relay ISUZU TROOPER 1995 Workshop Manual

CHASSIS ELECTRICAL 8-1
·SECTION 8
CHASSIS ELECTRICAL
'\f CAUTION: .
When fasteners are removed, always reinstall them at the same location from which they were removed.
If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct
part number fastener is not
available, a fastener of equal size and strength (or stronger) may be used.
Fasteners that are not reused, and those requiring thread
locking compound, will be called out. The correct
torque
values must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.
CONTENTS
General Information .................................... 8-2
Notes for Working on Electrical
Items .................................................... 8-2
Symbols and Abbreviations ................. 8-8
Symbols ............................................ 8-8
Abbreviations ................................... 8-9
Parts for Electrical Circuit ..................... 8-10
Wiring ............................................... 8-10
Fuse .................................................. 8-11
Fusible Link ....................................... 8-12
Circuit Breaker ................................... 8-12
Relay ................................................. 8-12
Relay Specifications and
Configurations ................................ 8-13
Diode ................................................. 8-14
Connector ......................................... 8-15
Reading the Circuit Diagram ................ 8-17
Main Data and Specifications .................... 8-19
Bulb Specifications ................................ 8-19
Fuse,
Fusible Link and
Circuit Breaker Location ..................... 8-21
Fuse
Block Circuit .................................. 8-22
Reference Table of Fuse, Fusible
Link and Circuit Breaker ..................... 8-23
Relay Location ....................................... 8-27
Diode Location .......................................
8-28
Grounding Point .................................... 8-29
Reference Table ................................ 8-29
Location ............................................ 8-31
Cable Harness Routing .......................... 8-34
System Repair .............................................. 8-38
Start and Charging ................................ 8-38
Engine Control Module
(ECM) ................................................... 8-47
Headlight and Fog Light ........................ 8-58
Front Side Marker Light, Parking Light,
Taillight, License Plate Light and
Illumination Light .............................. 8-76
Stoplight and Rear Defogger .............. 8-92
Turn Signal Light, Hazard
Warning
Light, Cornering Light,
Backup
Light and Horn ..................... 8-106
Dome Light, Luggage room Light,
Courtesy Light, Map Light,
Seat Belt Switch and
Warning Buzzer ................................. 8-128
Power Door Lock ................................. 8-142
Power
Window .................................... 8-156
Cruise
Control ...................................... 8-172
Anti-Lock Brake
System (ABS) ........... 8-178
Rear
Wheel Anti-Lock Brake
System (RWAL) ................................. 8-185
Transmission
Control Module
(TCM) ................................................. 8-192
A/T Shift Lock ...................................... 8-200
Windshield
Wiper/Washer and
Rear
Wiper/Washer .......................... 8-205
Headlight wiper /washer ..................... 8-232
Audio, Auto Antenna,
Cigarette
Lighter and digital clock ... 8-246
Power Door Mirror ............................... 8-254
Anti-theft System ................................ 8-270
Meter and Warning/Indicator Light ... 8-288
A/T Shift Indicator ............................... 8-336
Heater and
Air Conditioning ............... 8-340
Sun
Roof ............................................... 8-346
Power Seat ........................................... 8-360
Seat
Heater .......................................... 8-37 4
Supplemental Restraint
System (SRS) -AIR BAG ................... 8-382

