'78 BJ40 lighting wiring

[NielsC]

I'm redoing the wiring of the lightning sytem of my 78 BJ40 as the previous owner almost litterly threw in "his" wiring.

But I can't get my head arround how he did it.

He connected 2 wires going out of the dimmer switch at the steering column one from the HL terminal for the low beams, and one from the HU terminal for the high beams.
The side markers and rear lights are simply connected to the low beams.
So my light switch switches low beam , side markers and rear lights
in both the No1 and No2 position.

I tought it would be easy and drawed an all new wiring diagram with relays and fuses.

So i'd start at the light switch to see how it's wired, but this is were I can't get my head arround.
It has 5 terminals:

white/green -> At this wire I get 24volt when glowing ?? I follewed the wire and it is wired to the glow relay ???????
white/blue -> Constantly 24 volt. Wired to the ammeter - wich goes to the alternator I think/
Blue/red -> to the fuse box
Black/yellow -> to the fuse box
Black/white -> Goes to a metal box located above the side vent at the right where the passengers feet are.

Can someone tell me if this wiring makes any sence or what it should be like as im stuck at this point.

Thanks !

 

[lostmarbles]

Have you got an FSM wiring diagram to work from?

This is from the diagram for a 1979 BJ40:

 

[NielsC]

So there is a relay ? Is this the metal box at passenger side under the dashboard i was reffering to? have a fj40 bj40 manual from this forum and in that wiring diagram there was no relay... Where can i find this manual ?

 

[lostmarbles]

So there is a relay ? Is this the metal box at passenger side under the dashboard i was reffering to? have a fj40 bj40 manual from this forum and in that wiring diagram there was no relay... Where can i find this manual ?

My BJ40 is 12V and so is far less complicated than yours (electrically - that is)..

Best to post up photos if you want someone to identify "a metal box under the dash".

I have lots of different wiring diagrams from various different Toyota publications and I'm unsure where I got that "1979 USA & Canada BJ40 diagram" (that I copied part of above).

I've sent you a pm.

 

[bj40green]

He connected 2 wires going out of the dimmer switch at the steering column one from the HL terminal for the low beams, and one from the HU terminal for the high beams.
The side markers and rear lights are simply connected to the low beams.
So my light switch switches low beam , side markers and rear lights
in both the No1 and No2 position.

Hoi Niels,

Do you have 12V or 24V headlight bulbs?
Is your Cruiser an European model or Canadian model?
The European model is equipped with full 24V light bulbs.
The Canadian model is equipped with 12V headlight bulbs in a 24V set up. I know.... very confusing. That's the diagram Tom posted.

From what I read in your post the PO rerouted the wiring by bypassing the main headlight switch.

Rudi

 

[bj40green]

The Canadian model has "rear marker lights" on the rear side panels.
The European model not.
The Canadian model has a Headlight dimmer relay (#85926-60010) on the driver side panel close to the fuse box, vacuum buzzer and flasher.
The European model not.

Hope this helps.

Rudi

 

[Dieseler]

Just so we are on the same page do you still have the B motor and not a 3B transplant and possible wiring.
The metal box you are asking about should be the fuel relay or FCR if I have it correct.
I don't believe that year came with the dimmer of all the model years I have had only the 83 came with the dimmer.
your markers should be the only light on the first position then the headlights on the full out position something is wrong with that wiring hookup

 

[bj40green]

Hmmmmm, it seems that all those wires belong to the ignition key switch and not to the light switch.

Here we go..

So i'd start at the light switch to see how it's wired, but this is were I can't get my head arround.
It has 5 terminals:
white/green -> At this wire I get 24volt when glowing ?? I follewed the wire and it is wired to the glow relay ???????
From IGN KEY GLOW POSITION to GLOW PLUG RELAY

white/blue -> Constantly 24 volt. Wired to the ammeter - wich goes to the alternator I think/
From IGN KEY MOTHER CONTACT to ALTERNATOR, AMMETER and STOP FUSE.

Blue/red -> to the fuse box
From IGN KEY ACC POSITION to WIPER FUSE

Black/yellow -> to the fuse box
From IGN KEY ON POSITION to HEATER FUSE

Black/white -> Goes to a metal box located above the side vent at the right where the passengers feet are.
From IGN KEY START POSITION to STARTER RELAY, GLOW PLUG RELAY and EDIC CONTROLLER

Are you sure you're not mixing up something?
What you described is the wiring from the IGN KEY connector and not the light switch.

