Wiring Harnesses - Wiring Harness
Description and Operation
Introduction
CAUTION: Do not use any other heat shrink sleeve other than the approved glue lined heat shrink sleeve mentioned
in the repair procedure.
The purpose of this document is to promote quick and efficient minor repair to harness connectors or cables using approved
methods and the wiring harness repair kit. Repairs may only be made to cables and connectors which have been
mechanically, not electrically damaged. It also applies wher e the whole extent of the damage can be clearly identified and
rectified.
Care and neatness are essential requir ements in making a perfect repair.
Caution:
At the time of this first issue of the Harness Repair Guide, do not approve re pairs to any of the following circuits:
Any media orientated system transport network harnesses. Supplement restraint system (SRS) firing circuits (Air bags). Link lead assembles, which are unique to safety critical circuits such as anti-lock brake system (ABS) and
thermocouple circuits. An example of this is the ABS wheel speed sensors with moulded connectors.
4. Screened cables, leads and wiring harness(s).
If any harness(s) with defective electrical connector te rminals or wires from the above circuits are a concern,
new components must be installed.
Repair Kit
CAUTION: Where the repair procedure indica tes that a glue lined heat shrink sleeve should be applied, apply sufficient
heat to the glue lined heat shrink to melt the glue in order to provide a water tight seal. Do not over heat the glue lined
heat shrink sleeve so that the wiring harness insulation becomes damaged.
The wiring harness repair kit has been produced which comprises:
Pre-terminated wiring harness(s) of different sizes and types Three sizes of butt splice connectors A selection of colored cable identification sleeves Two sizes of glue lined heat shrink sleeves Crimping pliers A wire cutter and insulation stripper An electrical connector terminal extraction handle and tips
A suitable heat source, fo r shrinking heat shrink sleeves will be required.
The pre-insulated diamond grip range of el ectrical connector terminals and in-line, butt splice connectors contained within
the wiring harness repair kit are the only acceptable product for the repairs of wi ring harnesses. The butt connectors not
only grip the wire but also the insu lation, making a very secure joint.
If an electrical connector terminal is not included in the wiring harness repair kit then approval for the repair is NOT given
and in these circumstances a new wi ring harness must be installed.
Pre-Terminated Wiring Harness( s) and Butt Splice Connectors
All pre-terminated wiring harness(s) and butt splice connectors in the wiring harness repair kit are contained in bags which
can be resealed after use. Each bag is marked with the part number of the items stored within the bag. Each storage
compartment in the wiring harness repair kit is identified with the corresponding part number. Make sure that pre-
terminated wiring harness(s) and connectors are not mixed up it is advisable to only open one bag at a time and to reseal
sliding roof finisher and clips. Carpet covered trims line the trunk and are secured by fir tree fasteners to the sides and fro nt inner panel.
Rear View Mirrors
The.interior rear view mirror is an electrochromic unit that automatically da rkens to prevent glare from following vehicle
lights. This automatic function is selected by pressing the switch at the bottom of the mirror. Pressing the switch again
cancels this function. An LED then illuminates when automatic dipping is operative. The light sensing unit for the Night
Sentinel automatic lamp operating system is also incorporated in the mirror casing.
The door mirrors are cheater mounted, colo r-keyed units, remote electrically adjustable and heated. Adjustment of both
mirrors is carried out from the driver's door switchpack.A slider switch selects the mirror to be adjusted, and a disc switch
adjusts the selected mirror to the required position. Mirror ad justment can only be made when the ignition switch is in
position I or II or the driver's door is open, and the selector switch is moved from the central position. The door mirrors also
automatically darken under control of the electrochromic interior rear view mirror. Mirror heating elements operate on
selection of backlight heating.
Automatic dipping of passenger door mirror for kerb view when reversing, is fitted as part of the memory pack. With the
ignition switch in position II, the mirror selector switch in the left or right position and reverse gear selected, automatic
dipping is initiated by moving the mirror toggle switch rearwards and releasing. On receipt of the dip signal, the passenger
door mirror is driven downwards either 7 degrees, bottom of travel, or 4,5 to 5,5 seconds, whichever occurs first.
Subsequent rearward movement of the toggle switch achieves further dipping of the mirror in the same increments and
sequence. The mirror can be manu ally returned to the normal memorised positi on by moving the toggle switch forward with
reverse gear selected. The mirror will auto matically return to memorised position on deselection of reverse gear, or moving
ignition switch from position II.
