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GENERAL INFORMATION Go to SUP10 1st Rev. Technical Bulletin

ELECTRICAL SYSTEM

SECTION

CONTENTS POWER SUPPLY ROUTING ....................................... 2 Schematic ................................................................. 2 Wiring Diagram - POWER - ...................................... 3 BATTERY POWER SUPPLY - IGNITION SW. IN ANY POSITION......................................................3 ACCESSORY POWER SUPPLY - IGNITION SW. IN “ACC” OR “ON”................................................. 5 IGNITION POWER SUPPLY - IGNITION SW. IN “ON” AND/OR “START” ......................................... 6 STARTING SYSTEM ................................................... 9 Wiring Diagram - START -......................................... 9 CHARGING SYSTEM ............................................... 10 Wiring Diagram - CHARGE -....................................11 HEADLAMP ................................................................11 Wiring Diagram - H/LANP - .....................................11 PARKING LICENCE AND TAIL LAMPS ................... 12 Wiring Diagram - TAIL/L -........................................ 12 BACK-UP LAMP ....................................................... 13 Wiring Diagram - BACK/L - .................................... 13 TURN SIGNAL AND HAZARD WARNING LAMPS... 14 Wiring Diagram - TURN - ........................................ 14 ILLUMINATION.......................................................... 16 Wiring Diagram - ILL - ............................................ 16 COMBINATION MERERS ........................................ 18 Combination Meter.................................................. 18 Schematic .............................................................. 19 Wiring Diagram - METER - ................................... 20 CAN Communication .............................................. 22 SYSTEM DESCRIPTION .................................... 22 Construction ........................................................... 23 Meter/Gauge Operation and Odo/Trip Meter Segment Check in Diagnosis Mode ...............................23 DIAGNOSIS FUNCTION .....................................23 HOW TO ALTERNATE DIAGNOSIS MODE ........23 Trouble Diagnosis ....................................................24 PRELIMINARY CHECK .........................................24 SYMPTOM CHART ................................................25 POWER SUPPLY AND GROUND CIRCUIT

CHECK................................................................. 25 INSPECTION/VEHICLE SPEED SENSOR ... 25 INSPECTION/FUEL TANK GAUGE (MAIN) ... 26 INSPECTION/FUEL TANK GAUGE (SUB) ... 27 WARNING LAMPS .................................................... 28 Schematic ............................................................... 28 Wiring Diagram - WARN - ...................................... 29 CLOCK ...................................................................... 36 Wiring Diagram - CLOCK - ..................................... 36 CAN SYSTEM ............................................................ 37 Abbreviation List ...................................................... 37 CAN Diagnostic Support Monitor............................. 37 MONITOR ITEM LIST (CONSULT-III)................... 37 CAN System Specification Chart............................38 CAN Communication Signal Chart ......................... 38 TYPE1................................................................... 38 Wiring Diagram - CAN - .......................................... 39 Interview Sheet ....................................................... 40 CAN System (Type1) .............................................. 41 DIAGNOSIS SHEET.............................................41 Component Parts Location ...................................... 42 Malfunction Area Chart............................................ 43 BRANCH LINE...................................................... 43 SHORT CIRCUIT..................................................43 ECM Branch Line Circuit ......................................... 43 Data Link Connector Branch Line Circuit ................ 44 Combination Meter Branch Line Circuit................... 44 CAN Communication Circuit.................................... 45 HARNESS LAYOUT................................................... 47 Main Harness ......................................................... 47 INSTRUMENT PANEL.......................................... 47 BODY RH SIDE.................................................... 49 Engine Room Harness ............................................ 50 ENGINE COMPARTMENT .................................... 50 PASSENGER COMPARTMENT...........................52 Engine Harness ...................................................... 53 Engine Control Harness .......................................... 54 FUSE AND FUSIBLE LINK BOX............................... 55 Terminal Arrangement ............................................. 55

