Wiring Diagrams – Sedan and Wagon Page 12P–1
Page 12P–1
Section 12P
Wiring Diagrams – Sedan and 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...................................................................................................................... 6
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...................................................................................................................................... 13
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 – Sedan and Wagon Page 12P–2
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.................................................................................................................................................... 35
Step 7 Tape the Splice..................................................................................................................................... 36
5.4 ABS And SRS Wiring Repair............................................................................................................................... 37
ABS And SRS Wire Pigtail Repair ...................................................................................................................... 37
Wiring Repair........................................................................................................................................................ 37
Step 1 Open the Harness............................................................................................................................. 38
Step 2 Cut the Wire...................................................................................................................................... 38
Step 3 Select the Correct Size and Type of Wire ......................................................................................... 38
Step 4 Strip the Insulation ............................................................................................................................ 39
Step 5 Select and Position the Splice Sleeve............................................................................................... 39
Step 6 Insert First Wire Into Splice Sleeve and Crimp..................................................................................39
Step 7 Crimp the Second Wire in the Splice................................................................................................. 40
Step 8 Shrink the Insulation around the Splice............................................................................................. 40
Step 9 Close the Harness............................................................................................................................. 40
ABS And SRS Wiring Splice Repair................................................................................................................... 40
5.5 Splicing Twisted Or Shielded Cable................................................................................................................... 41
Step 1 Strip the Cable...................................................................................................................................... 41
Step 2 Prepare the Splice................................................................................................................................ 41
Step 3 Reassemble the Cable ......................................................................................................................... 42
Step 4 Tape the Joint....................................................................................................................................... 42
Wiring Diagrams – Sedan and Wagon Page 12P–3
Page 12P–3
5.6 Splicing In-Line Harness Diodes........................................................................................................................ 43
Step 1 Open the Harness................................................................................................................................. 43
Step 2 Remove Diode ...................................................................................................................................... 43
Step 3 Install the New Diode ........................................................................................................................... 44
5.7 Heated Oxygen Sensor (HO2S) Wiring Repairs ................................................................................................ 45
5.8 Terminal Removal................................................................................................................................................ 46
Push to Seat Connectors .................................................................................................................................... 46
Pull-to-Seat Connectors...................................................................................................................................... 46
Repairing Push-To-Seat And Pull-To-Seat Connectors ................................................................................... 46
Weather Pack® Connectors................................................................................................................................ 48
6 Reading 12P Wiring Diagrams............................................................................................................49
General Information............................................................................................................................................. 49
Sheet Identification.............................................................................................................................................. 50
Wire Identification................................................................................................................................................ 50
Wire Colour Abbreviations.................................................................................................................................. 50
Wiring Harness Abbreviations............................................................................................................................ 51
Wiring Harness Visual Identification.................................................................................................................. 52
Connectors........................................................................................................................................................... 52
Grid Reference..................................................................................................................................................... 52
Continuation Reference ...................................................................................................................................... 53
Multiple Continuation References...................................................................................................................... 53
Assembly Identification....................................................................................................................................... 53
Assembly Legend................................................................................................................................................ 54
Assembly Continuation....................................................................................................................................... 54
Assembly Connector Identification.................................................................................................................... 54
Assembly Circuit Identification .......................................................................................................................... 55
Information Within An Assembly........................................................................................................................ 55
Harness Splices................................................................................................................................................... 55
Ground Locations................................................................................................................................................ 56
Circuit Symbols.................................................................................................................................................... 57
7 Connector Location Illustrations........................................................................................................58
8 Electrical Schematics Contents..........................................................................................................60
9 Module Location Charts ......................................................................................................................61
Electrically Operated Mechanical Devices......................................................................................................... 61
Indicators, Alarms and Signal Devices.............................................................................................................. 62
Inductors .............................................................................................................................................................. 62
Measurement, Display and Test Devices........................................................................................................... 62
Modules, Systems and Sub-Assemblies ........................................................................................................... 63
Motors................................................................................................................................................................... 65
Other Devices and Equipment............................................................................................................................ 65
Power Supplies.................................................................................................................................................... 67
Regulators and Amplifiers .................................................................................................................................. 67
Resistors .............................................................................................................................................................. 67
Semi Conductors................................................................................................................................................. 67
Switches ............................................................................................................................................................... 67
Transducers ......................................................................................................................................................... 69
Transmission Paths, Conductors and Antennas.............................................................................................. 70
10 Special Tools ........................................................................................................................................71
Wiring Diagrams – Sedan and Wagon Page 12P–4
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 Sedan and Wagon 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
Section 12O Fuses, Relays and Wiring Harnesses in this Service Information. Further information on dev eloping a
diagnostic procedur e for electrical circuit diagnosis, electrical circuit test procedures, diagnostic tests and wiring repair
procedures is contained in this Section.