-·*; ~---
8-2 CHASSIS ELECTRICAL
GENERAL INFORMATION
The chassis electrical system is of 12-volt specifications with a negative ground polarity.
Wire sizes are appropriate
to respective circuits, and classified by color. (The classification of harnesses by
color is shown on the circuit diagram for ease of harness identification.)
The
wire size is determined by load capacity and the length of wire required.
The
vehicle harnesses are: body harness, chassis harness, engine room harness, instrument harness,
transmission harness, engine
ECGI harness, dome light harness, door harness, rear body harness, tailgate
harness,
SRS harness and battery cables.
The harnesses are protected either
by tape or corrugated tube, depending on harness location.
The circuit
for each system consists of the power source, wire, fuse, relay, switch, load parts and ground, all of
which are shown on the circuit diagram.
In this manual, each electrical device is classified by system. For major parts shown on the circuit based on
the circuit diagram
for each system, a summary, diagnosis oftroubles, inspection and removal and installation
procedures are detailed.
NOTES FOR WORKING ON ELECTRICAL ITEMS
Disconnecting the Battery Cable (Fig. 8-1)
Ground cable
Fig. 8-1
1. All switches should be in the "OFF" position.
2. Disconnect the battery ground cable.
3. Disconnect the battery positive cable.
W CAUTION:
It is important that the battery ground cable be
disconnected first.
Disconnecting the battery positive cable first can
result in a short circuit.
Connecting the Battery Cable
Follow the disconnecting procedure in the reverse
order.
\V CAUTION:
Clean the battery terminal and apply a light coat
of grease to prevent terminal corrosion.
Connector Handling
Disconnecting The Connectors (Fig. 8-2)
Fig. 8-2
Some connectors have a tang lock to hold the connec­
tors together during vehicle operation.
Some tang locks are released by pulling them towards
you
G).
Other tang locks are released by pressing them for­
ward®.
Determine which type oftang lock is on the connector
being handled.
Firmly grasp both sides (male and female)
of the
connector. Release the tang lock and carefully pull the
two halves
of the connector apart.
Never pull on the wires
to separate the connectors.
This
will result in wire breakage (Fig. 8-3).
.,
..

Fig. 8-3
• When removing the connector for relay (MR5B
type), unfasten the tang
lock of the connector by
using a screwdriver, then pull the relay out.
(Fig. 8-4)
Relay
~
Fig. 8-4
Connecting the Connector (Fig. 8-5)
Fig. 8-5
CHASSIS ELECTRICAL 8-3
Firmly grasp both sides (male and female) of the
connector.
Be sure that the connector pins and pin
holes match. Be sure that both sides of the connector
are
aligned with each other.
Firmly but carefully push the two sides of the connec­
tor together until a distinct click is heard.
Connector Inspection (Fig. 8-6)
OK
Test probe
Fig. 8-6
Use a circuit tester to check the connector for continu­
ity.
Insert the test probes from the connector wire
side. Never insert the circuit tester test probes into the
connector open end
to test the continuity (Fig. 8-7).
Broken
or open connector terminals will result.
NO
Fig. 8-7

8-8 CHASSIS ELECTRICAL
SYMBOLS AND ABBREVIATIONS
SYMBOLS
Symbol Meaning of Symbol
~ Fuse
~ Fusible link
----if\p-Fusible link wire
~ Switch
~ Switch
-a-
Switch
(Normal close type)
j Contact wiring I
[I] -I
Battery
~
Diode
~
Electronic Parts
--Nt-Resistor
=Q] Speaker
1~1 Buzzer I
-EJ-Circuit breaker
I Symb•:>l Meaning of Symbol
~
Bulb
~ Double filament bulb
-r@[}-Motor
~j-Variable register
Rheostat
Coil (inductor), solenoid,
~-magnetic valve I
§
Relay
-or-Connector
----@-Light emitting diode
~8-
Reed switch
---11----Condenser
I -o-Horn
~t Vacuum switching valve I
Fig. 8-23
•