EL-1

POWER SUPPLY ROUTING POWER SUPPLY ROUTING Schematic

PFP:00011 GKS0084U

TEL465N

EL-2

POWER SUPPLY ROUTING Wiring Diagram — POWER —

GKS0084V

BATTERY POWER SUPPLY — IGNITION SW. IN ANY POSITION

PG

TEL466N

EL-3

POWER SUPPLY ROUTING

TEL467N

EL-4

POWER SUPPLY ROUTING ACCESSORY POWER SUPPLY — IGNITION SW. IN “ACC” OR “ON”

PG

TEL468N

EL-5

POWER SUPPLY ROUTING IGNITION POWER SUPPLY — IGNITION SW. IN “ON” AND/OR “START”

TEL469N

EL-6

POWER SUPPLY ROUTING

PG

TEL470N

EL-7

POWER SUPPLY ROUTING

TEL471N

EL-8

STARTING SYSTEM STARTING SYSTEM Wiring Diagram - START -

PFP:23300 GKS0085F

TEL472N

EL-9

CHARGING SYSTEM CHARGING SYSTEM Wiring Diagram - CHARGE -

PFP:23100 GKS0085G

SC

TEL473N

EL-10

HEADLAMP HEADLAMP Wiring Diagram - H/LANP -

PFP:26010 GKS0085H

TEL474N

EL-11

PARKING LICENCE AND TAIL LAMPS PARKING LICENCE AND TAIL LAMPS Wiring Diagram - TAIL/L -

PFP:26550 GKS0085I

LT

TEL475N

EL-12

BACK-UP LAMP BACK-UP LAMP Wiring Diagram - BACK/L -

PFP:26550 GKS0085J

TEL476N

EL-13

TURN SIGNAL AND HAZARD WARNING LAMPS TURN SIGNAL AND HAZARD WARNING LAMPS Wiring Diagram - TURN -

PFP:26120 GKS0085K

LT

TEL477N

EL-14

TURN SIGNAL AND HAZARD WARNING LAMPS

TEL478N

EL-15

ILLUMINATION ILLUMINATION Wiring Diagram - ILL -

PFP:27545 GKS0085L

LT

TEL479N

EL-16

ILLUMINATION

TEL480N

EL-17

COMBINATION METERS COMBINATION METERS Combination Meter

PFP:24814 GKS0084G

PKID1613E

EL-18

COMBINATION METERS Schematic

TEL481N

EL-19

COMBINATION METERS Wiring Diagram - METER -

TEL482N

EL-20

COMBINATION METERS

TEL483N

EL-21

COMBINATION METERS CAN Communication SYSTEM DESCRIPTION CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only.

System diagram

PKID1614E

Input/Output signal chart T: Transmit R: Receive Signal name/Connecting unit

ECM

M&A

Engine coolant temperature signal

T

R

Engine speed signal

T

R

Glow indicator lamp signal

T

R

Malfunction indicator lamp signal

T

R

Oil pressure warning lamp signal

T

R

A/C switch signal

R

T

Brake switch signal

R

T

Vehicle speed signal

R

T

EL-22

COMBINATION METERS Fale-safe Function

Fale-safe operation

Tacho meter

Return to zero

Water temperature gauge Glow indicator lamp Warning lamp/indicator lamp

Oil pressure warning lamp

The lamp turns OFF

Malfunction indicator lamp

Construction

PKID1615E

Meter/Gauge Operation and Odo/Trip Meter Segment Check in Diagnosis Mode DIAGNOSIS FUNCTION ● ●

Odo/trip meter segment and clock segment can be checked in diagnosis mode. Meter/gauges can be checked in diagnosis mode.

HOW TO ALTERNATE DIAGNOSIS MODE 1.

Turn ignition switch to ON and change odo/trip meter to “TRIP A” or “TRIP B”.

2.

Turn ignition switch to OFF.

3.

Turn ignition switch to ON when pushing odo/trip meter switch.

4.

Confirm that trip meter indicates “0000.0”.

5.

Push odo/trip meter switch more than three times within 5 seconds.

6.

