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
• NOTE: The chart shows the electrical connector types, terminal pins/sockets, extractor tip and anti-backout tip.
Electrical connector terminal typePin or socketExtractor tipAnti-backout tip
Mulitlock 040 seriesDA
Mulitlock 040 seriesBA
Mulitlock 070 seriesBB
Mulitlock 040 seriesDB
Econoseal III 070 seriesDB
Econoseal III 070 seriesBB
Econoseal III 070 seriesBB
Econoseal III J2DB
Econoseal III 250 seriesBF
Econoseal III 250 seriesDB
Econoseal III 250 seriesBF
Econoseal III 250 seriesDB
Micro-timer II 1.5mmDC
Micro-timer II 1.5mmBC
Std power timer 4.8 flatDG
Std power timer 5.8 flatBD
Std power timer 5.8 flatBD
Std power timer 2.8 flatDD
Std power timer 4.8 flatDG
Std power timer 5.8 flatBD
Ford 2.8 flatDEH
Mulitlock 070 seriesDB
Mulitlock 070 seriesBB
Junior power timer 2.8 flatDD
Sumitomo TS90 connectorBBH
Modu IV gold platedDB
Mulitlock 040 series gold platedDA
Micro qualockDI
EECVDB
EECVDB
Kostal dia 1.50 seriesDJ
AMP 6.3 flatDB
Junior power timer 2.8 flatDD
2.8 seriesDBI
Sumitomo TS90 connectorDBH
Ducon 0.60 gold platedDK
The BPM electronically controls many vehicle functions. It responds when a switch is actuated by providing output signals to
the appropriate devices, either di rectly or indirectly via relays. In addition the BPM establishes an ISO network link with the
Security and Locking Control Module (SLC M) and utilizes the SCP network to exchange data between the body system
modules.
The following tables are publis hed for guidance purposes and only provide a rough indication of the correlation between
circuit inputs and outputs; due to the complexity and necess ary functional interaction required for the vehicle there are
many circuits where inpu ts and outputs overlap.
Malfunction of modules must always be analyzed using the PDU as recommended in Diagnosis and Testing.
Inputs/outputs
• NOTE: The reverse lights and rear fog lights are NOT controlled by the BPM; refer to Security and Locking Control Module.
Exterior lights circuit
BPM inputs from: BPM outputs to:
Front fog switch Rear fog switch Low beam switch High beam switch Side lights switch Headlamp flash switch Direction indicator switch Hazard switch
Front fog relay Low beam relay High beam relay Side marker and license plate relay Side and tail lights Direction indicators Hazard status bulb Indicators via SCP Front fog Low beam High beam Side light Direction Hazard warning Status LEDS Front fog Rear fog
Driver Door Module (DDM)
Interior lights circuit
BPM inputs from: BPM outputs to:
Header console courtesy light switch
SCPInstrument and switch illumination. Fade 1 (Header console courtesy lamps) Fade 2 (E-post courtesy lamps) Map lights Sun visor lamps Glovebox lamp Trunk lamps
Washer / wiper circuit
Wiper park switch Low screen wash switch Wiper slow speed switch Wiper fast speed switch Wiper intermittent switch Wash/wipe switch
Power wash relay Wiper motor run Screen wash pump Wiper fast/slow speed
Ignition circuit
Ignition position Auxiliary position Transit relay Mirror fold out Mirror fold flat
Central door locking circuit
Central locking button Valet switch SCP (door modules)
Central door locking relay SCP (door modules, security and locking control
module)
Sun roof ECU
Security system circuit
Hood security switch Horn switches Central locking button SCP (door modules, security and locking control
module)
ISO link (key transponder module)
Horn relay Active security sounder Passive security sounder Security status LED Central door locking relay SCP (door modules, security and locking control
module)
ISO link (key transponder module)
Steering column adjustment circuit
Column adjustment switchesColumn tilt motor Column reach motor
Gear shift interlock circuit
Neutral switch J-gate not in park Keylock solenoid Gearshift interlock solenoid
Seat heaters circuit
Seat heater switchesSeat heater relay Status LED
Seat buckle circuit
Seat buckleAudible warning SCP
The DDM is an integral part of the vehi cle security system. In conjunction with the BPM and SLCM via the SCP network, it
controls door locking, interior lighting, door window position and door mirror position. The DDM also provides an interface
via the SCP network, between the driver door switchpack and all door control modules which permits remote control of all
door window positions.
The following table is published for guidance purp oses only; for fault finding, always use the PDU as recommended in
Diagnosis and Testing:
Inputs/outputs
Passenger Door Module (PDM)
The Passenger Door Module provides local control of the pass enger door window position and puddle lamp. Door locking and unlocking is controlled by the BPM via the CDL relay.