8-12 CHASSIS ELECTRICAL
FUSIBLE LINK
The fusible link is primarily used to protect circuits
where high amounts
of current flow and where is
would not be practical to use a fuse. For example, the
starter circuit. When a current
overload occurs, the
fusible link melts open and interrupts the flow of
current so as to prevent the rest of the wiring harness
from burning.
Determine the cause
ofthe overload before replacing
the fusible link. The replacement fusible link must
have the same amperage specification as the original
fusible link.
Never replace a blown fusible link with fusible link of
a different amperage specification. Doing so can
result in an electrical fire or other serious circuit
damage.
A
blown fusible link is easily identified (Fig. 8-27).
Fusible Link Specifications
Normal Blown
Fig.
8-27
Type Rating
Case Color Maximum Circuit Current (A)
Connector
30A Pink 15
Connector 40A Green 20
Bolted 50 A Red 25
Bolted 60A Yellow 30
Bolted
BOA Black 40
CIRCUIT BREAKER (Fig. 8-28)
Push
Fig. 8-28
The circuit breaker is a protective device designed
to
open the circuit when a current load is in excess of
rated breaker capacity. If there is a short or other type
of overload condition in the circuit, the excessive
current
will open the circuit between the circuit
breaker
terminals. The reset knob pops out when the
circuit is open. Push the reset knob in
place to restore
the circuit after repairing it.
RELAY (Fig. 8-29)
Fig. 8-29
Battery and
load location may require that a switch be
placed some distance from either component. This
means a
longer wire and a higher voltage drop G).
The installation of a relay between the battery and the
load reduces the voltage drop®.
Because the switch controls the relay, amperage
through the switch can be reduced.
..

CHASSIS ELECTRICAL 8-13
RELAY SPECIFICATIONS AND CONFIGURATIONS (Fig. 8-30)
Name/ Rated Name/ Rated
Color voltage/Coil
Internal circuit Color voltage/Coil Internal circuit
resistance resistance
12V/ 12V/
® ~1 Approx.
~
®u~
Approx.
~£:=!:~ 1M 80 2M 80
a(( (MRSL)/ Minimum Black
operating ® ... J Brown operating ::Q __ j
voltage: 7V voltage: 7V ® 4 at 77°F (2S°C) at 77"F (2SOC)
~
® 18
®tiT
18-1M
•
:E:t: : ... J
(MR5)/ i @ . . @
Grey Grey ®~ 4
1M
:@ff
i
®~
(MRS)/
rou~ Minimum
u~ Black i 0 @ . 1M operating ~ : 4
(Case), ® ... J ® 1
® J Blue voltage:
9V
(Base) @ at 68°F (20°C)
:@j
12V @®
1T
m
1M Minimum
'
m~
(MRS)/ t (MRSB)/ operating ~ : Black/ ' 0 @ voltage: @ u
Black
Blue ® 4.3V at 77°F
@® (2SOC)
1
12V/
1@ .ff
1M Minimum
(Horn operating ® 8V
at 68°F (20°C) @ .
* Relay contact shown in the wiring diagram indicates condition before actuation.
Fig.
8-30

CONNECTOR
• The connector pin shape determines whether the
connector is
male or female (Fig. 8-32).
The connector housing configuration does
not
determine whether a connector is male or female.
• The symbol illustrated in the figure is used as
connector, in the circuit of this section (Fig. 8-33).
• Connector is identified with a number (Fig. 8-34).
• The applicable terminal number is shown for each
connector (Fig. 8-35).
• Connector terminal numbers are clearly shown.
Male side connector terminal numbers are in se­
quence
from upper right to lower left.
Female side connector terminal numbers are in
sequence
from upper left to lower right (Fig. 8-36).
Female connector
•
Connector pin shape
Fig. 8-32
Female side connector
I
·~
I Male s1de connector
Fig. 8-33
Male connector
·~ 0
CHASSIS ELECTRICAL 8-15
0.5 R/L
SHIFT LOCK
0.85W/L
Connector number
Fig. 8-34
0.5 R/L
SHIFT LOCK
0.85 W/L
Terminal number
Fig. 8-35
Female side connector Male side connector
Terminal number
Fig. 8-36
NOTE:
1. For those connectors on which specific terminal
numbers
or symbols are shown (such as ECM,
DERM for SRS), the terminal numbers or symbols
are used in the circuit diagram, irrespective
of the
above rule (Fig. 8-37).
2. The connectors used for relays have their own
terminal number assignment, irrespective of the
above
rule (Fig. 8-38).

