Fuses, Relays and Wi ring Harnesse s Page 12O–1
Page 12O–1
Section 12O
Fuses, Relays and Wiring Harne sses
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............................................................................................................................... 2
1.1 Fuses.......................................................................................................................................................................2
1.2 Circuit Breakers......................................................................................................................................................5
1.3 Fusible Links ..........................................................................................................................................................6
1.4 Relays......................................................................................................................................................................8
Passenger Compartment Relays ..........................................................................................................................8
Engine Compartment Relays.................................................................................................................................9
1.5 Diodes ...................................................................................................................................................................10
1.6 Wiring Harnesses.................................................................................................................................................11
1.7 Wiring Harness Connectors................................................................................................................................12
1.8 Electronic Control Device Locations..................................................................................................................13
2 Service Operations.............................................................................................................................. 16
3 Wiring Installation Diagrams.............................................................................................................. 17
3.1 Interior Body Wiring Harness..............................................................................................................................17
3.2 Rear Wiring Harnesses – 1..................................................................................................................................19
3.3 Rear Wiring Harnesses – 2..................................................................................................................................21
3.4 Rear Wiring Harnesses – 3..................................................................................................................................22
Fuses, Relays and Wi ring Harnesse s Page 12O–2
Page 12O–2
1 General Information
With the following exceptions, MY 2003 VY Regular Cab Fuses, Relays and Wiring Harnesses information carries over
from MY 2003 VY and V2 Series vehicles. For information not contained within this Section, refer to Section 12O Fuses,
Relays and Wiring Harnesses in the MY 2003 VY and V2 Series Service Information.
• Fuses
• Circuit Breakers
• Fusible Lin ks
• Relays
• Diodes
• Wiring Harnesses
• Wiring Harnes ses Connectors
• Electronic Control Device Locations
• Interior Body Wiring Harness
• Rear Wiring Harnes ses
1.1 Fuses
Fuses are a blade type mini construction, with the current
rating in amps indicated on the top of the fuse assembly,
above the element, or identified by the plastic body colour of
the fuse. The fuse current ratings and corresponding colour
are listed in the following table.
Figure 12O – 1
CURRENT RATING
(AMPS) FUSE COLOUR
3 Violet
5 Tan
7.5 Brown
10 Red
15 Blue
20 Yellow
25 White
30 Green
Fuses are located in two positions on MY 2003 Regular Cab vehicles. One group is located in the passenger
compartment fuse and relay panel assembly. Refer to Figure 12O – 2. A label on the inside of the instrument panel
lower cover indicates the circuits protected by each fuse.
Fuses, Relays and Wi ring Harnesse s Page 12O–3
Page 12O–3
Figure 12O – 2
Legend
1 F4 – Park Lamps Fuse (10A)
2 F5 – Stop Lamps Fuse (15A)
3 F6 – Interior Illumination Fuse (10A)
4 F7 – Hazard Lamps Fuse (15A)
5 F8 – Spare
6 F9 – Horn Fuse (15A)
7 F10 – Ignition Fuse (7.5A)
8 F11 – Instrument Illuminat i on Fuse (7.5A)
9 F12 – Turn Signals & Back-up Lamps Fuse (15A)
10 F13 – Trip Computer & Instruments Fuse (7.5A)
11 F14 – Cigar Lighter Fuse (20A)
12 F15 – Cruise & Power Mirrors Fuse (10A)
13 F16 – Radio & Cell Phone Fuse (7.5A)
14 F17 – Accessory Socket Fuse (20A)
15 F18 – Wiper Washer Fuse (20A)
16 F19 – Spare
17 F20 – Power Locks, Power Wi ndows & Theft Horn Fuse
(15A)
18 F21 – Instruments Fuse (10A)
19 F22 – Heated Rear Window Fuse (20A)
20 F23 – Radio & Cell Phone Fuse (15A)
21 F24 – Spare
22 F25 – Spare
23 F26 – SRS Fuse (15A)
24 F27 – Anti-lock Brakes Fuse (10A)
Fuses, Relays and Wi ring Harnesse s Page 12O–4
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The second group of fuses are located in the engine compartment fuse and relay panel assembly, situated forward of
the right-hand side front suspension strut tower. A label on the inside of the panel cover indicates the circuits protected
by each fuse. Refer to Figure 12O – 3.
