Wiring Diagrams – AWD Wagon Page 12P–1

Section 12P

Wiring Diagrams – AWD Wagon

ATTENTION

Before performing any service operation or other procedure described in this Section, refer to Section 00

Warnings, Cautions and Notes for correct workshop practices with regard to safety and/or property damage.

1 General Information ...............................................................................................................................4

2 Electrical Circuit Diagnosis...................................................................................................................5

Step 1 Identify the Problem............................................................................................................................... 5

Step 2 Specify the Problem............................................................................................................................... 5

Step 3 Investigate the Problem......................................................................................................................... 5

Step 4 Develop Possible Causes...................................................................................................................... 5

Step 5 Isolate the Most Possible Cause........................................................................................................... 6

Step 6 Verify ....................................................................................................................................................... 6

Problem Example................................................................................................................................................... 6

Step 1 Identify the Problem ............................................................................................................................ 6

Step 2 Specify the Problem............................................................................................................................ 6

Step 3 Investigate the Problem....................................................................................................................... 6

Step 4 Develop Possible Causes ................................................................................................................... 7

Step 5 Isolate the Most Possible Cause......................................................................................................... 8

Step 6 Verify................................................................................................................................................... 8

3 Test Procedures .....................................................................................................................................9

3.1 Electrical Fault Diagnosis..................................................................................................................................... 9

Possible Electrical Malfunctions.......................................................................................................................... 9

Circuit Faults........................................................................................................................................................ 10

Open ................................................................................................................................................................ 10

Short to Ground................................................................................................................................................ 10

Short to Voltage................................................................................................................................................ 10

High Resistance Problems............................................................................................................................... 10

3.2 Troubleshooting Test Equipment....................................................................................................................... 11

Jumper Wire......................................................................................................................................................... 11

Test Light.............................................................................................................................................................. 12

Self-Powered Test Light...................................................................................................................................... 12

Multimeters........................................................................................................................................................... 13

3.3 Digital Multimeter................................................................................................................................................. 14

Use Of A Multimeter............................................................................................................................................. 14

Selection Of Multimeters..................................................................................................................................... 14

Voltage Measurement.......................................................................................................................................... 15

Resistance Measurement.................................................................................................................................... 16

Resistance Testing........................................................................................................................................... 16

Continuity Testing ............................................................................................................................................... 16

Diode Testing....................................................................................................................................................... 17

Current Measurement.......................................................................................................................................... 17

4 Diagnostic Tests...................................................................................................................................18

4.1 Testing For Voltage ............................................................................................................................................. 18

4.2 Testing For Continuity......................................................................................................................................... 19

4.3 Testing For Voltage Drop.................................................................................................................................... 20

Wiring Diagrams – AWD Wagon Page 12P–2

4.4 Testing For Short To Ground.............................................................................................................................. 21

Using A Test Light Or Voltmeter......................................................................................................................... 21

Using A Self-Powered Test Light Or Ohmmeter................................................................................................ 22

Using A Short Finder........................................................................................................................................... 22

Using A Compass................................................................................................................................................ 22

Using A Circuit Breaker....................................................................................................................................... 22

4.5 Operating A Short Finder.................................................................................................................................... 23

Measuring Current............................................................................................................................................... 24

4.6 Detecting Intermittent Electrical Faults ............................................................................................................. 25

Diagnostic Procedure.......................................................................................................................................... 25

Checking Terminal Contact................................................................................................................................. 25

Meter Connections............................................................................................................................................... 26

Additional Information....................................................................................................................................... 26

5 Wiring Repair Procedures...................................................................................................................27

5.1 General Information............................................................................................................................................. 27

5.2 Performing Wiring Harness Repairs .................................................................................................................. 28

Soldering .............................................................................................................................................................. 28

The Five Points To Soldering.............................................................................................................................. 28

Step 1 Soldering Preparation ....................................................................................................................... 28

Step 2 Iron Preparation ................................................................................................................................ 29

Step 3 Forming a Heat Bridge...................................................................................................................... 29

Step 4 Soldering Iron Removal..................................................................................................................... 29

Step 5 Prevent Job Movement ..................................................................................................................... 30

Joining Wire ......................................................................................................................................................... 30

Twist Joint........................................................................................................................................................ 30

Splice Joint....................................................................................................................................................... 30

The Y Junction ................................................................................................................................................. 31

The T Junction.................................................................................................................................................. 31

5.3 Splicing Wiring Using Splice Clips..................................................................................................................... 32

Step 1 Open the Harness................................................................................................................................. 32

Step 2 Cut the Wire.......................................................................................................................................... 32

Step 3 Select the Correct Size and Type of Wire........................................................................................... 32

Step 4 Strip the Insulation............................................................................................................................... 33

Metric Size ....................................................................................................................................................... 33

AWG................................................................................................................................................................. 33

Step 5 Crimping the Joint................................................................................................................................ 34

Step 6 Solder.................................................................................................................................................... 36

Step 7 Tape the Splice..................................................................................................................................... 37

5.4 ABS And SRS Wiring Repair............................................................................................................................... 38

ABS And SRS Wire Pigtail Repair ...................................................................................................................... 38

Wiring Repair........................................................................................................................................................ 38

Step 1 Open the Harness............................................................................................................................. 39

Step 2 Cut the Wire...................................................................................................................................... 39

Step 3 Select the Correct Size and Type of Wire ......................................................................................... 39

Step 4 Strip the Insulation ............................................................................................................................ 40

Step 5 Select and Position the Splice Sleeve............................................................................................... 40

Step 6 Insert First Wire Into Splice Sleeve and Crimp..................................................................................40

Step 7 Crimp the Second Wire in the Splice................................................................................................. 41

Step 8 Shrink the Insulation around the Splice............................................................................................. 41

Step 9 Close the Harness............................................................................................................................. 41

ABS And SRS Wiring Splice Repair................................................................................................................... 41

5.5 Splicing Twisted Or Shielded Cable................................................................................................................... 42

Step 1 Strip the Cable...................................................................................................................................... 42

Step 2 Prepare the Splice................................................................................................................................ 42

Step 3 Reassemble the Cable ......................................................................................................................... 43

Step 4 Tape the Joint....................................................................................................................................... 43

Wiring Diagrams – AWD Wagon Page 12P–3

5.6 Splicing In-Line Harness Diodes........................................................................................................................ 44

Step 1 Open the Harness................................................................................................................................. 44

Step 2 Remove Diode ...................................................................................................................................... 44

Step 3 Install the New Diode ........................................................................................................................... 45

5.7 Heated Oxygen Sensor (HO2S) Wiring Repairs ................................................................................................ 46

5.8 Terminal Removal................................................................................................................................................ 47

Push to Seat Connectors .................................................................................................................................... 47

Pull-to-Seat Connectors...................................................................................................................................... 47

Repairing Push-To-Seat And Pull-To-Seat Connectors ................................................................................... 47

Weather Pack® Connectors................................................................................................................................ 49

6 Reading 12P Wiring Diagrams............................................................................................................50

General Information............................................................................................................................................. 50

Sheet Identification.............................................................................................................................................. 51

Wire Identification................................................................................................................................................ 51

Wire Colour Abbreviations.................................................................................................................................. 51

Wiring Harness Abbreviations............................................................................................................................ 52

Wiring Harness Visual Identification.................................................................................................................. 53

Connectors........................................................................................................................................................... 53

Grid Reference..................................................................................................................................................... 53

Continuation Reference ...................................................................................................................................... 54

Multiple Continuation References...................................................................................................................... 54

Assembly Identification....................................................................................................................................... 54

Assembly Legend................................................................................................................................................ 55

Assembly Continuation....................................................................................................................................... 55

Assembly Connector Identification.................................................................................................................... 55

Assembly Circuit Identification .......................................................................................................................... 56

Information Within An Assembly........................................................................................................................ 56

Harness Splices................................................................................................................................................... 56

Ground Locations................................................................................................................................................ 57

Circuit Symbols.................................................................................................................................................... 58

7 Connector Location Illustrations........................................................................................................59

8 Electrical Schematics Contents..........................................................................................................61

9 Module Location Charts ......................................................................................................................62

Electrically Operated Mechanical Devices......................................................................................................... 62

Indicators, Alarms and Signal Devices.............................................................................................................. 63

Inductors .............................................................................................................................................................. 63

Measurement, Display and Test Devices........................................................................................................... 63

Modules, Systems and Sub-Assemblies ........................................................................................................... 64

Motors................................................................................................................................................................... 66

Other Devices and Equipment............................................................................................................................ 66

Power Supplies.................................................................................................................................................... 67

Resistors .............................................................................................................................................................. 67

Regulators and Amplifiers .................................................................................................................................. 68

Semi Conductors................................................................................................................................................. 68

Switches ............................................................................................................................................................... 68

Transducers ......................................................................................................................................................... 70

Transmission Paths, Conductors and Antennas.............................................................................................. 71

10 Special Tools ........................................................................................................................................72

Wiring Diagrams – AWD Wagon Page 12P–4

1 General Information

Wiring diagram s are found throughout various Sections of the Service Information. The wiring diagrams containe d in this

Service Information are the specific systems wiring diagrams for MY2005 VZ AWD W agon vehicles. These wiring

diagrams are based on the Integrated Vehicle Electrical Design (IVED) wiring diagrams. There are two types of wiring

diagrams used in this Service Information:

• Service Information Wiring Diagrams.

• 12P Electrical Schematics.

The Service Information wiring diagrams only refer to the system under discussion and are used to:

• Present the overall circuitry for a total system.

• Assist in explaining the operation of part of a total system.

• Assist in diagnostics.

This Section is designed to assist technicians in understanding both forms of wiring diagrams.

Additional wiring, wiring harness and specific wiring harness installation information is con t ained in 12O Fuses, Relays

and Wiring Harnesses in this Service Information. Further information on developing a diagnostic procedure for electrical

circuit diagnosis, electrical circuit test procedures, diagnostic tests and wiring repair procedures is contained in this

Section.

Wiring Diagrams – AWD Wagon Page 12P–5

2 Electrical Circuit Diagnosis

The system wiring diagrams should be referred to when diagnosing vehicle electrical problems.

These diagrams should ALWAYS be the starting point when troubleshooting electrical problems.

The diagrams illustrate how a particular circuit should work by design, and should be understood before trying to

determine why it does not work.

NOTE

It is important to realise that no attempt is made

on the diagrams to represent components and

wiring as they appear in the vehicle

geographically.

For example, a metre length of wire is treated no differently in a wiring diagram from one which is only a few centimetres

long. Similarly, switches and other components are shown as simply as possible in schematic format and in an

inactivated state, with basic function onl y bei ng shown.

The following six-step proced ure is recommended when diagnosing a vehicle electrica l problem.

Step 1 Identify the Problem

Does a problem really exists?

To identify the problem, listen patiently and carefully to the owner/operator of the vehicle.

Step 2 Specify the Problem

Question the owner/operator to establish:

Is there a problem?

What is the problem?

Where is the problem?

How serious or extensive is the problem?

How often does the problem occur?

Does a trend exist?

Perform a system check to be sure you unde rstand what is wrong.

Do not waste time fixing only part of the problem. Do not begin d isassembly of components or testing until you have

narrowed down the possible causes.

Step 3 Investigate the Problem

Are you totally familiar with the system?

Read the system wiring diagram.

Study the diagram to understand how the affected circuit should work.

Check circuits that share wiring with the problem circuit. If the shared circuits operate correctly, then the shared wiring

must be OK. The cause of the problem must be within the wiring or components used by the problem circuit.

If several circuits fail at the same time, chances are the power (fuse) or ground circuit is faulty.

Step 4 Develop Possible Causes

Make yourself a mental or written check list.

Ask yourself would this cause the problem?

Use the system wiring diagram to develop a set of test points.

Narrow down the possible causes.

Wiring Diagrams – AWD Wagon Page 12P–6

Step 5 Isolate the Most Possible Cause

You must have the knowledge and the special tools/equipment.

Carry out the necessary tests and measurements as given in the appropriate system diagnosis, e.g. ENGINE

MANAGEMENT SYSTEM, CRUISE CONTROL, or at the test points that you have developed from the wiring diagrams.

