Toyota Hilux 2004, Hilux User Manual

HILUX

Electrical Wiring Diagram

Pub. No. DR114W

FOREWORD

This wiring diagram manual has been prepared to provide information on the electrical system of the HILUX.

Applicable models: KUN15, 16, 25, 26 Series

For service specifications and repair procedures of the above models other than those listed in this manual, refer to the following manuals;

Manual Name

D HILUX Repair Manual D HILUX New Car Features

All information in this manual is based on the latest product information at the time of publication. However, specifications and procedures are subject to change without notice.

Pub. No. DR172E

NCF271E

NOTICE

When handling supplemental restraint system components (removal, installation or inspection, etc.), always follow the direction given in the repair manuals listed above to prevent accidents and supplemental restraint system malfunction.

HILUX

ELECTRICAL WIRING DIAGRAM

Section Code

Page

INTRODUCTION A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

HOW TO USE THIS MANUAL B. . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING C. . . . . . . . . . . . . . . . . . . . . . . . . .

ABBREVIATIONS D. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 12 17

GLOSSARY OF TERMS AND SYMBOLS E. . . . . . . . . 18

RELAY LOCATIONS F. . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL WIRING ROUTING G. . . . . . . . . . . . . . .

SYSTEM CIRCUITS H. . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 36 59

GROUND POINT I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

POWER SOURCE (Current Flow Chart) J. . . . . . . . .

CONNECTOR LIST K. . . . . . . . . . . . . . . . . . . . . . . . . . . .

PART NUMBER OF CONNECTORS L. . . . . . . . . . . . .

OVERALL ELECTRICAL WIRING DIAGRAM M. . . . .

182 188 194 202 206

E2004

A INTRODUCTION

This manual consists of the following 13 sections:

No. Section Description

INDEX Index of the contents of this manual.

INTRODUCTION Brief explanation of each section.

HOW TO USE THIS

MANUAL

TROUBLE–

SHOOTING

D ABBREVIATIONS Defines the abbreviations used in this manual.

GLOSSARY OF TERMS AND

SYMBOLS

Instructions on how to use this manual.

Describes the basic inspection procedures for electrical circuits.

Defines the symbols and functions of major parts.

F RELAY LOCATIONS

ELECTRICAL

WIRING ROUTING

INDEX Index of the system circuits.

SYSTEM CIRCUITS

I GROUND POINT Shows ground positions of all parts described in this manual.

POWER SOURCE

(Current Flow Chart)

K CONNECTOR LIST

PART NUMBER OF

CONNECTORS

Shows position of the Electronic Control Unit, Relays, Relay Block, etc. This section is closely related to the system circuit.

Describes position of Parts Connectors, Splice points, Ground points, etc. This section is closely related to the system circuit.

Electrical circuits of each system are shown from the power supply through ground points. Wiring connections and their positions are shown and classified by code according to the connection method. (Refer to the section, ”How to use this manual”). The ”System Outline” and ”Service Hints” useful for troubleshooting are also contained in this section.

Describes power distribution from the power supply to various electrical loads.

Describes the form of the connectors for the parts appeared in this book. This section is closely related to the system circuit.

Indicates the part number of the connectors used in this manual.

OVERALL ELECTRICAL

WIRING DIAGRAM

Provides circuit diagrams showing the circuit connections.

HOW TO USE THIS MANUAL B

This manual provides information on the electrical circuits installed on vehicles by dividing them into a circuit for each system.

The actual wiring of each system circuit is shown from the point where the power source is received from the battery as far as each ground point. (All circuit diagrams are shown with the switches in the OFF position.)

When troubleshooting any problem, first understand the operation of the circuit where the problem was detected (see System Circuit section), the power source supplying power to that circuit (see Power Source section), and the ground points (see Ground Point section). See the System Outline to understand the circuit operation.

When the circuit operation is understood, begin troubleshooting of the problem circuit to isolate the cause. Use Relay Location and Electrical Wiring Routing sections to find each part, junction block and wiring harness connectors, wiring harness and wiring harness connectors, splice points, and ground points of each system circuit. Internal wiring for each junction block is also provided for better understanding of connection within a junction block. Wiring related to each system is indicated in each system circuit by arrows (from__, to__). When overall connections are required, see the Overall Electrical Wiring Diagram at the end of this manual.