All odo/trip meter and clock segments should be turned on. NOTE: If some segments are not turned on, (unified meter control unit) should be replaced. At this point, the unified control meter is turned to diagnosis mode.

PKID1619E

EL-23

COMBINATION METERS 7.

Push odo/trip meter switch. Indication of each meter/gauge should be as shown left during pushing odo/trip meter switch if it is no malfunctioning.

PKID1616E

Trouble Diagnosis PRELIMINARY CHECK

SEL269Y

NOTE: ● 1* : Refer to EL-23, “ HOW TO ALTERNATE DIAGNOSIS MODE“ . ●

2* : Refer to EL-25, “ POWER SUPPLY AND GROUND CIRCUIT CHECK“ .

●

3* : Refer to EL-25, “ SYMPTOM CHART“ .

EL-24

COMBINATION METERS SYMPTOM CHART Symptom

Check items

Fuel gauge indication is malfunctioning.

Speedometer is malfunctioning.

●

Fuel gauge unit circuit

●

Fuel gauge unit

●

Combination meter

●

Vehicle speed sensor circuit

●

Vehicle speed sensor

●

Combination meter

Before starting trouble diagnosis below, perform PRELIMINARY CHECK. Refer to EL-24, “ PRELIMINARY CHECK“ .

POWER SUPPLY AND GROUND CIRCUIT CHECK Power supply circuit check Terminals

Ignition switch position

(+) (-)

OFF

ACC

ON

45

Ground

Battery voltage

Battery voltage

Battery voltage

46

Ground

0V

0V

Battery voltage

Connector

Terminal

M143 M143

If NG, check the following. ● 7.5 A fuse [No.24, located in fuse block (J/B)] ● 10 A fuse [No.28, located in fuse block (J/B)] ● Harness for open or short between fuse and combination meter Ground circuit check Connector

Terminals

Continuity

M142

33 - Ground

Yes

M143

56, 68 - Ground

Yes

INSPECTION/VEHICLE SPEED SENSOR

1. CHECK VEHICLE SPEED SENSOR OUTPUT 1.

Remove vehicle speed sensor from transmission.

2.

Check voltage between combination meter connector terminals 62 and 63 while quickly turning speed sensor pinion. Terminals (+)

Value (Approx.)

(-)

Connector

Terminal

Connector

Terminal

M143

62

M143

63

0.5 V

OK or NG OK >> Vehicle speed sensor is OK. NG >> GO TO 2.

EL-25

COMBINATION METERS

2. CHECK VEHICLE SPEED SENSOR Check resistance between vehicle speed sensor terminals 1 and 2. Terminals (+)

Value (Approx.)

(-)

Connector

Terminal

Connector

Terminal

E209

1

E209

2

250 Ω

OK or NG OK >> Check harness for open or short between speedometer and vehicle speed sensor. NG >> Replace vehicle speed sensor.

INSPECTION/FUEL TANK GAUGE (MAIN)

1. CHECK GROUND CIRCUIT FOR FUEL TANK GAUGE UNIT Check harness continuity between fuel tank gauge unit connector C11 terminal 2 and ground. Terminals (+)

Continuity

(-)

Connector

Terminal

C11

2

Ground

Yes

OK or NG OK >> GO TO 2. NG >> Repair harness connector.

2. CHECK GAUGE UNIT Check gauge unit. Refer to EL section in SM4E-Y61GG2. OK or NG OK >> GO TO 3. NG >> Repair or replace fuel tank gauge unit.

3. CHECK HARNESS FOR OPEN OR SHORT 1.

Disconnect combination meter connector and fuel tank gauge unit connector.

2.

Check continuity between combination meter connector M143 terminal 59 and fuel tank gauge unit connector C11 terminal 1. Terminals (+)

3.

(-)

Continuity

Connector

Terminal

Connector

Terminal

M143

59

C11

1

Yes

Check continuity between combination meter connector M143 terminal 59 and ground. Terminals (+)

(-)

Connector

Terminal

M143

59

Ground

Continuity

No

OK or NG OK >> Fuel tank gauge is OK. NG >> Repair harness or connector.