TEST, DON'T GUESS.

Before replacing a component, check power, signal and ground wires at the component wiring harness connector. If

these check OK, the component is most likely to be faulty. FIND THE CAUSE AND REPAIR.

Step 6 Verify

Test the repair.

Has the problem been fixe d?

Ask yourself why did the problem occur/part fail?

Will it happen again?

Have I created any other problems?

CURE THE CAUSE NOT THE EFFECT.

OPERATE THE CIRCUIT AND ROAD TEST THE VEHICLE BEFORE RET URNING IT TO THE CUSTOMER.

Problem Example

Step 1 Identify the Problem

A customer brings in a vehicle reporting that the headlamps are not operating correctly.

Step 2 Specify the Problem

The driver is questioned and it is established that the LH headlamp is not operating on high beam, or when the flash

switch is operated.

Step 3 Investigate the Problem

Perform a system check on the headlamp circ uit. It is noted that:

1 Headlamps operate correctly on low beam.

2 On high beam, the headlamp high beam lamps oper ate corr ectly but the left hand headlamp inboard high beam

lamp does not operate on high beam.

3 When the high beam flash switch is operated, the LH headlamp inboard high beam lamp still does not operate on

high beam.

READ THE SYSTEM WIRING DIAGRAM.

This is the step that will save time and labour. Remember, it is essential to understand how a system should work, before

trying to determine why it doesn't work.

Wiring Diagrams – AWD Wagon Page 12P–7

Step 4 Develop Possible Causes

Once the circuit is understood, read the diagram again, this time keeping in mind what you have learn ed by operating the

circuit. It is recommended to read the System Wiring Dia gram from the battery positive terminal or fuse (being the source

of electrical supply) to ground (battery negative terminal).

As both low beam headlamps work, fuses F102, F31 and F30, the headlamp switch, low beam headlamp relay, the low

beam ground circuit, and both low beam headlamp filaments are OK. Furthermore, since the RH inboard high beam lamp

works on high beam and flash, the headlamp and flash switch and the high beam head lamp relay are OK.

Since the LH outboard high beam headlamp is working correctly, the lead from the headla m p relay to the lamp assembly

must be OK. Therefore the fault must be in circuit 2140 between the splice after fuse F31 and connector E119_L–X1 pin

The cause must be:

1 In circuit 2140, from the splice after fuse F31 to

connector E119_L–X1 pin 4.

2 In the lead from connector E119_L–X1 pin 4 to the LH

inboard high beam headl amp bulb.

3 The LH headlamp high beam bulb.

The possible causes have b een quickly narrowed down to a

specific area prior to working on the vehicle itself.

Read the system wiring diagram again to develop a set of

test points. Start from the positive and proceed to the

negative/ground.

Figure 12P – 1

Wiring Diagrams – AWD Wagon Page 12P–8

Step 5 Isolate the Most Possible Cause

Figure 12P – 2 is an example of how to isolate the cause of the problem. Remembering it has already been determined

the fault is between the splice after fuse F31 and the LH inboard hig h beam headlamp bulb, check the simple things first.

Figure 12P – 2

Step 6 Verify

Test the repair by performing a system check on the headlamp circuit. This of course means making sure that both hig h

beam lamps, both low beam lamps and high beam indicator are all working. Ask yourself:

Has the problem been fixe d?

Why did the problem occur or why did the part fail?

Will it happen again?

Have I created any other problems?

CURE THE CAUSE NOT THE EFFECT.

OPERATE THE CIRCUIT AND ROAD TEST THE VEHICLE BEFORE RET URNING IT TO THE CUSTOMER.

Wiring Diagrams – AWD Wagon Page 12P–9

3 Test Procedures

3.1 Electrical Fault Diagnosis

The proper operation of electrical circuits especially low amperage input/output circuits (electronic components etc)

depend upon good continuity between circuit connectors.

It is important before component replacement and/or during norma l trouble shooting procedures that a thorough visual

inspection of all terminals or connectors is performed and any questionable mating connector/termina ls be repaired or

replaced.

All mating surfaces should be clean, properly formed, clean and mak ing positive contact.

Some typical causes of connector problems are:

1 Improper ly formed contacts and/or connector plugs.

2 Damaged contacts or plugs due to improper engagement.

3 Corrosion, body sealer or other contaminants on the contact mating surfaces.

4 Incomplete ma ting of the connector halves during initial assembly or during subsequent trouble shooting or repairs.

5 Tendency for connectors to come apart due to vibration and/or temperature cycling.

6 Terminal not fully seated in connector body (t erminal backed out).

7 Inadequate terminal crimps to the wire or poor solder joint.

NOTE

When inserting test probes during diagnosis,

always try to test from the back of the terminal

and avoid spreading terminals as this may cause

poor continuity.

IMPORTANT: Do not backprobe 'Weather Pack'

type connectors as damage to the cable seals will

result.

When carrying out wiring checks, rather than probe terminals and connectors with incorrect sized multime ter or test lead

connectors, use adaptors include d in kit J35616-A or KM-609. This is will prevent any possibility of spreading or

damaging wiring harness terminals.

Possible Electrical Malfunctions

There are five possible electrical malfunctions, as follows:

1 Loss of batter y power (loose connections/cor r osion).

2 Defective device.

3 High r esistance (dirty, loose or corroded connections).

4 Open circuit.

5 Grounded or short circuit.

Electrical circuits should be tested at:

1 Easily discon nected connections.

2 Easy to reach access points.

Wiring Diagrams – AWD Wagon Page 12P–10

Circuit Faults

The various failures that occur in a circuit will dictate what must be done to repair the problem. These failures can be

categorised as follows:

Open

An open circuit is a physical b r eak in the path of current flow. In a series circuit, the circuit stops operating. In parallel

circuits, an open in one individual circuit will stop the operation of that particular circuit, but other indiv idual parallel

circuits will continue to operate. T he ohmmeter is useful in finding an open circuit with continuity checks.

Short to Ground

A short to ground is where the circuit is grounded d ue to an insulation breakage. The conductor touches ground, causing

a fuse or fusible link to blow. If there is no fuse, the circuit may burn, and even cause flames. If the short occurs after the

load, circuit control may be lost causing the circuit to operate when it is not wanted. The test light is a good device in this

case. Insert the test light in place of the fuse. Disconnect circuit components in a systematic and logical manner. W he n

the test light goes out, the part of the circuit with the short to ground will be found.

Short to Voltage

The short to voltage is a condition where a circuit, due to insulation breakage, causes the conductor to contact the

voltage of another circuit. This will cause the circuit (or both circuits) to ope rate improperly. This problem can cause odd

things to occur and can be difficult to find. To locate this type of problem, a thorough examination, using the diagn ostic

procedure described at the beginning of this Section, must be performed. Observe the symptoms to recognise

associated circuits involved. Isolation by rem ovin g fuses will help isolate the circuit branches involved. Then voltage and

resistance checks at strategic locations will isolate the problem.

High Resistance Problems

A high resistance problem is often hardest to find. This is a condition where it is important to use test meters. High

resistance can be caused b y loose, dirty or corroded connectors. Current flow will be lowered, which can cause incorrect

circuit operation or inoperative compo ne nts.

Wiring Diagrams – AWD Wagon Page 12P–11

3.2 Troubleshooting Test Equipment

Jumper Wire

A jumper wire is an in-line fuse hol der connected to a set of

test leads and it is use for by-passing open circuits. The in-

line fuse holder (1) should be fitted with a five-amp fuse.

Never use a jumper wire across an y load as this will cause a

direct battery short and blow the fuse. When properly used,

jumper wires are simple, effective testing aid s . T he y are

used to complete a circuit by allowing current to ' jump'

across a suspected open or break, and so act as a test of

continuity.

When a jumper wire is used, it replac es a suspected faulty

portion of a circuit with a known good conductor. If the

circuit works properly when the jumper wire is in place, but

does not work properly without the jumper wire, an open

circuit is indicated in the area that has been jumped. Use a

jumper wire to by-pass only non-resistive parts of a circuit,

such as switches, connectors and sections of wiring.

Y12P203

Figure 12P – 3

Y12P204

Figure 12P – 4

Legend

1 Alligator Clips With In-Line Fuse

2 Alligator Clips

3 Pin Terminal

4 Spade Terminal

5 Probe Tip

6 Alligator Clip

7 Battery

8 Switch

9 Motor

Wiring Diagrams – AWD Wagon Page 12P–12

Test Light

A test light is made up of a 12 volt light bulb with a pair of

leads attached and is used to test for voltage. After

grounding one lea d, touch the other lead to various points

along the circuit where voltage should be present. When the

bulb illuminates, there is volta ge present at the point being

tested.

Never use a low-impedance test light on circuits that

contain solid-state components, since damage to these

components may result.

Legend

1 Fuse

2 Connector

3 Probe

4 Test Light

5 Motor

Y12P205

Figure 12P – 5

When a test light is specified, a LOW-POWER test light

must be used. Do not use a high wattage test light. While a

particular brand of test light is not suggested, a simple test

on any test light will ensure it's suitability for circuit testing.

Connect an accurate ammeter such as the high-imp ed ance

digital multimeter (1) in series with the test light (2) being

tested, and power the test light - ammeter circuit with the

vehicle battery (3). If the ammeter indicates less than 0.3 A

(300 mA) current flow, the test light is OK to use. If more

than 0.3 A (300 mA), DO NOT USE.

Y12P206

POW ER

FUSED

1000V

MAX 750V~

1000V---

MAX

10A COM uA mA

DATA

HOLD SELECT RANGE

ºC

ADP

mA/A uA

P U SH SE LE C T

kHz

0.3% V

DC AMPS

Figure 12P – 6

Self-Powered Test Light

A self-powered test light is used to check for continuity. This tool is made up of a 3 V ligh t bulb, battery and two leads. If

the leads are touched together, the bulb will illuminate.

A self-powered test light is used only on an unpowered circuit. First, disconnect the vehicle's battery, or remove the fuse

which feeds the circuit being worked on. Select two specific points along the circuit through which there should be

continuity. Connect one lead of the self-po wered test light to each point. If there is continuity, the test light's circuit will be

completed and the bulb will illuminate.

An increasing number of circuits include solid state control modules. Volta ges in these circuits should be tested ONLY

with a 10 Megohm or higher impedance digital voltmeter or multimeter.

Never use a self-pow ered test light on circuits

that contain solid-state components, since

damage to these components may result.

Wiring Diagrams – AWD Wagon Page 12P–13

Multimeters

Analogue versus Digit al Meters

Digital multimeters outperform most types of analogue meters for a variety of reasons. Digital multimeters are more

accurate. The internal circuitry is not the only factor affecting analogue meter accuracy. The pointer can appear to be in

different positions when the gauge is viewed from different angles. Digital displays leave n o such do ubt about there

reading.

The digital multimeter shows a + symbol in front of the reading when the positive meter lead is connected to a positive

power source and the negati ve lead is connected to ground. If the digital multimeter leads are reversed, a – symbol

appears in front of the reading to indicate reverse polarity.

A digital multimeter, has an electronic d igita l readout of the value of the measurement being made. This type of meter

has electronic circuitry for precise measurements. It can be accurate within 0.1 percent, much more accurate than

analogue meters. The digital multimeter is becoming the preferred choice for electrical diagnosis and testing, especially

for testing electronic systems.

The impedance of an analogue meter is less than 10 Megohm. A meter with less than 10 Megohm impedanc e must not

be used on circuits that contain solid state compon ents because:

The low impedance of the meter could cause incorrect readings.

The meter could allow too much current to flow through the circuit bei ng tested.

The excess current coul d damage sensitive electronic components.

A digital multimeter with at least 10 Megohm input impedance is needed for use on Holden vehicles. This input

impedance applies to the meter only when it is used on the voltage scale. T his means that the meter resists load ing

down the circuit being measured with a resistance of 10 million ohms. On automotive circuits, this high resistance

permits measurement of very sensitive circuits without damaging or altering them.