B HOW TO USE THIS MANUAL

[A]

Stop Light

[B]

[D]

∗ The system shown here is an EXAMPLE ONL Y . It is different to the actual

circuit shown in the SYSTEM CIRCUITS SECTION.

From Power Source System (See Page 66)

15A STOP

7.5A GAUGE

[C]

WRGW

S 6

Stop Light SW

IBIB3

IB1

[G]

Rear

Lights

IB2

C 7

Combination Meter

)

S/D

W/G

(

IE114

[E]

ABS ECU

Stop

[H]

BV1

Rear Combination Light RH

R 7

I 5

2111

B18

GRWBWB

[ I ]

[J]

(Shielded)

[K]

Stop

Rear Combination Light LH

R 6

)

S/D

(

[F]

L 4

Light Failure Sensor

H17

High Mounted Stop Light

YG RL

[M]

BV1

B18

[L]

[A] : System Title [B] : Indicates a Relay Block. No shading is used and

only the Relay Block No. is shown to distinguish it from the J/B

Example: Indicates Relay Block No.1

[C] : ( ) is used to indicate different wiring and

connector, etc. when the vehicle model, engine type, or specification is different.

[D] : Indicates related system. [E] : Indicates the wiring harness and wiring harness

connector. The wiring harness with male terminal is shown with arrows (

Outside numerals are pin numbers.

Female Male ( )

The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component’s location, e.g, ”E” for the Engine Compartment, ”I” for the Instrument Panel and Surrounding area, and ”B” for the Body and Surrounding area.

When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector.

[F] : Represents a part (all parts are shown in sky blue).

The code is the same as the code used in parts position.

[G] : Junction Block (The number in the circle is the J/B

No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts.

Example:

3C indicates that it is inside Junction Block No.3

[H] : Indicates the wiring color.

Wire colors are indicated by an alphabetical code. B = Black W = White BR = Brown L = Blue V = V iolet SB = Sky Blue R = Red G = Green LG = Light Green P = Pink Y = Yellow GR= Gray O = Orange The first letter indicates the basic wire color and the

second letter indicates the color of the stripe.

Example: L – Y

(Blue)Y(Yellow)

[I] : Indicates a wiring Splice Point (Codes are ”E” for the

Engine Room, ”I” for the Instrument Panel, and ”B” for the Body).

The Location of splice Point I 5 is indicated by the shaded section.

[J] : Indicates a shielded cable.

[K] : Indicates the pin number of the connector.

The numbering system is different for female and male connectors.

Example:

Numbered in order from upper left to lower right

Numbered in order from upper right to lower left

Female

[L] : Indicates a ground point.

The first letter of the code for each ground point(s) indicates the component’s location, e.g, ”E” for the Engine Compartment, ”I” for the Instrument Panel and Surrounding area, and ”B” for the Body and Surrounding area.

[M] : Page No.

Male

B HOW TO USE THIS MANUAL

[N]

[O]

[P]

[Q]

System Outline

Current is applied at all times through the STOP fuse to TERMINAL 2 of the stop light SW . When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL 8 of the light failure sensor, and also flows through the rear lights warning light to TERMINAL 4 of the light failure sensor.

Stop Light Disconnection Warning

When the ignition SW is turned on and the brake pedal is pressed (Stop light SW on), if the stop light circuit is open, the current flowing from TERMINAL 7 of the light failure sensor to TERMINALS 1, 2 changes, so the light failure sensor detects the disconnection and the warning circuit of the light failure sensor is activated. As a result, the current flows from TERMINAL 4 of the light failure sensor to TERMINAL 11 to GROUND and turns the rear lights warning light on. By pressing the brake pedal, the current flowing to TERMINAL 8 of the light failure sensor keeps the warning circuit on and holds the warning light on until the ignition SW is turned off.

