Body Electrical System

General Information

General Troubleshooting Information

Before Troubleshooting

1. 1

   Check the related fuses in the applicable fuse/relay box.

2. 2

   Check the battery for damage, state of charge (SOC), cleanliness and tight connections.

3. 3

   Check the tension of the generator belt.

Connector Handling

1. 1

   Make sure the connectors are clean and there are no loose wire terminals.

2. 2

   Make sure that multi-cavity connectors are filled with grease (except waterproof connectors and oxygen sensor connectors).

3. 3

   All connectors have push-type locks (A).

   

4. 4

   Some connectors have a clip on the side used to secure them to a bracket on the body or another component. This clip has a latching lock.

5. 5

   Some mounted connectors cannot be disconnected unless you first release the lock and remove the connector from the mounting bracket (A).

   

6. 6

   Never try to disconnect connectors by pulling on their wires. Pull on the connector halves instead.

7. 7

   Always reinstall plastic covers.

   

8. 8

   Before connecting connectors, make sure the terminals (A) are in place and not bent.

   

9. 9

   Check that the lock (A) and rubber seals (B) are not loose.

   

10. 10

    The rear of some connectors is filled with grease. Add grease if necessary. If the grease (A) is contaminated, replace it.

    

11. 11

    Insert the connector fully and make sure it is securely locked.

12. 12

    Route the wires so that the open end of the cover faces downward.

    

Wire Handling and Harness

1. 1

   Secure wires and wire harnesses to the frame with wire ties at the designated points.

2. 2

   Carefully remove the clips; do not damage their locks (A).

   

3. 3

   Insert pliers (A) under the base of the clip and through the opening at an angle, then squeeze the expansion tabs to release the clip.

   

4. 4

   After installing harness clips, make sure the harness does not interfere with any moving parts.

5. 5

   Keep wire harnesses away from exhaust pipes and other hot parts, sharp edges of brackets and holes, and exposed screws and bolts.

6. 6

   Install grommets correctly into the grooves (A). Do not leave grommets twisted (B).

   

Testing and Repair

1. 1

   Do not use wires or harnesses with damaged insulation.

   Replace them or repair by wrapping the damaged wire with electrical tape.

2. 2

   After installing parts, make sure wires are not pinched under them.

3. 3

   When using electrical test equipment, follow the manufacturer's instructions and the instructions in this manual.

4. 4

   If possible, insert the test probe from the wire side (except waterproof connectors).

   

5. 5

   Use a probe with a tapered tip.

   Refer to the Wiring Repair Kit user manual (Publication No.: TRK 015).

   

Five-Step Troubleshooting

1. 1

   Verify the Complaint

   Operate all components in the problem circuit to verify the customer complaint. Note the symptoms. Do not begin disassembly or testing until you have narrowed down the problem area.

2. 2

   Circuit Analysis

   Find the circuit diagram of the problem circuit.

   Determine how the circuit should operate by tracing the current path from the power source through the circuit components to ground. If several circuits fail at the same time, the probable cause is a fuse or ground.

   Based on the symptoms and your understanding of circuit operation, identify one or more possible causes of the problem.

3. 3

   Isolate the Problem by Testing the Circuit

   Perform circuit tests to verify the diagnosis made in step 2. Keep in mind that a logical and simple procedure is the key to effective troubleshooting.

   Check the most likely cause of failure first. Try to perform tests at points that are easily accessible.

4. 4

   Repair the Problem

   Once the specific problem is identified, perform the repair. Be sure to use proper tools and safe procedures.

5. 5

   Verify the Circuit Operates Correctly

   Operate all components in the repaired circuit under all conditions to confirm that the entire problem is resolved. If the cause was a blown fuse, check all circuits protected by that fuse. Make sure there are no new problems and that the original problem does not recur.

Transmitter Installation

Electronic control computers are designed so that their operation is not interrupted by other radio signals. However, they may be affected by a remote control transmitter even at a distance of less than 25 W, if the transmitter antenna or cable is connected to the computer. To prevent this, follow the instructions below.

1. 1

   Install the antenna on the roof or rear bumper.

2. 2

   Keep antenna cables at least 200 mm away from the computer or wiring, as they transmit radio signals.

3. 3

   Reduce the standing wave ratio by using appropriate antennas and cables.

4. 4

   Do not install a remote control transmitter with a high output signal.

5. 5

   After installing the transmitter, check the engine by generating radio signals while the engine is running at idle.

Power Windows and Sunroof Reset

If the negative (-) battery cable was disconnected or a fuse was replaced, initialize the sunroof/power window operation again with the default setting when the motor stops.

Trip Computer, Clock and Audio Reset

When reconnecting the battery cable after disconnection, recharging a discharged battery, or installing the memory fuse located in the driver's side panel after removal, be sure to reset the systems listed in the table below.

Also, when replacing or reinstalling fuses after they have been removed, perform the reset according to the table below.