Door mirror fold-back where fitted, to facilitate parking in conf ined spaces, can be initiated when the ignition switch is in
position I or II, the mirror selector switch is in the centra l position and vehicle speed is below 19 km/h (12 mph). Mirror
fold-back is then initiated by moving the toggle switch rear wards and releasing it. The door mirrors are returned to the
normal driving position by agai n moving toggle switch rearwards. There is no speed constraint on this operation. In the
event of a fold-back mirror becoming 'out of position' due to acci dental impact, it must only be re-positioned by initiating
the fold-back sequence.
Loss of power supplies will result in loss of mirror fold-back memory. In the event of such a memory loss with mirrors in the
normal position, fold-back will operate on second movement of the toggle swit ch. On loss of memory with mirrors in the
fold-back position, they will return to the no rmal position on next fold-back operation.
Bumpers
Each bumper comprises a beam mounted to the body via two strut assemblies, and a moulded polypropylene cover
incorporating side armatures and chrome plated blades. Each strut is secured to the BIW by three bolts and supports the
beam on a single bolt/height adjuster. The front bumper cover which is moulded to form a lo wer air intake for the cooling
pack, also incorporates left and right handed twin fog lamps, brake coolin g ducts. Side marker lamps fitted for some
markets serve only as reflectors for UK and Europe. A plastic undertray secured to the lower edge of the front bumper,
improves airflow and minimises the ingres s of road grime in that area. Standard bumpers have glass mat thermoplastic
(GMT) beams mounted on GMT struts. For certain markets, aluminium bumper beams are installed on menasco energy
absorbing struts. Whilst both types of front bumper provide a fu lly integrated 'soft front end' that satisfies bumper impact
requirements, the energy absorbing front and rear bumpers are further designed to withstand 5mph (8kph) impacts with no
visible damage sustained. Side markers/re flectors, and direction indicators are designed for ease of ac cess from the outside
of the bumper. For adjustment and bulb change, the fog lamps are accessed from th e bumper interior. The bumper covers
are body coloured and matched. Replacement covers are supplied complete with side armatures and are finished in primer
Trunk
The trunk houses the spare wheel, the battery, an electrical carrier containing electrical fuses, relays and modules and a
compact disc auto-changer attached to body bracketry. The trun k is fitted with push-fit liners to the sides and front inner
panel.The carpet covered floor is in two removable sections, one covering the spare wheel and wheel changing equipment,
the other covering the battery and electrical carrier. The front and rear edges of the floor board loca te in blocks on the fuel
tank backboard and the rear of the body , which provide two height settings to accommodate the difference in thickness
between the space saver and full sized spare wheels. A moulded finisher covering the rear of the trunk below the sill is
secured to the rear panel by tabs and fir tree fasteners. Finisher panels fitted over the rear lamp units provide for access
from the trunk. Finisher panels fitted to the rear lamp units provide trunk inte rior access to the lamps. The trunk lid
underside is fitted with a removable mo ulded liner and two trunk illumination light s. Trunk locking is based on a central
latch and striker, operated electrically through the central lo cking system by an adjacent actuator or by key in a barrel lock
Installation
16. Remove handbrake trim finisher. Refer to 76.13.63.
17. Move gear selector to position'R'.
18. Slacken and remove nut securing gear selector inner cable to
'J' gate stud.
19. Slacken gear selector outer cable adjustme nt nut at front of
support bracket.
20. Release cable from'J' gate an d position to pemit carpet
withdrawal.
21. With assistance lift and remove carpet, exercising care to
avoid damaging adjacent fittings.
1. With assistance, position carpet in vehicle ensuring that seat
harness and handbrake lever are correctly positioned in
apertures.
2. Ensure that
gear selector is in position 'R'.
3. Inst
all gear selector cable in 'J' gate.
1. Position gear selector cable in support bracket.
2. Connect inner cable to 'J' gate stud and fit and
tighten securing nut.
4. Adjust
gear selector cable.
1. Adjust selector cable nuts so that selector lever freely
moves to 'R' position in gate.
2. Tighten gear selector ca ble locknut, ensuring that
tabwasher tangs engage in bracket slots.
5. Ensure that
gear selector cable
to tunnel grommet is correctly
seated.
6. Fit and secure handbrake trim finisher. Refer to 76.13.63.
7. Fully seat carpet side and rear retaining clips.
8. Fit front sill treadplates. Refer to operations in this section.
9. Fit rear sill treadplates. Refer to operations in this section.
10. Position and fully seat rear heel boards and rotate 1/4 turn
fasteners to secure.