Service Hints

S6 Stop Light SW

2–1 : Closed with the brake pedal depressed

L4 Light Failure Sensor

1, 2, 7–Ground : Approx. 12 volts with the stop light SW on

4, 8–Ground : Approx. 12 volts with the ignition SW at ON position

11–Ground: Always continuity

: Parts Location

Code See Page Code See Page Code See Page

C7 34 L4 36 R7 37

H17 36 R6 37 S6 35

: Relay Blocks

Code See Page Relay Blocks (Relay Block Location)

1 18 R/B No.1 (Instrument Panel Brace LH)

[R]

[S]

[T]

[U]

: Junction Block and Wire Harness Connector

Code See Page Junction Block and Wire Harness (Connector Location)

IB 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel)

3C 22 Instrument Panel Wire and J/B No.3 (Instrument Panel Brace LH)

: Connector Joining Wire Harness and Wire Harness

Code See Page Joining Wire Harness and Wire Harness (Connector Location)

IE1 42 Floor Wire and Instrument Panel Wire (Left Kick Panel)

BV1 50 Luggage Room Wire and Floor Wire (Luggage Room Left)

: Ground Points

Code See Page Ground Points Location

BL 50 Under the Left Center Pillar

BO 50 Back Panel Center

: Splice Points

Code See Page Wire Harness with Splice Points Code See Page Wire Harness with Splice Points

I5 44 Cowl Wire B18 50 Luggage Room Wire

[N] : Explains the system outline.

[O] : Indicates values or explains the function for reference during troubleshooting.

[P] : Indicates the reference page showing the position on the vehicle of the parts in the system circuit.

Example : Part ”L4” (Light Failure Sensor) is on page 36 of the manual.

∗ The letter in the code is from the first letter of the part, and the number indicates its order in parts

starting with that letter.

Example : L 4

[Q] : Indicates the reference page showing the position on the vehicle of Relay Block Connectors in the system circuit.

Example : Connector ”1” is described on page 18 of this manual and is installed on the left side of the instrument

panel.

[R] : Indicates the reference page showing the position on the vehicle of J/B and Wire Harness in the system circuit.

Parts is 4th in order Light Failure Sensor

Example : Connector ”3C” connects the Instrument Panel Wire and J/B No.3. It is described on page 22 of this

manual, and is installed on the instrument panel left side.

[S] : Indicates the reference page describing the wiring harness and wiring harness connector (the female wiring

harness is shown first, followed by the male wiring harness). Example : Connector ”IE1” connects the floor wire (female) and Instrument panel wire (male). It is described on

page 42 of this manual, and is installed on the left side kick panel.

[T] : Indicates the reference page showing the position of the ground points on the vehicle.

Example : Ground point ”BO” is described on page 50 of this manual and is installed on the back panel center.

[U] : Indicates the reference page showing the position of the splice points on the vehicle.

Example : Splice point ”I5” is on the Cowl Wire Harness and is described on page 44 of this manual.

B HOW TO USE THIS MANUAL

The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points ( checked this way.

I GROUND POINT

EA, IB

and

shown below) can also be

FAN MAIN Relay

A/C Relay No.2

A/C Relay No.3

Radiator Fan Motor

Headlight Cleaner Relay

Headlight LH

Headlight RH

Front Turn Signal Light RH

Front Clearance Light RH

Front Turn Signal Light LH

Front Clearance Light LH

Door Lock Control SW

Door Courtesy SW RH

Door Lock Motor RH

Door Lock Control Relay

Blower Resistor

Idle–Up SW

A/C Amplifier

Radio and Player

HEATER Relay

Auto Antenna Motor

W–B

W–B W–B

W–B

W–B W–B

W–B

W–B W–B W–B

W–B

W–B W–B W–B

W–B

BR BR

E 3

W–B

E 3

W–B

E 3

W–B

E 3

W–B

E 2

W–B

E 4

W–B

E 5

W–B

E 4

W–B

E 5

W–B

E 6E 4

B 4

W–B

I 4 I 8

W–B

IA1

IB1

4BA1

W–B

444

Cigarette Lighter

O/D Main SW

Clock

Front Fog Light RH

Front Fog Light LH

Brake Fluid Level SW

I 4

W–B

EA2

W–B

J 1

Junction Connector

W–B

I 5

W–B

I 5

15 ID1

W–B W–B

I 5

W–B

I 5

W–B

W–B(4A–GZE)

IC3

W–B

I 6

W–BW–B

I 6

W–B

I 2

W–B

W–BW–B

I 2

W–B

I 2

W–B

W–BW–B W–B

B 5I 5

W–B

B 5

W–B

B 5

W–B

B 5

W–B

W–BW–B

I 3I 3

A/C Control Assembly

Blower Motor

Blower SW

Parking Brake SW

Combination Meter

Combination SW

Cruise Control ECU

Remote Control Mirror SW

Turn Signal Flasher

Defogger SW

Combination SW

Unlock Warning SW

Power Window Master SW

Power Window Control Relay

Door Courtesy SW LH

Door Lock Control SW

Door Lock Motor LH

Fuel Control SW

Woofer Speaker Amplifier

Combination Meter

BRBR

Combination Meter

Fuel Sender

W–B

∗ The system shown here is an EXAMPLE ONLY. It is different to the actual circuit shown in the SYSTEM CIRCUITS SECTION.