Wiring Diagrams – Sedan and Wagon Page 12P–5
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 bef ore trying to determine
why it does not work.
NOTE
It is important to realise that no attempt is made on
the diagrams to represent compon ents 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 only being sho wn.
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 share d 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.
Wiring Diagrams – Sedan and Wagon Page 12P–6
Page 12P–6
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.
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 operate 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 headla mp 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 – Sedan and Wagon Page 12P–7
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 learned 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 (batter y 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 headlam p 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 4.
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 – Sedan and Wagon Page 12P–8
Page 12P–8
Step 5 Isolate the Most Possible Cause
Figure 12P – 2 is an example of how to isolate the caus e of the problem. Remembering it has already been determined the
fault is between the splice after fuse F31 an d the LH inboard high 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 – Sedan and Wagon Page 12P–9
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 bod y (terminal 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 connectio ns/corrosion).
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 – Sedan and Wagon Page 12P–10
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 individual parallel circuits
will continue to operate. The 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 flame s . 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. When 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 bre akage, causes the conductor to contact the voltage of
another circuit. This will cause the circuit (or both circuits) to operate 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 diagnostic procedure described
at the beginning of this Section, must be performed. Observe the symptoms to recognise associated circuits involved.
Isolation by removing fuses will help isolate the circuit br anches 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 – Sedan and Wagon Page 12P–11
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.
V
Y12P203
1
Figure 12P – 3
V
Y12P204
1
2
5
6
34
8
7
9
M
3
3
3
8
8
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 – Sedan and Wagon Page 12P–12
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
V
Y12P205
1
3
4
5
2
M
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.
V
Y12P206
1
2
3
~
POW ER
FUSED
1000V
MAX 750V~
1000V---
MAX
10A COM uA mA
V
DATA
HOLD SELECT RANGE
ºC
V
~V
ADP
mA/A uA
P U SH SE LE C T
P U SH SE LE C T
1
kHz
0.3% V
~
DC AMPS
Figure 12P – 6
Wiring Diagrams – Sedan and Wagon Page 12P–13
Page 12P–13
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 t wo 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 vehic le' 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-powered test light to each point. If there is continu ity, 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-powered test light on circuits
that contain solid-state components, since
damage to these components may result.
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 no such doubt about there reading.
The digital multimeter shows a + symbol in front of the reading when the positive meter le ad is connected to a positive power
source and the negative lead i s 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 igital read out 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, espec ially for testing
electronic systems.
The impedance of an analogue meter is less than 10 Megohm. A meter with less than 10 Megohm impedance must not be
used on circuits that contain solid state comp onents 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 imped ance
applies to the meter only when it is used on the voltage scal e. This means that the meter resists loa din g 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 t he other le ad. High inp ut
impedance pro vides 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 flow'.
Wiring Diagrams – Sedan and Wagon Page 12P–14
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 using 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 allow 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 damag ed 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 repl aced.
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 po wer from the device the y are testing for use on computers. Many analogue meters use 9 volts
to power the resistance test which is enough to destroy sensitive digital co mponents. Digital multimeters have an input
impedance of about 10 Mego hms which is much higher than analogue multimeters. The high impedance means that the
meter will draw very little power from the device under test. This means the meter will provide a more accurate measurement
and will not damage 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, appl y basic theories and use the correct test equipment.
