Gradually drain brake fluid from the brake fluid tank.
CAUTION
• Brake fluid contains ingredients that dissolve paint on the
bodywork of a vehicle. Quickly wipe off brake fluid when it
is spilled.
• Measure height of the fluid level when continuity is detected be-

tween terminals 1 and 2.
Standard value 36.1 ± 3 mm
• If the measured value deviates from the standard value, replace
the brake fluid tank.
#042 Inspection of stop lamp switch

OFF –
ON 1–2
54-11-4
54-11
#044 Inspection of engine oil pressure switch
the switch. (See Gr12.)
(1) Inspection without applying air pressure
• Make sure that there is continuity between terminal 1 and body.
(2) Inspection by applying air pressure

• Gradually apply air pressure to the switch starting from 0 kPa {0
kgf/cm2}.
• Measure the degree of air pressure at the moment when conti-
nuity is not detected between terminal 1 and body, and make
sure to confirm if the value meets the standard.
Standard value
50 ± 10 kPa {0.5 ± 0.1 kgf/cm2}
(operating pressure)
#054 Inspection of backup lamp switch

OFF –
ON 1–2
#056 Inspection of switch

the switch.
• Transmission neutral switch (See Gr22.)
• Torque limit switch (See Gr22.)
OFF –
ON 1–2
#170 Inspection of automatic door switch <Folding door>

Continuity Operating Night illumi-
Switch position
terminal illumination nation
CLOSE 1–6 –
(+) 2–3 (–)
OPEN 1–5 (+) 7–4 (–)
54-11-5
#001 to #179 SWITCH
#171 Inspection of automatic door switch <Swing door>
Switch position Continuity terminal Night illumination
CLOSE 1–6
N (neutral) – (+) 2–3 (–)
OPEN 1–5
#172 Inspection of switch

the switch.
• Room lamp switch (front and rear)
• Step lamp switch
Continuity Operating Night
Switch position
terminal illumination illumination
OFF – –
(+) 6–1 (–)
ON 7–8 (+) 4–1 (–)
• Fog lamp switch

Switch position
OFF 2–7 –
(+) 6–1 (–)
ON 7–8 (+) 4–1 (–)
#173 Inspection of rear wiper and washer switch

Switch position
ON 7–8 (+) 4–1 (–)
N (neutral) – – (+) 6–1 (–)
WASH 2–7 (+) 3–1 (–)
#179 Inspection of emergency switch <Folding door>

Manual –
Automatic 1–2
54-11-6
#180 to #249 RELAY 54-11
#182 Inspection of relay (normally open type 6 pin)
• Perform continuity check and operation check, and if any fault is
found, replace the relay.
#183 Inspection of relay

• It is difficult to inspect the control unit and other unit directly.
Therefore, its condition should be judged indirectly through the
inspections of the harnesses and related parts in each system.
• If any fault is not found in the related parts, and the problem still
remains in the system, replace the control units or other units.
#187 Inspection of starter relay

#195 Inspection of glow relay


54-11-7
#180 to #249 RELAY
54-11-8
#250 to #349 SENSOR 54-11
#258 Inspection of fuel level sensor
• Measure resistance values between terminals 1 and 2 at EMP-
TY and FULL positions.
• Check that resistance values continuously change while bringing
the float arm from EMPTY position to FULL position.
at FULL position 0 +20 Ω
Standard value at 1/2 position 50 ± 3 Ω
at EMPTY position 150 ± 10 Ω
the sensor. (See Gr13.)
#262 Inspection of water temperature sensor

<For water temperature gauge>
• Dip the sensor in a container filled with engine oil.
• Raise the oil temperature to the specified one while stirring oil.
• Measure resistance values between terminals 1 and body.
Terminal 1: water temperature gauge connected side
Terminal 2: not used
153.9 Ω
50°C
(reference value)
Standard
value 80°C 51.9 +4.9
–4.4 Ω
100°C 27.4 +1.9
–1.2 Ω
<For engine control>

• Dip the sensor in a container filled with engine oil.
• Raise the oil temperature to the specified one while stirring oil.
• Measure the resistance value between each terminal.
20°C 2.45 ± 0.14 kΩ
Standard
80°C 0.32 kΩ (reference value)
value
110°C 147.1 ± 2 Ω
#263 Inspection of engine speed sensor

• Measure the resistance value between terminals 1 and 2.
Standard value
860 ± 86 Ω
(at 20°C)
54-11-9
#250 to #349 SENSOR, #350 to #409 CONTROL UNIT
#265 Inspection of vehicle speed sensor
• With the 24 volts DC applied to between terminals 1 and 2, slow-
ly turn the shaft of the sensor.
• Measure the maximum value (high pulse voltage) and the mini-
mum value (low pulse voltage) of the voltage generated at each
terminal.
Between terminals Low pulse voltage 1.5 V or less
1 and 3 of 8-pulse 23.5 V or
output High pulse voltage
Standard more
value
Between terminals Low pulse voltage 0.5 V or less
1 and 4 of 25-pulse
output High pulse voltage 8±1V
• If the measurement value deviates from the standard value, re-
place the sensor. (See Gr22.)
#274 Inspection of water separator sensor

Condition Continuity terminal
ON (when coolant quantity is ap-
1–2
prox. 100 mL)
OFF –
• If any fault is found, replace the sensor. (See Gr13.)
#350 Inspection of control units and other units

• Since the units alone cannot be readily checked in the off-vehi-
cle state, check the harness, switch and other related parts in
each system.
• Fot unit that procedure a diagnosis code, confirm the code and
identify the cause of the failure.
If any fault is found, replace the ECU or unit.
• If any fault is not found in the related parts, and the problem still
remains in the system, replace the control units or other units.
54-11-10
#410 to #509 MOTOR 54-11
#411 Inspection of blower motor
• Make sure that the motor operates when battery voltage is ap-
plied between terminals 1 and 2.
• If any fault is found, replace the motor. (See Gr55.)
#422 Inspection of wiper motor

<Front>
• Check the motor for correct operation as follows. If any fault is
found, replace the motor. (See Gr63.)
• Connect a switch to wiper motor as shown.
(1) Inspection of motor operation
• Set switch to HIGH position to check that the motor rotates at
high speed.
• Set switch to LOW position to check that the motor rotates at low
speed.
(2) Inspection of automatic stop position
• Set switch to LOW position to let the motor rotate at low speed.
• When the crank arm is in a position except automatic stop posi-
tion (outside the angles shown), set switch to OFF position.
• Check to see that the crank arm stops at the automatic stop po-
sition (within the angles range shown).
<Rear>
• Check the motor for correct operation as follows. If any fault is
found, replace the motor. (See Gr63.)
• Wire the motor as illustrated.
(1) Inspection of motor operation
• Make sure that the motor rotates when the switch is turned on.
(2) Inspection of automatic stop position
• Make sure that the shaft stops at the automatic stop position
when the switch is turned off.
54-11-11
#410 to #509 MOTOR, #510 to #559 ACTUATOR
#428 Inspection of windshield washer motor
<Front>
<Rear>
#491 Inspection of heater motor

plied between terminals 1 and 4 (LOW) and between terminals 1
and 3 (HIGH).
#510 Inspection of door lock actuator

• Apply battery voltage between each terminal. Confirm that the
actuator operates.
LOCK (+) 1–3 (–)
UNLOCK (+) 2–3 (–)
54-11-12
#560 to #609 MAGNETIC VALVE 54-11
#565 Inspection of 3-way magnetic valve
the 3-way magnetic valve.
(1) Operation check
• Gradually apply DC current between terminals 1 and 2 starting
from 0 V.
• Measure the voltage at which the 3-way magnetic valve oper-
ates. (Determine ON/OFF of the magnetic valve by operating
noises.)
Standard value
22 V or less
(minimum operating voltage)
(2) Inspection of continuity and air tightness

• Negative pressure when inspected: –99.99 kPa {–750 mmHg}
54-11-13
#610 to #649 BUZZER, HORN
#614 Inspection of back buzzer
[Inspection]
the buzzer.
• Make sure to confirm if the buzzer intermittently sounds by ap-
plying the battery voltage between terminals 1 and 2.
[Installation]
• Install the back buzzer to the frame in the range of angles as il-
lustrated.
CAUTION
• Beware that if the installed angle of the buzzer is out of the
range as illustrated, water in the buzzer will not be drained
normally.
#615 Inspection of electric horn

