ZJ 8W - 01 GENERAL INFORMATION 8W - 01 - 1

8W-01 GENERAL INFORMATION

INDEX
page page

DESCRIPTION AND OPERATION TROUBLESHOOTING TESTS . . . . . . . . . . . . . . . . 6

CIRCUIT IDENTIFICATION . . . . . . . . . . . . . . .... 3 TROUBLESHOOTING TOOLS . . . . . . . . . . . . . . . 5
CONNECTOR/GROUND LOCATIONS . . . . . . .... 1 TROUBLESHOOTING WIRING PROBLEMS . . . . . 6
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . .... 3 SERVICE PROCEDURES
ELECTROSTATIC DISCHARGE (ESD) CONNECTOR AND TERMINAL REPLACEMENT . . 9
SENSITIVE DEVICES . . . . . . . . . . . . . . . . . . . . 5 CONNECTOR REPLACEMENT . . . . . . . . . . . . . . 8
HOW TO USE THIS GROUP . . . . . . . . . . . . . . . . 1 DIODE REPLACEMENT . . . . . . . . . . . . . . . . . . . 11
NOTES, CAUTIONS, and WARNINGS . . . . . . . . . 1 TERMINAL REPLACEMENT . . . . . . . . . . . . . . . . 10
SECTION IDENTIFICATION . . . . . . . . . . . . . . . . . 1 TERMINAL/CONNECTOR REPAIR-MOLEX
SPLICE LOCATIONS . . . . . . . . . . . . . . . . . . . . . . 1 CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . 7
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TERMINAL/CONNECTOR REPAIR—THOMAS
TAKE OUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 AND BETTS CONNECTORS . . . . . . . . . . . . . . . 8
WIRE CODE IDENTIFICATION . . . . . . . . . . . . . . . 2 WIRING REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING SPECIAL TOOLS
INTERMITTENT AND POOR CONNECTIONS .... 5 WIRING/TERMINAL . . . . . . . . . . . . . . . . . . . . . . 11

DESCRIPTION AND OPERATION tions, helpful information, and system diagrams. The
intention is to organize information by system, con-
HOW TO USE THIS GROUP sistently from year to year.
The purpose of this group is to show the electrical
circuits in a clear, simple fashion and to make trou- CONNECTOR/GROUND LOCATIONS
bleshooting easier. Components that work together Section 8W-90 contains connector/ground location
are shown together. All electrical components used in illustrations. The illustrations contain the connector/
a specific system are shown on one diagram. The feed ground number and component identification. Con-
for a system is shown at the top of the page. All nector/ground location charts in Section 8W-90
wires, connectors, splices, and components are shown reference the illustration number for components and
in the flow of current to the bottom of the page. Wir- connectors.
ing which is not part of the circuit represented is ref- Section 8W-80 shows each connector and the cir-
erenced to another page/section, where the complete cuits involved with that connector. The connectors
circuit is shown. In addition, all switches, compo- are identified using the number on the Diagram
nents, and modules are shown in the at rest posi- pages.
tion with the doors closed and the key removed
from the ignition. SPLICE LOCATIONS
If a component is part of several different circuits, Splice Location charts in Section 8W-70 show the
it is shown in the diagram for each. For example, the entire splice, and provide references to other sections
headlamp switch is the main part of the exterior the splice serves.
lighting, but it also affects the interior lighting and Section 8W-95 contains illustrations that show the
the chime warning system. It is important to real- general location of the splices in each harness. The
ize that no attempt is made on the diagrams to illustrations show the splice by number, and provide
represent components and wiring as they a written location.
appear on the vehicle. For example, a short
piece of wire is treated the same as a long one. NOTES, CAUTIONS, and WARNINGS
In addition, switches and other components are Throughout this group additional important infor-
shown as simply as possible, with regard to mation is presented in three ways; Notes, Cautions,
function only. and Warnings.
NOTES are used to help describe how switches or
SECTION IDENTIFICATION components operate to complete a particular circuit.
Sections in Group 8W are organized by sub-sys- They are also used to indicate different conditions
tems. The sections contain circuit operation descrip-
8W - 01 - 2 8W - 01 GENERAL INFORMATION ZJ
DESCRIPTION AND OPERATION (Continued)
that may appear on the vehicle. For example, an WIRE CODE IDENTIFICATION
up-to and after condition. Each wire shown in the diagrams contains a code
CAUTIONS are used to indicate information that (Fig. 1) which identifies the main circuit, part of the
could prevent making an error that may damage the main circuit, gauge of wire, and color. The color is
vehicle. shown as a two letter code which can be identified by
WARNINGS provide information to prevent per- referring to the Wire Color Code Chart (Fig. 2)
sonal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a
vehicle is being serviced.