NOTE

Impedance is the resistance to current flow

through the meter, from one lead to the other

lead. High input impedance provides greater

sensitivity, and prevents the meter from affecting

the circuit being tested. Resistance is measured

in ohms. Impedance and resistance both mean

'opposition to current flo w'.

Wiring Diagrams – AWD Wagon Page 12P–14

3.3 Digital Multimeter

One of the most useful diagnostic tools is the digital multimeter. These basic oper ating procedures for a multimeter may

vary with the make of meter and the manufacturer's operating instructions should be read and understood before usin g

the multimeter.

Use Of A Multimeter

1 Always turn meter OFF when not in use.

2 Ensure the meter face reads zero.

3 If applicabl e, touch the le ads together then adjust the resistance reading to zero each time a resistance range is

selected or changed.

4 If you are not sure of the reading you expect to get, always select the highest scale, then reduce to allo w an

effective reading.

5 When meas uring current, ensure the meter can handle the load a nd that the test leads are in the correct jacks.

6 Treat the instrument with the respect it deserves.

NOTE:

Voltage readings are taken in parallel (i.e. over the load).

Current readings are taken in series (i.e. bre ak the circuit and use meter leads to complete the open circuit).

Resistance: Disconnect all external power, which includes the discharging of capacitors in electronic components.

Selection Of Multimeters

The best type of multimeter is one which has:

Internal protection so that it cannot be damaged if, for example, voltage is put through when the meter is set on ohms.

The fuse protects the meter and is the only thing that has to be replaced.

One that you can use to carry out a diode check facility which also provides an audible signal.

An audible signal when carrying out continuity checks.

A data hold facility so when a reading is taken that reading will remain on the display after the leads are removed.

A multimeter today also has to have a hi gh impedance factor. The common analogue type multimeter may be inadequate

and may actually damage sen sitive electronic circuitry. Analogue meters, due to their low internal resistance (input

impedance), draw too much power from the device they are testing for use on computers. Many analogue meters use

9 volts to power the resistance test which is eno ugh to destroy sensitive digital components. Digital multimeters have an

input impedance of about 10 Megohms which is much higher than analogue multimeters. The high impedance means

that the meter will draw very little power from the device under test. T his means the meter will provide a more accurate

measurement and will not da mage delicate electronic components.

The multimeter used should also be able to test temperature and high amperages. This allows the one tool to do a vast

amount of work in the area of diagnosis.

Auto diagnosis is the art of the mechanical trade. To be able to fault find, rectify the fault and have the vehicle back to the

owner/operator with minimum del ay is what leads to repeat business for the workshop. To do this you must be able to

refer to available literature, apply basic theories and use the correct test equipment.

Wiring Diagrams – AWD Wagon Page 12P–15

Voltage Measurement

With the Volts DC mode selected, the digital multimeter will

operate as a voltmeter.

When using a voltmeter, the circuit po wer must be ON and

the voltmeter must be connected with the correct polarity.

This means the red lead should be on the p ositive (+ ) side

of the load or circuit and the black lead should be on th e

negative (–) side of the load or circuit.

The voltmeter must be connected in parallel with the load or

circuit. It has a high internal resistance and takes onl y a

small amount of current. The meter will display the voltage

difference between the points where the meter leads are

attached. If the voltmeter is connected in series, the meter's

high internal resistance will reduce the circ uit current,

resulting in an incorrect reading.

Testing for correct supply voltage is usually the first thing

measured in a circuit. If there is no voltage present, or if the

supply voltage is too high or too low, the voltage problem

should be corrected before further testing.

NOTE

Voltage readings should always be taken in

parallel, i.e. across the load.

To make the reading:

1 Select VOLTS DC.

2 Plug the black test probe into the COM input jack and

the red test probe into the V input jack.

3 Touch the probe tips to the circuit across the load or

power source.

4 View the reading, being sure to note the unit of

measurement.

D H

R H

0102030

m V

Y12P208

POWER

FUSED

1000V

MAX 750V~

1000V---

MAX

10A COM uA mA

DATA

HOLD SELECT RANGE

ºC

mA/A uA

PUSH SE LECT

PUSH SE LE CT

kHz

0.3% V

Figure 12P – 7

Wiring Diagrams – AWD Wagon Page 12P–16

Resistance Measurement

With the resistance mode selected, the digital multimeter will

operate as an ohmmeter.

The ohmmeter can be connected without regard to polarity,

unless there is a diode in the circuit. Always remember,

however, that an ohmmeter must NEVER be connected to a

live circuit, which could blow a fuse in the meter or damage

the meter.

The ohmmeter has its own battery, which provides the

necessary voltage for testing. If an ohmmeter is connected

into a 'live' circuit the ohmmeter will be damaged.

Components or circuits MUST BE DISCONNECTED FROM

THE POWER SOURCE when being tested.

Resistance Testing

Resistance measurements must be made with the circuit

power OFF, otherwise damage to the meter or the circuit

may result.

To make the resistance test:

1 Remov e the po wer from the ci rcuit and select Ω.

2 Plug the black test probe into the COM input jack and

the red test probe into the Ω input jack.

3 Touch the probe tips across the component or the part

of the circuit to be tested.

4 View the reading, being sure to note the unit of

measurement.

NOTE

1000 ohms = 1 kΩ.

1 000 000 ohms = 1 MΩ.

D H

R H

0102030

m V

Y12P209

POWER

FUSED

1000V

MAX 750V~

1000V---

MAX

10A COM uA mA

DATA

HOLD SELECT RANGE

ºC

mA/A uA

PUSH SE LECT

PUSH SE LE CT

kHz

0.3% V

Figure 12P – 8

Continuity Testing

A continuity test is a quick test that distinguishes between an open and a closed circuit.

A digital multimeter with a continuity beeper allows you to complete many continuity tests easily and quickly as the meter

beeps when it detects a closed circuit. T he level of resistance required to trigger the beeper varies from model to model

of meter.

Continuity tests determine:

• Good or blown fuses.

• Open or shorted conductors.

• Operation of switches.

• Circuit paths.

NOTE

Circuits which include any solid state control

modules, such as the Powertrain Control Module

(PCM), should be tested only with a 10 Megohm

or higher impedance di gital multimeter.

Diodes and solid state components in a circuit can cause an ohmmeter to give a false reading. To find out if a component

is affecting a measurement, take a reading once, reverse the leads and take a second reading. If the readings differ, the

solid state component is affecting the measurement.

Wiring Diagrams – AWD Wagon Page 12P–17

Diode Testing

A diode is like an electronic switch. It can be turned ON if the voltage is ab ove a certain level, generally about 0.6 V for a

silicon diode, and allo ws current to flo w in one direction.

Some meters have a special mode called diode test. In this mode the readings across the diode should be 0.6 V to 0.7 V

in one direction and indicate an open circuit in the other. This indicates a good diode. If both readings ar e open circuit,

the diode is open. If both readings indicate contin uity, the diode is shorted.

Current Measurement

With the AMPS DC mode selected, the digital multimeter will

operate as an ammeter.

An ammeter is an instrument that measures current flow in a

circuit. For this reason ammeters MUST be connected in

series. The ammeter must also be connected into the circuit

according to polarity.

Current measurements are different from other

measurements made with a digital multimeter. Current

measurements are made in series, unlike voltage or

resistance measurements, which are made in parallel. The

entire current being measured flows through the meter.

Also, the tests probes must be plugged into a different set of

input jacks on the meter.

Do not leave the test leads plugged into the

current input jacks and then attempt a

voltage measurement. This causes a direct

short across the source voltage through the

low-value resistor inside the digital

multimeter and if the meter is not adequately

protected, can cause extreme damage to the

meter and to the circuit, and injury to the

operator.

To take a current reading:

1 Remov e the po wer from the ci rcuit, cut or open the

circuit and select A.

2 Plug the black test probe into the COM input jack and

the red test probe into the 10A input jack.

3 Touch the probe tips across the cut or open circuit as

shown in Figure 12P – 9.

4 View the reading, being sure to note the unit of

measurement.

NOTE

If the test leads are reversed, a – s ign shows on

the meter display.

D H

R H

0102030

m V

Y12P210

POWER

FUSED

1000V

MAX 750V~

1000V---

MAX

10A COM uA mA

DATA

HOLD SELECT RANGE

ºC

ADP

mA/A uA

PUSH SE LECT

PUSH SE LE CT

kHz

0.3% V

Figure 12P – 9

Wiring Diagrams – AWD Wagon Page 12P–18

4 Diagnostic Tests

4.1 Testing For Voltage

To perform a voltage test:

1 Connect one lead of a test light to a good ground. If

using a voltmeter, ensure the voltmeter's negative

(COM) lead is connected to ground (battery negative).

2 Switch the met er to V and connect the other lead of

the test light or voltmeter to a selected test point on a

connector or terminal.

3 If the test light illuminates, there is voltage present. If

using a voltmeter, note the voltage reading. It should

be within one volt of the measured battery voltage,

unless otherwise specified in the system diagnosis.

Legend

1 Power From Battery

2 Fuse

3 Switch

4 Relay Coil

5 Meter

6 Voltage Test Point

7 Voltage Test Point

VY12P211

D H

R H

0102030

m V

POWER

FUSED

1000V

MAX 750V~

10 00V -- -

MAX

10A COM uA mA

DATA

HOLD SELECT RANGE

ºC

ADP

mA/A uA

PUSH SEL ECT

kHz

0.3% V

Figure 12P – 10

Wiring Diagrams – AWD Wagon Page 12P–19

4.2 Testing For Continuity

To test for continuity:

1 Disconnect the battery ground lead.

2 Connect one lead of a self-powered test light or

ohmmeter to one end of the part of the circuit under

test.

3 Switch the meter to Ω and co nnect the other lead to

the other end of the circuit.

4 If the self-powered test light illuminates, there is

continuity. If you are using an ohmmeter, low or no

resistance means good continuity.

Legend

1 Meter Switched To Ohms

2 Switch Terminal

Y12P212

D H

R H

0102030

m V

POWER

FUSED

1000V

MAX 750V~

1000 V---

MAX

10A COM uA mA

DATA

HOLD S ELECT RANGE

ºC

ADP

mA/A uA

PUSH SEL ECT

kHz

0.3% V

Figure 12P – 11

Wiring Diagrams – AWD Wagon Page 12P–20

4.3 Testing For Voltage Drop

This test checks for voltage being lost along a wire or

through a connection or switch.

1 Switch the volt meter to V and connect the positive

lead to the end of the wire (or to one side of the

connection or switch) which is closest to the battery.

2 Connect the negative lead to the other end of the wire

(or other side of the connection or switch).

3 Operate the cir cuit.

4 The voltmeter will show the difference in voltage

between the two points. A difference (or drop) of more

than 1 volt indicates a problem.

Legend

1 Power From Battery

2 Fuse

3 Switch

4 Relay Coil

5 Meter

Y12P213

D H

R H

0102030

m V

POWER

FUSED

1000V

MAX 750V~

10 00V -- -

MAX

10A COM uA mA

DATA

HOLD SELECT RANGE

ºC

ADP

mA/A uA

PUSH SEL ECT

kHz

0.3% V

Figure 12P – 12

Wiring Diagrams – AWD Wagon Page 12P–21

4.4 Testing For Short To Ground

Using A Test Light Or Voltmeter

To test for a short to ground using a test light or a voltmeter:

1 Remov e the blown fuse and disconnect the load.

2 Ensure that fus e block is p owered and connect a test

light or voltmeter across the fuse terminals.

3 Beginning near the fuse block, wiggle the harness

from side to side. Continue this at convenient points

about 150 mm apart while watching the test li ght or

voltmeter.

4 If the test light illuminates, or the voltmeter registers,

there is a short to ground in the wiring near that poi nt.

Legend

1 Power From Battery With Fuse Removed

2 Starting Test Point

3 Switch

4 Disconnected Load

5 Meter Set To Volts

6 Short To Ground

Y12P214

D H

R H

0102030

m V

POWER

FUSED

1000V

MAX 750V~

10 00V -- -

MAX

10A COM uA mA

DATA

HOLD SELECT RANGE

ºC

ADP

mA/A uA

PUSH SEL ECT

kHz

0.3% V

Figure 12P – 13

Wiring Diagrams – AWD Wagon Page 12P–22

Using A Self-Powered Test Light Or Ohmmeter

To test for a short to ground using a self-powered test light

or an ohmmeter:

1 Remov e the blown fuse and disconnect the battery

and load.