Rudi

 

[NielsC]

I will check again to be sure when i get home from work.
It is a full 24 volt european model btw. With stock B engine.

 

[NielsC]

I checked it again and im sure its the wires of the light switch that i was reffering to. I also find it very weird how the wires are going. Where are the wires supposed to go to exactly ? And what are the correct colours? Also where can I find the correct wiring diagram for an 1978 bj40 european model?
Niels

 

[lostmarbles]

Oops. Sorry for posting that crazy Canadian 24V wiring before ...

But I still don't have anything for 1978 .... only 1979 (which could well be because 1979 is the year of manufacture of my own BJ40 )

So here (hopefully) is the factory 24V headlight wiring for a 1979 European BJ40 (which hopefully didn't change from 1978):





PS. I wish Toyota would say "dipper switch" instead of "dimmer switch". That would better describe its function to me anyway.

 

[bj40green]

Hi Niels,

Or you're still wrong or the PO made a mess of it.
Here is the Starter switch (IGN key) wiring with all the colors you mentioned.


This is the 5 wire headlight switch diagram.


The headlight switch


And here is the dimmer switch.


Send me a PM with your email address and I'll give you a link for the FSM to download including the wiring diagrams.

BTW: there is no "European" wiring diagram. There is universal wiring diagram (for all markets) and a NON USA & Canada wiring diagram for this series and era Cruisers.
Sometimes when it's specific for a market it's mentioned in the diagram like "ARL only" which means Australia or something like "Sweden only".

Rudi

 

[NielsC]

Today I did some more investigating in the wiring, I really think the PO really did make a mess out of it.

So this is what I found out:

Light switch:

White/green: goes to glow relay and ignition switch G terminal.
I seriously don't see the use of this ???

White/Blue: constant 24 volt, goes to the alternator trough the ammeter

Blue/red: goes to fuse box, but there is no wire on the other side of the fuse so it its disconnected.

Black/yellow: goes to the fuse box, and the other side of the fuse it turns into Red/White and goes to the dimmer switch.
From the dimmer switch it will go to high beam or low beam.

Black/white: goes to the little box on the right side above the side vent ( see picture)

This is the box i was reffering to:

above the vents

Blue/red from light switch not connected:

the fuse at the bottom

wwhite/green goes to this relay, glow relay i guess and ignition switch G terminal:

My main question is what the metal box the black/white wire goes into is?

And why the white/green wire could be connected to the glow relay/G terminal at ign. switch?

I also don't know why the blue/red that is connected to nothing at the fusebox is or was for.

I think PO used a piece of an old wiring loom with the same type of plug that fits the lighting switch...
Also the positions of the terminals in the plug are not the same as in the manual.

The manuals says it should be like:

- -
---

I have something like this:

---
--

PO seriously made a mess of it !!!!

 

[bj40green]

Interesting to see what wires are hooked up to the starter switch. Are they the same colors?
Maybe those two connectors are mixed up?
Can you glow and start the motor?

Rudi

 

[NielsC]

Yeah it starts and glows fine. The lights work too but is wired very bad. Bad ground bad cables bad contacts ... So i wanted to do all the wiring again and do it the proper way. But then i found this s***ty wiring...

 

[lostmarbles]

My best guesses for the identities of your "boxes" are:

 

[NielsC]

Hi, I don't think mine has EDIC, there is no electro motor on the injector pump and I have to shut the engine off with a push rod.

 

[lostmarbles]

Hi, I don't think mine has EDIC, there is no electro motor on the injector pump and I have to shut the engine off with a push rod.

Well I think they probably left the EDIC relay (aka Fuel Control Relay) in place despite removing other parts of the EDIC system.

 

[NielsC]

Yeah i'm starting to think this too...
But then remains the main question... Why the hell are the glow relay, and fuel control relay connected to the light switch?????

I think I am going to start all over and make my own (correct) wiring loom for the lighting. And disconnect the wires from fuel control relay and glow relay.

 

[fj401978]

Wow, the good thing is, you have two of the best gurus on here helping you out..bj40green and lostmarbles! Hope you can get this all straightened out...good luck!