WARNING: ALWAYS WEAR SAFETY GLASSES FOR

EYE PROTECTION.

WARNING: USE SAFETY STANDS ANYTIME A PRO-

CEDURE REQUIRES BEING UNDER A VEHICLE.

WARNING: BE SURE THAT THE IGNITION SWITCH

ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.

WARNING: SET THE PARKING BRAKE WHEN

WORKING ON ANY VEHICLE. AN AUTOMATIC Fig. 1 Wire Code Identification
TRANSMISSION SHOULD BE IN PARK. A MANUAL
TRANSMISSION SHOULD BE IN NEUTRAL.

WARNING: OPERATE THE ENGINE ONLY IN A

WELL-VENTILATED AREA.

WARNING: KEEP AWAY FROM MOVING PARTS

WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.

WARNING: TO PREVENT SERIOUS BURNS, AVOID

CONTACT WITH HOT PARTS SUCH AS THE RADIA-
TOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATA-
LYTIC CONVERTER, AND MUFFLER.

WARNING: DO NOT ALLOW FLAME OR SPARKS

NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.

WARNING: ALWAYS REMOVE RINGS, WATCHES, Fig. 2 Wire Color Code Chart
LOOSE HANGING JEWELRY, AND LOOSE CLOTH-
ING.
ZJ 8W - 01 GENERAL INFORMATION 8W - 01 - 3
DESCRIPTION AND OPERATION (Continued)
CIRCUIT IDENTIFICATION CONNECTORS
All circuits in the diagrams use an alpha/numeric Connectors shown in the diagrams are identified
code to identify the wire and its function (Fig. 3). To using the international standard arrows for male and
identify which circuit code applies to a system, refer female terminals (Fig. 4). A connector identifier is
to the Circuit Identification Code Chart. This chart placed next to the arrows to indicate the connector
shows the main circuits only and does not show the number (Fig. 4).
secondary codes that may apply to some models.

Fig. 4 Connector Identification

For viewing connector pin outs, with two terminals
or greater, refer to section 8W-80. This section iden-
tifies the connector by number and provides terminal
numbering, circuit identification, wire colors, and
functions.
All connectors are viewed from the terminal end
unless otherwise specified. To find the connector loca-
tion in the vehicle refer to section 8W-90. This sec-
tion uses the connector identification number from
the wiring diagrams to provide a figure number ref-
erence.

TAKE OUTS
The abbreviation T/O is used in the component
location section to indicate a point in which the wir-
ing harness branches out to a component.
Fig. 3 Circuit Identification
SYMBOLS
Various symbols are used throughout the Wiring
Diagrams. These symbols can be identified by refer-
ring to the symbol identification chart (Fig. 5).
8W - 01 - 4 8W - 01 GENERAL INFORMATION ZJ
DESCRIPTION AND OPERATION (Continued)

Fig. 5 Symbol Identification

ZJ 8W - 01 GENERAL INFORMATION 8W - 01 - 5
DESCRIPTION AND OPERATION (Continued)
ELECTROSTATIC DISCHARGE (ESD) SENSITIVE CAUTION: Most of the electrical components used
DEVICES in today’s vehicle are solid state. When checking
All ESD sensitive components are solid state and a voltages in these circuits use a meter with a 10-me-
symbol (Fig. 6) is used to indicate this. When han- gohm or greater impedance.
dling any component with this symbol comply with
• Ohmmeter - Used to check the resistance
the following procedures to reduce the possibility of
between two points of a circuit. Low or no resistance
electrostatic charge build up on the body and inad-
in a circuit means good continuity.
vertent discharge into the component. If it is not
known whether the part is ESD sensitive, assume CAUTION: - Most of the electrical components used
that it is. in today’s vehicle are Solid State. When checking
(1) Always touch a known good ground before han- resistance in these circuits use a meter with a
dling the part. This should be repeated while han- 10-megohm or greater impedance. In addition, make
dling the part and more frequently after sliding sure the power is disconnected from the circuit.
across a seat, sitting down from a standing position, Circuits that are powered up by the vehicle electri-
or walking a distance. cal system can cause damage to the equipment and
(2) Avoid touching electrical terminals of the part, provide false readings.
unless instructed to do so by a written procedure.
(3) When using a voltmeter, be sure to connect the • Probing Tools - These tools are used for probing
ground lead first. terminals in connectors (Fig. 7). Select the proper
(4) Do not remove the part from its protective size tool from Special Tool Package 6807, and insert
packing until it is time to install the part. it into the terminal being tested. Use the other end
(5) Before removing the part from its package, of the tool to insert the meter probe.
ground the package to a known good ground on the
vehicle.