Wiring Diagrams – Sedan and Wagon Page 12P–15
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
Mk
+
V
Y12P208
1
2
34
~
POWER
FUSED
1000V
MAX 750V~
1000V---
MAX
10A COM uA mA
V
DATA
HOLD SELECT RANGE
ºC
V
~V
A
DP
mA/A uA
PUSH SE LECT
PUSH SE LE CT
1
kHz
0.3% V
~
Figure 12P – 7
Wiring Diagrams – Sedan and Wagon Page 12P–16
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
Mk
+
V
Y12P209
2
1
4
~
POWER
FUSED
1000V
MAX 750V~
1000V---
MAX
10A COM uA mA
V
DATA
HOLD SELECT RANGE
ºC
V
~V
A
DP
mA/A uA
PUSH SE LECT
PUSH SE LE CT
1
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 digital 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 on ce, reverse the leads and take a second reading. If the readings differ, the solid
state component is affecting the measurement.
Wiring Diagrams – Sedan and Wagon Page 12P–17
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 indicat e an open circuit in the other. This indicates a good diode. If both readings are open circuit, the
diode is open. If both readings indicate continuity, 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
Mk
+
V
Y12P210
1
2
43
~
POWER
FUSED
1000V
MAX 750V~
1000V---
MAX
10A COM uA mA
V
DATA
HOLD SELECT RANGE
ºC
V
~V
ADP
mA/A uA
PUSH SE LECT
PUSH SE LE CT
1
kHz
0.3% V
~
Figure 12P – 9
Wiring Diagrams – Sedan and Wagon Page 12P–18
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
2
4
3
5
6
7
1
D H
R H
~
0102030
m V
Mk
+
~
POWER
FUSED
1000V
MAX 750V~
10 00V -- -
MAX
10A COM uA mA
V
DATA
HOLD SELECT RANGE
ºC
V
~V
ADP
mA/A uA
PUSH SEL ECT
PUSH SEL ECT
1
kHz
0.3% V
~
V
Figure 12P – 10
Wiring Diagrams – Sedan and Wagon Page 12P–19
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
V
Y12P212
2
1
D H
R H
~
0102030
m V
Mk
+
~
POWER
FUSED
1000V
MAX 750V~
1000 V---
MAX
10A COM uA mA
V
DATA
HOLD S ELECT RANGE
ºC
V
~V
ADP
mA/A uA
PUSH SEL ECT
PUSH SEL ECT
1
kHz
0.3% V
~
O
Figure 12P – 11
Wiring Diagrams – Sedan and Wagon Page 12P–20
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 sho w the difference in vo ltage
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
V
Y12P213
2
3
5
1
D H
R H
~
0102030
m V
Mk
+
~
POWER
FUSED
1000V
MAX 750V~
10 00V -- -
MAX
10A COM uA mA
V
DATA
HOLD SELECT RANGE
ºC
V
~V
ADP
mA/A uA
PUSH SEL ECT
PUSH SEL ECT
1
kHz
0.3% V
~
V
4
Figure 12P – 12
Wiring Diagrams – Sedan and Wagon Page 12P–21
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
V
Y12P214
1
2
6
3
5
D H
R H
~
0102030
m V
Mk
+
~
POWER
FUSED
1000V
MAX 750V~
10 00V -- -
MAX
10A COM uA mA
V
DATA
HOLD SELECT RANGE
ºC
V
~V
ADP
mA/A uA
PUSH SEL ECT
PUSH SEL ECT
1
kHz
0.3% V
~
V
4
Figure 12P – 13
Wiring Diagrams – Sedan and Wagon Page 12P–22
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
V
Y12P215
1
2
6
3
5
D H
R H
~
0102030
m V
Mk
+
~
POWER
FUSED
1000V
MAX 750V~
10 00V -- -
MAX
10A COM uA mA
V
DATA
HOLD SELECT RANGE
ºC
V
~V
ADP
mA/A uA
PUSH SEL ECT
PUSH SEL ECT
1
kHz
0.3% V
~
O
4
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 bod y 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 can 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 grou nd, the
compass will stop 'kicking'. Thus, the compass can pinpoint the problem without removing 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 more effectively used to find troubles. A turn signal
flasher makes a convenient circuit breaker. Solder a lead 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 needle deflection. To slow it down, insert a rheostat in series with the flasher. By cutting in additional
resistance, the flashing rate of the unit ma y be slowed down to produce good compass needle deflection.
