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8DÐ8 WIRING SYSTEM
5. The wiring harness between engine and chassis
should be long enough (2). Tension of the wire (1) may
causes chafing or damage due to various vibrations.
Splicing Wire
1. If the harness is taped, remove the tape. To avoid wire
insulation damage, use a sewing Òseam ripperÓ
(available from sewing supply stores) to cut open the
harness.
If the harness has a black plastic conduit, simply pull
out the desired wire.
2. Begin by cutting as little wire off the harness as
possible. You may need the extra length of wire later
if you decide to cut more wire off to change the location
of a splice. You may have to adjust splice locations to
make certain that each splice is at least 1Ð1/2Ó
(40 mm) away from other splices, harness branches,
or connectors.
3. When replacing a wire, use a wire of the same size as
the original wire.
Check the stripped wire for nicks or cut stands. If the
wire is damaged, repeat the procedure on a new
section of wire. The two stripped wire ends should be
equal in length.
4. Select the proper clip to secure the splice.
To determine the proper clip size for the wire being
spliced, follow the directions included with your clips.
Select the correct anvil on the crimper. (On most
crimpers your choice is limited to either a small or
large anvil.)
Overlap the two stripped wire ends and hold them
between your thumb and forefinger as shown in the
figure.
The center the spline clip (1) under the stripped wires
and hold it in place.cOpen the crimping tool to its full width and rest one
handle on a firm flat surface.
cCenter the back of the splice clip on the proper anvil
and close the crimping tool to the point where the back
of the splice clip touches the wings of the clip.
cMake sure that the clip and wires are still in the correct
position. Then, apply steady pressure until the
crimping tool closes as shown in the figure.
2
11
Page 2602 of 3573

WIRING SYSTEM 8DÐ9
Before crimping the ends of the clip (1), be sure that:
cThe wires extend beyond the clip in each direction.
cNo strands of wire are cut loose, and
cNo insulation is caught under the clip.
Crimp the splice again, once on each end.
Does not let the crimping tool (2) extend beyond the edge
of the clip or you may damage or nick the wires as shown
in the figure.
5. Apply 60/40 resin core solder to the opening in the
back of the clip as shown in the figure.
Follow the manufacturerÕs instructions for the solder
equipment you are using.6. Center and roll the splicing tape.
The tape should cover the entire splice.
Roll on enough tape (1) to duplicate the thickness of
the insulation on the existing wires.
Does not flag the tape (2). Flagged tape may not
provide enough insulation, and the flagged ends will
tangle with the other wires in the harness as shown in
the figure.
If the wire does not belong in a conduit or other
harness covering, tape the wire again. use a winding
motion to cover the first piece of tape as shown in the
figure.
1
2
12
Page 2603 of 3573
8DÐ10 WIRING SYSTEM
Symbols and Abbreviations
Symbols
Symbol Meaning of Symbol
Fuse
Fusible link
Fusible link wire
Switch
Switch
Contact wiring
Battery
Diode
Electronic parts
Resistor
Speaker
Buzzer
Circuit breakerSymbol Meaning of Symbol
Bulb
Double filament bulb
Motor
Variable register
Rheostat
Coil (inductor), solenoid,
magnetic valve
Relay
Connector
Light emitting diode
Reed switch
Condenser
Horn
Vacuum switching valve
+
–
Switch
(Normal close type)
M
Page 2604 of 3573

WIRING SYSTEM 8DÐ11
Abbreviation Meaning of Abbreviation
A
ABS
ASM
AC
A/C
ACC
A/T
C/B
CSD
DIS
EBCM
ECGI
ECM
ECU
EFE
EGR
4A/T
4WD
FL
FRT
H/L
IC
IGAmpere (S)
Anti-lock brake system
Assembly
Alternating current
Air conditioner
Accessories
Automatic transmission
Circuit breaker
Cold start device
Direct ignition system
Electronic brake control module
Electronic control gasoline injection
Engine control module
Electronic control unit
Early fuel evaporation
Exhaust gas recirculation
4-speed automatic transmission
Four-wheel drive
Fusible link
Front
Headlight
Integrated circuit
IgnitionAbbreviation Meaning of Abbreviation
kW
LH
LWB
M/T
OD
OPT
PCM
QOS
RH
RR
SDM
SRS
ST
STD
SW
SWB
3A/T
V
VSV
W
WOT
W/
W/OKilowatt
Left hand
Long wheel base
Manual transmission
Over drive
Option
Powertrain control module
Quick on start
Right hand
Rear
Sensing and diagnostic module
Supplemental restraint system
Start
Standard
Switch
Short wheel base
3-speed automatic transmission
Volt
Vacuum switching valve
Watt (S)
Wide open throttle
With
Without
Abbreviations
Page 2605 of 3573
8DÐ12 WIRING SYSTEM
Parts for Electrical Circuit
Wiring Ð Wire color
All wires have colorÐcoded insulation.