Fig. 7 Probing Tool

Fig. 6 Electrostatic Discharge Symbol INTERMITTENT AND POOR CONNECTIONS

Most intermittent electrical problems are caused
DIAGNOSIS AND TESTING by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a
TROUBLESHOOTING TOOLS problem. Before condemning a component or wiring
When diagnosing a problem in an electrical circuit assembly check the following items.
there are several common tools necessary. These tools • Connectors are fully seated
are listed and explained below. • Spread terminals, or terminal push out
• Jumper Wire - This is a test wire used to con- • Terminals in the wiring assembly are fully
nect two points of a circuit. It can be used to bypass seated into the connector/component and locked in
an open in a circuit. position
• Dirt or corrosion on the terminals. Any amount
WARNING: NEVER USE A JUMPER WIRE ACROSS of corrosion or dirt could cause an intermittent prob-
A LOAD, SUCH AS A MOTOR, CONNECTED lem
BETWEEN A BATTERY FEED AND GROUND. • Damaged connector/component casing exposing
the item to dirt and moisture
• Voltmeter - Used to check for voltage on a cir-
• Wire insulation that has rubbed through causing
cuit. Always connect the black lead to a known good
a short to ground
ground and the red lead to the positive side of the
• Wiring broke inside of the insulation
circuit.
8W - 01 - 6 8W - 01 GENERAL INFORMATION ZJ
DIAGNOSIS AND TESTING (Continued)
TROUBLESHOOTING TESTS
Before beginning any tests on a vehicles electrical
system use the Wiring Diagrams and study the cir-
cuit. Also refer to the Troubleshooting Wiring Prob-
lems section in this section.

TESTING FOR VOLTAGE

(1) Connect the ground lead of a voltmeter to a
known good ground (Fig. 8).
(2) Connect the other lead of the voltmeter to the
selected test point. The vehicle ignition may need to
be turned ON to check voltage. Refer to the appropri-
ate test procedure.

Fig. 9 Testing for Continuity

TESTING FOR A SHORT TO GROUND ON
FUSES POWERING SEVERAL LOADS
(1) Refer to the wiring diagrams and disconnect or
isolate all items on the fused circuit.
(2) Replace the blown fuse.
(3) Supply power to the fuse by turning ON the
ignition switch or re-connecting the battery.
(4) Start connecting the items in the fuse circuit
one at a time. When the fuse blows the circuit with
the short to ground has been isolated.

TESTING FOR A VOLTAGE DROP

Fig. 8 Testing for Voltage (1) Connect the positive lead of the voltmeter to
the side of the circuit closest to the battery (Fig. 10).
TESTING FOR CONTINUITY
(2) Connect the other lead of the voltmeter to the
(1) Remove the fuse for the circuit being checked
other side of the switch or component.
or, disconnect the battery.
(3) Operate the item.
(2) Connect one lead of the ohmmeter to one side
(4) The voltmeter will show the difference in volt-
of the circuit being tested (Fig. 9).
age between the two points.
(3) Connect the other lead to the other end of the
circuit being tested. Low or no resistance means good
TROUBLESHOOTING WIRING PROBLEMS
continuity.
When troubleshooting wiring problems there are
TESTING FOR A SHORT TO GROUND six steps which can aid in the procedure. The steps
(1) Remove the fuse and disconnect all items are listed and explained below. Always check for non-
involved with the fuse. factory items added to the vehicle before doing any
(2) Connect a test light or a voltmeter across the diagnosis. If the vehicle is equipped with these items,
terminals of the fuse. disconnect them to verify these add-on items are not
(3) Starting at the fuse block, wiggle the wiring the cause of the problem.
harness about six to eight inches apart and watch (1) Verify the problem.
the voltmeter/test lamp. (2) Verify any related symptoms. Do this by per-
(4) If the voltmeter registers voltage or the test forming operational checks on components that are
lamp glows, there is a short to ground in that gen- in the same circuit. Refer to the wiring diagrams.
eral area of the wiring harness.
ZJ 8W - 01 GENERAL INFORMATION 8W - 01 - 7
DIAGNOSIS AND TESTING (Continued)
(8) Center the heat shrink tubing over the joint,
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
(9) Secure the wire to the existing ones to prevent
chafing or damage to the insulation
(10) Connect battery and test all affected systems.