Figure 12O – 3
Legend
1 F36 – Spare
2 F37 – Spare
3 F38 – Spare
4 F39 – Spare
5 F28 – Fuel Pump Fuse (15A)
6 F29 – Engine & BCM Fuse (10A)
7 F30 – Right-hand Headlamp Fuse (20A)
8 F31 – Left-hand Headlamp Fuse (20A)
9 F32 – Automatic Transmission Fuse (15A)
10 F33 – Engine Sensors Fuse (15A)
11 F34 – Fuel Injectors & Ignition Modules Fuse (15A)
12 F35 – Fuel Injectors & Ignition Modules Fuse (15A)
Fuses, Relays and Wi ring Harnesse s Page 12O–5
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1.2 Circuit Breakers
A circuit breaker is a circuit protection device that will trip
when the circuit current exceeds its rating. The circuit
breaker is activated by heat and will reset after being
allowed to cool. The circ uit bre aker has a limi ted num ber of
tripping cycles before its tripping time will change. The
circuit breaker w ill cont inu e to open and close unti l the
cause of the excess current is corrected.
Figure 12O – 4
In the MY 2003 VY Regular Cab vehicles all the circuit breakers are located in the passenger compartment fuse and
relay panel assembly and have a 20A current rating. A label on the inside of the panel cover indicates the circuits
protected by each circuit breaker. Refer to Figure 12O – 5.
Figure 12O – 5
Legend
1 F1 – Power Windows Circuit Breaker (20A)
2 F2 – Power Seats Circuit Breaker (20A) 3 F3 – Spare
Fuses, Relays and Wi ring Harnesse s Page 12O–6
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1.3 Fusible Links
The chassis and engine electrical wiring is protected against
short circuit damage by fusible links.
Plug-in type fusible links (1) have an inspection window (2)
that allows a visual check of the condition of the element (3).
Figure 12O – 6
The plug-in type fusible links are located in the engine compartment fuse and relay panel assembly. Refer to Figure
12O – 7 for the location and us age of the fusible links. A label on the inside of the panel cover indicates the circuits
protected by each fusible link.
Figure 12O – 7
Legend
1 F101 – Engine Cooling Large Fan (30A)
2 F102 – Lighting (60A)
3 F103 – Anti Lock Brakes (60A)
4 F104 – Engine (60A)
5 F105 – Main (60A)
6 F106 – Blower Fan (40A)
7 F107 – Engine Cooling Small Fan (30A)
Fuses, Relays and Wi ring Harnesse s Page 12O–7
Page 12O–7
A one-wire type fusible link, consisting of an insulated fuse
wire (1) is attached to the battery harness with cable ties.
This is integrated as part of the battery harness and is
located adjace nt to the battery harness po sitiv e term ina l.
Figure 12O – 8
Fuses, Relays and Wi ring Harnesse s Page 12O–8
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1.4 Relays
There are a variety of relay assemblies (1) used in the MY 2003 VY Regular Cab vehicles. The relays are located in the
engine compartment and passenger compartment fuse and relay panel assemblies.
Figure 12O – 9
Passenger Compartment Relays
The passenger compartment fuse and relay panel assembly is located behind the instrument panel lower cover. A label
on the inside of the cover indicates the relay location and the circuits protected by each relay. Refer to Figure 12O – 10.
Figure 12O – 10
Legend
1 R17 – Spare
2 R18 – Relay Assembly – Park Lamps (4 Pi n Micro)
3 R19 – Flasher Assembly – Turn Signal (3 Pin)
4 R20 – Relay Assembly – Accessory Control (4 Pin Mini)
5 R21 – Relay Assembly – Ignition Control (4 P i n Mini)
6 R22 – Relay Assembly – Power Windows (4 Pin Mini)
7 R23 – Relay Assembly – Blower Inhibit (4 Pin Mini)
8 R24 – Relay Assembly – Interi or Illumi nation (4 Pin Mini)
9 R25 – Relay Assembly – Defog (4 Pin Micro)
10 R26 – Spare
11 R27 – Spare
Fuses, Relays and Wi ring Harnesse s Page 12O–9
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Engine Compartment Relays
The engine compartment fuse and relay panel assembly is located forward of the right-hand side front suspension strut
tower. A label on the inside of the cover indica tes the relay location and the circuits protected by each relay. Refer to
Figure 12O – 11.