READING THE CIRCUIT DIAGRAM
In this manual, each system has its own parts location
illustration,
circuit diagram and connector list used in
the circuit diagram.
PARTS LOCATION: The parts location shows the
location of the parts CD and the connector® used in
each harness routing ® (fig. 8-40).
PARTS LOCATION
EBCM-,
RR ABS SPEED SENSOR (RHI "',~ M-11 ,,
C-39 M-12~'-, RELAY: UPSHIFT-2 ~
CHASSIS ELECTRICAL 8-17
CIRCUIT DIAGRAM: The circuit diagram shows the
powersupply@the load or loads® and the grounding
point(s)
® (Fig. 8-41 ).
CONNECTOR LIST: The connector configuration
shows
each connector's configuration (J) and the pin
number® (Fig. 8-42).
RELAY & FUSE BO~"'
7
~<-:;;;:~:~:_::0:;;::::'=l-\,.-..:._::::;;,...6
IFL-1, FL-2, FL-6, F-91 , "" ;;~~~~~~~;g~~k~
C-33
C-34
Fig. 8-40
STARTERSW
RR ABS SPEED SENSOR ILHI
C-94 DATA LINK CONNECTOR
GSENSOR
FUSE BOX IC-3, C-4, C-10, C-141
BRAKE SW IW/CRUISE CONTROL! STOPLIGHT SW (W/0 CRUISE CONTROL!
FRT ABS SPEED SENSOR ILHI