EL-26

COMBINATION METERS INSPECTION/FUEL TANK GAUGE (SUB)

1. CHECK GROUND CIRCUIT FOR FUEL TANK GAUGE UNIT Check harness continuity between fuel tank gauge unit connector C18 terminal 3 and ground. Terminals (+)

Continuity

Connector

Terminal

C18

3

(-) Ground

Yes

OK or NG OK >> GO TO 2. NG >> Repair harness connector.

2. CHECK GAUGE UNIT Check gauge unit. Refer to EL section in SM4E-Y61GG2. OK or NG OK >> GO TO 3. NG >> Repair or replace fuel tank gauge unit.

3. CHECK GAUGE UNIT 1.

Disconnect combination meter connector and fuel tank gauge unit connector.

2.

Check continuity between combination meter connector M143 terminal 58 and fuel tank gauge unit connector C18 terminal 1. Terminals (+)

(-)

Continuity

Connector

Terminal

Connector

Terminal

M143

58

C18

1

3.

Yes

Check continuity between combination meter connector M143 terminal 58 and ground. Terminals (+)

(-)

Connector

Terminal

M143

58

Ground

Continuity

No

OK or NG OK >> Fuel tank gauge is OK. NG >> Repair harness or connector.

EL-27

WARNING LAMPS WARNING LAMPS Schematic

TEL484N

EL-28

WARNING LAMPS Wiring Diagram - WARN -

TEL485N

EL-29

WARNING LAMPS

TEL486N

EL-30

WARNING LAMPS

TEL487N

EL-31

WARNING LAMPS

TEL488N

EL-32

WARNING LAMPS

TEL489N

EL-33

WARNING LAMPS

TEL490N

EL-34

WARNING LAMPS

TEL491N

EL-35

CLOCK CLOCK Wiring Diagram - CLOCK -

TEL493N

EL-36

CAN SYSTEM CAN SYSTEM Abbreviation List

PFP:23710 GKS00841

Abbreviations in CAN communication signal chart, and the diagnosis sheet are as per the following list. Abbreviation

Unit name

SELECT SYSTEM (CONSULT-III)

CAN DIAG SUPPORT MNTR (CONSULT-III)

DLC

Data link connector

—

—

ECM

ECM

ENGINE

—

M&A

Combination meter

—

METER/M&A

CAN Diagnostic Support Monitor

GKS00842

Use “CAN DIAG SUPPORT MNTR” for detecting the root cause.

MONITOR ITEM LIST (CONSULT-III) ECM 0: Error at present, 1 – 39: Error in the past (The number means the number of times the ignition switch is turned OFF→ON.) ITEM

CAN DIAG SUPPORT MNTR

Description

TRANSMIT DIAG

Signal transmission status

Normal

Error

PRSNT

PAST

PRSNT

PAST

OK

OK or

UNKWN

0

UNKWN

0

1 – 39* VDC/TCS/ABS ECM METER/M&A

Not used even though indicated Signal receiving status from the combination meter

BCM/SEC

OK

OK or 1 – 39*

Not used even though indicated

TCM *: 39 or higher number is fixed at 39 until the self-diagnosis result is erased.

EL-37

CAN SYSTEM CAN System Specification Chart

GKS00843

Determine CAN system type from the following specification chart. Then choose the correct diagnosis sheet. Body type

Truck

Axle

4WD

Engine

ZD30DDTi

Transmission

M/T

Brake control

–

CAN system type

1

Diagnosis sheet

EL-40

CAN communication signal chart

EL-37

CAN Communication Signal Chart

GKS00844

TYPE 1 NOTE: Refer to EL section, “Abbreviation List” for the abbreviations of the connecting units. T: Transmit Signal name/Connecting unit