2 Connect one lead of a self-powered test light or

ohmmeter to the fuse terminal on the load side.

3 Connect the other lead to a known good ground.

4 Beginning near the fuse block, wiggle the harness

from side to side. Continue this at convenient points

about 150 mm apart while watching the self-p owered

test light or ohmmeter.

5 If the self-powered test light illuminates or flickers, or

the ohmmeter changes or registers, there is a short to

ground in the wiring near that point.

Legend

1 Power From Battery With Fuse Removed

2 Starting Test Point

3 Switch

4 Disconnected Load

5 Meter Set To Ohms

6 Short To Ground

Y12P215

D H

R H

0102030

m V

POWER

FUSED

1000V

MAX 750V~

10 00V -- -

MAX

10A COM uA mA

DATA

HOLD SELECT RANGE

ºC

ADP

mA/A uA

PUSH SEL ECT

kHz

0.3% V

Figure 12P – 14

Using A Short Finder

A short finder is a device used for locating hidden shorts. These create a magnetic field in the shorted circuit and allow

you to read its location through body trim or sheet metal.

Using A Compass

An ordinary magnetic compass may be used to locate grounded circuits. It makes use of the fact that a wire carrying

current creates a magnetic field. In circuits that are protected by a circuit breaker, a short or ground ca n be quickly

located by use of an ordinary magnetic compass. Turn the circuit breaker on and off and start following the wiring with

the compass, the compass will 'kick' each time the circuit breaker closes. As the compass passes the point of the short

or ground, the compass will stop 'kicking'. Thus, the compass can pinpoint the problem without remov ing trim, cover

plates or tape. If the circuit is fused, the problem can be found in the same manner by substituting a circuit breaker for

the fuse.

Using A Circuit Breaker

By using a circuit breaker as a substitute for a fuse, other tools can be mo re effectively used to find troubles. A turn

signal flasher makes a convenient circuit bre aker. Sold er a l ead to each terminal of the turn signal flasher, and each lead

with a terminal from an old fuse. If this unit is inserted in the junction block in place of a fuse, it may operate too fast to

produce good compass needl e deflecti on. T o slow it down, insert a rheostat in series with the flasher. By cutting in

additional resistance, the flashing rate of the unit may be slowed down to produce good compass needle deflection.

Wiring Diagrams – AWD Wagon Page 12P–23

4.5 Operating A Short Finder

To use a short finder:

1 Remov e the blown fuse, leaving the battery

connected.

2 Connect the short finder (2) across the fuse terminals.

3 Close all switches (6) in series with the circuit you are

troubleshooting.

4 Operate the short finder. The short finder will pulse

current to the short. This creates a pulsating magnetic

field (5) surrounding the circuit wiring between the fuse

block and the short.

5 Beginning at the fuse block, slowly move the short

finder meter (4) along the circuit wiring. The short

finder meter will show current pulses through sheet

metal and body trim. As long as the meter is between

the fuse block and the short, the needle will move with

each current pulse. When yo u have moved the meter

past the point of the short, the needle will stop movi ng

(10). Examine the wiring in that area for the short to

ground.

Never use a short finder on circuits that

contain solid-state components, since

damage to these components may result.

NOTE

Short finders are particularly useful for 'hidden'

shorts as the meter will read the short location

through body trim or sheet metal.

Y12P216

Figure 12P – 15

Legend

1 Power From Battery With Fuse Removed

2 Short Finder Pulse Generator

3 Fuse Panel With Fuse Removed

4 Short Finder Meter

5 Pulsating Magnetic Field

6 Switch

7 Short To Ground

8 Solenoid

9 No Pulsating Magnetic Field

10 Needle Stops Moving Here

Wiring Diagrams – AWD Wagon Page 12P–24

Measuring Current

To measure the current flowing in a circuit, the ammeter

must be connected in series in the circuit. Current

measurements always involve a component being removed

or disconnected from the circuit or the circuit being opened.

The circuit current flows through the meter, which displays

the current in amps or milliamps.

Two commonly used locations for taking current

measurements are at a fuse and at the batter y.

Never use a meter set on a current scale to

measure voltage. Severe damage to the

meter, the circuit, or both will result.

Legend

1 Power From Battery With Fuse Removed

2 Fuse Block

3 Meter Set To Ohms

4 Switch

5 Load

Y12P217

D H

R H

0102030

m V

POWER

FUSED

1000V

MAX 750V~

10 00V -- -

MAX

10A COM uA mA

DATA

HOLD SELECT RANGE

ºC

ADP

mA/A uA

PUSH SEL ECT

kHz

0.3% V

Figure 12P – 16

Wiring Diagrams – AWD Wagon Page 12P–25

4.6 Detecting Intermittent Electrical Faults

Diagnostic Procedure

This procedure can be used to detect interm ittent terminal contact or a broken wire with an intermittent connection inside

its insulation.

Some digital multimeters, such as Tool No. 3588, have the ability to monitor current, resistance or voltage while

recording the minimum (MIN) and maxim um (MAX) values measured.

When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector or part of a circuit

which may have an intermittent connec tion, but at the time is operating normally. Using Tool No. 3588:

1 Set the digital multimeter to read voltage. Since the MIN MAX mode does not use auto rang ing, manually select the

voltage range necessary before proceeding.

2 Connect the meter to both sides of a suspect connector (still connected) or from one end of a suspect circuit to the

other. This will continuously monitor the terminal contacts or length of wire being check ed.

3 Press the MIN MAX button. The meter should read 100 ms RECORD (100 millisecond record) and emit a 0.25

second beep. The meter is now ready to record and will generate an audible tone for any change in voltage. At this

point, press the PEAK MIN MAX button, which will record any voltage variations that occur for at least 1

millisecond.

4 Simulate the condition that may be causing an intermittent connection, either by wiggling connections or wiring, test

driving or performing other operations. If an open or resistance is created, a voltage drop will occur and the meter

will emit a tone for as long as the open or res istance exists. Any change in voltage will cause the meter to emit a

tone for no less than 0.25 second.

Use the MIN and MAX values when the meter is out of sigh t or sound range, in noisy areas or for test driving when it ma y

not be possible to monitor the meter.

To check the MIN and MAX recorded voltages, press MIN MAX button once for MAX and twice for MIN. A variation

between MIN and MAX recorded voltages (unless nearly 0 volts) suggests an intermittent open or res istance e x ists and

should be repaired as necessary. Refer to 5 Wiring Repair Procedures in this Section for repair procedures.

NOTE

The 100 ms RECORD mode is NOT the amount

of time allowed to perform a specific procedur e. It

is the amount of time used to record each

snapshot of information used for calculating AVG

when in the MIN MAX mode.

Checking Terminal Contact

Before replacing a suspect fault y component, it is important to check terminal contact between a connector and the

component, or bet ween in-li ne mating connectors.

Frequently, a diagnostic chart leads to a step that reads for example ‘Check for poor connection’. Mating terminals must

be inspected to ensure good terminal contact. A poor connection between the male and female terminals at a conn ector

may be the result of contamination or deformation.

Contamination is caused by the connector bodies being improperly connected, a missing or damag ed connector seal, or

damage to the connector itself, exposing the terminals to moisture and dirt. Contamination, usually in the engine

compartment or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.

Deformation is caused by probing the matin g side of a co nnector terminal without the proper adaptor, improperly joining

the connector bodies or repeatedly separating and reconnecting the connector bodies together. Deformation, usually to

the female terminal contact tang, can result in poor terminal contact, causing an open or intermittentl y open circuit.

Wiring Diagrams – AWD Wagon Page 12P–26

To check terminal contact:

1 Separ ate the connector bodies or the component connector.

2 Inspect the connector bodies or component for contamination. Contamination will result in a white or green build-up

within the connector body or b etween the terminals, causing hig h resista nce, intermittent contact, or an open

circuit. An engine compartment or underbody connector that shows signs of contamination should be replaced if it

is serviced (refer to VZ Parts information for connectors that are serviced) or the relevant wiring harness should b e

replaced.

3 Using an equivalent male terminal, check the retention force of the female terminal in question by inserting and

removing the male terminal to the female terminal in the connector b od y. Good terminal contact will require a

certain amount of force to separate the terminals.

4 Using a known good condition equivalent female terminal, compare the retention force of this terminal to the female

terminal in question by inserting and removing the male terminal. If the retention force is significantly different

between the two female terminals, rep lace th e female terminal in question.

If a visual (physical) check does not reveal the cause of the problem, the vehicle may be able to be driven with a digital

multimeter connected to the suspected circuit. An abnormal voltage reading when the problem occurs indicates the

problem may be in that circuit.

Meter Connections

The procedure for detecting in termittent faults was based on the digital multimeter set to read voltage. Whether us ing

current, voltage or resistance settings to detect intermittent faults, it will be necessary to connect the meter into the

circuit.

The following are examples of various methods of connecting the meter into a circuit to be checked.

1 Backprobe both ends of the connector and either hold meter leads in place while manipulating the connector or,

tape the leads to the harness for continuous monitoring while performing other operations or while test driving.

Do not backprobe 'Weather Pack' type

connectors as damage to the cable seals will

result.

2 Disconnect the harness at both ends of a suspect circuit where it connects either to a component or to other

harnesses. Use connector test adaptor kit, Tool No. J35616-A or KM-609 to connect the meter onto the circuit.

Additional Information

Turn off power to the test circuit before attempting in-circuit resistance measureme nts to prevent false readings or

damage to the meter. Do not use the meter to measure resistance through a solid state module. Continuity tests that

work well for detecting intermittent shorts to ground can be performe d by setting the meter to ohms when pressing the

PEAK MIN MAX button. An audible tone will be heard whenever the meter detects continuity for at least 1 millisecond.

The instruction manual accompanying the multimeter is often a good source of informatio n and sh ould be read

thoroughly bef ore using the meter as well as kept on hand for reference during new procedures.

Wiring Diagrams – AWD Wagon Page 12P–27

5 Wiring Repair Procedures

5.1 General Information

Except for some specific connector bodies, wiring harness terminals, terminal seals and connector bodies are generally

not serviced individually.

Specific terminals, with seals (if fitted) are serviced only as an assembly with a wiring pigtail attached. Refer to VZ Parts

Information for a listing of serviced terminals and connector bodies.

When conducting wiring harness repairs that involve replacement of damaged terminal/s, remove the terminal/s from the

connector body (refer instructions in this Volume) and splice ne w terminal/ s with wiring pigtail into the wiring harness

(refer instructions in this Volume).

If a specific wiring harness terminal or connector body is damaged beyond repair, and the terminal or connector body is

not serviced, that particular wiring harness must be replaced.

Specific instructions on how to replace each individual wiring harness are not included in this manual. Installation details

of wiring harnesses are included on th e wiring installation diagrams in Section 12O Fuses, Relays & Wiring harnesses.

Wiring Diagrams – AWD Wagon Page 12P–28

5.2 Performing Wiring Harness Repairs

Special wiring repair procedures have been

developed for use on the ABS and SRS due to

the sensitive nature of their circuitry. The

procedures in 5.4 ABS And SRS Wiring Repair

are the only recommended and approved ABS

and SRS wiring repair methods. The following

wiring repair methods are not to be used on ABS

or SRS wiring.

Soldering

These are the five points upon which an electrical soldering

joint is judged.

With electrical wiring only resin flux can be used. Acid flux

creates a corrosion problem that makes it unsuitab le for this

work.

Do not clean resin flux off after soldering as the resin acts

as an anti-corrosive to protect the soldered area.

Legend

1 Little Or No Solder Penetration Into The Insulated Area

2 Undamaged Insulation

3 Full Solder Penetration

4 Smooth, Glossy Finish

5 No Excess Solder

Figure 12P – 17

The Five Points To Soldering

Step 1 Soldering Preparation

The job must be clean and bright (1). Acid corroded or

greasy wiring ends (2) sho uld be stripped back.