Wiring Diagrams – Sedan and Wagon Page 12P–23
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.
V
Y12P216
1
2
4
3
7
6
8
9
5
10
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 – Sedan and Wagon Page 12P–24
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
V
Y12P217
1
2
D H
R H
~
0102030
m V
Mk
+
~
POWER
FUSED
1000V
MAX 750V~
10 00V -- -
MAX
10A COM uA mA
V
DATA
HOLD SELECT RANGE
ºC
V
~V
ADP
mA/A uA
PUSH SEL ECT
PUSH SEL ECT
1
kHz
0.3% V
~
A
4
3
5
Figure 12P – 16
Wiring Diagrams – Sedan and Wagon Page 12P–25
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, hav e the ability to monitor current, resistance or voltage while recording
the minimum (MIN) and maximum (MAX) values measured.
When diagnosing circuits that have voltage applied, use the voltage setting to monitor a connector or p art of a circuit which
may have an intermittent connection, 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 an d will g en erate 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 resistance 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 sight or sound range, in noisy areas or for test driving when it may
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 resistance exists and should be
repaired as necessary. Refer to 5 W iring Repair Procedures in this Section for repair proc edures.
NOTE
The 100 ms RECORD mode is NOT the amount of
time allowed to perform a s pecific procedure. 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 connector may be
the result of contamination or deformation.
Contamination is caused by the connector bodies being improperly connected, a missing o r damaged 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 cont act, causing an open or intermittently open circuit.
Wiring Diagrams – Sedan and Wagon Page 12P–26
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 high resistance, intermittent contact, or an open circuit. An
engine compartment or underbod y 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 shou ld be 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 ody. 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, replace the 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 using
current, voltage or resistance settings to detect intermittent faults, it will be necessary to connect the meter into the circ uit.
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 measurements to prevent false readings or damage
to the meter. Do not use the meter to measure resistance through a sol id state module. Continuity tests that work well for
detecting intermittent shorts to ground can be performed 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 information and should b e read thoroughly
before using the meter as well as kept on hand for reference during new procedures.
Wiring Diagrams – Sedan and Wagon Page 12P–27
Page 12P–27
5 Wiring Repair Procedures
5.1 General Information
Except for some specific connector bodies, wiring harness terminals, terminal seals and c onnector 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 Vol ume) an d splice new 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 the wiring installation diagrams in Section 12O Fuses, Relays & Wiring harnesses.
Wiring Diagrams – Sedan and Wagon Page 12P–28
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 – Sedan and Wagon Page 12P–29
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
2
1
Figure 12P – 21
Wiring Diagrams – Sedan and Wagon Page 12P–30
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 – Sedan and Wagon Page 12P–31
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 aroun d the original 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 – Sedan and Wagon Page 12P–32
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 capabiliti es 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
must not be used where th ere is the p ossibilit y of fue l
contact.
Wiring Diagrams – Sedan and Wagon Page 12P–33
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 jaws 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 – Sedan and Wagon Page 12P–34
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
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 st ill in the correct position
before closing the crimping tool with steady pressure.
Figure 12P – 32
Wiring Diagrams – Sedan and Wagon Page 12P–35
Page 12P–35
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
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
Wiring Diagrams – Sedan and Wagon Page 12P–36
Page 12P–36
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
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 – Sedan and Wagon Page 12P–37
Page 12P–37
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 connec tors and terminals). 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 larg e 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 terminals 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 compon ents, 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 shoul d 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 – Sedan and Wagon Page 12P–38
Page 12P–38
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 capabiliti es 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
must not be used where th ere is the p ossibilit y of fue l
contact.