ECM

M&A

Engine coolant temperature signal

T

R

Engine speed signal

T

R

Glow indicator lamp signal

T

R

Malfunction indicator lamp signal

T

R

Oil pressure warning lamp signal

T

R

A/C switch signal

R

T

Brake switch signal

R

T

Vehicle speed signal

R

T

R: Receive

LAN

EL-38

CAN SYSTEM Wiring Diagram — CAN —

GKS00845

TEL494N

EL-39

CAN SYSTEM Interview Sheet

GKS0084F

LAN

SKIB8898E

EL-40

CAN SYSTEM CAN System (Type 1)

GKS00847

DIAGNOSIS SHEET

PKID1611E

EL-41

CAN SYSTEM Component Parts Location

GKS00848

PKID1612E

1.

Data link connector M10

2.

ECM F2

3.

Combination meter M143

LAN

EL-42

CAN SYSTEM Malfunction Area Chart

GKS0084A

BRANCH LINE Malfunction Area

Reference

ECM branch line circuit

EL-43, “ECM Branch Line Circuit”

Data link connector branch line circuit

EL-44, “Data Link Connector Branch Line Circuit”

Combination meter branch line circuit

EL-44, “Combination Meter Branch Line Circuit”

SHORT CIRCUIT Malfunction Area

Reference

CAN communication circuit

EL-45, “CAN Communication Circuit”

ECM Branch Line Circuit

GKS0084B

INSPECTION PROCEDURE

1. CHECK CONNECTOR 1. 2. 3.

Turn the ignition switch OFF. Disconnect the battery cable from the negative terminal. Check the following terminals and connectors for damage, bend and loose connection (unit side and connector side). – ECM – Harness connector F6 – Harness connector M51 OK or NG OK >> GO TO 2. NG >> Repair the terminal and connector.

2. CHECK HARNESS FOR OPEN CIRCUIT 1. 2.

Disconnect the connector of ECM. Check the resistance between the ECM harness connector terminals. ECM harness connector Connector No. F2

Resistance (Ω)

Terminal No. 236

235

Approx. 108 – 132

OK or NG OK >> GO TO 3. NG >> Repair the ECM branch line.

3. CHECK POWER SUPPLY AND GROUND CIRCUIT Check the power supply and the ground circuit of the ECM. Refer to EC-2, “Wiring Diagram” . OK or NG OK >> ● Present error: Replace the ECM. ● Past error: Error was detected in the ECM branch line. NG >> Repair the power supply and the ground circuit.

EL-43

CAN SYSTEM Data Link Connector Branch Line Circuit

GKS0084C

INSPECTION PROCEDURE

1. CHECK CONNECTOR 1. 2. 3.

Turn the ignition switch OFF. Disconnect the battery cable from the negative terminal. Check the terminals and connectors of the data link connector for damage, bend and loose connection (connector side and harness side). OK or NG OK >> GO TO 2. NG >> Repair the terminal and connector.

2. CHECK HARNESS FOR OPEN CIRCUIT Check the resistance between the data link connector terminals. Data link connector Connector No.

Resistance (Ω) Terminal No.

M10

6

14

Approx. 54 – 66

OK or NG OK >> ● Present error: Check the following items again. – Not received CONSULT-III data [SELF-DIAG RESULTS, CAN DIAG SUPPORT MNTR (“ECU list” included)]. – Procedure for detecting root cause. ● Past error: Error was detected in the data link connector branch line circuit. NG >> Repair the data link connector branch line.

Combination Meter Branch Line Circuit

GKS0084D

INSPECTION PROCEDURE

1. CHECK CONNECTOR 1. 2. 3.

Turn the ignition switch OFF. LAN Disconnect the battery cable from the negative terminal. Check the terminals and connectors of the combination meter for damage, bend and loose connection (unit side and connector side). OK or NG OK >> GO TO 2. NG >> Repair the terminal and connector.

2. CHECK HARNESS FOR OPEN CIRCUIT 1. 2.

Disconnect the connector of combination meter. Check the resistance between the combination meter harness connector terminals. Combination meter harness connector Connector No. M143

Resistance (Ω)

Terminal No. 66

67

OK or NG OK >> GO TO 3. NG >> Repair the combination meter branch line.