Keep the job and your hands clean at all times.

Figure 12P – 18

Wiring Diagrams – AWD Wagon Page 12P–29

Step 2 Iron Preparation

The soldering iron (1) must be tinned and hot BEFORE

application. Preheat the solderin g iron to slightly above

solder melting point before applying solder (2) or applying it

to the job to allow for heat loss on contact.

The commencement of 'flux spit ' is an indication of correct

preheat temperature.

Figure 12P – 19

Step 3 Forming a Heat Bridge

Apply the full face of the soldering iron to the job and

immediately add solder to the 'V' formed by the iron and the

job.

This is known as heat bridge where the melting solder

speeds up the heat transfer and cuts down the job heating

time.

Figure 12P – 20

Step 4 Soldering Iron Removal

Remove the soldering iron (1) the instant the job is

complete. This prevents the solder (2) travelling outside the

intended deposit area.

VY12P46

Figure 12P – 21

Wiring Diagrams – AWD Wagon Page 12P–30

Step 5 Prevent Job Movement

Prevent job movement until the solder cools.

A soldered joint (1) can be weakened if the two components

being joined move in re lation to each other just as the liquid

solder changes to a solid state.

Making a second attempt to solder the joint is undesirable

as prolonged heating is nec essary to remelt the solder.

Arrange support (2) before you start and use it until the

solder cools.

Figure 12P – 22

Joining Wire

Twist Joint

The twist joint is simple and strong.

1 Strip 20 mm of insulatio n from each wire (1).

2 Twist the strands to compact them.

3 Join them toge t her by twisting (2).

4 Complete the join by soldering.

5 Use PVC tape to insulate the joint.

NOTE

To prevent a short or grounded circuit, remove

all the 'spikes' from the join before insulating.

Spikes can be formed by wire strands or solder

itself. These can cut through the insulation. Figure 12P – 23

Splice Joint

To splice join conductors:

1 Strip back 20 mm of insulation and spread the strands

(1).

2 Push the strands togeth er an d twist the ends in

opposite directions to compact the joint (2).

3 Solder the joint.

4 Use PVC tape to insulate the joint.

NOTE

A good splice may be a little harder to achieve

but it makes a neater join that is less bu lky when

taped. Figure 12P – 24

Wiring Diagrams – AWD Wagon Page 12P–31

The Y Junction

The Y junction is used to inst all a branch connection parallel

with the original.

1 Use a shar p blade to remove approximately 20 mm of

insulation from the original wire (1).

2 Strip the insulation on the branch wire by

approximately 20 mm.

3 Twist the branch wire around the ori ginal wire (2).

4 Solder the connection.

5 Use PVC tape to insulate the joint.

Figure 12P – 25

The T Junction

The T junction is used to achieve a 90 degree branch

connection.

1 Use a shar p blade to remove approximately 20 mm of

insulation from the original wire.

2 Strip the insulation on the branch wire by

approximately 20 mm.

3 Twist the branch wire around the original wire.

4 Solder the connection.

5 Use PVC tape to insulate the joint.

Figure 12P – 26

Wiring Diagrams – AWD Wagon Page 12P–32

5.3 Splicing Wiring Using Splice Clips

Splice clips are included in Terminal Repair Kit, Tool No. J38125-A. The splice clip is a general-purpose wire repair

device. It may not be acceptable for applications having special requirements such as moisture sealing.

Step 1 Open the Harness

A wiring harness may be wrapped in tap e or enclosed in a

plastic conduit.

If it is conduit encased, simply open the conduit and pull out

the desired wire.

If the harness is wrapped in tape, use a seam splitter (1) to

open the harness. This prevents damage to the insulation of

the wire inside the harness. Seam splitters are readily

available from sewing supply stores.

When using a seam splitter, use the bla de with the pointed

end (2) to start a small split in the tape away from any wires.

Use the blade with the rounded end (3) to slit the tape as far

as necessary. Be careful to avoid cutting into any wire

insulation. Figure 12P – 27

Step 2 Cut the Wire

Leave as much wire on the harness as possible. More can be cut off later to adjust the location of the splice if necessary.

NOTE

Ensure that each splice is at least 40 mm away

from other splices, harness branches and

connectors. This helps prevent moisture from

bridging adjacent splices and causing damage.

Do not nick or cut any copper strands as this

could limit the current-carrying capabilities of the

wire.

Step 3 Select the Correct Size and Type of Wire

The wire must be of a size equal to or greater than the original except for fusible links. The wire insulation must have the

same or higher temperature rating:

General purpose insulation (PVC) is used in areas not su bject to high temperatures.

Cross-linked polyethylene (XLPE) insulation wire is used where high temperatures are expected.

NOTE

XLPE insulated wire may be used to replace

PVC, but PVC must not be used to replace

XLPE. XLPE insulation is not fuel resistant, so

XLPE covered wire m ust n ot be used where there

is the possibility of fuel contact.

Wiring Diagrams – AWD Wagon Page 12P–33

Step 4 Strip the Insulation

Find the wire size using a wire gauge (AWG).

A wire stripper, labelled in AWG sizes, is needed for

stripping away the insulation. If the wire size is not kno wn,

start with the largest stripper hole and work down until a

clean strip of insulation is removed without nicking or cutting

the wire. Set the stripper guide to a 7.5 mm long strip.

The splice should be at least 40 mm away from any other

splices or outlets.

Figure 12P – 28

Metric Size

0.22 0.35 0.5 0.8 1.0 2.0 3.0 5.0 8.0 13.0 19.0 32.0 50.0

AWG

24 22 20 18 16 14 12 10 8 6 4 2 1/0

Use the following procedure when using a wire stripper:

Hold both handles in the right han d, with gripper ja ws to the

left.

Hold the wire in the left hand and press the end of the wire

against the guide and up into t he correct notch of the upper

blade.

Close left handle first, to grip the wire firmly before cutting

the insulation.

If the stripper castings stick open after stripping the wire,

pull the handles outward to snap the tool closed.

Check the stripped wire for nicks or cut strands.

If the wire is damaged, repeat the procedure on a new

section of wire. The two stripped sections of wire to be

joined should be of equal le ngth.

Do not place your fingers between the

gripper casting and the cutter casting at any

time. Do not lay these castings against your

hands when open. The stripper castings are

designed to snap shut when fully opened,

and may cause injury.

Figure 12P – 29

Legend

1 Gripper Jaws

2 Gripper Casting

3 Stripped Wire

4 Cutter Casting

5 Insulation

6 Guide

7 Blades

Wiring Diagrams – AWD Wagon Page 12P–34

Step 5 Crimping the Joint

1 Select the corr ect sized clip.

2 Unlock the crimping tool.

3 Slightly close the clip using the nose of the crimping

tool as shown in Figure 12P – 30.

4 Select the corr ect crimper anvil.

Legend

1 Nose

2 Former

3 Small Anvil

4 Lock

5 Former

6 Large Anvil

7 Clip

Figure 12P – 30

5 Overlap the two stripped wire ends (1) and hold them

between the thumb and forefinger as sh own in

Figure 12P – 31.

6 Centre the splice clip (2) under the stripped wires and

hold in place as shown.

• Ensure that the wires extend beyond the clip in each

direction.

• Ensure no insulation is caught under the clip.

• Strands of wire are not cut or loose.

Figure 12P – 31

Wiring Diagrams – AWD Wagon Page 12P–35

7 Full y op en the crimping tool and rest one handle on a

firm, flat surface.

8 Centre the back of the splice clip on the proper anvil

(2) and close the crimping tool to the point where the

former touches the wings of the clip (1).

9 Verify the clip and wires are still in the correct position

before closing the crimping tool with steady pressure.

Figure 12P – 32

10 Crimp the splice clip a second and third time, once at

each end (1). Do not let the crimping tool e xtend

beyond the edge of the clip when doing so.

Figure 12P – 33

Wiring Diagrams – AWD Wagon Page 12P–36

Step 6 Solder

Apply 50/50 resin core solder to the hole in the back of the

clip as shown in Figure 12P – 34.

Figure 12P – 34

Ensure there are none of the faults shown in

Figure 12P – 35

Legend

1 Poor Solder Application With Bad Solder Fillets

2 Excessive Burning Which Cannot Be Covered With 50 Mm

Splice Tape

3 Insulation Clamped Under The Clip

4 Sharp Solder Spikes

5 Wires Not Fully Inserted Into The Clip

6 Tape Width Less Than 50 mm

Figure 12P – 35

Wiring Diagrams – AWD Wagon Page 12P–37

Step 7 Tape the Splice

Centre and roll a 50 mm x 50 mm piece of ta pe around the

splice joint.

If the wire is not in conduit or another harness covering,

tape it again using a winding motion, entirely overlapping

the first piece.

Legend

1 Example Of Properly Rolled Tape

2 Tape Again If Needed

3 Example Of Bad (Flagged) Taping

Figure 12P – 36

Wiring Diagrams – AWD Wagon Page 12P–38

5.4 ABS And SRS Wiring Repair

Special wiring repair procedures have been developed for use on the Anti-lock Br aking System (ABS) and Supplemental

Restraint System (SRS) due to the sensitive nature of the circuitr y. These specific procedures and instructions must be

followed when working with ABS and SRS wiring, and wiring components (such as connectors and termi nals). Terminal

Repair Kit, Tool No. J38125-A contains special sealed splices for use in repairing ABS and SRS wiring.

A special crimping tool, heat torch, and instruction manual for these spl ice s are also included.

Two critical features of the sealed splices are a special heat shrink sleeve with sealing adhesive to prod uce an

environmentally seale d splice and a cross hatched (knurled) core crimp to provide necessary contact integrity for the

sensitive, low energy circuits.

Terminal Repair Kit J38125-A also serves as a generic terminal repair kit. The kit contains a large sampling of common

GM electrical terminals and the correct tools to attach them to wires and remove them from connectors. The terminals in

the kit are NOT to be used to replace damaged termin als in the ABS and SRS wiring.

The following procedure for repairing ABS

and SRS wiring is the only recommended and

approved repair method. No alternative repair

methods are to be used.

ABS And SRS Wire Pigtail Repair

Read and understand the instruction repair manual before conducting ABS and SRS wiring repairs using this kit.

If a wiring pigtail (a wire or wires attached directly to the device, not by a connector) is damaged, the entire component

(with pigtail) must be replaced.

Examples of pigtail components are the wheel speed sensors or clock spring coil. Absolutely no wire, connector or

terminal repairs are to be attempted on these components, REPLACE THE COMPONENT.

Wiring Repair

NOTE

Before conducting SRS wiring repair, disable the

SRS, refer to Section 12M Occupant Protection

System.

If any wiring, except the pigtail, is damaged, the wiring should be repaired by splicing in a new section of wire of the

same gauge size (0.5, 0.8, 1.0, etc.). The splices and Splice Crimping Tool from Terminal Repair Kit J38125-A must be

used for these repairs.

The following wiring repair procedures must be used to ensure the integrity of the sealed splice application.

Wiring Diagrams – AWD Wagon Page 12P–39

Step 1 Open the Harness

A wiring harness may be wrapped in tap e or enclosed in a

plastic conduit.

If it is conduit encased, simply open the conduit and pull out

the desired wire.

If the harness is wrapped in tape, use a seam splitter (1) to

open the harness. This prevents damage to the insulation of

the wire inside the harness. Seam splitters are readily

available from sewing supply stores.

When using a seam splitter, use the bla de with the pointed

end (2) to start a small split in the tape away from any wires.

Use the blade with the rounded end (3) to slit the tape as far

as necessary. Be careful to avoid cutting into any wire

insulation.

The crimp and sealed splice sl eeves may be used on all

types of insulation exc ept Tefzel and coaxial and may only

be used to form a one-to-one splice.

Figure 12P – 37

Step 2 Cut the Wire

Leave as much wire on the harness as possible. More can be cut off later to adjust the location of the splice if necessary.

NOTE

Ensure that each splice is at least 40 mm away

from other splices, harness branches and

connectors. This helps prevent moisture from

bridging adjacent splices and causing damage.