Fig. 10 Testing for Voltage Drop

(3) Analyze the symptoms. Use the wiring dia-
grams to determine what the circuit is doing, where
the problem most likely is occurring and where the
diagnosis will continue.
(4) Isolate the problem area.
(5) Repair the problem.
(6) Verify proper operation. For this step check for Fig. 11 Wire Repair
proper operation of all items on the repaired circuit.
Refer to the wiring diagrams. TERMINAL/CONNECTOR REPAIR-MOLEX
CONNECTORS
(1) Disconnect battery.
SERVICE PROCEDURES (2) Disconnect the connector from its mating half/
component.
WIRING REPAIR (3) Insert the terminal releasing special tool 6742
When replacing or repairing a wire, it is important into the terminal end of the connector (Fig. 12).
that the correct gauge be used as shown in the wir-
ing diagrams. The wires must also be held securely
in place to prevent damage to the insulation.
(1) Disconnect battery negative cable
(2) Remove 1 inch of insulation from each end of
the wire.
(3) Place a piece of heat shrink tubing over one
side of the wire. Make sure the tubing will be long
enough to cover and seal the entire repair area.
(4) Spread the strands of the wire apart on each
part of the exposed wire (example 1). (Fig. 11)
(5) Push the two ends of wire together until the
strands of wire are close to the insulation (example
2) (Fig. 11)
(6) Twist the wires together (example 3) (Fig. 11)
(7) Solder the connection together using rosin core
type solder only. Do not use acid core solder.
Fig. 12 Molex Connector Repair
8W - 01 - 8 8W - 01 GENERAL INFORMATION ZJ
SERVICE PROCEDURES (Continued)
(4) Using special tool 6742 release the locking fin-
gers on the terminal (Fig. 13).
(5) Pull on the wire to remove it from the connec-
tor.
(6) Repair or replace the connector or terminal, as
necessary.

Fig. 15 Removing Wire Terminal

(8) Push in the single lock tab on the side of the
connector (Fig. 16).

Fig. 13 Using Special Tool 6742

TERMINAL/CONNECTOR REPAIR—THOMAS AND
BETTS CONNECTORS
(1) Disconnect battery.
(2) Disconnect the connector from its mating half/
component.
(3) Push in the two lock tabs on the side of the
connector (Fig. 14).

Fig. 16 Single Lock Tab

CONNECTOR REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector that is to be repaired
from its mating half/component
(3) Remove the connector locking wedge, if
required (Fig. 17)
(4) Position the connector locking finger away from
the terminal using the proper pick from special tool
kit 6680. Pull on the wire to remove the terminal
from the connector (Fig. 18) (Fig. 19).
Fig. 14 Thomas and Betts Connector Lock Release (5) Reset the terminal locking tang, if it has one.
Tabs (6) Insert the removed wire in the same cavity on
(4) Insert the probe end of special tool 6934 into the repair connector.
the back of the connector cavity (Fig. 15). (7) Repeat steps four through six for each wire in
(5) Grasp the wire and tool 6934 and slowly the connector, being sure that all wires are inserted
remove the wire and terminal from the connector. into the proper cavities. For additional connector pin-
(6) Repair or replace the terminal. out identification, refer to the wiring diagrams.
(7) Install the wire and terminal in the connector. (8) Insert the connector locking wedge into the
Fully seat the terminal in the connector. repaired connector, if required.
ZJ 8W - 01 GENERAL INFORMATION 8W - 01 - 9
SERVICE PROCEDURES (Continued)
CONNECTOR AND TERMINAL REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector (that is to be
repaired) from its mating half/component.
(3) Cut off the existing wire connector directly
behind the insulator. Remove six inches of tape from
the harness.
(4) Stagger cut all wires on the harness side at
1/2 inch intervals (Fig. 20).
(5) Remove 1 inch of insulation from each wire on
the harness side.
(6) Stagger cut the matching wires on the repair
connector assembly in the opposite order as was done
on the harness side of the repair. Allow extra length
for soldered connections. Check that the overall
length is the same as the original (Fig. 20).
Fig. 17 Connector Locking Wedge
(9) Connect connector to its mating half/compo-
nent.
(10) Connect battery and test all affected systems.