CAUTION
• Bending the stay changes the sound quality of the horn, de-
grading the horn performance.
• Never bend or damage the stay.
[Inspection]
• Make sure to confirm whether the horn sounds by applying the
battery voltage between terminals 1 and 2 (no (+)(–) polarity).
• Remove foreign substances adhered to the resonator and dia-
phragm.
• If any fault is found, replace the horn.
[Installation]
• Install in the direction as illustrated.
54-11-14
54-11
#630 Inspection of buzzer
• Make sure that the buzzer sounds when battery voltage is ap-
• If any fault is found, replace the buzzer.
54-11-15
#720 to #749 INTERIOR, #750 to #859 OTHERS
#720 Inspection of clock and harness
• Measure the voltage between terminals 1 and 3. Is it 24 V.
• With the starter switch set in “ACC” position, measure the volt-
age between terminals 1 and 4. Is it 24 V.
• With the lighting switch or the fog lamp switch in “ON” position,
measure the voltage between terminals 1 and 2. Is it 24 V.
• If any abnormality in voltage is found, there may be a broken
harness or faulty connection. Correct the harness connection or
replace the harness.
• If no abnormality in voltage is found, there may be a faulty con-
nection between the clock and harness or a faulty clock. Correct
the harness connection or replace the clock. (See Gr63.)
#750 Inspection of blower resistor

• Measure resistance values between each terminal.
Switch position Terminal Resistance value
Standard Low 1–4 7.37 Ω
value Medium high 3–4 6.21 Ω
Medium low 2–4 4.03 Ω
the blower resistor. (See Gr55.)
#754 Inspection of cigarette lighter

the cigarette lighter.
• Make sure that there is continuity between heater element and
body.
• Make sure that when plug is pushed in by hand, it immediately

returns to its original position.
• Place the starter switch at ACC or ON position.
• Push plug into the socket in the cab.
• Measure the time required for plug to automatically return.
Standard value 15 ± 5 seconds
• Check to see that heater element is red-hot.
#759 Inspection of brake pad wear indicator

• Make sure that there is continuity between terminals 1 and 2.
• If any fault is found, replace the brake pad wear indicator. (See
Gr35.)
54-11-16
#750 to #859 OTHERS 54-11
#763 Inspection of heater switch
<Front heater switch>
OFF –
LO (low) 1–5
ME (medium) 1–3–5
HI (high) 1–4–5
<Rear heater switch>

OFF –
LO (low) 1–2
HI (high) 1–3
#764 Inspection of glow plug

• Measure resistance value of glow plug as shown.
Standard value
Approx. 3.8 Ω
(cold resistance of glow plug)
the glow plug. (See Gr11.)
54-11-17
#860 BATTERY
DANGER
• Since flammable hydrogen gas is generated by the battery be sure to obey the following warnings:
• Do not short-circuit the (+) and (–) terminals on the battery.
• Keep sparks and lit cigarettes away from the battery.
• Do not wear metal objects on your arms and lean over battery.
• Because the battery electrolyte is made of diluted sulfuric acid and is corrosive, when handling battery
wear safety glasses and rubber gloves to protect the eyes and hands.
WARNING
• Make sure that you disconnect battery cable (–) first when you disconnect battery cables.
CAUTION
• Make sure that all electrical switches of the vehicle are OFF before connecting battery cables.
• Make sure that you connect battery cable (+) before you connect battery cable (–).
• To prevent a short-circuit be sure that disconnected battery cables do not accidentally touch the battery
terminals.
Service standards
Location Maintenance item Standard value Limit Remedy
Charge or
– Specific gravity of battery electrolyte (20°C) 1.280 1.220
replace
54-11-18
54-11
Service procedure
Inspection of battery
(1) Visual inspection
• If terminal is corroded, scrub off the corrosion from it using a
wire brush.
• If cracks or defects are found on battery, replace it since the
cracks or defects can cause liquid spills.
• If bleed hole of vent plug is clogged, clean the hole.
(2) Inspection of fluid level

• Make sure that the battery electrolyte level is between UPPER
and LOWER.
• If the level is below LOWER, remove vent plug and fill the bat-
tery with distilled water or battery replenisher to UPPER.
(3) Measurement of specific gravity

Measure the specific gravity of the battery electrolyte. If the mea-
sured value is lower than the limit, charge the battery.
NOTE
• The specific gravity of the battery electrolyte depends on
the liquid temperature. Use the following formula to convert
the actual value to the value for a temperature of 20°C.
S20 = St + 0.0007 (t–20)
S20 : Specific gravity at a temperature of 20°C

St : Specific gravity actually measured with the temperature
at t°C
t : Temperature of battery electrolyte
54-11-19
#860 BATTERY
(4) Charging
• Although, as a rule, battery charging should be done with the
battery removed from the vehicle, if you have to charge the bat-
tery while it is on the vehicle, make sure that you stop the engine
and disconnect battery cable (–).
• Remove vent plug before charging the battery.
• For the recommended charge time and current, see the follow-
ing table to avoid overcharging.
Upper limit
Charge current of fluid
Charge time (H)
(A) temperature
(°C)
*Amount of
Value of 5-hour
Normal discharge (Ah)
rating capacity ×1.2 45
charge Charge
10 (to 1.5)
current (A)
Value of 5-hour
Quick rating capacity 0.5 55
charge
1.5
* Amount of discharge (Ah) =

Amount of
discharge(%)
5-hour rating capacity (Ah) ×
100
• Use the graph shown on the left to calculate the amount of dis-
charge (%).
• Use diluted sulfuric acid, made up of sulfuric acid and refined or
distilled water, as the battery electrolyte.
DANGER
• Keep open flame away from the battery while charging to
prevent explosion.
• It is dangerous to generate sparks while charging the bat-
tery.
• Do not charge battery if the electrolyte level is below LOW-
ER LEVEL, since it can cause early deterioration, heating,
or explosion. Make sure to add the fluid to the specified lev-
el before charging.
WARNING
• Do not let the battery electrolyte level rise and overflow
while charging the battery.
• After charging the battery, tighten vent plug, wash away sul-
furic acid from the battery using water, and dry the surface.
54-11-20
#890 METER CLUSTER 54-11
Inspection procedure
Inspection: Meter cluster
• It is difficult to inspect the control unit and other unit directly.
Therefore, its condition should be judged indirectly through the
inspections of the harnesses and related parts in each system.
• If the related harnesses and parts are normal but the meter indi-
cation is faulty, replace the meter cluster.
54-11-21
54-12 STARTER AND ALTERNATOR
54-12-1
#930 STARTER
<With glow relay>
Removal sequence
1 Starter relay
2 Glow relay
3 Starter
WARNING
• Before removing the starter, dis-
connect the (–) battery cable and in-
sulate the cable and the (–) battery
terminal with tape.
• It is dangerous to leave the (–) bat-
tery cable connected since the bat-
tery cable voltage is always present
at terminal B.
Installation sequence
Follow the removal sequence in reverse.
<Without glow relay>
Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Nut (harness mounting) 9.8 to 11.8 {1.0 to 1.2} –
54-12-2
54-12
M E M O
54-12-3
#930 STARTER
Disassembly sequence
1 Stopper ring 12 Yoke 23 Gear shaft
2 Pinion stopper 13 Rear bearing 24 Washer
3 Pinion 14 Washer 25 Internal gear
4 Spring 15 Armature 26 Overrunning clutch
5 Magnetic switch 16 Ball 27 Lever
6 Shim 17 Cover 28 Front bearing
7 Rear bracket 18 Rubber packing 29 Oil seal
8 Brush spring 19 Planetary gear 30 Front bracket
9 Brush (–) 20 Rubber packing
10 Brush holder 21 Plate : Non-reusable parts
11 Brush (+) 22 E-ring
54-12-4
54-12
CAUTION
• When the armature is removed, the ball may come out with it. Take care not to lose the ball.
• Do not remove the rear and front bearing unless defects are evident.
• It is not necessary to remove the pinion when only the motor section needs to be disassembled for inspection, like
when inspecting brushes and related parts.
• Be sure to remove the pinion before disassembling any other parts.
Assembly sequence
Follow the disassembly sequence in reverse.
• Whenever the magnetic switch is replaced, the pinion gap must be adjusted.
• The rubber packing is serviceable if any defect is not found.
Service standards (Unit: mm)

– Pinion gap 0.5 to 2.0 – Adjust
No-load charac- Current 85 A or less – Correct or

– teristics With 23 V applied
Rotation speed 3100 rpm or higher – replace
26.7 to 36.1 N 14.7 N

8 Brush spring pressure Replace
{2.7 to 3.7 kgf} {1.5 kgf}
9,11 Brush length 17.5 11 Replace
Commutator outside diameter 32 31.4
0.1 or Replace
Runout of commutator periphery –
15 higher
Correct or
Mold depth between segments 0.5 to 0.8 0.2 or less
replace