Do not nick or cut any copper strands as this

could limit the current-carrying capabilities of the

wire.

Step 3 Select the Correct Size and Ty pe of Wire

The wire must be of a size equal to or greater than the original except for fusible links. The wire insulation must have the

same or higher temperature rating:

General purpose insulation (PVC) is used in areas not su bject to high temperatures.

Cross-linked polyethylene (XLPE) insulation wire is used where high temperatures are expected.

NOTE

XLPE insulated wire may be used to replace

PVC, but PVC must not be used to replace

XLPE. XLPE insulation is not fuel resistant, so

XLPE covered wire m ust n ot be used where there

is the possibility of fuel contact.

Wiring Diagrams – AWD Wagon Page 12P–40

Step 4 Strip the Insulation

NOTE

The following procedures must be followed in the order

listed. If wire strands are damaged, the procedure must be

repeated until a clean strip with all wire strands intact is

obtained.

If it is necessary to add a length of wire to the existing

harness, be certain to use the same size as the original

wire.

To find the correct wire size, either find the wire on the ABS

or SRS wiring diagram, or measure it with a wire gauge.

If unsure about the wire size, begin with the largest opening

in the wire stripper and work do wn until achieving a clean

strip of the insulation. Strip approximately 7.5 mm of

insulation from each wire to be spliced. Be careful to avoid

nicking or cutting any of the strands. Check the stripped wire

for nicks or cut strands. If the wire is damaged, repeat this

procedure after removing the damaged s ecti on.

Figure 12P – 38

Step 5 Select and Position the Splice Sleeve

Select the proper sealed splice sleeve according to wire size. The splice sleeves and tool nests are colour coded (refer to

Table 12P-1).

WIRE SIZE (mm)

SPLICE

CRIMP

PART No.

CRIMP TOOL

NEST

COLOUR 0.5 0.8 1.0 2.0 3.0 5.0

12089189 RED SALMON SALMON

12089190 BLUE BLUE BLUE

12089191 YELLOW YELLOW YELLOW

Table 12P-1

Using the J38125-A Splice Crim p Tool, position the splice sleeve in the proper colour nest of the hand crimp tool. Place

the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop.

The sleeve has a stop in the middle of the barrel to prevent the wire from going further. Close the hand crimper ha ndles

slightly to hold the splice sleeve firmly in the prop er nest.

Step 6 Insert First Wire Into Splice Sleeve and Crimp

1 Insert the wire into the splice sleeve (1) until it hits the

barrel stop (2).

2 Close the handles of the crimp tool tightly at position

(3) until the crimper handles open when released. The

crimper handles will not open until the proper amount

of pressure has been applied to the splice sleeve.

3 Gently tug the wire to ensure the crimp is secure.

Figure 12P – 39

Wiring Diagrams – AWD Wagon Page 12P–41

Step 7 Crimp the Second Wire in the Splice

1 Cut a length of heat shri nk tubing (1) which will allow

an overlap of at least 10 mm at each end of the finally

crimped joint.

2 Slide the heat shrink tubing over the harness wire

which has already been crimped (2).

3 Repeat the Step 5 operations for the second end of

the splice (3).

Figure 12P – 40

Step 8 Shrink the Insulation around the Splice

1 Bring the ultratorch (part of J3 8125-A) to operating

temperature.

2 Using the torch, apply heat where the barrel is crimped

as shown in Figure 12P – 41.

3 Gradually move the heat barrel from the centre toward

each end of the tubing, softening and shrink ing the

tubing completely as the heat is moved along the

insulation. A small amount of sealant will come out of

the end of the tubing when suf f icient shrinking is

achieved.

4 Allow the splice sleeve to cool.

Step 9 Close the Harness

Using a multimeter, check continuity of repaired wiring. If

wiring is OK, tape the harness wires.

Figure 12P – 41

ABS And SRS Wiring Splice Repair

If any of the original equipment splices (three wires or more) in the ABS and SRS wiring are damaged they should be

repaired by applyin g a n ew splice (not sealed) from the Terminal Repair Kit J38125-A. Ca refully follow the instructions

included in the kit for proper splice clip application. Cloth duct tape may be substituted for splice tape if necessary.

Wiring Diagrams – AWD Wagon Page 12P–42

5.5 Splicing Twisted Or Shielded Cable

Twisted or shielded cable is used to protect wiring from electrical noise. Two-conductor cable is used between the radio

and the Delco-Bose speaker amplifier units and other applications where low level, sensitive signals mu st be carried.

Step 1 Strip the Cable

1 Remove the outer jacket (1). Use care not to cut into

the drain wire (2) of the mylar tape(3).

2 Unwrap the mylar tape. Do not remove the tape

because it will be used to re-wrap the conductors after

the splice has been made.

Y12P47

Figure 12P – 42

Step 2 Prepare the Splice

1 Straighten the conductors and stagger th e splices by

65 mm.

2 Follow the instructions for splicing copp er wire.

Y12P48

Figure 12P – 43

Wiring Diagrams – AWD Wagon Page 12P–43

Step 3 Reassemble the Cable

1 Re-wrap the conductors with the mylar tape, taking

care not to wrap the drain wire (1) in the tape.

NOTE

Apply the mylar tape with the aluminium side

inward to ensure good electrical connection.

2 Follow the instructions for splicing co pper wire and

splice the drain wire.

3 Wrap the drain wire around the conductors and tape

with mylar tape.

Y12P49

Figure 12P – 44

Step 4 Tape the Joint

Tape over the entire cable using a winding motion while

applying the tape.

VY12P50

Figure 12P – 45

Wiring Diagrams – AWD Wagon Page 12P–44

5.6 Splicing In-Line Harness Diodes

Many vehicle electrical systems use a diode to isolate circu its and protect the components from voltage spikes. To install

a new diode:

Step 1 Open the Harness

A wiring harness may be wrapped in tap e or enclosed in a

plastic conduit.

If it is conduit encased, simply open the conduit and pull out

the desired wire and dio de.

If the harness is wrapped in tape, use a seam splitter (1) to

open the harness. This prevents damage to the insulation of

the wire inside the harness. Seam splitters are readily

available from sewing supply stores.

When using a seam splitter, use the bla de with the pointed

end (2) to start a small split in the tape away from any wires.

Use the blade with the rounded end (3) to slit the tape as far

as necessary. Be careful to avoid cutting into any wire

insulation.

If the diode is taped to the harness, remove all of the tape.

Figure 12P – 46

Step 2 Remove Diode

1 Check and record the orientation and current flow

direction and of the diode.

NOTE

The colour band (1) or the letter K impressed

into the end of the diode indicated the cath ode.

2 Remov e the faulty diode from the harness using a

suitable soldering tool.

NOTE

If the diode is located next to a connector

terminal, remove the terminal from the connector

to prevent heat damage from the soldering tool.

3 Strip away as much insulation from the wire as is

needed to attach the new diode.

Figure 12P – 47

Wiring Diagrams – AWD Wagon Page 12P–45

Step 3 Install the New Diode

1 Check the curr ent flow direction of the new diode,

being sure to install the new diode with the correct

bias.

2 Solder the new diode to the wire using 50/50 resin

cored solder.

NOTE

Use heat sinks across the diode wire ends to

protect the diode from excessive heat.

3 If removed, reinstall the termi nal into the connector.

4 To prevent shorts to ground and water intrusion,

completely cover all exposed wire and diode

attachment points with tape.

5 Tape the diode to the harness or connector using

electrical tape.

Figure 12P – 48

Wiring Diagrams – AWD Wagon Page 12P–46

5.7 Heated Oxygen Sensor (HO2S) Wiring

Repairs

NOTE

Do not solder repairs as this c oul d resu lt in the air

reference being obstructed.

If the heated oxygen sensor pigtail wiring, connector or terminal is damaged, the entire oxygen sensor assembly must be

replaced. Do not attempt to repair the wiring, connector or terminals. For the sensor to function pro perly, it must have a

clean air reference. The clean air reference is obtained through the oxygen sensor signal and heater wires. Any attempt

to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade the ox ygen

sensor performance.

The following guidelines should be used when servicing the heated oxygen sensor:

Do not apply contact cleaner or other materials to the sensor or vehicle harness co nnectors. These materials may get

into the sensor causing poor performa nce.

The sensor pigtail and harness wires must not be damaged or the wires inside exposed. T his could provide a path for

foreign materials to enter the sensor and cause performance problems.

Do not sharply bend or kink the sensor or vehicle lead wires. Sharp bends and kinks could block the referenc e air path

through the lead wire.

Do not remove or disconnect the oxyg en sensor ground wire where fitted. Vehicles with a ground wire sensor may re ly

on this ground as the only ground contact to the sensor. Removing the ground wire will also cause poor eng ine

performance.

To prevent damage due to water intrusion, ensure the peripheral seal on the vehicle harness connector remains intact.

Wiring Diagrams – AWD Wagon Page 12P–47

5.8 Terminal Removal

The following general terminal removal procedures can be used on most types of connect ors. T he removal procedures

are divided into three general groups; Push-to-Seat, Pull-to-Seat and Weather Pack ®.

Push to Seat Connectors

Push-to-Seat connectors, refer to Figure 12P – 49, are

those which have the terminal inserted in the rear of the

connector body when assembled.

Legend

1 Connector Body

2 Terminal

3 Locking Tang

4 Insertion Direction

Figure 12P – 49

Pull-to-Seat Connectors

Pull-to-Seat connectors, refer to Figure 12P – 50, have the

terminal inserted in the front of the connector body when

assembled.

Use the proper pick(s) or tool(s) that apply to the

appropriate terminal and connector.

Legend

1 Connector Body

2 Terminal

3 Locking Tang

4 Insertion Direction

Figure 12P – 50

Repairing Push-To-Seat And Pull-To-Seat Conne ctors

The following steps will enabl e repair of Push-to-Seat or Pull-to-Seat type connectors. The steps are illustrated with

typical connectors. A specific connector may differ, but the repair steps are similar. Some connectors do not require all

the steps shown.

To repair a connector:

1 Lift up the connector body retaining tangs (1) and pull

mating connector bodies (2) apart, or disconnect the

connector from the component.

2 Remov e an y anti - backout combs that may be fitted to

the connector.

Anti-backout combs are designed to keep the terminal from

backing out of the connector.

NOTE

The anti-backout combs must be removed prior

to terminal removal and must be replaced when

the terminal is repaired and reseated. Figure 12P – 51

Wiring Diagrams – AWD Wagon Page 12P–48

3 If fitted, open any connector secondary locks (1).

A secondary lock aids in terminal retentio n and is usually

moulded as part of the connector body.

Figure 12P – 52

4 Grasp the lead and push the terminal (1) to the

forward most position in the connector bod y (2). Hold

the lead at this position.

5 Locate the terminal lock tang (3) in the connector

canal.

6 Insert the proper size pick (4) (refer to Terminal Repair

Kit J38125-A) straight into the connector canal at the

mating end of the connector.

7 Depr ess the locking tang to unseat the terminal.

8 For push-to-seat connectors, gently pull on the lead to

remove the terminal through the back of the

connector.

9 For pull-to-seat connectors, gently push on the lead to

remove the terminal through the front of the connector.

NOTE

Never use force to remove a terminal from a

connector.

Figure 12P – 53

10 Inspect terminal and connector for damage.

11 Repair or replace parts as necessar y.

Refer to VZ Parts Information for availability of

terminal / pigtail or connector body assemblies that are

serviced separately.

12 Reform lock tang (1) using a wide pick (2) a nd reseat

terminal in connector body.

13 Reinstall any anti-backout combs and join the

connector bodies.

Figure 12P – 54

Wiring Diagrams – AWD Wagon Page 12P–49

Weather Pack® Connectors

To remove Weather Pack® terminals:

1 Lift up the connector body retaining tangs and pull the

mating connector bodies apart, or disconnect the

connector from the component.

2 If fitted, open s econ dary lock (1) or remove the anti-

backout comb.

A secondary lock aids in terminal retentio n and is usually

moulded to the connector body.