The ”Current Flow Chart” section, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood.

J POWER SOURCE (Current Flow Chart)

The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts.

10A ECU–B

7.5A DOME

Battery

30A AM2

Starter

S 2

Fusible Link Block

Short Pin

15A EFI

10A HAZARD 20A RADIO NO.1 10A HORN

100A ALT

Engine Room R/B (See Page 20)

System ABS

ABS and Traction Control Cruise Control Electronically Controlled Transmission Multiplex Communication System

Cigarette Lighter Combination Meter Headlight Interior Light Key Reminder and Seat Belt Warning Light Auto Turn Off Theft Deterrent and Door Lock Control

20A

10A

Fuse

STOP

DOME

Power Source

E 6

3 EA2 1 EA1

BBBBB E 7

E 7

B–O

1.25B FL MAIN

7.5A AM2

15A HAZ–RADIO

INJECTION Relay

50A MAIN

W–B

B–W

60A ABS

Page

194 187 180 166 210

214 230 112 122

40A DOOR LOCK CB

7.5A DOME

TAIL Relay

G–W

Battery

EB1

W–R

EB1

W–R

AM2

I 2

WWW

I 2 I 2

I 8

Ignition SW

AM1

W–L

15A TAIL

20A DEFOG

15A RAD CIG

STARTER Relay

E 7

W–B

B–W

IG2

ACC

IG1

B–Y

W–R

P–L

∗ The system shown here is an EXAMPLE ONLY. It is different to the actual circuit shown in the SYSTEM CIRCUITS SECTION.

B HOW TO USE THIS MANUAL

K CONNECTOR LIST

I14 I15 I16 J1 J2

Dark Gray Gray Black

ABB AABCCCDDDD

678

[B]

[A]

A A

J4 K1 K2 L1

Dark Gray

AAA

A AAA

ABB AABCCCDDDD

L2 L3 L4 M1 M2 M3

1 7

Black

1 2

[D]

234 8910

123

6 7 8 9 10 1112

3456 8

BlackGrayGray

21 43

Gray

1 2

M4 N1 N2 O1 O2

123

[C]

Dark Gray

[A] : Indicates connector to be connected to a part. (The numeral indicates the pin No.) [B] : Junction Connector

Indicates a connector which is connected to a short terminal.

Junction Connector

Junction connector in this manual include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to a wire harness from a different part.) Wire harness sharing the same short terminal grouping have the same color.

Same Color

Short Terminal

[C] : Parts Code

The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter.

[D] : Connector Color

Connectors not indicated are milky white in color.

L PART NUMBER OF CONNECTORS

Code

A 1

A/C Ambient Temp. Sensor A 2 A/C Condenser Fan Motor 90980–11237 D 5 Diode (Interior Light) 90980–10962 A 3 A/C Condenser Fan Relay 90980–10940 D 6 Diode (Moon Roof) 90980–1 1608 A 4 A/C Condenser Fan Resistor 90980–10928 A 5 A/C Magnetic Clutch A 6 A/T Oil Temp. Sensor A 7 ABS Actuator

[A]

A 8 ABS Actuator A 9 ABS Speed Sensor Front LH

ABS Speed Sensor Front RH

A10 A11

Airbag Sensor Front LH Door Courtesy SW Rear LH A12

Airbag Sensor Front RH Door Courtesy SW Rear RH A13 Airbag Squib 90980–11194 Door Key Lock and Unlock SW LH

[B] [C]

[A] : Part Code [B] : Part Name [C] : Part Number

Toyota Part Number are indicated.

Part Number

90980–11070

90980–11271 90980–11413 90980–11151 90980–11009 90980–10941 90980–11002

90980–11856

90980–11070

Code

D 4 Diode (Courtesy)

D 7 Door Lock Control Relay 90980–10848 D 8 Door Lock Control SW LH D 9 Door Lock Control SW RH

D10

Door Courtesy SW LH

D11

Door Courtesy SW RH

D12

Door Courtesy SW Front LH

D13

Door Courtesy SW Front RH D14 D15 D16 D17 Door Key Lock and Unlock SW RH

Part NumberPart NamePart Name

90980–11608

90980–11148

90980–11097

90980–11156

90980–11170

Not all of the above part numbers of the connector are established for the supply.