Figure 12O – 11
Legend
1 R1 – Start Relay (4 Pin)
2 R2 – Blower Relay (4 Pin)
3 R3 – Headlamp Hi-beam Relay (4 Pin)
4 R4 – E.F.I. Relay (4 Pin)
5 R5 – Engine Cooling Fan Relay 2 – [V6] (4 Pin)
Engine Cooling Fan Relay 1 – [V8] (4 Pin)
6 R8 – Horn Relay (4 Pin Micro)
7 R9 – Spare
8 R12 – Spare
9 R10 – Fog Lamp Relay (4 Pin Micro)
10 R13 – Spare (4 Pin Micro)
11 R16 – Fuel Pump Relay (4 Pin Micro)
12 R15 – Spare
13 R11 – A/C Relay (4 Pin Micro)
14 R14 – Headlamp Lo-beam Relay (4 Pin Micro)
15 R7 – Engine Cooling Fan Relay 1 – [V6] (5 Pin)
Engine Cooling Fan Relay 2 – [V8] (5 Pin)
16 R6 – Engine Cooling Fan Relay 3 – [V8] (5 Pin)
Fuses, Relays and Wi ring Harnesse s Page 12O–10
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1.5 Diodes
All vehicles with air conditioning have an air conditioning
compressor clutch suppression diode (1) fitted to the engine
wiring harness.
For location of the air conditioning compressor clutch
feedback diode, refer to the following figures in Section 120
Fuses, Relays and Wiring Harnesses in the MY 2003 VY
and V2 Series Service Information.
a. Powertrain Harness – 3, V6 Engine, item 6.
b. Powertrain Harness – 12, GEN III V8 Engine, item 10.
Figure 12O – 12
Fuses, Relays and Wi ring Harnesse s Page 12O–11
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1.6 Wiring Harnesses
Refer to Figure 12O – 13 for the location of the wiring harnesses used in the MY 2003 VY Regular Cab vehicles. For a
detailed layout of the vario us wiring harnesses and connectors refer to 3 W iring Installation Diagrams.
Figure 12O – 13
Legend
1 Battery Wiring Harness
2 Main Wiring Harness
3 Right-hand Door W i ring Harness
4 Roof Lamp Harness
5 Body Wiring Harness
6 Left-hand Door Wiri ng Harness
7 Powertrain Harness
Fuses, Relays and Wi ring Harnesse s Page 12O–12
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1.7 Wiring Harness Connectors
The majority of the wiring harness connectors used on MY 2003 VY Regular Cab vehicles are of an interlocking design.
The male and female connector bodies, when pushed together, cannot be pulled apart due to the presence of a locking
tang on the connector body. Some connectors have anti-backout combs fitted for increased connector terminal security.
Fuses, Relays and Wi ring Harnesse s Page 12O–13
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1.8 Electronic Control Device Locations
The following figures illustrate the location of the various electronic control devices fitted to MY 2003 VY Regular Cab
vehicles.
Ensure that the precautionary and special handling instructions are followed (where applicable) for each electronic
control device as des cribed in the corresponding section s.
Figure 12O – 14
Legend
1 Fusible Links
2 Relays & Fuses – Engine Compartm ent
3 Cruise Control Module
4 Powertrain Control Module (P CM) – V6 Engine
5 Direct Ignition System (DIS) Module – V6 Engine
6 ABS Hydraulic Modulator
Fuses, Relays and Wi ring Harnesse s Page 12O–14
Page 12O–14
Figure 12O – 15
Legend
1 Relays & Fuses – Instrument P anel
2 Body Control Module
3 Powertrain Control Module – Gen III V8 Engine
4 Steering Wheel Radio & CD Player Control s
5 Powertrain Interface Module (PIM) – GEN III V8 Engine
6 Sensing & Diagnostic Module – Occupant Protection System
7 Ambient Light Sensor
Fuses, Relays and Wi ring Harnesse s Page 12O–15
Page 12O–15
Figure 12O – 16
Legend
1 Door Ajar Warning Switch (2 Places)
2 Radio Assembly
3 Vehicl e Speed Sensor – Manual Transmiss i on
(V6 Shown, V8 Similar)
4 Vehicle Speed Sensor – Automatic Transmission
5 Anti-theft Horn
6 Modular Fuel Pump & Sender Assembly
7 Front Door Speaker Assembly (2 Places)
Fuses, Relays and Wi ring Harnesse s Page 12O–16
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2 Service Operations
All the service operations associated with Fuses, Relays and Wiring Harnesses for MY 2003 VY Regular Cab vehicles
carry over from those described in Section 12O Fuses, Relays and Wiring Harnesses in the MY 2003 VY and V2 Series
Service Informatio n.