Anti-backout combs are designed to keep the terminal from

backing out of the connector.

NOTE

The anti-backout combs must be removed

before terminal removal and must be replaced

when the terminal is repaired and reseated.

Figure 12P – 55

3 Grasp the lead and push the terminal to the forward

most position. Hold the lead at this position.

4 Insert the Weather Pack® terminal removal tool (1)

into the front (mating end) of the connector cavity until

it rests on the cavity shoulder.

5 Gently pull on the lead (2) to remove the terminal

through the back of the connector.

NOTE

Never use force to remove a terminal from a

connector.

6 Inspect the terminal and connector for damage.

7 Repair or repla ce parts as necessary. Refer to VZ

Parts Information for availability of terminal / pigtail or

connector body assemblies that are serviced

separately. Figure 12P – 56

8 Use the Weath er Pack ® pick (1) to reform the male

lock tang (2) or the female lock tang (3).

9 Reseat the terminal in the connector body.

10 Close the secondary lock an d reinstall the connector

to the component or mating connector.

Figure 12P – 57

Wiring Diagrams – AWD Wagon Page 12P–50

6 Reading 12P Wiring Diagrams

General Information

Wiring diagrams are found in all Sections of the Service Manual. The wiring diagrams are based on the Integrated

Vehicle Electrical Design (IVE D) wiring diagrams, which are used by majo r manufacturers throughout the world. The

wiring diagrams are used to:

Present the overall circuitry for a total system.

Assist in explaining the operation of part of a total system.

Assist in diagnostics.

These notes are designed to assist technicians in understanding the 12P wiring diagrams.

Additional wiring, wiring harness and specific wiring harness installation information is con t ained in the Holden Service

Information Package (SIP) CD-ROM. Also contained is addition al information on developing a diagnostic procedure for

electrical circuit diagnosis, el ectrical circuit test procedures, diagnostic tests and wiring repair procedures.

The coloured 12P Electrical Schematic Wirin g Dia grams cover every electrical circuit in the vehicle. Because of this, the

wiring diagrams tend to be large and complex, sometimes spreading over several sheets for a single piece of equipment

within the vehicle. The equip m ent is grouped according to the table of contents at the start of the Electrical Schematic

Wiring Diagrams.

Figure 12P – 58

Legend

1 Sheet Identification

2 Wire Identification 3 Grid Reference

4 Continuation Reference 5 Assembly Identification

6 Assembly Continuation

Wiring Diagrams – AWD Wagon Page 12P–51

Sheet Identification

The bottom left corner of each wiring electrical schematic

diagram sheet identifies the sheet.

The sheet number is shown as well as a title for the sheet.

The sheet title describes the circuits covered on that

particular sheet.

Figure 12P – 59

Wire Identification

The number alongside th e wire is the circuit number. The

circuit number is unique to that circuit and is not repeated

for any other circuit.

The letters under the circuit number indicate the wire colour.

The wire colour in Figure 12P – 60 is purple. If the wire is

two-coloured, the first colour indicates the main bod y colour

of the wire and the second colour refers to the thin colour

stripe. For example, a purple wire with a red stripe would be

shown PU/RD.

The letters under the wire colour indicate which wiring

harness this wire belongs to. In this example, F.B.H.

indicates the Front Body Harness.

A list of Wire Colour and Wiring Harness Abbreviations is

given in this Section. Figure 12P – 60

Wire Colour Abbreviations

BK Black D-GN Dark green L-GN Light green RD Red

BU Blue GN Green OG Orange TN Tan

BN Brown GY Grey PK Pink WH White

D-BU Dark blue L-BU Light blue PU Purple YE Yellow

Wiring Diagrams – AWD Wagon Page 12P–52

Wiring Harness Abbreviations

Figure 12P – 61

Wiring Diagrams – AWD Wagon Page 12P–53

Wiring Harness Visual Identification

When some wiring harness es are shown in location

illustrations, they have a distinctive identification.

Using the coding shown in the Wiring H arne ss Abbreviation

list, the wiring harness (1) shown in Figure 12P – 62 is

identified as the front body har ness.

Figure 12P – 62

Connectors

Connectors generally have a two number identification.

The connector identification n umber (1) – i n

Figure 12P – 63, indicates the wires are joined by an X2 01

connector.

The (2) alphanumeric identifies the pin in the connector – in

this example, the yellow wire is joined at pin A2 and the

purple wire is joined at pin A3 in connector X201.

The pin identifier (2) may be either a letter, a number or an

alphanumeric combinatio n.

The connector physical appearance and pin locations may

be identified from the illustrated con nector listing at the end

of this Section. Figure 12P – 63

Grid Reference

A series of evenly spaced grid reference n umbers are

spread across the bottom of each sheet.

These grid references are use d to establis h the position of

circuits on the sheet. For example, the circuit 230, grey wire

shown in Figure 12P – 64 is at Grid 48.

Figure 12P – 64

Wiring Diagrams – AWD Wagon Page 12P–54

Continuation Reference

The circuit 230 grey wire shown in Figure 12P – 65 is at grid

reference 48. The open box at the bottom of the circuit

contains the Continuation Reference, which indicates the

circuit continues on Sheet 126 at grid reference 15.

The A15 alongside the open box indicates the continuation

of the circuit is connected to assembly A15.

Figure 12P – 65

Multiple Continuation References

In Figure 12P – 66, circuit 32 continues on Sheet 26, Sheet

25 or Sheet 24. The sheet selected depends on whether the

vehicle has a V6 or V8 engine.

Figure 12P – 66

Assembly Identification

An assembly in a coloured ele ctrical schematic wiring

diagram is usually identified by an alphanumeric in large

characters on the body of the assembly. It is also identified

by an abbreviated text referen ce at the end of the assembly.

In this example, the assembly is the Electronic Braking and

Traction Control Assembly.

If only the alphanumeric on the body of the assembly is

given, the specific assembly identity may be determined

from the assembly connector information inc lud ed at the

end of this Section. The type of assembly may be identifi ed

by the initial letter of the code as shown in the assembly

legend.

Figure 12P – 67

Wiring Diagrams – AWD Wagon Page 12P–55

Assembly Legend

A SYSTEMS, SUB-ASSEMBLIES AND MODULES

B TRANSDUCERS

E OTHER DEVICES AND EQUIPMENT

G POWER SUPPLIES

H INDICATORS, ALARMS AND SIGNAL DEVICES

L INDUCTORS

M MOTORS

N REGULATORS AND AMPLIFIERS

P MEASUREMENT, DISPLAY AND TEST DEVICES

R RESISTORS

S SWITCHES

V SEMI-CONDUCTORS

W TRANSMISSION PATHS, CONDUCTORS AND ANTENNAS

X TERMINALS, PLUG AND SOCKET CONNECTIONS

Y ELECTRICALLY OPERATED MECHANICAL DEVICES

Assembly Continuation

When there are too many circuits connected to one

assembly to fit on one sheet, the assembly is continued o n

another sheet.

This is indicated by an unfinished e nd to the assembly

illustration and a direction to the conti nu ation sheet number.

In Figure 12P – 68, assembly A37 is shown as continuing

on sheet 29.

Figure 12P – 68

Assembly Connector Identification

If an assembly has many wiring connections, it may have

more than one connector joining it to the wiring harness.

These connectors are usually numbered X1, X2, X3 . . .

Assembly connectors generally have a two number

identification with the identification numbers shown on either

side of the wire adjacent to the assembl y.

The first number is the connector identification number – in

Figure 12P-20, the wires are connected at the Assembly

A37 X1 connector.

The second number identifies the pin in the connector – in

this example, the yello w wire is join ed at pin 8 and the

purple wire is joined at pin 9 in the A37 X1 connector.

The connector physical appearance and pin locations may

be identified from the illustrated con nector listing at the end

of this Section.

Figure 12P – 69

Wiring Diagrams – AWD Wagon Page 12P–56

Assembly Circuit Identification

Where it assists in understandin g the circuit, a wire may be

identified at the point where it connects with an assembly.

In Figure 12P – 70, the orange wire suppl ies a signal to the

Body Control Module from the ignition c ontact on the ignition

switch.

Figure 12P – 70

Information Within An Assembly

Where it will clarify the operation of a circuit, the first stage

of an assembly operation is shown.

Figure 12P – 71 shows the operatio n of the Boot Solenoid

Relay within the Body Control Module and the effect this has

on circuit 56.

Figure 12P – 71

Harness Splices

A harness splice is shown in Figur e 12P – 72. A harness

splice is where a number of wires are bonded together

within a wiring harness.

Figure 12P – 72

Wiring Diagrams – AWD Wagon Page 12P–57

Ground Locations

Where ground location points are shown, they are identified

by the type of connector (in this case X119), and the

location of the Ground Point termination. In Figure 1 2P – 7 3

there are two ground points – GP3 and GP4.

The physical location of these ground points is given as the

Engine Assembly in Figure 12P – 73 and is shown in the

Ground Point diagram in this Section.

Figure 12P – 73

Wiring Diagrams – AWD Wagon Page 12P–58

Circuit Symbols

Standard circuit symbols are used in the wiring diagrams and are shown in Figure 12P – 74.

WIRE SHIELD

CIRCUIT

BREAKER

MULTI POSITION

SWITCH

GROUND /

EARTH 2

GROUND /

EARTH

FUEL LEVEL

SENDER

WIRE SPLICE ANTENNAVARIABLE RESISTORRESISTOR

MANUALLY OPERATED

SWITCH

BREAK CONTACT

SWITCH

SWITCH WITH

CENTRE OFF

SWITCH WITH

TWO MAKES

MAKE CONTACT

SWITCH

TWISTED PAIR

SYMBOL

PNP TRANSISTOR NPN TRANSISTOR

INDUCTOR

LAMP

X1-A

X2-A

POS

NEG

BATTERY

PWR

GND

HORN /

SPEAKER

RET SIG

MAGNETIC

SENSOR

RESISTOR

FUEL PUMP WITH

LEVEL SENDER

IGNITION SWITCH

SENSOR

CAPACITOR ELECTRIC MOTORPLUG TYPE

CONNECTOR

F104

FUSELUG TYPE

CONNECTOR

SPEEDOMETER

KMH

SPEEDOMETER

0200

LED

RELAY

Coil Asm

F/Injector

COIL - FUEL

INJECTOR

DIODE

X3-1

START

IGN

ACC

START

BATT IGN KEY CHASSIS

GND CONTACT

RUNACCOFF

SLIP

RING

CONTACT

BATT

SLIP RING

VY12P112

MULTIPLE

SINGLE

WIRE SHIELD

Figure 12P – 74

Wiring Diagrams – AWD Wagon Page 12P–59

7 Connector Location Illustrations

A coloured Electrical Schem atic Diagram such as the one shown in Figure 12P – 75 shows a number of connectors. To

locate the position of the connectors on the vehicle and to identify the pin numbers on the connector, a system of links is

used.

Figure 12P – 75

When the cursor is moved over the connector or assembly on a computer screen, it changes to a pointing finger. If the

left mouse button is clicked while the cursor is at position (1) in Figure 12P – 75, the Con nector Location Illustration

shown in Figure 12P – 76 appears.

The Connector Location Illustration has the connector information highlighted and detailed views of the connector

physical location in the vehicle shown.

Wiring Diagrams – AWD Wagon Page 12P–60

Figure 12P – 76

When the cursor is moved over the connector pin number, it

changes to a pointing finger. If the left mouse button is

clicked while the cursor is at position (2) in Figure 12P – 75,

details of the connector and the connector pin num bers

appear as shown in Figure 12P – 77.

Figure 12P – 77

Wiring Diagrams – AWD Wagon Page 12P–61

8 Electrical Schematics Contents

System Wiring Diagram Descrip tio n Diagram Sheet No.