C TROUBLESHOOTING

SW 2

To Ignition SW IG Terminal

Fuse

[A]

[B]

Relay

[C]

Solenoid

VOLTAGE CHECK

(a) Establish conditions in which voltage is present at the check

point. Example:

[A] – Ignition SW on [B] – Ignition SW and SW 1 on [C] – Ignition SW, SW 1 and Relay on (SW 2 off)

(b) Using a voltmeter, connect the negative lead to a good ground

VoltmeterSW 1

point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter.

CONTINUITY AND RESISTANCE CHECK

Ohmmeter

Diode

Digital Type Analog Type

(a) Disconnect the battery terminal or wire so there is no voltage

between the check points.

(b) Contact the two leads of an ohmmeter to each of the check

points.

If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity.

minimum) for troubleshooting of the electrical circuit.

Test Light

Disconnect

To Ignition SW IG Terminal

Fuse Case

Short [A]

SW 1

Short [B]

Disconnect

RelayLight

Short [C]

Disconnect

SW 2 Solenoid

FINDING A SHORT CIRCUIT

(a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on.

Example:

[A] – Ignition SW on [B] – Ignition SW and SW 1 on [C] – Ignition SW, SW 1 and Relay on (Connect the

Relay) and SW 2 off (or Disconnect SW 2)

(d) Disconnect and reconnect the connectors while watching the

test light. The short lies between the connector where the test light stays lit and the connector where the light goes out.

(e) Find the exact location of the short by lightly shaking the

problem wire along the body.

CAUTION:

(a) Do not open the cover or the case of the ECU unless

absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.)

(b) When replacing the internal mechanism (ECU part) of

the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part).

DISCONNECTION OF MALE AND FEMALE CONNECTORS

To pull apart the connectors, pull on the connector itself, not the wire harness.

HINT : Check to see what kind of connector you are

disconnecting before pulling apart.

Pull Up

Press Down Press Down

Pull Up

C TROUBLESHOOTING

Reference:

Example: (Case 1)

Terminal Retainer

HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device)

1. PREPARE THE SPECIAL TOOL

0.2

Tool

(mm)

HINT : To remove t he ter mina l from t he connector, please

construct and use the special tool or like object shown on the left.

2. DISCONNECT CONNECT OR

3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER.

(a) Locking device must be disengaged before the terminal

locking clip can be released and the terminal removed from the connector.

(b) Use a special tool or the terminal pick to unlock the secondary

locking device or terminal retainer.

NOTICE: Do not remove the terminal retainer from connector body.

Terminal Retainer

[Retainer at Full Lock Position]

Stopper

[Retainer at Temporary Lock Position]

Example: (Case 2)

Terminal Retainer

Secondary Locking Device

[A] For Non–Waterproof Type Connector

HINT : The needle insertion position varies according to the

connector’s shape (number of terminals etc.), so check the position before inserting it.

”Case 1”

Raise the terminal retainer up to the temporary lock position.

”Case 2”

Open the secondary locking device.

Tab

Tool

Example:

(Case 1)

Tool

[Male]

Terminal Retainer

Access Hole

( Mark)

Retainer at Full Lock Position

[Female]

Tool

[B] For Waterproof Type Connector

HINT : Termina l retaine r color is differ ent

according to connector body. Example:

Terminal Retainer

: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black

”Case 1”

Type where terminal retainer is pulled up to the temporary lock position (Pull Type).

Insert the special tool into the terminal retainer access hole (YMark) and pull the terminal retainer up to the temporary lock position.

HINT : The needle insertion position varies

according to the connector’s shape (Number of terminals etc.), so check the position before inserting it.

Example: (Case 2)

[Male]

Retainer at Temporary Lock Position

[Male] [Female]

Terminal Retainer

Tool

Press Down

[Female]

”Case 2”

Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown.

Tool

C TROUBLESHOOTING

Retainer at Full Lock Position

Retainer at Temporary Lock Position

[Male] [Female]

Push the terminal retainer down to the temporary lock position.