Nut (tightening cable to terminal M) 8.9 to 12.7 {0.9 to 1.3} –
Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Lever contact surface of magnetic switch
Sliding surfaces of gear shaft and overrunning Multipurpose grease
As required
clutch [NLGI No. 2 (Li soap)]
Sliding surfaces of lever and overrunning clutch
Sliding surfaces of armature and gear shaft
Ball
Molykote AG650 As required
Teeth of planetary gear and internal gear
Washer
Multipurpose grease
Oil seal [NLGI No.2 (Li soap)] As required
or grease attached to oil seal
Fitting surface of spline part of gear shaft with spline part Multemp OA-171
of overrunning clutch As required
(Kyodo Yushi Co., Ltd.)
54-12-5
#930 STARTER
Special tools
Bearing remover and

installer MH063596
Removal and installation
A: MH063614
A: Bearing remover of front bearing
and installer B: MH063618
B: Bearing Installer
Work before disassembly

Mating mark: Rear bracket and yoke
Disassembly procedure
Disassembly: Pinion
• For removal of the pinion, current must be supplied to the starter
such that the pinion springs out.
WARNING
• When the starter is energized, the pinion will spring out and
rotate. Be careful not to touch it with your hands.
• The magnetic switch may become very hot during inspec-
tions. Be careful when touching it.
CAUTION
• Do not energize the pull-in coil P for longer than 10 sec-
onds, and do not energize the holding coil H for longer than
30 seconds. If these periods are exceeded, the coils may
overheat and burn out.
• To make the pinion spring out, be sure to energize the start-
er such that its parts are positioned correctly. If the starter
is not energized and the lever is pulled to make the pinion
come out, the front bracket and/or lever may be damaged
by the shock inflicted upon them when the stopper ring is
removed.
• When current is supplied to the starter, a large current (100
A or higher) will flow. For inspection purposes, use booster
cables or similarly thick cables. It is also important to en-
sure that all connections are secure.
54-12-6
54-12
• Connect the starter as illustrated.
• The following operations are performed with current supplied to
the starter. Thus, the entire procedure for removal of the pinion
must be completed within 30 seconds.
• Turn ON switches 1 and 2 to supply current to the starter. The
pinion will spring out and rotate.
• After the pinion starts to rotate, quickly (within five seconds) turn
OFF switch 2 to stop the pinion’s rotation.
CAUTION
• When switches 1 and 2 are turned ON, the pull-in coil P and
holding coil H are both energized. The circuit is connected
such that no voltage is applied to starter terminal B, so cur-
rent flows to the pull-in coil while the pinion rotates. To pre-
vent the pull-in coil from burning out, it is essential to turn
OFF switch 2 quickly (within five seconds) after the pinion
starts to rotate.
• Apply a pipe-shaped implement to the pinion stopper.

• Using a hammer, lightly tap the pipe-shaped implement to re-
move the stopper ring from the ring groove of the pinion stopper.
• Remove the stopper ring and pinion.
• Turn OFF switch 1 to de-energize the starter.
CAUTION
• When the starter is de-energized, the mechanism will at-
tempt to pull in the pinion. Thus, the stopper ring may slip
back into the ring groove of the pinion stopper. If this hap-
pens, energize the starter and go through the pinion remov-
al procedure again.
54-12-7
#930 STARTER
Disassembly: Yoke and brush holder
• Use the following method to remove the yoke and brush holder
in order to prevent the commutator of the armature from being
damaged by the brushes.
• Lift the brushes away from the commutator and hold them lift-
ed by applying the brush springs against the sides of the
brush springs.
• Pull part A of each brush spring and pull up the brushes.

• Hold the brushes in position with the brush springs as illustrat-
ed.
• Remove the yoke and brush holder.
Disassembly: Gear shaft and internal gear

• Remove the E-rings and then the gear shaft and internal gear
from the overrunning clutch.
Proceed as follows if the gear shaft cannot be removed due to
interference of the splined section of gear shaft with internal
parts of the overrunning clutch.
• Press the gear shaft against the overrunning clutch.
• Turn the gear shaft approx. 1/8 of a turn to change the posi-
tion of splined section.
Disassembly: Front bearing
54-12-8
54-12
Inspection: Magnetic switch
the switch.
(1) Test for coil open circuit
• Check that continuity exists between terminals S and M.
• Check that continuity exists between terminal M and the body.
(2) Test for fused-together contacts

• Check that continuity does not exist between terminals B and M.
(3) Test for contact-to-contact continuity

• Push in the end of the magnetic switch to close the internal con-
tacts. Then, check that continuity exists between terminals B
and M.
Inspection: Brush spring pressure

• Using new brushes, measure the load required to separate each
brush spring from its brush.
• If either measurement is lower than the specified limit, replace
the brush springs.
54-12-9
#930 STARTER
Inspection: Brush (–)
(1) Brush length
• If either brush (–) is shorter than the limit, it must be replaced.
CAUTION
• Brush (–) must be replaced together with the brush holder.
(2) Armature commutator contact surface of brush

• If the commutator contact surface of either brush is rough or un-
evenly worn, rectify it with emery paper (#300 to 500).
Inspection: Brush holder

• Thoroughly clean the (+) brush holder and the (–) holder plate,
then, check that continuity does not exist between them.
• If continuity exists, there is a short circuit and the brush holder
must be replaced.
Inspection: Yoke
(1) Test for coil open circuit
• Check that continuity exists between the cable and the (+)
brush.
• If there is no continuity, there is an open circuit and the yoke or
(+) brush must be replaced.
(2) Test for coil grounding

• Check that continuity does not exist between the yoke and the
(+) brush.
• If continuity exists, the coil is grounded. Inspect the insulation,
and replace the yoke and the (+) brush if the insulation cannot
be rectified.
CAUTION
• The coil may be grounded to the yoke due to the accumula-
tion of worn-off metal particles from the brushes and/or ar-
mature.
Inspection: Brush (+)

(1) Brush length
• If either brush (+) is shorter than the limit, it must be replaced.
(2) Armature commutator contact surface of brush

• If the commutator contact surface of either brush is rough or un-
evenly worn, rectify it with emery paper (#300 to 500).
54-12-10
54-12
Inspection: Armature
(1) Test for coil short circuit
• Hold an iron rod parallel with the armature.
• Slowly rotate the armature by hand.
• If the iron rod vibrates or is pulled toward the armature, the coil
is short-circuited and the armature must be replaced.
(2) Test for coil grounding

• Check that continuity does not exist between the commutator
and the core (or shaft).
• If continuity exists, the coil is grounded and the armature must
be replaced.
(3) Commutator outside diameter

• If the measured value exceeds the limit, replace the armature.
(4) Runout of commutator periphery

• If the reading exceeds the specified limit, replace the armature.
(5) Condition of commutator surface
• If the surface is rough or has stepped wear, rectify it with emery
paper (#300 to 500).
• After rectifying the surface, check the extent of commutator
runout.
(6) Mold depth between segments

• If the measurement is lower than the specified limit, rectify or re-
place the armature.
• To rectify the armature, grind the illustrated portions.
54-12-11
#930 STARTER
• If the mold is worn as illustrated, rectify or replace the armature.
: Acceptable
X : Unacceptable
Inspection: Overrunning clutch

• If the following inspections reveal any abnormality, replace the
overrunning clutch.
• Turn the shaft in direction B and check that it rotates smoothly.
• Turn the shaft in direction A and check that it locks.
Assembly procedure
Assembly: Front bearing
• Press-fit the front bearing -A and -B.
• After the press fitting, caulk the front bearing using the claws on
-A.
CAUTION
• Avoid re-caulking previously caulked points.
Assembly: Yoke and brush holder

• To install the yoke and brush holder, follow the removal se-
quence in reverse.
(See “ Disassembly: Yoke and brush holder”.)
54-12-12
54-12
Assembly: Magnetic switch
• Fit the magnetic switch onto the lever with terminal S aligned as
illustrated.
Assembly: Pinion
• For installation of the pinion, it is not necessary to supply current
to the starter.
• Fit the pinion stopper and pinion onto the overrunning clutch,
making sure they are oriented as illustrated.
• Fit the stopper ring into the ring groove of the overrunning
clutch.
• Pull the pinion hard and securely fit the stopper ring into the ring
groove of the pinion stopper.
Inspection after assembly

Inspection: Performance and pinion gap
• After assembling the starter, perform inspections with current
supplied to it.
WARNING
• When the starter is energized, the pinion will spring out and
rotate. Be careful not to touch it with your hands.
• The magnetic switch may become very hot during inspec-
tions. Be careful when touching it.
CAUTION
• Do not energize the pull-in coil P for longer than 10 sec-
onds, and do not energize the holding coil H for longer than
30 seconds. If these periods are exceeded, the coils may
overheat and burn out.
• When current is supplied to the starter, a large current (100
A or higher) will flow. For inspection purposes, booster ca-
bles or similarly thick cables must therefore be used. Also,
it is important to ensure that all connections are secure.
54-12-13
#930 STARTER
(1) Performance test
• Set the voltage to 23 volts DC.
CAUTION
• The voltage applied must not exceed 24 V.