Wiring Diagrams – Sedan and Wagon Page 12P–39
Page 12P–39
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 – Sedan and Wagon Page 12P–40
Page 12P–40
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 coo l.
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 – Sedan and Wagon Page 12P–41
Page 12P–41
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 must 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.
V
Y12P47
1
2
3
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 co pper wire.
V
Y12P48
Figure 12P – 43
Wiring Diagrams – Sedan and Wagon Page 12P–42
Page 12P–42
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 spli cing copper wire and
splice the drain wire.
3 Wrap the drain wire around the conductors and tape
with mylar tape.
V
Y12P49
1
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 – Sedan and Wagon Page 12P–43
Page 12P–43
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 – Sedan and Wagon Page 12P–44
Page 12P–44
Step 3 Install the New Diode
1 Check the curr ent flow direction of the ne w 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 – Sedan and Wagon Page 12P–45
Page 12P–45
5.7 Heated Oxygen Sensor (HO2S) Wiring
Repairs
NOTE
Do not solder repairs as this could result 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 oxygen 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 h arness co nnectors. These materials may get into
the sensor causing poor performance.
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 engine performance.
To prevent damage due to water intrusion, ensure the peripheral seal on the vehicle harness connector remains intact.
Wiring Diagrams – Sedan and Wagon Page 12P–46
Page 12P–46
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 gener al 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 – Sedan and Wagon Page 12P–47
Page 12P–47
3 If fitted, open any connector secondar y 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 – Sedan and Wagon Page 12P–48
Page 12P–48
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 – Sedan and Wagon Page 12P–49
Page 12P–49
6 Reading 12P Wiring Diagrams
General Information
Wiring diagram s are found in all Sections of the Service Manual. T he wiring diagrams are based on the Integrated Vehicle
Electrical Design (IVED) wiring diagrams, which are used by major 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, th e
wiring diagrams tend to be large and complex, sometimes spreading over several sheets for a single piece of equipment
within the vehicle. The equipment 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 – Sedan and Wagon Page 12P–50
Page 12P–50
Sheet Identification
The bottom left corner of each wiring electrical schem atic
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 – Sedan and Wagon Page 12P–51
Page 12P–51
Wiring Harness Abbreviations
Figure 12P – 61
Wiring Diagrams – Sedan and Wagon Page 12P–52
Page 12P–52
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 X201
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 – Sedan and Wagon Page 12P–53
Page 12P–53
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 – Sedan and Wagon Page 12P–54
Page 12P–54
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 – Sedan and Wagon Page 12P–55
Page 12P–55
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 – Sedan and Wagon Page 12P–56
Page 12P–56
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 – Sedan and Wagon Page 12P–57
Page 12P–57
Circuit Symbols
Standard circuit symbols are used in the wiring diagrams and are shown in Figure 12P – 74.
S
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
55
TWISTED PAIR
SYMBOL
PNP TRANSISTOR NPN TRANSISTOR
INDUCTOR
LAMP
X1-A
X2-A
POS
NEG
RH
LH
BATTERY
PWR
GND
HORN /
SPEAKER
RET SIG
MAGNETIC
SENSOR
RESISTOR
M
FUEL PUMP WITH
LEVEL SENDER
IGNITION SWITCH
SENSOR
M
CAPACITOR ELECTRIC MOTORPLUG TYPE
CONNECTOR
F104
FUSELUG TYPE
CONNECTOR
SPEEDOMETER
KMH
SPEEDOMETER
0200
LED
31
25
RELAY
L2
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
S
SINGLE
WIRE SHIELD
Figure 12P – 74
Wiring Diagrams – Sedan and Wagon Page 12P–58
Page 12P–58
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 Connector 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 sho wn.