CHASSIS ELECTRICAL 8-21
FUSE, FUSIBLE LINK AND CIRCUIT BREAKER LOCATION
ooooo 112~12~1~1~1
00 E
EEr 00 ~
Relay & fuse box
SJOOO 7-6
I lw ;;::;~ Fuse box ~ ~
1l1~~ ~lff~UIH~Inll
w~ F-a FL-4 ~
00 FL·S~ r---, F-11 'l2~J1~ 1~1&11~11~1,\l~31hl1~1
0
0
FL-6 'F-i2
I' ~
\a~ a~;
0000
0000
I ~
l/
~
j
~/~/ e:;?' v II I / / .I / /
('-/ .
~~
-~-~;,a~ ~~ --.:_
~~~~ -
Relay & Fuse box Fuse box
Fuse
Fuse Fuse
No. Capacity Indication on label No. Capacity Indication on label No. Capacity Indication on label
F-1 --C-1 10A STARTER RELAY
C-14 15A STOP A!f CONT
F-2 10A 02 SENSOR HEATER C-2 15A (SEAT HEATER)
C-15 20A (AUDIO [8))
F-3
15A HORN HAZARD C-3 15A
TURN BACK C-16 10A CLOCK (8] ROOM
F-4
15A H/LAMP-LH C-4 10A ELEC.IGN. C-17 25A RR DEFOG
F-5
15A H/LAMP-RH C-5
15A FRTWIPER & C-18 20A (DOOR LOCK)
F-6 --WASHER C-19
25A BLOWER
F-7
- -C-6 10A RRWIPER & C-20 10A (AIR
CON)
F-8
15A (FRT.FOG) WASHER C-21 10A SRS-1
F-9 20A ABS C-7 10A (H/LAMP C-22 10A SRS-2
F-10
15A FUEL PUMP WIPER) C-23 lOA SRS-3
F-11 -
-C-8 15A ENGINE C-24 10A SRS-4
F-12
15A TAIL C-9 15A IGN. COIL CIRCUIT BREAKER
FUSIBLE
LINK
C-10 10A METER GAUGE
C/8-1 --FL-1 80A MAIN C-11 10A
(AUDIO IACC])
C/8-2 30A (P/W, P/S, S/R)
FL-2 50 A KEYSW MIRROR
FL-3 30A ECM C-12 20A CIGARETTE 02: Oxygen
FL-6 40A (ASS 4/WHEEL ONLY) C-13 10A (ANTI THEFT)
Fig. 8-44

8-22 CHASSIS ELECTRICAL
FUSE BLOCK CIRCUIT
GENERATOR -------------------~s~w~------------~~s~w~--~~~~ r- / B L 1------CHARGE SIGNAL &W _/
FL-1 80A .-----, B 11.'1 MAIN
+ Lt--
l£h
~----/ IG~----------~O~.$~B/V~-----------,
3W REL~HT1NG 1J ---'"~L 3
RELA~PUMP 4 1...---. 12 2 B/0
1.25 B/0
SW
3RJ8
5W
~~~·~ F-1 0 0 F-2 10A
I F-315A
F-8
0 0 F-7 0 0 F-81SA
F-920A
9;nlaool
I
Oz SENSOR HEATER
HORN HAZARD
H/LAMP-LH
H/LAMP-RH
(FRT. FOG)
lABS) -I ABS
I ,--------__:<;;:R·.:.:W.::..Acc·L;;:-1 ____ ----Jv F-10 1SA 2 810
I
~ECM RELAY; ECM MAIN ¢~,...,..J>--+2'-'RIW~_::2~1-o.....-<:>-f-·4.:._ __ _. ~J~CTOR
L...-_.ECM
FL-t 40A ABS 4/WHEEL ONLY
"
.... ...
SW
5W
3 8IY
F-11 0 0 F-1215A
~------' FUSE BOX
CIB-2 30A ~.,.;
C-110A :
C-215A
C-31SA
C-410A
I
J
FUEL PUMP
TAIL
P/W, PIS. SIR
STARTER RELAY
(SEAT HEATER)
TURN BACK
ELEC.IGN.
e-s
15A 1 ""'-.0---t-----+----il FRT WIPER & WASHER
"""' -
I 3W/G
C-810A '---f-+----+.:3.:BIR::::..+---¢""''-£>---i-----f-----jl RR WIPER & WASHER
ABS HYORAULIC UNIT
STARTERSW
FL-2 _JJ OFF
~ ...
..:..AKEYSW 3 W/B ay ' o.N". 3UB
~~--~--~,~------~-0 ~~IG~2Y-----------~ o-: ST 3W/B 81 -.,IG1
FUSE BOX
I
I g1~ 1 J'-:::s:R:s-:1 =I RELAY; STARTER
STARTER I r-
L~---'~-j.t 3 B/V
I I 3UB
sw
C-710A
~';::--~--~-'---~~~HI~LA~M~P~W~IP~E~R~l~~ C-81SA ""'-'>--1---...__---i ENGINE
C-111SA I J~======~l IGN. COIL (G)
C-10 10A
C-1110A
k'-1:>----t----t
~==~I
METER GAUGE
""''-£>---f----------1 (AUDIO[ACC)) MIRROR
C-12 20A
::...1310A I
C-141SA -r"\'-1)----f----t
C-15 20A L,-.
CIGARETTE
(ANTITHEFT)
STOP A/T CONT.
(AUDIO[ B))
C-1810A """"-'-.0---f----------t_j CLOCK[B) ROOM
L---+------------------------iB lt~;_ ~=~~~:~:~::~~~: C-17 2SA I
G1820A
RR DEFOG
= sw (DOOR LOCK) RELAY; HEATER &A/C .:._ __________________ .:.:3~W'-'---------------------~2to~.....-4 3UR C-19 2SA ...... BLOWER
A/C : AIR CONDITIONING ECM : ENGINE CONTIIOL MODULE 0, :OXYGEN ABS
:ANTI-LOCK
BRAKE BYBTEM
RWAL: REAR WHEEL ANTI-LOCK BRB : SUPPLEMENTAL RESTRAINT SYSTEM
C-20 10A (AIR CON)
Fig. 8-45
•