the starter. Thus, the entire test (consisting of measurement of
the current flowing through the starter and measurement of the
starter’s rotational speed) must be completed within 30 seconds.
• Turn ON the switch to supply current to the starter. The pinion
will spring out and rotate.
CAUTION
• When the switch is turned ON, the pull-in coil P and holding
coil H are both energized. When the large current from the
DC power supply flows from terminal B to terminal M, the
supply of current to the pull-in coil P is cut; only the holding
coil H remains energized. To prevent the holding coil from
burning out, it is essential to complete all operations within
30 seconds.
• Measure the current and the starter’s rotational speed. To

measure the rotational speed, shine a stroboscope on the pin-
ion.
• Turn OFF the switch to de-energize the starter.
• If either measurement is out of specification, disassemble and
inspect the starter again.
(2) Pinion gap


the starter. Thus, the entire procedure for measurement of the
pinion gap must be completed within 30 seconds.
• Turn ON switches 1 and 2 to supply current to the starter. The
pinion will spring out and rotate.
54-12-14
54-12
• After the pinion starts to rotate, quickly (within five seconds) turn
OFF switch 2 to stop the pinion’s rotation.
CAUTION
• When switches 1 and 2 are turned ON, the pull-in coil P and
holding coil H are both energized. The circuit is connected
such that no voltage is applied to starter terminal B, so cur-
rent flows to the pull-in coil while the pinion rotates. To pre-
vent the pull-in coil from burning out, it is essential to turn
OFF switch 2 quickly (within five seconds) after the pinion
starts to rotate.
• Pull out the end of the overrunning clutch and then lightly
push in the end of the overrunning clutch and measure the
amount of movement in the axial direction, i.e., the pinion
gap.
• Turn OFF switch 1 to de-energize the starter.
• If the measurement is out of specification, replace the lever.
54-12-15
#940 ALTERNATOR
Removal sequence
1 Chassis harness
*a: Tension pulley bracket
2 Belt
3 Alternator
WARNING
• Before removing the alternator, disconnect the (–) battery cable and insulate the cable and the (–) battery
terminal with tape.
• It is dangerous to leave the (–) battery cable connected since the battery cable voltage is always present
at terminal B.
Installation sequence
Follow the removal sequence in reverse.
• After installing the alternator, adjust the belt tension. (See Gr14.)
Service standards
At 1500 rpm 30 A or more –
Alternator output current Correct or
*
( when alternator is hot and
producing 27 V)
At 2500 rpm 60 A or more –
replace
3 At 5000 rpm 80 A or more –
Adjustment voltage of regulator 28.5 ± 0.5 V – Replace
(at 5000 rpm, 5 A is loaded)
*The hot condition is that which occurs after the alternator has been running at normal ambient temperature at 5000
rpm and maximum output for 30 minutes.
54-12-16
54-12
Nut (harness mounting) 10 to 15 {1.0 to 1.5} –
Inspection: Alternator
(1) Alternator output current (bench test)
• Connect the alternator as illustrated.
CAUTION
• Wires with sufficient thickness should be used for wiring
and each connection should be securely fastened.
B: Terminal B
E: Terminal E
L: Terminal L
R: Terminal R
• Increase load resistance to the maximum (condition under which

the load current hardly flows).
• Turn switch A and B ON.
• Run alternator at 5000 rpm for 30 minutes by adjusting load re-
sistance so that electric current can conform to the following
standard.
Alternator nominal current
Current
Approx. 80 A
• Measure the current at each specified revolution of alternator.
• If the measured value deviates from the standard value, disas-
semble and check alternator.
(2) Adjustment voltage of regulator (bench test)

• Connect the alternator as illustrated.
B: Terminal B
E: Terminal E
L: Terminal L
R: Terminal R
• Turn switch ON.

• Run alternator at low speeds.
• Increase the speed of alternator to 5000 rpm and measure the
voltage (adjustment voltage) at this speed. At the same time,
make sure that the current is 5 amperes or less at 5000 rpm.
• If the measured value deviates from the standard value, do as
follows:
• If higher than the standard value: Replace the regulator.
• If lower than the standard value: Inspect the alternator related
parts before replacing the regulator.
54-12-17
#940 ALTERNATOR
(3) Inspection of terminal B for discoloration and corrosion
• Check the bolt and nut of terminal B for discoloration and corro-
sion.
• If any discoloration or corrosion is found, polish the bolt threads
and the seating surface of the nut using a wire brush. Also clean
the terminal of the harness.
• If they cannot be cleaned by polishing, replace the faulty part(s).
When replacing the nut, it must be replaced as the terminal set.
(See later section.)
54-12-18
54-12
Disassembly sequence
1 Pulley 9 Field coil
2 Fan 10 Stator
3 Spacer 11 Plate L
4 Rear bearing 12 Regulator
5 Rotor 13 Cover
6 Cover 14 Terminal B
7 Front bearing 15 Rectifier
8 Front bracket 16 Rear bracket
• Do not remove the rear and front bearing, stator, or brush unless faulty.
Assembly sequence
Follow the disassembly sequence in reverse.
Service standards
9 Field coil resistance (at 20°C) 4.2 to 5.1 Ω – Replace

Nut (rectifier mounting) 12.7 to 18.6 {1.3 to 1.9} –
Nut (rectifier mounting) 5.9 to 9.8 {0.6 to 1.0} –
54-12-19
#940 ALTERNATOR
Inspection before removal
Inspection: Pulley
• Hold the outer periphery of the pulley and rotate the fan slowly
clockwise. Then hold the fan and rotate the pulley slowly coun-
terclockwise. If any of the following conditions is found, replace
the pulley.
• Does not rotate
• Dragging
• Rotate unsmoothly
• Hold the outer periphery of the pulley and strongly rotate the fan
clockwise. If it rotates one or more turns, replace the pulley.
Removal procedure
Removal: Rotor & front bracket
• Remove the bolts securing the front bracket and rear bracket.
• Insert the tip of a flat-blade screwdriver between the front brack-
et and the stator.
• Separate the rotor and front bracket from the stator and rear
bracket by prying them with the screwdriver.
CAUTION
• Do not insert the screwdriver deeply as it may damage the
stator coil, resulting in short-circuit.
Removal: Pulley
• Hold the rotor in a vise.
• Loosen the pulley using the hexagonal hole of the pulley.
• Remove the pulley.
CAUTION
• When holding the rotor in a vise, hold at the roots of the
claws of the core.
• If it is held at the claw of the core, the claw may break.
54-12-20
54-12
Disassembly: Field coil
• Remove screw A (2 places).
CAUTION
• If screw B are removed first, the weight of field coil may be
placed on the joining portion with regulator which is fixed
with screw A, causing break of the joining portion. To avoid
this, remove screw A first.
• Remove screw B (3 places).

CAUTION
• If screw B are removed, the field coil will fall under its own
weight. Keep the field coil supported with your hand.
• Remove field coil.

CAUTION
• Do not remove the field coil forcibly, otherwise the portion
that joins with the regulator may be caught by the stator
coil.
Disassembly: Stator
• Disconnect lead of stator from rectifier. The lead is soldered to
the diode of the rectifier at 8 places.
CAUTION
• Unsolder within as short a time period as possible (within 5
seconds).
• Diode can be easily damaged by heat.
Inspection: Field coil
• Measure the resistance between the terminals of field coil.
field coil.
Inspection: Stator
the stator.
(1) Continuity between each lead wire
• Check that there is continuity between each stator lead.
• lf there is no continuity, the lead has broken.
54-12-21
#940 ALTERNATOR
(2) Continuity between each lead wires and the core
• Check that there is no continuity between lead wires and the
core.
• If there is continuity, the lead wire has short-circuited.
Inspection: Rectifier
• Check the function of diodes within rectifier properly. If any
fault is found, replace the rectifier.
If resistance is infinite in both cases, the diode is open.
If resistance is close to 0 Ω in both cases, the diode has shorted.
A, B, C, D: Lead connecting area of stator coil