Wires belonging to a systemÕs main harness will have a
single color (1). Wires belonging to a systemÕs subcircuits
will have a colored stripe (2). Striped wires use the
following code to show wire size and colors.
Example: 0.5 G / R
Red (Stripe color)
Green (Base color)
Wire size (0.5 mm
2)
Wiring Ð Wire Color Coding
Abbreviations are used to indicate wire color within a circuit diagram.
Refer to the following table.
Color Coding Meaning Color Coding Meaning
B Black BR Brown
W White LG Light green
R Red GR Grey
G Green P Pink
Y Yellow LB Light blue
L Blue V Violet
O Orange
1
2
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WIRING SYSTEM 8DÐ13
Wiring Ð Wire Size
The size of wire used in a circuit is determined by the
amount of current (amperage), the length of the circuit,
and the voltage drop allowed. The following wire size and
load capacity, shown below, are specified by AWG
(American Wire Gauge). (Nominal size means
approximate cross sectional area (1).)
Wiring Ð Wire Size Table
Nominal sizeCross sectional Outside diameter Allowable
area (mm2) (mm) current (A)
0.3 0.372 1.5 9
0.5 0.563 1.7 12
0.85 0.885 1.9 16
1.25 1.287 2.2 21
2 2.091 2.7 28
3 3.296 3.6 37.5
5 5.227 4.4 53
8 7.952 5.5 67
15 13.36 7.0 75
20 20.61 8.2 97
1
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8DÐ14 WIRING SYSTEM
Fuse
Fuses are the most common form of circuit protection
used in vehicle wiring. A fuse is a thin piece of wire or strip
of metal encased in a glass or plastic housing. It is wired
in series with the circuit it protects. When there is an
overload of current in a circuit, such as a short of a ground,
the metal strip is designed to burn out and interrupt the
flow of current. This prevents a surge of high current from
reaching and damaging other components in the circuit.
Determine the cause of the overloaded before replacing
the fuse.
The replacement fuse must have the same amperage
specification as the original fuse.
Never replace a blown fuse with a fuse of a different
amperage specification.
Doing so can result in an electrical fire or other serious
circuit damage. A blown fuse is easily identified as shown
in the figure.
Page 2608 of 3573
WIRING SYSTEM 8DÐ15
Fusible Link
The fusible link is primarily used to protect circuits where
high amounts of current flow and where it would not be
practical to use a fuse. For example, the starter circuit.
When a current overload occurs, the fusible link melts
open and interrupts the flow of current so as to prevent
the rest of the wiring harness from burning.
Determine the cause of the overload before replacing the
fusible link. the replacement fusible link must have the
same amperage specification as the original fusible link.
Never replace a blown fusible link with fusible link of a
different amperage specification. Doing so can result in
an electrical fire or other serious circuit damage.
A blown fusible link is easily identified as shown in the
figure.
Normal Blown
Fusible Link Specifications
Type Rating Case Color Maximum Circuit Current (A)
Connector 30A Pink 15
Connector 40A Green 20
Bolted 50A Red 25
Bolted 60A Yellow 30
Bolted 80A Black 40