11. Install console heater ducting and fit and tighten securing
screw.
12. Fit 'B' post trim pads. Refer to operations in this section.
13. Fit lower 'A' post trim pads. Refer to 76.13.30.
14. Fit centre console asse mbly. Refer to 76.25.01.
15. Fit fascia centre ve nt veneer panel. Refer to 76.47.06.
16. Fit centre console finisher vene er panel. Refer to 76.47.26.
17. Fit 'J' gate surround. Refer to 76.25.24.
18. Fit rear seat cushion. Refer to 76.70.37.
19. Fit front seats. Refer to 76.70.01.
20
.
Connect ground cable to batt ery terminal and fit battery
cover. Refer to 86.15.15.
Instrument Panel and Console - Floor Console
Removal and Installation
Removal
1. Turn ignition switch to posi tion II and apply footbrake.
2. Move gear selector to the the 'D' position. and release
footbrake.
3. Turn ignition switch to position'O'
4. Remove battery cover and disc onnect ground cable from
battery terminal. Refer to 86.15.19.
5. Where fitted, remove centre cons ole rear extension. Refer to
76.25.05.
6. Remove fascia centre veneer panel. Refer to 76.47.06.
7. Using a thin plastic lever, ca refully release the rear air
distribution control grill tang s at top and sides and remove
grill complete with veneer panel and control.
8. Disconnect cigar lighter and ashtray illumination harness
(white) multiplug at RH rear. of console.
9. Slacken and remove the two co nsole rear securing screws.
10. Remove 'J' gate finisher and veneer panel. Refer to 76.25.24
and 76.25.26.
11. Remove fascia centre veneer panel. Refer to 76.47.06.
Instrument Panel and Console - Floor Console Finish Panel
Removal and Installation
Removal
1. Apply handbrake and turn ignition key to II.
2. Depress brake pedal, move gear selector to position N and turn
ignition key to O.
3. Remove battery cover and di sconnect cable from earth
terminal. Refer to Section 86.15.19.
4. Remove 'J 'gate finisher. Refer to 76.25.24.
5. Slacken and remove the two nuts and two screws securing
the retaining panel.
6. Position retaining panel for access, disconnect SPORT mode
and cruise control ON/OFF swit ch multiplugs and remove
retaining panel complete with switches.
7. Remove and discard bushes from retaining plate.
8. Carefully withdraw veneer pane l, releasing front locating
tongue from upper slot in comsole.
Wipers and Washers - Wipers and Washers
Description and Operation
Windshield Wiper
The single wiper system is driven via a sh ort linkage, by an electric motor installed in (external on later models) a moulded
plastic weatherproof housing o ff the plenum wet area. The motor and housing are secured to the BIW bulkhead by three
bolts at the top and three screws (two on later models) with locking clips at the bottom. The complete assembly is handed
for left or right hand drive installation.
The windshield wiper is operated via the RH control column stalk switch. Operating modes are normal, high speed, flick wipe
and six settings of intermittent operation with delays ranging from 2 to 20 seconds.
Windshield Washer
The windshield washer is of wiper arm mounted running jet configuration. The je t assembly comprises two conventional
nozzles plus four nozzles of silicone rubbe r 'duckbill' design. If the system is initially operated at low ambient temperatures ,
the 'duckbill' nozzles permit an y frozen residual washer fluid to be ejected un der pump pressure. The washer jet feed tube
supplied assembled to the wiper ar m, fits at its lower end onto a central connector on the pl enum cover. Washer fluid is
conveyed by a rubber tube, from the washer pump to the jet assembly via a manifold on the underside of the plenum cover.
The windshield washer pump is installed on the rear face of the washer fluid reservoir. The 6.3 liter washer reservoir is
installed on the RH side of th e vehicle in a cavity formed by the front bu mper, the front wheel arch liner and the brake
bumper cover and remove both lamps from cover.
14. Release sidemarker lamp/refle ctor clips and remove both
lamps/reflectors from bumper cover.
15. Remove direction indicators fr om bumper assembly. Refer to
Section 417.01.
16. Remove powerwash jet assemb lies and hoses from top of
bumper assembly. Refer to Section 501-16.
17. Remove bumper blades.
1. Slacken and remove three screws securing each blade
to bumper cover.
2. Slide each blade forward to release two side tangs from cover and remove blade from bumper.
18. Rotate three splitter vane fasteners 1/4 turn counter-
clockwise and remove splitter vane from air intake.
19. Release tangs securing brake cooling ducts to cover and
remove ducts from bumper.