E, G: Heat sink area
F: Regulator connecting area
• Inspection should be conducted twice, changed over the positive

probe and the negative probe of the tester.
• When inspecting using a tester, the current flowing through the
rectifier is smaller than usual. Therefore, an incorrect resistance
value may be indicated on the tester.
Additionally, incorrect indications become larger as the range of
the tester gets smaller. Set the tester to the largest possible
scale.
Assembly procedure
Assembly: Stator
• To install the stator, follow the disassembly sequence in reverse.
(See “ Disassembly: Stator”.)
54-12-22
54-13 ON-VEHICLE INSPECTION AND
ADJUSTMENT
54-13-1
#950 INSPECTION OF ALTERNATOR
Performance test
• The on-vehicle inspection is only a simplified check. Use a test
bench for accurate checking.
• Connect the meters to the alternator as shown.
WARNING
• To prevent possible injury, be sure to disconnect the nega-
tive terminal of the battery and insulate it with tape before
working on the wiring. With the negative terminal (–) of the
battery connected, battery voltage is always applied to ter-
minal B.
• To connect to switch, use a lead wire with the same or larg-
er diameter than that of the chassis harness connected to
terminal B.
• Turn on switch and make sure that voltmeter indicates battery

voltage.
• Start the engine.
• Immediately turn on the switches for all lamps on the vehicle.
• Immediately accelerate the engine to the speed indicated below
and measure the alternator’s output current.
Approx. 3100 rpm
• The alternator is considered to be good if the measured value is
70% or more of the nominal output current.
Alternator nominal output
Voltage Output current
24 V 80 A
54-13-2
#951 INSPECTION OF REGULATOR 54-13
Service standards
– Adjusting voltage 28.5 ± 0.5 V – Replace
• Connect the meters to the alternator as shown.

WARNING
• To prevent possible injury, be sure to disconnect the nega-
tive terminal of the battery and insulate it with tape before
working on the wiring. With the negative terminal (–) of the
battery connected, battery voltage is always applied to ter-
minal B.
• To connect to switch, use a lead wire with the same or larg-
er diameter than that of the chassis harness connected to
terminal B.
• Turn off the switches for lamps, heater, etc. so that electric loads
may not be applied during the inspection.
• Turn on switch and then start the engine.
• If the output current is 5 amperes or less when the engine speed
is raised to the appropriate speed indicated below, then mea-
sure the voltage at terminal B.
Approx. 3100 rpm
• If the output current is in the range from 5 amperes, the mea-
sured value (regulated voltage) will be slightly lower.
• If the output current is 5 amperes or more, do one of the follow-
ing:
• Run the engine for a while to charge the battery.
• Replace the battery with a fully-charged one.
• If the measured value deviates from the standard value, conduct
checking again on the test bench.
54-13-3
#955 INSPECTION OF PREHEATING SYSTEM
1. Preparation for inspection
Service standards
60°C or higher No pre-glow operation –
Pre-glow
0 to 60°C About 12 seconds –
time
0°C or below About 12 seconds –
60°C or higher No after-glow operation –
Coolant After-glow
– 0 to 60°C No after-glow operation – Inspect
temperature time
60°C or higher No illumination –
Indicator
lamp ON 0 to 60°C No illumination –
time
• Turn the starter switch to OFF.

• Connect a check lamp to the glow plug.
• Remove the water temperature sensor from the engine, and

close the sensor mounting hole with the plug (M16 × 1.5 mm).
54-13-4
54-13
• Connect the extension harness between the water temperature
sensor and connector.
• Place the water temperature sensor in a container of water.
• Conduct the following test while changing the temperature of
water in the container. If anything abnormal is found, check rele-
vant components.
(1) Pre-glow time and indicator lamp ON time checking

• Turn the starter switch to ON (without starting the engine), and
confirm that the pre-glow time and indicator lamp ON time at
each water temperature conform with standard values.
• Measure the illuminating time of the check lamp to measure the
pre-glow time.
• Measure the meter cluster glow lamp illuminating time to mea-
sure the indicator lamp ON time.
(2) After-glow time checking
• Start the engine, and measure how long the illumination of check
lamp lasts after the glow lamp on the meter cluster goes out to
ensure that the after-glow time conforms with the standard val-
ue.
2. Inspection Based on Diagnosis Codes

2.1 Diagnosis code list
NOTE
different.
Warning lamp lit

Code Message
Flashes RED ORANGE
P0380 Relay for Glow Relay 26 – –
P0381 Glow Lamp 89 – –
2.2 Diagnosis code generation conditions and inspection items

P0380: Relay for Glow Relay (Warning lamp flashes: 26)
Diagnosis code is generated under either of the following conditions.
• Glow drive relay circuit remains shorted to battery as detected for approx. 1
second.
Generation conditions • Glow drive relay circuit remains shorted to ground as detected for approx. 1
second.
• Glow drive relay circuit remains open as detected for approx. 1 second.
• Glow drive relay circuit remains overloaded as detected for approx. 1 second.
System recovers if signal remains normal for 1 second when starter switch is ON
Recoverability
position.
Control effected by electronic control unit • Suspend glow control
Service data 8D: Glow Relay
Actuator test AF: Relay for Glow Relay
Electronic control unit connector 01 : Glow drive relay
Inspection
#201: Glow drive relay
Electrical equipment
#350: Engine electronic control unit
Electronic circuit diagram Glow drive relay system (See 220 .)
54-13-5
P0381 : Glow Lamp (Warning lamp flashes: 89)
Diagnosis code is generated under either of the following conditions.
• Glow indicator circuit remains shorted to battery as detected for approx. 1 sec-
ond.
Generation conditions • Glow indicator circuit remains shorted to ground as detected for approx. 1
second.
• Glow indicator circuit remains open as detected for approx. 1 second.
• Glow indicator circuit remains overloaded as detected for approx. 1 second.
System recovers if signal remains normal for 1 second when starter switch is ON
Recoverability
position.
• Warning output
Control effected by electronic control unit
• Normal control is effected.
Service data 8E: Glow Relay Indicator Lamp
Actuator test B0: Glow Indicator Lamp
Electronic control unit connector 02 : Glow indicator lamp
Inspection
Meter cluster
Electronic circuit diagram Glow drive relay system (See 220 .)
3. Multi-Use Tester Service Data

CAUTION
• It is possible to see service data and actuator tests simultaneously.
No. Item Data Inspection condition Requirement

With engine coolant temperature at or
below 60°C, turn starter switch OFF
ON
and ON. Inspect immediately after
turning ON starter switch.
8D Glow Relay ON/OFF above 60°C.
OFF
and ON. Inspect 40 seconds after turn-
ing starter switch ON.
[Actuator test] AF: Relay for Glow Relay
ON
and ON. Inspect immediately after
turning ON starter switch.
8E Glow Relay Indicator Lamp ON/OFF above 60°C.
OFF
and ON. Inspect 40 seconds after turn-
ing starter switch ON.
[Actuator test] B0: Glow Indicator Lamp
54-13-6
54-13
4. Actuator Tests Performed Using Multi-Use Tester
No. Item Explanation Confirmation method
Glow drive relay drive signal Actuation noise should be
heard.
[Service data]
8D: Glow Relay
AF Relay for Glow Relay
Glow indicator lamp illumination signal Actuation noise should be

heard.
[Service data]
8E: Glow Relay Indicator
B0 Glow Indicator Lamp Lamp
54-13-7
5. Inspection Performed at Electronic Control Unit Connectors
• The following inspection should assist troubleshooting by enabling you to verify whether or not electronic control
unit signals are correctly transmitted via the vehicle harnesses and connectors.
The numbers in the table 01 , 02 , etc. cross-refers you to the corresponding numbers in the table in “2. Inspec-
tion Based on Diagnosis Codes”.
5.1 Electronic control unit connector terminal layout
5.2 Inspection procedure

• Some inspections are performed with the connectors removed. Others are performed with the connectors fitted.
CAUTION
• Do not touch terminals that are irrelevant to the inspection being performed. When using a tester, be
careful not to cause a short circuit across the terminals being measured.
Check item Measurement method

[Conditions]
• Keep the vehicle harnesses connected to the electronic control unit con-
nector halves. (Inspection is made at the back of the vehicle connectors.)
01 • Carry out the actuator test “AF - Relay for Glow Relay” using Multi-Use
Glow drive relay voltage Tester.
[Normal status]
Terminals (+) - (–): A73 - A7
• Battery voltage
[Conditions]
• Keep the vehicle harnesses connected to the electronic control unit con-
nector halves. (Inspection is made at the back of the vehicle connectors.)
02 • Carry out the actuator test “B0 - Glow Indicator Lamp” using Multi-Use
Glow indicator lamp illumination Tester.
[Normal status]
Short the terminal A51 to ground.
• The glow indicator lamp should illuminate.
54-13-8
#956 INSPECTION OF STARTER CONTINUOUS ENERGIZING PREVENTING FUNCTION 54-13
1. Inspection Based on Diagnosis Codes
1.1 Diagnosis code list
NOTE
different.
Warning lamp lit