Fuses, Relays and Wi ring Harnesse s Page 12O–17
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3 Wiring Installation Diagrams
3.1 Interior Body Wiring Harness
Figure 12O – 17
Fuses, Relays and Wi ring Harnesse s Page 12O–18
Page 12O–18
Legend
1 Body Wiring Harness to Right-hand Front Door Wi ri ng
Harness Connect or (X600)
2 Door Ajar Indicator Switch (S2)
3 Body Wiring Harness to Main Wi ring Harness Connector
(X200)
4 Ground Lead Terminal (X118 – GP7)
5 Rear Window Defog Grid Ground Lead
6 Rear Window Defog Grid Connector (R22-X2)
7 Ground Lead Terminal (X118 – GP13)
A For harness continuat i on, ref er to 3.2 Rear Wiri ng
Harnesses – 1.
B For harness continuat i on, ref er to 5. Wiri ng Inst al l ation
Diagrams – Util ity, Roof Lam p Harness – 2 in MY 2003 VY
and V2 Series Service Information.
C For harness continuat i o n, ref er to 5. Wiring Inst al lation
Diagrams – Util ity, I nterior Body Wiring Harness – 2 in
MY 2003 VY and V2 Series Service Information.
D Harness clipped to underbody as shown.
For views A, B, C and D, refer to 5. Wiring Installation Diagrams –
Utility, Roof Lamp Harness – 1 in MY 2003 VY and V2 Series
Service Information.
Fuses, Relays and Wi ring Harnesse s Page 12O–19
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3.2 Rear Wiring Harnesses – 1
Figure 12O – 18
Fuses, Relays and Wi ring Harnesse s Page 12O–20
Page 12O–20
Legend
1 Body Wiring Harness
2 Rear Body Wiring Harness
3 Fuel Pump Assembly Connector (M8)
A Body wiring harness cli pped to underside of s ubfram e
assembly as shown (1 place).
B Rear body wiring harness c lipped to subframe assembly as
shown (12 places).
C Body wiring harness clipped to subframe assembly as
shown (9 places).
For views C, D, E & F, refer to 3.3 Rear Wiring Harness es – 2.
For views H, I & J, refer to 3.4 Rear Wi ri ng Harnesses – 3.
Fuses, Relays and Wi ring Harnesse s Page 12O–21
Page 12O–21
3.3 Rear Wiring Harnesses – 2
Figure 12O – 19
Legend
1 Rear Body Wiring Harness
2 Rear Body Wiring Harness to Body Wiring Harness
Connector (X403)
3 Body Wiring Harness to Rear Body Wiring Harness
Connector (X403)
4 Body Wiring Harness
5 Rear Wheel Speed Sensor Connector (B76)
A Body wiring harness clipped to subframe assembly as
shown (1 place).
For location of views C, D, E & F, refer to 3.2 Rear Wiring
Harnesses – 1.
Fuses, Relays and Wi ring Harnesse s Page 12O–22
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3.4 Rear Wiring Harnesses – 3
Figure 12O – 20
Fuses, Relays and Wi ring Harnesse s Page 12O–23
Page 12O–23
Legend
1 Licence Plate Lam p Harness
2 Licence Plate Lam p Harness to Rear Body Wiring Harness
Connector (X909)
3 Rear Body Wiring Harness to Licence Plat e Lamp Harness
Connector (X909)
4 Rear Body Wiring Harness to Trailer Wiring Harness
Connector (X908)
5 Rear Body Wiring Harness to Right-hand Tai l Lamp Harness
Connector (X903)
6 Right-hand Tail Lamp Harness to Rear Body Wiring Harness
Connector (X903)
7 Right-hand Tail Lamp Harness
8 Left-hand Tail Lamp Harness
9 Left-hand Tail Lamp Harness t o Rear Body Wiri ng Harness
Connector (X904)
10 Rear Body Wiring Harness to Left-hand Tail Lam p Harness
Connector (X904)
11 Rear Body Wiring Harness
12 Trailer Wiring Harness to Rear Body Wiring Harness
Connector (X38A)
13 Trailer Wiring Harness
14 Trailer Wiring Harness to Right-hand Tai l Lamp Harness
Connector (X38B)
15 Trailer Wiring Harness to Rear Body Wiring Harness
Connector (X908)
16 Trailer Wiring Connector (X109)
For location of views H, I & J, refer t o 3.2 Rear Wiring
Harnesses – 1.