Wiring Diagrams – Sedan and Wagon Page 12P–59
Page 12P–59
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 Page 12P–60
Page 12P–60
8 Electrical Schematics Contents
System Wiring Diagram Descrip tio n Diagram Sheet No.
Aftermarket provisions 092
Brakes 022 to 024
Charge / energy store 074
Engine 001 to 018
Engine / transmission cool ing 031 to 032
Entertainment 067 to 070
Entry control 044 to 045
Exterior lighting 048 to 058
Fuel storage and hand ling 025
Fuse chart and relay box l ayout 00A
Ground points and paths 00B to 00C
Horn 073
HVAC 026 to 030
Integrating component 098 to 106
Integrating function 107
Interior lighting 036 to 041
Memory seats 034
Mirrors 059 to 060
Moveable roof 047
Occupant information 063 to 066
Occupant protection 042 to 043
Power and ground distribution 075 to 091
Power seats 033 & 035
Po we r windows 046
Serial data links 093 to 097
Telephone 072
Theft deterrent 071
Transmission 019 to 021
Washer / wipers 061 to 062
Wiring Diagrams Page 12P–61
Page 12P–61
9 Module Location Charts
Electrically Operated Mechanical Devices
Component Code Location
Actuator temperature valve (air mix motor) Y037 028.23
028.40
Camshaft position actuator Y004 003.40
003.44
003.48
003.52
Canister purge solenoid valve Y123 004.32
014.02
Drivers seat adjuster horizontal actuator Y064 034.25
Drivers seat belt tensioner Y128 042.39
043.43
Drivers seat inner adjuster front vert actuator Y067 033.26
034.04
Drivers seat inner adjuster rear vert actuator Y069 033.30
034.15
Drivers seat recline actuator Y074 034.33
Front side door lock actuator Y013 044.14
044.49
Inside air valve vacuum solenoid Y019 028.30
Intake manifold runner control Y021 003.35
Lift gate lock Y023 044.06
Passengers seat adjuster horizontal actuator Y081 035.16
Passengers seat belt tensioner Y129 042.28
043.32
Passengers seat inner adjuster front vert actuator Y084 035.20
Passengers seat inner adjuster rear vert actuator Y086 035.24
Passengers seat recline actuator Y091 035.12
Rear compartment lid latch a ctuator Y029 045.33
Rear side door lock actuator Y031 044.24
044.33
Reverse lock out solenoid Y144 011.52
Throttle actuator Y038 007.11
017.36
Wiring Diagrams Page 12P–62
Page 12P–62
Indicators, Alarms and Signal Devices
Component Code Location
Rear object sensor alarm H031 065.14
Seat belt alarm H012 033.15
034.45
Inductors
Component Code Location
A/C clutch coil L007 029.23
029.41
Fuel injector solenoid L002 004.02
004.07
004.12
004.17
004.22
004.27
013.02
013.06
013.12
013.17
013.24
013.29
013.33
014.39
Ignition coil assembly L003 009.15
009.19
009.24
009.34
009.39
009.44
Measurement, Display and Test Devices
Component Code Location
Driver information displa y P006 066.36
Instrument cluster P003 063.28
064.29
095.23
096.27
Wiring Diagrams Page 12P–63
Page 12P–63
Modules, Systems and Sub-Assemblies
Component Code Location
Blower motor & A/C compressor A014 028.28
095.18
Blower & air inlet A013 026.25
Body control A015 027.40
034.44
044.44
045.21
045.33
046.03
046.11
046.14
046.40
046.44
046.51
049.14
050.14
061.21
062.23
063.21
070.24
071.10
071.23
071.37
071.45
073.05
095.06
096.13
098.30
099.28
100.28
101.28
102.28
103.28
104.28
105.28
106.28
Communication interface A5 017.10
018.05
093.31
095.13
096.13
097.28
Daytime running lamp control A025 048.32
Driver information displa y control A035 065.16
Drivers seat adjuster memory A021 034.28
060.11
095.38
096.42
Electronic brake and traction control A038 022.28
095.45