Code Message
Flashes RED ORANGE
P0615 Starter Safety Relay (Over Load) 48 – O
P0616 Starter Safety Relay (Low) 48 – O
P0617 Starter Safety Relay (High) 48 – O
1.2 Diagnosis code generation conditions and inspection items

P0615: Starter Safety Relay (Over Load) (Warning lamp flashes: 48)
Current flowing in the safety relay remains above the specified value for 3 sec-
Generation conditions
onds.
System recovers if current flowing in the safety relay remains normal for 1 sec-
Recoverability
ond.
Control effected by electronic control unit • Normal control
Service data 8F: Starter Safety Relay
Actuator test B1: Starter Safety Relay
Electronic control unit connector 01 : Safety relay
Inspection
#201: Safety relay
Electronic circuit diagram Safety relay system (See 210 .)
P0616: Starter Safety Relay (Low) (Warning lamp flashes: 48)

Generation conditions Safety relay circuit remains shorted to ground or open as detected for 3 seconds.
Recoverability System recovers if signal becomes with starter switch ON position.
Inspection
#201: Safety relay
P0617: Starter Safety Relay (High) (Warning lamp flashes: 48)

Generation conditions Safety relay circuit remains shorted to battery as detected for 3 seconds.
Recoverability System recovers if signal becomes with starter switch ON position.
Inspection
#201: Safety relay
54-13-9
#956 INSPECTION OF STARTER CONTINUOUS ENERGIZING PREVENTING FUNCTION
2. Multi-Use Tester Service Data
CAUTION
• It is possible to see service data and actuator tests simultaneously.
No. Item Data Inspection condition Requirement

Carry out the actuator test “B1 - Starter
safety relay” using Multi-Use Tester. ON
The relay should be ON.
8F Starter Safety Relay ON/OFF
When not testing OFF
[Actuator test] B1: Starter Safety Relay
3. Actuator Tests Performed Using Multi-Use Tester

No. Item Explanation Confirmation method
Starter safety relay drive signal Actuation noise should be
heard.
[Service data]
8F: Starter Safety Relay
B1 Starter Safety Relay
54-13-10
54-13
4. Inspection Performed at Electronic Control Unit Connectors
• The following inspection should assist troubleshooting by enabling you to verify whether or not electronic control
unit signals are correctly transmitted via the vehicle harnesses and connectors.
The numbers in the table 01 , etc. cross-refers you to the corresponding numbers in the table in “1. Inspection
Based on Diagnosis Codes”.
4.1 Electronic control unit connector terminal layout
4.2 Inspection procedure

• Some inspections are performed with the connectors removed. Others are performed with the connectors fitted.
CAUTION
• Do not touch terminals that are irrelevant to the inspection being performed. When using a tester, be
careful not to cause a short circuit across the terminals being measured.
Inspection item Procedures

[Conditions]
• Keep the vehicle harnesses connected to the electronic control unit connector halves. (Inspection is
made at the back of the vehicle connectors.)
01
[Normal status]
Safety relay voltage
Terminals (+) - (–): A81 - A49
• Relay ON: 24 V
• Relay OFF: 0 V
54-13-11
#960 HEADLAMP AIMING
1. Preparation before Adjustment
• Park the vehicle on a level place.
WARNING
• Be sure to put tire chocks securely in place.
• Unload the vehicle and make sure no one is in it.

• Inflate the tires to the specified pressure.
• Seat one person of an equivalent mass (75 kg) in the vehicle.
• Start the engine and check that the battery is being charged.
• Place convergent lamp tester and the vehicle facing each other
as shown in the drawing.
• Align the center of headlamp bulb and the center of convergent
lens of convergent lamp tester. (The drawing shows the left-
hand headlamp.)
• When adjusting one headlamp, mask the other to avoid light
leakage.
2. Adjustment
WARNING
• Do not mask a lit headlamp for more than 10 minutes or the heat generated might cause a fire.
• Make adjustment of the main beam by turning the screws so that

the center of hot zone of main beam is positioned as shown in
the illustration.
• Make adjustment of the main/dipped beam by turning the
screws so that the elbow point of cut-off line of the lower beams
is positioned as shown in the illustration.
• The adjustment must be finished by “tightening” the screw.
Adjusting direction for optical axis

Right-hand headlamp Left-hand headlamp
Upward Downward Leftward Rightward Upward Downward Leftward Rightward
Screw for main beam Counter- Counter-
Clockwise – – Clockwise
vertical adjustment clockwise clockwise
Screw for main beam Counter- Counter-
Clockwise Clockwise
horizontal adjustment clockwise clockwise
Screw for main/dipped
Counter- Counter-
beam vertical adjust- Clockwise Clockwise
clockwise clockwise
ment
Screw for main/dipped
Counter- Counter-
beam horizontal adjust- Clockwise Clockwise
clockwise clockwise
ment
(Turning direction of the screws in the table is as viewed from the front.)
54-13-12
54-13
54-13-13
#961 FOG LAMP AIMING
1. Preparation before Adjustment
• Park the vehicle on a level place and put tire chocks.
• Unload the vehicle and make sure no one is in it.
• Inflate the tires to the specified pressure.
• Seat one person of an equivalent mass (75 kg) in the vehicle.
• Start the engine and check that the battery is being charged.
• Place convergent lamp tester and the vehicle facing each other
as shown in the drawing.
• Align the center of fog lamp bulb and the center of convergent
lens of convergent lamp tester. (The drawing shows the left-
hand fog lamp.)
• When adjusting one headlamp, mask the other to avoid light
leakage.
WARNING
• Do not mask a lit headlamp for more than 10 minutes or the
heat generated might cause a fire.
2. Adjustment
• Turn on fog lamp.
• Make adjustment by the following procedure so that the fog lamp
cut-off line is in the illustrated position.
• Both right and left fog lamps should be adjusted in the same
manner.
• The adjustment must be finished by “tightening” the screw.
• Horizontal adjustment is unnecessary.
Adjusting direction for optical axis