The following table is published for guidance purp oses only; for fault finding, always use the PDU as recommended in
Diagnosis and Testing:
Inputs/outputs
DDM inputs from:DDM outputs to:
Driver door switch Driver door switchpack (window switches) Driver door switchpack (mirror switches) Driver door switchpack (memory switches)
Driver door window lift motor Driver rear door window lift motor via SCP Passenger door window lift motor via SCP Passenger rear door window lift motor via SCP Driver door mirror motors Passenger door mirror motors via SCP Driver seat module via SCP
PDM inputs from:PDM outputs to:
Passenger door switch Passenger window lift switch DDM via SCP
Passenger door actuator unlock Passenger door actuator superlock Puddle lamp Passenger door window lift motor BPM via SCP
Driver Rear Door Module (DRDM)
The Driver Rear Door Module provides local control of the driver rear door window position and puddle lamp. Door locking
and unlocking is controlled by the BPM via the CDL relay.
The following table is published for guidance purp oses only; for fault finding, always use the PDU as recommended in
Diagnosis and Testing:
Inputs/outputs
Passenger Rear Door Module (PRDM)
The Passenger Rear Door Module provides local control of th e passenger rear door window position and puddle lamp. Door
locking and unlocking is controlled by the BPM via the CDL relay.
The following table is published for guidance purp oses only; for fault finding, always use the PDU as recommended in
Diagnosis and Testing:
Inputs/outputs
Roof Console Switch Module (RCSM)
DRDM inputs from:DRDM outputs to:
Driver rear door switch Driver rear window lift switch DDM via SCP
Driver rear door actuator unlock Driver rear door actuator superlock Puddle lamp Driver rear door window lift motor BPM via SCP
PRDM inputs from:PRDM outputs to:
Passenger rear door switch Passenger rear window lift switch DDM via SCP
Passenger rear door actuator unlock Passenger rear door actuator superlock Puddle lamp Passenger rear door window lift motor BPM via SCP
Parts List
The Center Console Switch Module comprises the integral switches identified in the illustration above. All switches with the
exception of the Traction Control Switch are connected to BPM inputs. The Traction Control Switch is connected to an ABS
unit input.
ItemPart NumberDescription
1—Central locking switch
2—Valet switch
3—Left hand seat heater switch (where fitted)
4—Right hand seat heater switch (where fitted)
5—Traction control switch (where fitted)
6—Hazard warning switch
Body System - General Information -
Lubricants, Fluids, Sealants and Adhesives
Torques
UnitSpecification
For removal of water-based stains from carpets.'Fibrefresh' carpet shampoo
'1001' Foam Shampoo
'Novatreat'
For removal of grease or oil based stains from carpets.'Genklene' (Trichloroethane)
'Spot Remover'
ComponentNm
Fascia
Instrument pack to support panel1.8
Fascia to support bracket22 - 28
Fascia to console3
Tunnel bracket to body22 - 28
Bolster to tunnel bracket1.5
Instrument pack to fascia3.0
Strut to fascia2.0
Fascia support strut to body7 - 10
CPU bracket to fascia5 - 7
Fascia demister bracket to fascia1.5
Fascia and air con. location to body1.0
Air dist. box duct to air dist. box1.0
Airbag carrier mounting bracket to fascia5 - 7
Instrument pack suppo rt bracket to fascia5 - 7
Airbag bracket to fascia2.0
Air dist. box to fascia2.0
Inst. pack support bracket to fascia5 - 7
Fascia assembly to body22 - 28
Airbag door brackets to fascia5 - 7
Airbag door bracket to fascia and strut4.0
Airbag door bracket to door frame assembly4.0
Hood
Hood lock to body7 - 10
Hood buffer assembly7 - 10
Gas strut - ball pin to weld nut7 - 10
Hood lever5 - 7
Clamp - hood adjust cable6 - 8
Interior
Sun Visor fixings1.8
Sunblind to parcel shelfTighten to prevailing torque.
Sunblind bezel assembly1.0
Coat hook3.0
Seat belts
Front belt buckle to bracket fixing30 - 40
Front belt reel bracket to body fixing30 - 40
Front belt anchor fixing30 - 40
Front belt upper guide fixing7 - 10
Height adjuster to 'B' post screws23 - 27
Height adjuster to seat belt anchor retaining nut30 - 40
Rear inertia belt anchor fixing30 - 40
Rear inertia belt bracket to body fixing30 - 40
Rear inertia belt reel secu ring bracket to body fixing30 - 40
Rear inertia belt buckle bracket to body fixing30 - 40
Sliding Roof Panel
Sliding roof assembly frame to BIW roof4 - 5
Sliding roof panel to frame4 - 5
Trunk
Compact disc autochanger bracket to body9 - 11