Aftermarket provisions 093

Brakes 022 to 023

Charge / energy store 075

Engine 001 to 018

Engine / transmission cool ing 030 to 031

Entertainment 068 to 071

Entry control 044 to 045

Exterior lighting 048 to 058

Fuel storage and hand ling 024

Fuse chart and relay box l ayout 00A

Ground points and paths 00B to 00C

Horn 074

HVAC 025 to 029

Integrating component 099 to 107

Integrating function 108

Interior lighting 035 to 042

Memory seats 034

Mirrors 059 to 060

Moveable roof 047

Occupant information 063 to 067

Occupant protection 043

Power and ground distribution 076 to 092

Power seats 032 to 033

Po we r windows 046

Serial data links 094 to 098

Suspension 021

Telephone 073

Theft deterrent 072

Transmission 019 to 020

Washer / wipers 061 to 062

Wiring Diagrams – AWD Wagon Page 12P–62

9 Module Location Charts

Electrically Operated Mechanical Devices

Component Code Location

Actuator temperature valve (air mix motor) Y037 025.23

025.40

Camshaft position actuator Y004 010.39

010.44

010.48

010.52

Canister purge solenoid valve Y123 004.01

011.32

Drivers seat belt tensioner Y128 043.43

Drivers seat inner adjuster front vert actuator Y067 032.24

034.05

Drivers seat adjuster horizontal Y064 034.24

Drivers seat inner adjuster rear vert actuator Y069 032.28

034.15

Drivers seat recliner Y074 034.33

Front side door lock actuator Y013 044.14

044.49

Inside air valve vacuum solenoid Y019 025.31

Intake manifold runner control Y021 010.35

Liftgate lock Y023 044.07

Liftgate window release Y007 045.34

062.23

Passenger seat adjuster horizontal Y081 033.25

Passenger seat inner adjuster front vert Y084 033.29

Passenger seat inner adjuster rear vert Y086 033.33

Passenger seat recliner Y091 033.21

Passengers seat belt tensioner Y129 043.33

Rear side door lock actuator Y031 044.24

044.32

Throttle actuator Y038 007.37

014.11

Wiring Diagrams – AWD Wagon Page 12P–63

Indicators, Alarms and Signal Devices

Component Code Location

Rear object sensor alarm H031 066.12

Seat belt alarm H012 032.13

034.45

Inductors

Component Code Location

A/C clutch coil L007 028.23

028.40

Fuel injector solenoid L002 003.02

003.07

003.12

003.17

003.23

003.29

003.34

003.39

011.02

011.07

011.12

011.17

011.22

011.27

Ignition coil assembly L003 016.14

016.19

016.24

016.34

016.39

016.43

Measurement, Display and Test Devices

Component Code Location

Driver information displa y P006 067.35

Instrument cluster P003 054.07

054.46

063.28

064.29

097.23

098.24

Sports Auxiliary Gauges P002 065.27

Wiring Diagrams – AWD Wagon Page 12P–64

Modules, Systems and Sub-Assemblies

Component Code Location

Automatic level control A008-Comp 021.44

Automatic level control A008-Sens 021.17

Blower motor & A/C compressor A014 025.26

097.17

098.38

Blower & air inlet A013 026.26

Body control A015 027.40

034.45

044.44

045.22

046.03

046.14

046.40

046.51

048.14

049.14

054.20

054.33

061.22

061.49

063.22

069.24

072.10

072.25

072.37

072.45

074.05

097.06

097.13

099.30

100.28

101.28

102.28

103.28

104.28

105.28

106.28

107.28

Communication interface A005 007.10

018.06

018.22

094.28

095.28

097.12

098.13

Daytime running lamp control A025 050.30

Driver information displa y controller A035 067.16

Drivers memory seat A021 034.28

060.11

097.33

098.34

Electronic brake and traction control A037 022.28

098.49

Electronic ignition control A040 006.14

006.30

Wiring Diagrams – AWD Wagon Page 12P–65

Component Code Location

Engine control A043 008.28

009.28

010.28

011.28

012.28

013.28

014.28

015.28

016.28

017.17

097.42

097.53

Front side rail inflator restraint A096 043.24

043.38

Heater & A/C evaporator A060 027.35

Inflation restraint sensor A065 043.28

097.13

098.19

Inflation restraint side impact sensor A066 043.30

043.46

Instrument panel inflator restraint A062 043.03

Navigation control processor A139 067.28

Outside rear view memory mirror A073 060.27

Powertrain control A084 001.28

002.28

003.28

004.28

005.28

006.28

007.28

018.47

019.29

098.24

Radio, clock & CD player A133 068.28

069.31

070.27

097.28

098.29

099.34

Rear window wiper and washer module A122 045.34

062.33

Steering wheel inflator restraint A106 043.15

Sunroof control A108 047.23

Throttle actuator control A111 007.24

018.19

095.09

095.13

Transmission control A112 020.28

097.34

097.48

Vehicle dynamic control A116 023.23

097.45

097.53

Wiper dwell control A121 061.49

Wiring Diagrams – AWD Wagon Page 12P–66

Motors

Component Code Location

Front side windo w regulator M010 046.11

046.44

Rear side windo w regulator M014 046.19

046.32

Blower motor M003 026.27

027.17

Engine cooling fans M007 030.35

030.44

031.32

Fuel pump motor M008 024.29

Outside rear view mirror M011 034.36

059.25

059.37

060.08

060.48

Rear window wiper M012 062.41

Starter motor M015 075.20

Sunroof motor M016 047.27

Washer motor M019 061.35

Wiper motor M017 061.05

Other Devices and Equipment

Component Code Location

Automatic transmission control pos ition indicator lamp E125 035.03

036.04

037.52

042.02

Back/up lamp E056 052.25

052.34

Dome lamp E067 035.32

038.07

040.06

042.32

Front floor console compartment lamp E016 036.40

039.29

Front fog lamp E069 058.19

059.26

Front side door courtesy lamp E072 037.01

037.17

Front side turn signal lamp E075 054.08

054.45

Headlamp E119 048.35

048.47

049.33

049.45

053.06

053.50

High mounted stop lamp E079 057.25

Wiring Diagrams – AWD Wagon Page 12P–67

Component Code Location

Ignition lock cylinder bulb E030 035.13

036.24

037.47

042.13

Instrument panel compartment lamp E082 035.08

036.32

039.42

042.08

Reading lamp E094 035.42

035.50

038.31

038.40

040.27

040.36

042.42

042.50

Rear compartment courtesy lamp E036 035.20

038.50

039.13

040.48

042.19

Rear licence plate lamp E044 057.31

057.39

Rear side door courtesy lamp E099 037.07

037.12

Rear turn signal lamp E101 054.14

054.39

Stepwell lamp E105 036.10

036.17

037.36

037.41

Stop/tail lamp E048 053.19

053.38

Sunshade lamps E120 038.17

038.23

040.16

040.22

Turn signal lamp E076 054.02

054.51

Power Supplies

Component Code Location

Battery G001 075.04

Generator G008 075.35

Resistors

Component Code Location

Blower motor resistors R006 027.26

Hill descent control resistor R030 056.48

Rear window defog R022 029.28

Wiring Diagrams – AWD Wagon Page 12P–68

Regulators and Amplifiers

Component Code Location

Radio rear speaker N006 070.26

071.28

Semi Conductors

Component Code Location

A/C compressor diode V005 028.30

028.46

Level ride diode V005 021.33

Liftgate window release diode V005 045.41

Rear wiper diode V005 062.40

062.47

Switches

Component Code Location

Automatic transmission downshift switch S018 094.23

Automatic transmission shift program paddle switch S023 099.08

Automatic transmission shift program switch S022 019.51

094.15

Brake fluid level indicator switch S036 063.03

Cruise control switch S043 007.19

018.05

018.20

094.27

Door lock switch S063 044.39

Driver seat adjuster memory switch S052 034.25

Driver seat adjuster and recliner switch S051 034.09

Driver seat adjuster switch S050 032.25

Electronic traction control switch S073 094.31

094.40

Front top stowage compartment lid release switch S094 036.40

039.29

Hazard warning switch S120 055.22

Headlamp automatic control switch S125 048.16

049.16

Hill descent control switch S025 094.47

Hood theft deterrent switch S135 072.38

Ignition & start switch S149 108.26

Instrument panel lamp s witch S142 035.08

036.32

039.42

042.08

Interior lamp switch S156 041.34

107.05

107.17

107.22

Wiring Diagrams – AWD Wagon Page 12P–69

Component Code Location

Liftgate release switch S161 045.22

Liftgate window release switch S069 040.43

Outside rear view mirror remote control switch S169 059.24

060.27

Park brake switch S181 063.08

Passenger seat adjuster and recliner switch S176 033.25

PRNDL switch S187 019.41

046.28

079.36

Radio control switch S208 099.29

Rear compartment courtesy lamp S189 035.20

038.51

039.14

040.49

042.20

072.24

Side window (master) switch S222 046.27

Side window switch S221 046.23

046.32

Steering wheel horn switch S007 074.23

Stop lamp, traction & cruise control releas e switch S220 005.42

005.45

013.24

018.43

053.18

053.39

056.12

056.42

Sun roof switch S228 047.27

Trip odometer reset switch S237 063.47

064.28

Turn signal & headlamp switch S231 049.16

048.17

054.14

054.39

055.32

Windshield wiper & washer switch S247 061.20

062.27

Wiring Diagrams – AWD Wagon Page 12P–70

Transducers

Component Code Location

A/C refrigeration pressure sensor B018 001.24

009.18

Accelerator pedal position sensor B022 007.16

014.39

Ambient air temperature sensor B023 025.07

Ambient light sensor B055 100.11

Camshaft position sensor B028 004.35

010.05

010.13

010.20

010.28

Crankshaft position sensor B030 004.48

016.50

Duct air temperature sensor B034 025.14

Engine coolant temperature sensor B039 004.11

009.32

Engine oil level sensor B041 013.24

Engine oil pressure sensor B042 001.43

013.13

Front wheel speed sensor B052 022.05

022.12

023.04

023.11

Heated oxygen sensor B057-LT-FR 002.06

Heated oxygen sensor B166-RT-FR 002.33

Heated oxygen sensor B056 015.38

Heated oxygen sensor B057 015.07

Heated oxygen sensor B058 015.50

Heated oxygen sensor B166 015.22

Horn B009 072.11

074.37

074.46

Inside air temperature sensor B059 025.02

Knock sensor B065-SNSR1 004.20

Knock sensor B065-SNSR2 004.26

Knock sensor B065 016.03

016.10

M.A.P. Sensor B067 001.34

009.45

Mass airflow with intake air temperature sensor B069 001.13

009.09

Navigation speaker assembly B104 067.48

Radio front speaker dash upp er B112 070.02

070.53

Wiring Diagrams – AWD Wagon Page 12P–71

Component Code Location

Radio rear speaker B125 071.35

Radio RH & LH front speaker B108 070.07

070.47

Radio RH & LH rear speaker B117 070.17

070.38

Rear object sensor B133 066.06

066.17

066.28

066.40

Rear wheel speed sensor B076 022.18

022.24

023.17

023.24

Steering wheel angle sensor B161 023.50

097.24

Vehicle lateral accel erometer B001 022.34

Vehicle speed sensor B083 019.43

Yaw rate sensor B085 023.37

Transmission Paths, Conductors and Antennas

Component Code Location

Navigation antenna W002_GPS 2 067.39

Radio power antenna W006 069.48

103.43

Wiring Diagrams – AWD Wagon Page 12P–72

10 Special Tools

TOOL NUMBER ILLUSTRATION DESCRIPTION TOOL

CLASSIFICATION

3588

(3545GM)

DIGITAL MULTIMETER

Must have at least 10 MΩ input

impedance and be capable of reading

frequencies.

Previously released.

Available

J21008-A

SELF POWERED TEST LIGHT

Used during electrical circuit diagnostic

checks (or use commercially available

equivalent).

Previously released.

Mandatory

J34142-B

CT-40-C

UNPOWERED TEST LIGHT

Must have current draw of less than

0.3 A.

Previously released.

Mandatory

J35616-A

(KM609)

CONNECTOR TEST ADAPTOR KIT

Used when carrying out electric al

diagnostic circuit checks.

Previously released.

Desirable

J8681-A

UNIVERSAL SHORT FINDER

Used during electrical circuit diagnostic

checks for detecting short circuits.

Previously released.

Desirable