Locking Lug

from rear.

Tool

4. INSTALL TERMINAL TO CONNECTOR (a) Insert the terminal.

HINT:

1. Make sure the terminal is positioned correctly.

2. Insert the terminal until the locking lug locks firmly.

3. Insert the terminal with terminal retainer in the temporary lock

position.

(b) Push the secondary locking device or terminal retainer in to

the full lock position.

5. CONNECT CONNECT OR

ABBREVIATIONS

The following abbreviations are used in this manual. 2WD = Two Wheel Drive Vehicles

4WD = Four Wheel Drive Vehicles A/C = Air Conditioner A/T = Automatic Transmission ABS = Anti–Lock Brake System ADD = Automatic Disconnecting Differential CAN = Controller Area Network CD = Compact Disc DLC3 = Data Link Connector 3 ECT = Electronic Control Transmission

ABBREVIATIONS D

ECU = Electronic Control Unit EDU = Electronic Driving Unit EGR = Exhaust Gas Recirculation IC = Integrated Circuit INT = Intermittent J/B = Junction Block LCD = Liquid Crystal Display LH = Left–Hand M/T = Manual Transmission R/B = Relay Block RH = Right–Hand SRS = Supplemental Restraint System SW = Switch TEMP. = Temperature VRV = Vacuum Regulating Valve VSV = Vacuum Switching Valve w/ = With w/o = Without

∗ The titles given inside the components are the names of the terminals (terminal codes) and are not treated as being

abbreviations.

E GLOSSARY OF TERMS AND SYMBOLS

FUSIBLE LINK

BATTERY

Stores chemical energy and converts it into electrical energy . Provides DC current for the auto’s various electrical circuits.

CAPACITOR (Condenser)

A small holding unit for temporary storage of electrical voltage.

CIGARETTE LIGHTER

An electric resistance heating element.

CIRCUIT BREAKER

Basically a reusable fuse, a circuit breaker will heat and open if too much current flows through it. Some units automatically reset when cool, others must be manually reset.

DIODE

A semiconductor which allows current flow in only one direction.

1. SINGLE FILAMENT

2. DOUBLE FILAMENT

GROUND

The point at which wiring attaches to the Body , thereby providing a return path for an electrical circuit; without a ground, current cannot flow.

HEADLIGHTS

Current flow causes a headlight filament to heat up and emit light. A headlight may have either a single (1) filament or a double (2) filament

HORN

An electric device which sounds a loud audible signal.

IGNITION COIL

Converts low–voltage DC current into high–voltage ignition current for firing the spark plugs.

(for Medium Current Fuse)

(for High Current Fuse or Fusible Link)

DIODE, ZENER

A diode which allows current flow in one direction but blocks reverse flow only up to a specific voltage. Above that potential, it passes the excess voltage. This acts as a simple voltage regulator.

PHOTODIODE

The photodiode is a semiconductor which controls the current flow according to the amount of light.

DISTRIBUTOR, IIA

Channels high–voltage current from the ignition coil to the individual spark plugs.

FUSE

A thin metal strip which burns through when too much current flows through it, thereby stopping current flow and protecting a circuit from damage.

A heavy–gauge wire placed in high amperage circuits which burns through on overloads, thereby protecting the circuit. The numbers indicate the crosssection surface area of the wires.

FUEL

LIGHT

Current flow through a filament causes the filament to heat up and emit light.

LED (LIGHT EMITTING DIODE)

Upon current flow, these diodes emit light without producing the heat of a comparable light.

METER, ANALOG

Current flow activates a magnetic coil which causes a needle to move, thereby providing a relative display against a background calibration.

METER, DIGITAL

Current flow activates one or many LED’s, LCD’s, or fluorescent displays, which provide a relative or digital display .

MOTOR

A power unit which converts electrical energy into mechanical energy , especially rotary motion.

Opens and closes

operational.

black dot at the junction are

RELAY

1. NORMALLY CLOSED

2. NORMALLY OPEN

RELAY, DOUBLE THROW

RESISTOR

RESISTOR, TAPPED

RESISTOR, VARIABLE or RHEOSTAT

Basically, an electrically operated switch which may be normally closed (1) or open (2). Current flow through a small coil creates a magnetic field which either opens or closes an attached switch.

A relay which passes current through one set of contacts or the other.