Up Down
Rotating direction of
Clockwise Counter-clockwise
screw
(Turning direction of the screws in the table is as viewed from the
front.)
54-13-14
54-14 CONNECTOR CONFIGURATION
CHART
54-14-1
CONNECTOR CONFIGURATION CHART
AA type
Number shows
Female connector Male connector
number of pins
AA1A
AA2A
AA2B
AA3A
AA3B
AA4A
AA4B
AA6A
AA6B
54-14-2
54-14
Number shows
number of pins
AA8A
AA10A
AA12A
AB type
Number shows
number of pins
AB1A
AB2A
AB2B
AB2C
AB3A
AB3B
54-14-3
Number shows
number of pins
AB4A
AB6A
AB6B
AB8A
AB8B
AB12A
AB12B
AB14A
54-14-4
54-14
Number shows
number of pins
AB14B
AB16A
AB16B
AB52A
AB52B
AC type
Number shows
number of pins
AC1A
AC1B
AC2A
54-14-5
Number shows
number of pins
AC2B
AC2C
AC2D
AC3A
AC4A
AC4B
AD type
Number shows
number of pins
AD1A
AD2A
AD2B
54-14-6
54-14
AE type
Number shows
number of pins
AE2A
AE3A
AE5A
AE7A
AE9A
AE11A
AE13A
AE15A
AE16A
54-14-7
Number shows
number of pins
AE16B
AE16C
AE17A
AG type
Number shows
number of pins
AG16A
AG20A
AH type
Number shows
number of pins
AH10A
54-14-8
54-14
Number shows
number of pins
AH12A
AH12B
AH16A
AH18A
AH18B
54-14-9
Number shows
number of pins
AH22A
AH24A
AH26A
AJ type
Number shows
number of pins
AJ2A
AJ4A
54-14-10
54-14
Number shows
number of pins
AJ8A
AJ10A
AJ12A
AJ16A
54-14-11
Number shows
number of pins
AJ20A
AK type
Number shows
number of pins
AK2A
AK3A
AK4A
AK6A
AK8A
54-14-12
54-14
Number shows
number of pins
AK10A
AK12A
AK14A
AK18A
AK20A
AK20B
54-14-13
Number shows
number of pins
AK22A
AK22B
AL type
Number shows
number of pins
AL1A
AL2A
AL2B
54-14-14
54-14
Number shows
number of pins
AL3A
AL3B
AL3C
AL3D
AL3E
54-14-15
Number shows
number of pins
AL4A
AL4B
AL6A
AL6B
AL8A
AL8B
54-14-16
54-14
AM type
Number shows
number of pins
AM1A
AM1B
AM2A
AM2B
AM2C
AM4A
AM4B
AM6A
AM6B
54-14-17
Number shows
number of pins
AM8A
AM8B
AM10A
AM10B
AN type
Number shows
number of pins
AN1A
AN2A
AN2B
AN3A
AN4A
54-14-18
54-14
Number shows
number of pins
AN4B
AN6A
AN6B
AN8A
AN8B
AP type
Number shows
number of pins
AP1A
AP1B
AP2A
AP2B
54-14-19
Number shows
number of pins
AP2C
AQ type
Number shows
number of pins
AQ1A
AQ3A
AQ3B
AQ5A
AQ6A
AQ8A
AQ12A
54-14-20
54-14
AR type
Number shows
number of pins
AR2A
AR2B
AR2C
AR2D
AR2E
AR2F
AR2G
AR2H
AR3A
54-14-21
AS type
Number shows
number of pins
AS1A
AS2A
AS2B
AT type
Number shows
number of pins
AT4A
AU type
Number shows
number of pins
AU2A
AU6A
AU8A
AU10A
54-14-22
54-14
Number shows
number of pins
AU12A
AU13A
AU16A
AU16B
AU16C
AV type
Number shows
number of pins
AV1A
AV2A
AW type
Number shows
number of pins
AW1A
54-14-23
Number shows
number of pins
AW1B
AW1C
AW2A
AX type
Number shows
number of pins
AX2A
AX3A
AX4A
AY type
Number shows
number of pins
AY2A
54-14-24
54-14
AZ type
Number shows
number of pins
AZ2A
BA type
Number shows
number of pins
BA3A
BB type
Number shows
number of pins
BB2A
BB3A
BC type
Number shows
number of pins
BC3A
BD type
Number shows
number of pins
BD6A
54-14-25
Number shows
number of pins
BD8A
BD12A
BD16A
BD20A
BE type
Number shows
number of pins
BE6A
BF type
Number shows
number of pins
BF6A
BF8A
BF10A
54-14-26
54-14
Number shows
number of pins
BF12A
BG type
Number shows
number of pins
BG10A
BG12A
BG16A
BJ type
Number shows
number of pins
BJ5A
BJ7A
BJ9A
54-14-27
BM type
Number shows
number of pins
BM2A
BM2B
BM2C
BM3A
BM4A
BN type
Number shows
number of pins
BN1A
BQ type
Number shows
number of pins
BQ1A
BQ2A
54-14-28
54-14
Number shows
number of pins
BQ3A
BQ3B
BR type
Number shows
number of pins
BR1A
BR2A
BR4A
BR4B
BS type
Number shows
number of pins
BS1A
54-14-29
Number shows
number of pins
BS2A
BS3A
BS4A
BS6A
BS8A
BT type
Number shows
number of pins
BT2A
BT3A
54-14-30
54-14
Number shows
number of pins
BT4A
BT6A
BT8A
BT10A
BT12A
BT16A
BT16B
BT16C
BT20A
54-14-31
Number shows
number of pins
BT20B
BT20C
BU type
Number shows
number of pins
BU4A
BU6A
BW type
Number shows
number of pins
BW2A
BW2B
BW3A
BW3B
54-14-32
54-14
Number shows
number of pins
BW4A
BW4B
BW6A
BW6B
BW8A
BW10A
BX type
Number shows
number of pins
BX2A
54-14-33
Number shows
number of pins
BX3A
BX5A
BX7A
BX9A
BX11A
54-14-34
54-14
Number shows
number of pins
BX13A
BX15A
BX17A
BX19A
BY type
Number shows
number of pins
BY4A
54-14-35
BZ type
Number shows
number of pins
BZ12A
BZ16A
BZ22A
BZ26A
CA type
Number shows
number of pins
CA2A
CB type
Number shows
number of pins
CB16A
54-14-36
54-14
CD type
Number shows
number of pins
CD35A
CD55A
CE type
Number shows
number of pins
CE2A
CE4A
CE12A
CE16A
CE20A
54-14-37
CF type
Number shows
number of pins
CF21A
CH type
Number shows
number of pins
CH2A
CH2B
CH3A
CK type
Number shows
number of pins
CK3A
CL type
Number shows
number of pins
CL14A
54-14-38
54-14
CM type
Number shows
number of pins
CM28A
CM30A
CM35A
CN type
Number shows
number of pins
CN2A
CN12A
CN16A
54-14-39
CP type
Number shows
number of pins
CP40A
CP40B
CP80A
CQ type
Number shows
number of pins
CQ2B
CQ3A
54-14-40
54-14
Number shows
number of pins
CQ8A
CR type
Number shows
number of pins
CR16A
CS type
Number shows
number of pins
CS2A
CT type
Number shows
number of pins
CT3A
CT3B
CT10A
54-14-41
CU type
Number shows
number of pins
CU6A
CU9A
CU12A
CU15A
CU17A
CU18A
CV type
Number shows
number of pins
CV8A
CW type
Number shows
number of pins
CW16A
54-14-42
54-14
Number shows
number of pins
CW25A
CW31A
CW32A
CX type
Number shows
number of pins
CX30A
CX32A
CX32B
CX32C
CY type
Number shows
number of pins
CY17A
54-14-43
Number shows
number of pins
CY22A
CY24A
CY28A
CY31A
DA type
Number shows
number of pins
DA20A
DA22A
DA25A
DB type
Number shows
number of pins
DB2A
54-14-44
54-14
DC type
Number shows
number of pins
DC3A
DD type
Number shows
number of pins
DD1A
DD2A
DD2B
DD2C
DD2E
DD2F
DD3A
54-14-45
Number shows
number of pins
DD4A
DD4C
DD5A
DD6A
DD6B
DD6C
DD6E
DD7A
DD8A
54-14-46
54-14
Number shows
number of pins
DD9A
DD10A
DD10B
DD11A
DD12A
DD12B
DD12C
DD13A
DD13B
54-14-47
Number shows
number of pins
DD14A
DD14B
DD15A
DD15B
DD16A
DD16B
DD18A
DD20A
DD22A
54-14-48
54-14
DE type
Number shows
number of pins
DE3A
DE7A
DF type
Number shows
number of pins
DF3A
DG type
Number shows
number of pins
DG1A
DG1B
DG1C
DG1D
DG2A
54-14-49
Number shows
number of pins
DG2B
DG2C
DG2D
DG2E
DG2F
DG2G
DG2H
DG2J
DG2K
54-14-50
54-14
Number shows
number of pins
DG2L
DG2M
DG3A
DG3B
DG4A
DG4B
DG4C
DG5A
DG5B
54-14-51
Number shows
number of pins
DG5C
DG5D
DG6A
DG6B
DG6C
DG8A
DG8B
DG10A
DG12A
54-14-52
54-14
DH type
Number shows
number of pins
DH2A
DH5A
DH6A
DH10A
DH14A
DH18A
DH20A
DH22A
54-14-53
DJ type
Number shows
number of pins
DJ10A
DJ10B
DK type
Number shows
number of pins
DK2A
DK2B
DK3A
DK4A
DL type
Number shows
number of pins
DL4A
54-14-54
54-14
DM type
Number shows
number of pins
DM3A
DM4A
DN type
Number shows
number of pins
DN4A
DP type
Number shows
number of pins
DP5A
DQ type
Number shows
number of pins
DQ2A
DQ2B
DQ2C
54-14-55
Number shows
number of pins
DQ2D
DQ2E
DQ2F
DQ3A
DQ3B
DQ3D
DQ4A
DQ4B
DQ4C
54-14-56
54-14
Number shows
number of pins
DQ8A
DR type
Number shows
number of pins
DR2A
DS type
Number shows
number of pins
DS2A
DS6A
DT type
Number shows
number of pins
DT1A
DT2A
DT3A
54-14-57
Number shows
number of pins
DT4A
DU type
Number shows
number of pins
DU2A
DV type
Number shows
number of pins
DV4A
DW type
Number shows
number of pins
DW2A
DX type
Number shows
number of pins
DX2A
54-14-58
54-14
DY type
Number shows
number of pins
DY1A
DY1B
DZ type
Number shows
number of pins
DZ1A
EA type
Number shows
number of pins
EA8A
EA8B
EB type
Number shows
number of pins
EB8A
54-14-59
EC type
Number shows
number of pins
EC2A
ED type
Number shows
number of pins
ED2A
EE type
Number shows
number of pins
EE2A
EF type
Number shows
number of pins
EF2A
EG type
Number shows
number of pins
EG4A
54-14-60
54-14
EH type
Number shows
number of pins
EH2A
EJ type
Number shows
number of pins
EJ9A
EK type
Number shows
number of pins
EK2A
EL type
Number shows
number of pins
EL2A
EM type
Number shows
number of pins
EM40A
EM81A
54-14-61
EN type
Number shows
number of pins
EN4A
EN5A
EP type
Number shows
number of pins
EP34A
EQ type
Number shows
number of pins
EQ4A
EQ4B
EQ5A
EQ5B
54-14-62
54-14
ER type
Number shows
number of pins
ER2A
ER6A
ER8A
ES type
Number shows
number of pins
ES2A
ES2B
ES2C
ES3A
ES3B
54-14-63
Number shows
number of pins
ES4A
ET type
Number shows
number of pins
ET1A
ET1B
ET1D
ET2A
ET2B
ET2C
ET2D
ET2F
54-14-64
54-14
Number shows
number of pins
ET2G
ET2L
ET3A
ET3B
ET3C
ET4A
ET4B
ET5A
ET5B
54-14-65
Number shows
number of pins
ET5D
ET6A
ET6B
ET6C
ET8A
ET8B
ET10A
ET32A
EU type
Number shows
number of pins
EU1A
54-14-66
54-14
EV type
Number shows
number of pins
EV2A
EW type
Number shows
number of pins
EW12A
EX type
Number shows
number of pins
EX5A
EY type
Number shows
number of pins
EY3A
EZ type
Number shows
number of pins
EZ3A
54-14-67
FA type
Number shows
number of pins
FA2B
FA3A
FA5A
FB type
Number shows
number of pins
FB55A
GA type
Number shows
number of pins
GA1A
GA2A
GA2B
54-14-68
54-14
Number shows
number of pins
GA3A
GA3B
GA4A
GA4B
GA6A
GA6B
GA8A
GA10A
GA12A
54-14-69
GB type
Number shows
number of pins
GB1A
GB2A
GB2B
GB3A
GB3B
GB4A
GB4B
GB6A
GB6B
54-14-70
54-14
Number shows
number of pins
GB8A
GB10A
GB12A
GC type
Number shows
number of pins
GC32A
GD type
Number shows
number of pins
GD1A
GD2A
GD3A
54-14-71
Number shows
number of pins
GD3B
GE type
Number shows
Female connector
number of pins
GE58A
GE96A
GF type
Number shows
number of pins
GF31A
GF32A
GF34A
54-14-72
54-14
Number shows
number of pins
GF35A
GF35B
GG type
Number shows
number of pins
GG12A
GG16A
GG22A
GG26A
GH type
Number shows
number of pins
GH3A
54-14-73
GJ type
Number shows
number of pins
GJ2A
GJ2B
GK type
Number shows
number of pins
GK7A
GL type
Number shows
number of pins
GL2A
GM type
Number shows
number of pins
GM2A
GN type
Number shows
number of pins
GN2A
54-14-74
54-14
GP type
Number shows
number of pins
GP8A
GP8B
GQ type
Number shows
number of pins
GQ9A
GR type
Number shows
number of pins
GR13A
GR15A
GS type
Number shows
number of pins
GS2A
GS2B
54-14-75
Number shows
number of pins
GS2C
GS2D
GS3A
GT type
Number shows
number of pins
GT24A
GT28A
GT32A
GU type
Number shows
number of pins
GU24A
54-14-76
54-14
GV type
Number shows
number of pins
GV12A
GV16A
GV20A
GW type
Number shows
number of pins
GW3A
GW3B
GW4A
54-14-77
GX type
Number shows
number of pins
GX1A
GX2A
GY type
Number shows
number of pins
GY4A
GZ type
Number shows
number of pins
GZ2A
HA type
Number shows
number of pins
HA2A
HA4A
HA7A
54-14-78
54-14
Number shows
number of pins
HA15A
HA36A
HA46A
HB type
Number shows
number of pins
HB4A
HC type
Number shows
number of pins
HC11A
HD type
Number shows
number of pins
HD2A
HD2B
54-14-79
Number shows
number of pins
HD3A
HD4A
HD4B
HD5A
HE type
Number shows
number of pins
HE2A
HE3A
HF type
Number shows
number of pins
HF3A
54-14-80
54-14
HG type
Number shows
number of pins
HG2A
HG3A
HG3B
HG4A
HH type
Number shows
number of pins
HH2A
HH2B
HH2C
HH3A
54-14-81
Number shows
number of pins
HH3B
HH3C
HH6A
HH8A
HH10A
HH10B
HH12A
HH12B
HH16A
54-14-82
54-14
Number shows
number of pins
HH18A
HH18B
HH18C
HH20A
HH28A
HH28B
HH38A
HH40A
HH40B
54-14-83
Number shows
number of pins
HH60A
HH81A
HJ type
Number shows
number of pins
HJ2A
HJ2B
HJ2C
HJ3A
HJ3B
HJ3C
HJ4A
54-14-84
54-14
Number shows
number of pins
HJ4B
HJ6A
HJ94A
HK type
Number shows
number of pins
HK2A
HK2B
HK6A
HK11A
54-14-85
HL type
Number shows
number of pins
HL3A
HM type
Number shows
number of pins
HM5A
HN type
Number shows
number of pins
HN3A
HN3B
HN5A
HN5B
HN6A
HN14A
54-14-86
54-14
Number shows
number of pins
HN14B
HN14C
HN14D
HP type
Number shows
number of pins
HP23A
HQ type
Number shows
number of pins
HQ1A
HQ2A
HQ4A
HQ4B
54-14-87
Number shows
number of pins
HQ5A
HQ5B
HQ8A
HQ8B
HQ8C
HQ10A
HQ10B
HQ10C
HR type
Number shows
number of pins
HR3A
54-14-88
54-14
HS type
Number shows
number of pins
HS2A
HS3A
HS4A
HS5A
HS5B
HT type
Number shows
number of pins
HT7A
HU type
Number shows
number of pins
HU2A
HU2B
54-14-89
Number shows
number of pins
HU2C
HU2D
HU3A
HV type
Number shows
number of pins
HV3A
PC type
Number shows
number of pins
PC4A
PE type
Number shows
number of pins
PE8A
PE10A
54-14-90
54-14
Number shows
number of pins
PE10B
PE12A
PE12B
PE14A
54-14-91
Number shows
number of pins
PE18A
PE20A
54-14-92
(EURO 3)
Shop Manual
electrical
FEBRUARY 2013
310 (H)
Pub.No.00ELB0012, FEBRUARY 2013

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(EURO 3)

Pub.No.00ELB0012, FEBRUARY 2013

Shop Manual GROUP INDEX

electrical GENERAL ................................................

©2013 Mitsubishi Fuso Truck & Bus Corporation Printed in Japan

1. ENGINE volume (Pub.No.00ELB0010)

Group No. Group subject

2. CHASSIS volume (Pub.No.00ELB0011)

3. ELECTRICAL volume (Pub.No.00ELB0012)

54-10 ELECTRICAL EQUIP-

54-12 STARTER AND

54-14 CONNECTOR CONFIG-

1 Basic vehicle type B Front engine bus with frame

Power version number

Load carrying capacity of truck class (tonnage)

Vehicle type (B: Bus)

Vehicle type (B: Bus)

Tooth profile (H: Hypoid gear)

On-vehicle Inspection and Adjustment

DANGER Precautions that should be taken in handling potentially dangerous substances

Suggestions or supplementary information for more efficient use of equipment or

Terms and Units

• Left and right

Example: 390 N·m {40 kgf·m}

Unit SI unit {metric unit} Conversion factor

1.6 Major harness division

1.9 Code number: #001 to #999

• Vehicle identification number (VIN) <Type B>

(1) (2) (3) (4) (5) (6) (7)

(1) Geographic area

• An engine name plate indicates the following item.

• Perform service operations on a level surface. Before starting,

• Take extreme care when removing/installing heavy items such

• Never work in shoes that have oily soles.

• Prepare replacement parts ready for installation.

• To facilitate correct reassembly of parts, make alignment marks

• Wear safety goggles when using a grinder or welder. Wear

3. Handling of Sensors, Relays and Electronic Control Units

• When separating connectors, grasp the connectors themselves

• Before washing the vehicle, cover electrical parts to keep them

4. Handling Precautions for Electric Circuits

4.1 Inspection of harnesses

(1.2) Non-waterproof connectors

(2) Inspections with connectors separated

• When using a multimeter to check continuity, do not allow the

4.2 Inspection of connectors

• Check whether wires have been separated from their terminals

• Check that male and female terminals fit together tightly.

(2) Checking for loose terminals

4.3 Inspections when a fuse blows

• The main causes of short circuits are as follows:

4.4 Inspection of chassis ground

• Never disconnect the battery cables with the engine running.

• Never perform inspections using a high-voltage multimeter.

• Keep alternators dry.

• Never operate an alternator with the B and L terminals short-cir-

• Connectors and other parts to be checked are those included or

• Current flows backward as shown below.

1.1 Systems and diagnosis code displaying methods