095.53
Wiring Diagrams Page 12P–64
Page 12P–64
Component Code Location
Electronic brake and traction control A037 015.50
024.28
096.50
Electronic ignition control A040 016.13
016.31
Engine control A043 001.28
002.28
003.28
004.28
005.28
006.28
007.28
008.28
009.28
010.18
095.42
095.53
Front side rail inflator restraint A096 043.24
043.38
Heater & A/C evaporator A060 027.36
Inflation restraint sensor A065 042.28
043.28
095.13
096.21
Inflation restraint side impact sensor A066 043.30
043.46
Instrument panel inflator restraint A062 041.11
043.03
Navigation control A139 066.28
Outside rear view mirror memory A073 060.28
Powertrain control A084 011.28
012.28
013.28
014.28
015.28
016.28
017.28
018.47
019.25
024.15
024.28
096.24
Radio, clock & CD player A133 069.29
070.32
095.28
096.32
098.33
Wiring Diagrams Page 12P–65
Page 12P–65
Component Code Location
Rear object sensor control A098 065.28
Steering wheel inflator restraint A106 042.32
043.14
Sunroof control A108 047.23
Throttle actuator control A111 017.22
018.19
097.09
097.13
Transmission control A112 020.28
021.28
095.35
095.48
Vehicle dynamic control A116 023.24
095.45
095.53
Windshield wiper dwell A121 061.49
Motors
Component Code Location
Front side windo w regulator M010 046.11
046.44
Rear side windo w regulator M014 046.20
046.33
Blower motor M003 026.27
027.17
Engine cooling fans M007 031.28
032.33
Fuel pump motor M008 025.34
Outside rear view mirror M011 034.36
059.25
059.37
060.07
060.48
Rear wiper motor M012 062.41
Starter motor M015 074.20
Sunroof actuator motor M016 047.27
Washer motor M019 061.39
Wiper motor M017 061.04
Other Devices and Equipment
Component Code Location
Automatic transmission control pos ition indicator lamp E125 036.02
037.53
040.03
Back/up lamp E056 053.17
053.23
053.31
053.38
Wiring Diagrams Page 12P–66
Page 12P–66
Component Code Location
Dome lamp E067 036.31
038.07
040.32
Front floor console compartment lamp E016 041.29
Front fog lamp E069 058.19
058.26
Front side door courtesy lamp E072 037.02
037.17
Front side turn signal lamp E075 055.11
055.44
Headlamp E119 049.34
049.48
050.33
050.46
052.08
052.51
High mounted stop lamp E079 056.18
056.28
High mounted stop lamp E080 056.08
Ignition lock cylinder bulb E030 036.13
037.47
040.13
Instrument panel compartment lamp E082 036.08
040.08
041.42
Reading lamp E094 036.42
036.50
038.31
038.40
040.43
040.51
Rear compartment courtesy lamp E036 036.19
038.50
040.18
041.12
Rear licence plate lamp E044 056.36
056.44
Rear side door courtesy lamp E099 037.07
037.13
Rear turn signal lamp E101 055.19
055.24
055.44
055.50
Step well lamp E105 037.36
037.42
Stop/tail lamp E048 052.15
052.25
052.34
052.43
Sun shade lamp E120 038.16
038.23
Turn signal lamp E076 055.06
055.50
Wiring Diagrams Page 12P–67
Page 12P–67
Power Supplies
Component Code Location
Battery G001 074.04
Generator G008 074.36
Regulators and Amplifiers
Component Code Location
Radio antenna amplifier N003 070.11
Radio rear speaker amplifier N006 067.26
068.28
Resistors
Component Code Location
Blower motor resistors R006 027.26
Rear window defog R022 030.25
030.32
Semi Conductors
Component Code Location
Engine wiring harness fuse block diode V005 029.29
029.47
045.39
Switches
Component Code Location
Automatic transmission downshift switch S018 093.23
Automatic transmission shift program switch S022 019.51
093.15
Automatic transmission shift program paddle switch S023 098.09
Back up lamp switch S032 054.31
054.45