EL-44

Approx. 108 – 132

CAN SYSTEM

3. CHECK POWER SUPPLY AND GROUND CIRCUIT Check the power supply and the ground circuit of the combination meter. Refer to EL-20, “Wiring Diagram — METER — ”. OK or NG OK >> ● Present error: Replace the combination meter. ● Past error: Error was detected in the combination meter branch line. NG >> Repair the power supply and the ground circuit.

CAN Communication Circuit

GKS0084E

INSPECTION PROCEDURE

1. CONNECTOR INSPECTION 1. Turn the ignition switch OFF 2. Disconnect the battery cable from the negative terminal. 3. Disconnect all the unit connectors on CAN communication system. 4. Check terminals and connectors for damage, bend and loose connection. OK or NG OK >> GO TO 2. NG >> Repair the terminal and connector.

2. CHECK HARNESS CONTINUITY (SHORT CIRCUIT) Check the continuity between the data link connector terminals. Data link connector Connector No. M10

Continuity Terminal No.

6

14

No

OK or NG OK >> GO TO 3. NG >> Check the harness and repair the root cause.

3. CHECK HARNESS CONTINUITY (SHORT CIRCUIT) Check the continuity between the data link connector and the ground. Data link connector Connector No. M10

Continuity Terminal No.

Ground

6

No

14

No

OK or NG OK >> GO TO 4. NG >> Check the harness and repair the root cause.

EL-45

CAN SYSTEM

4. CHECK ECM AND COMBINATION METER TERMINATION CIRCUIT 1. 2.

Remove the ECM and the combination meter. Check the resistance between the ECM terminals. ECM

Resistance (Ω)

Terminal No. 236

3.

235

Approx. 108 – 132

Check the resistance between the combination meter terminals. Combination meter

Resistance (Ω)

Terminal No. 66

67

Approx. 108 – 132

OK or NG OK >> GO TO 5. NG >> Replace the ECM and/or the combination meter.

5. CHECK SYMPTOM Connect all the connectors. Check if the symptoms described in the “Symptom (Results from interview with customer)” are reproduced. Inspection result Reproduced>>GO TO 6. Non-reproduced>>Start the diagnosis again. Follow the trouble diagnosis procedure when past error is detected.

6. CHECK UNIT REPRODUCTION Perform the reproduction test as per the following procedure for each unit. 1. Turn the ignition switch OFF 2. Disconnect the battery cable from the negative terminal. 3. Disconnect one of the unit connectors on CAN communication system. NOTE: ECM and combination meter have a termination circuit. Check other units first. 4. Connect the battery cable to the negative terminal. Check if the symptoms described in the “Symptom (Results from interview with customer)” are reproduced. NOTE: Although unit-related error symptoms occur, do not confuse them with other symptoms. Inspection result Reproduced>>Connect the connector. Check other units as per the above procedure. Non-reproduced>>Replace unit whose connector was disconnected.

EL-46

HARNESS LAYOUT HARNESS LAYOUT Main Harness

PFP:24010 GKS00850

INSTRUMENT PANEL

PG

TEL265V

EL-47

HARNESS LAYOUT

TEL266V

EL-48

HARNESS LAYOUT BODY RH SIDE

TEL267V

PG

EL-49

HARNESS LAYOUT Engine Room Harness

GKS0085A

ENGINE COMPARTMENT

TEL268V

EL-50

HARNESS LAYOUT

TEL269V

EL-51

HARNESS LAYOUT PASSENGER COMPARTMENT

TEL270V

EL-52

HARNESS LAYOUT Engine Harness

GKS0085B

PG

TEL271V

EL-53

HARNESS LAYOUT Engine Control Harness

GKS0085C

TEL272V

EL-54

FUSE AND FUSIBLE LINK BOX FUSE AND FUSIBLE LINK BOX Terminal Arrangement

PFP:24381 GKS00857

PG

CEL662M

EL-55