Fig. 20 Stagger Cutting Wires

(7) Remove 1 inch of insulation from each wire.
(8) Place a piece of heat shrink tubing over one
side of the wire. Be sure the tubing will be long
Fig. 18 Terminal Removal enough to cover and seal the entire repair area.
(9) Spread the strands of the wire apart on each
part of the exposed wires.
(10) Push the two ends of wire together until the
strands of wire are close to the insulation.
(11) Twist the wires together.
(12) Solder the connection together using rosin
core type solder only. Do not use acid core solder.
(13) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing
(14) Repeat steps 8 through 13 for each wire.
(15) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair.
(16) Re-connect the repaired connector.
(17) Connect the battery, and test all affected sys-
tems.

Fig. 19 Terminal Removal Using Special Tool

8W - 01 - 10 8W - 01 GENERAL INFORMATION ZJ
SERVICE PROCEDURES (Continued)
TERMINAL REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector being repaired from
its mating half. Remove connector locking wedge, if
required (Fig. 21).
(3) Remove connector locking wedge, if required
(Fig. 21).

Fig. 23 Terminal Removal Using Special Tool

(5) Cut the wire 6 inches from the back of the
connector.
(6) Remove 1 inch of insulation from the wire on
the harness side.
(7) Select a wire from the terminal repair assem-
bly that best matches the color wire being repaired.
Fig. 21 Connector Locking Wedge Tab (Typical) (8) Cut the repair wire to the proper length and
remove 1 inch of insulation.
(4) Position the connector locking finger away
(9) Place a piece of heat shrink tubing over one
from the terminal using the proper pick from special
side of the wire. Make sure the tubing will be long
tool kit 6680. Pull on the wire to remove the terminal
enough to cover and seal the entire repair area.
from the connector (Fig. 22) (Fig. 23).
(10) Spread the strands of the wire apart on each
part of the exposed wires.
(11) Spread the strands of the wire apart on each
part of the exposed wires.
(12) Push the two ends of wire together until the
strands of wire are close to the insulation.
(13) Twist the wires together.
(14) Solder the connection together using rosin
core type solder only. Do not use acid core solder.
(15) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
(16) Insert the repaired wire into the connector.
(17) Install the connector locking wedge, if
required, and reconnect the connector to its mating
half/component.
Fig. 22 Terminal Removal (18) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair.
(19) Connect battery, and test all affected systems.
ZJ 8W - 01 GENERAL INFORMATION 8W - 01 - 11
SERVICE PROCEDURES (Continued)
DIODE REPLACEMENT SPECIAL TOOLS
(1) Disconnect the battery.
(2) Locate the diode in the harness, and remove WIRING/TERMINAL
the protective covering.
(3) Remove the diode from the harness, pay atten-
tion to the current flow direction (Fig. 24).

Probing Tool Package 6807

Fig. 24 Diode Identification

(4) Remove the insulation from the wires in the
harness. Only remove enough insulation to solder in
the new diode.
(5) Install the new diode in the harness, making
sure current flow is correct. If necessary refer to the
appropriate wiring diagram for current flow.
(6) Solder the connection together using rosin core Terminal Pick 6680
type solder only. Do not use acid core solder.
(7) Tape the diode to the harness using electrical
tape making, sure the diode is completely sealed
from the elements.
(8) Re-connect the battery, and test affected sys-
tems.

Terminal Removing Tool 6932

Terminal Removing Tool 6934