Brake fluid level indicator switch S036 063.03
Cruise control switch S043 017.19
018.05
018.20
093.27
Clutch pedal position switch S042 001.37
001.40
018.35
Door lock switch S063 044.39
Driver seat adjuster memory switch S052 034.24
Driver seat adjuster & recline switch S051 034.08
Driver seat adjuster switch S050 033.27
Electronic traction control switch S073 024.31
093.32
093.41
Front top stowage compartment lamp switch S094 041.29
Wiring Diagrams Page 12P–68
Page 12P–68
Component Code Location
Hazard warning switch S120 051.22
Headlamp automatic control switch S125 049.15
050.15
Hood theft deterrent switch S135 071.38
Ignition & start switch S149 107.28
Instrument panel lamp s witch S142 036.08
040.08
041.42
Interior lamp switch S156 039.27
106.04
106.17
106.22
Outside rear view mirror remote control switch S169 059.23
060.26
Park brake switch S181 063.08
Passenger seat adjuster & recline switch S176 035.17
PRNDL switch S187 019.41
021.44
054.11
054.22
078.36
Radio control switch S208 098.28
Rear compartment courtesy lamp switch S189 036.20
038.51
040.20
041.13
071.23
Rear compartment lid release switch S195 045.21
Side window (master) switch S222 046.28
Side window switch S221 046.22
046.33
Steering wheel horn switch S007 073.23
Stop lamp, traction & cruise control releas e switch S220 006.25
015.45
018.44
057.30
Sun roof switch S228 047.27
Trip odometer reset switch S237 063.47
064.27
Turn signal & headlamp switch S231 049.17
050.17
051.31
Windshield wiper & washer switch S247 061.22
062.11
Wiring Diagrams Page 12P–69
Page 12P–69
Transducers
Component Code Location
A/C refrigeration pressure sensor B018 002.18
011.24
Accelerator pedal position sensor B022 007.39
Ambient air temperature sensor B023 028.08
Ambient light sensor B055 099.11
Camshaft position sensor B028 003.05
003.13
003.20
003.28
014.34
Crankshaft position sensor B030 009.50
014.48
Duct air temperature sensor B034 028.14
Engine coolant temperature sensor B039 002.31
Engine oil level sensor B041 005.24
Engine oil pressure sensor B042 005.12
011.43
Front wheel speed sensor B052 022.06
022.12
023.04
023.11
024.03
024.10
Heated oxygen sensor B057-LT-FR 012.05
Heated oxygen sensor B166-RT-FR 012.33
Heated oxygen sensor B056 008.38
Heated oxygen sensor B057 008.06
Heated oxygen sensor B058 008.50
Heated oxygen sensor B166 008.21
Horn B009 071.11
073.37
073.46
Inside air temperature sensor B059 028.02
Knock sensor B065-SNSR1 014.19
Knock sensor B065-SNSR2 014.26
Knock sensor B065 009.03
009.09
M.A.P. Sensor B067 002.45
011.34
Mass airflow with intake air temperature sensor B069 002.09
011.12
Navigation speaker assembly B104 066.48
Radio front speaker dash upp er B112 067.02
067.53
Wiring Diagrams Page 12P–70
Page 12P–70
Component Code Location
Radio RH & LH front speaker B108 067.07
067.47
Radio RH & LH rear speaker B117 067.17
067.38
Rear object sensor B133 065.06
065.17
065.28
065.40
Radio amplifier rear speak er B131 068.30
068.41
Rear wheel speed sensor B076 022.19
022.26
023.18
023.25
024.17
024.24
Steering angle sensor B161 023.50
095.24
Vehicle speed sensor B083 010.06
019.43
021.44
Yaw rate sensor B085 023.38
Transmission Paths, Conductors and Antennas
Component Code Location
Radio antenna W004 070.13
Radio power antenna W006 070.49
102.43
Navigation antenna W002_GPS_2 066.39
Wiring Diagrams Page 12P–71
Page 12P–71
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
or
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