An electrical component with a fixed resistance, placed in a circuit to reduce voltage to a specific value.

A resistor which supplies two or more different non adjustable resistance values.

A controllable resistor with a variable rate of resistance. Also called a potentiometer or rheostat.

SPEAKER

An electromechanical device which creates sound waves from current flow.

SWITCH, MANUAL

Opens and closes

1. NORMALLY OPEN

2. NORMALLY CLOSED

SWITCH, DOUBLE THROW

A switch which continuously passes current through one set of contacts or the other.

SWITCH, IGNITION

A key operated switch with several positions which allows various circuits, particularly the primary ignition circuit, to become operational.

circuits, thereby stopping (1) or allowing (2) current flow.

(Reed Switch Type)

SENSOR (Thermistor)

A resistor which varies its resistance with temperature.

SENSOR, SPEED

Uses magnetic impulses to open and close a switch to create a signal for activation of other components.

SHORT PIN

Used to provide an unbroken connection within a junction block.

SOLENOID

An electromagnetic coil which forms a magnetic field when current flows, to move a plunger, etc.

SWITCH, WIPER PARK

Automatically returns wipers to the stop position when the wiper switch is turned off.

TRANSISTOR

A solidstate device typically used as an electronic relay; stops or passes current depending on the voltage applied at ”base”.

WIRES

(1) NOT CONNECTED

(2) SPLICED

Wires are always drawn as straight lines on wiring diagrams. Crossed wires (1) without a

not joined; crossed wires (2) with a black dot or octagonal ( ) mark at the junction are spliced (joined) connections.

F RELAY LOCATIONS

[Engine Compartment]

Injector Drive (EDU)

Skid Control ECU with Actuator

Engine Room R/B Engine Room J/B

[Instrument Panel]

Theft Warning ECU

4WD Control ECU

R/B No.3

Transmission Control ECU

A/C Amplifier

Shift Lock Control ECU

Engine ECU

Airbag Sensor Assembly Center

Transponder Key ECU

Turn Signal Flashe

Transponder Ke Amplifier

Driver Side J/B

F RELAY LOCATIONS

Engine Compartment Left (See Page 20)

: Engine Room R/B : Engine Room J/B

(Inner Circuit : See Page 26)

* 1:100A ALT (for High Current) * 2:80A GLOW (for High Current) * 3:50A BATT P/I (for High Current) * 4:30A AM2 (for High Current) * 5:40A MAIN (for High Current) * 6:40A ABS NO.1 (for High Current) * 7:40A FR HTR (for High Current) * 8:30A ABS NO.2 (for High Current)

Unit A

17.5A

ALT-S

15A

1 TURN-HAZ

220A

H-LP RH

220A

H-LP LH

Unit C

1215A

FOG

1210A

HORN

1 1

1225A

EFI

17.5A ECU-B

130A

DCC

115A 2

RAD

17.5A DOME

Unit D

Unit B

Back View

Side View

Unit A

(from Engine Room Main Wire)

21 43

34 12

(from Engine Room Main Wire)

21 43

43 21

Top View

Side View

(from Engine Wire) Wire Coler : B

Unit D

1F 1G 1A

(from Engine Room Main Wire) Wire Coler : B

(from Engine Room Main Wire) Wire Coler : W

F RELAY LOCATIONS

Engine Compartment Left (See Page 20)

: Engine Room R/B : Engine Room J/B

Unit B

Top View

(Inner Circuit : See Page 27)

Back View

2 3

4 5

6 7

2 3

6 7

(from Engine Room Main Wire)

2 3

4 5

6 7

1 2

4 5

6 7

(from Engine Room Main Wire)

Unit C

ST Relay

GLOW Relay

Memo

F RELAY LOCATIONS

[Engine Room R/B and Engine Room J/B Inner Circuit]

Unit A

100A ALT

80A GLOW

50A BATT P/I

30A AM2

40A MAIN

40A ABS NO.1

40A FR HTR

30A ABS NO.2

Unit D

15A TURN-HAZ

7.5A ALT-S 12

2121

30A DCC 7.5A ECU-B

15A RAD

7.5A DOME

20A H-LP RH

20A H-LP LH

Unit B

12 15A FOG

10A HORN

25A EFI

FOG Relay

HORN Relay

MAIN Relay

EDU Relay

+ 214 hidden pages

Toyota Hilux 2004, Hilux User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual