Wiring and Circuit Protection (18.01)
Electric Distribution/E lectronic Control (18.00)
18-1-10 Workshop Manual May 2007
Motor
Diodes
The simplest way of describing a diode is ‘a non return
valve’. The current will flow through the diode from the
anode to the cathode, due to the construction of it though
current cannot come back. Diodes are used to reduce the
possibilities of ‘back feed’. This is where current comes
through the circuit the wrong way for one reason or another.
Below is the circuit symbol for a diode.
Light Emitting Diode (LED)
The light emitting diode (LED) works on the same principal
as the diode. The main difference is that in the
manufacturing process one of the materials is replaced by
another. This replacement mate rial has certain properties
that when a certain voltage passes through it glows.
Transistor
A transistor in simplistic term s is a switch with no moving
parts. The ‘switching’ is controlled by electronics and
currents etc. rather than a physical switch being operated.
Below is the circuit symbol for it. The example shown below
is one of the most common basic type used called a
‘Bipolar’.
Field Effect Transistor (FET)
A field effect transistor (FET) is, in simplistic
terms, a switch with no moving parts. The
‘switching’ is controlled by electronics and
currents etc. rather than a physical switch
being operated. The main difference
between this and the type of transistor shown above is this
one operates using a magnetic field.
Earth / Ground
For an electrical current to ‘flow’ around a circuit it has to
start from a power source and go to an earth / ground. If
there are any breaks in this circ uit then current will not flow,
this is called an ‘Open circuit’
There are 2 types of earth, Signal Earth and Chassis Earth,
these are referred to sometimes as a Quiet Earth and Noisy
Earth respectively.
Some sensors for example specify a Signal / Quiet Earth.
While components such as pumps and motors can have a
Chassis / Noisy Earth. The reason behind this is that pumps,
motors and the like can generate ‘electrical noise’ by the
way of their operation. Some of this ‘electrical noise can be
transferred through wires, it is this ‘electrical noise’ that can
have an adverse effect on sensor signals and affect the
control readings.
Keeping Signal / Quiet and Chassis / Noisy
earths separate reduces th e effect of ‘electrical
noise’ being transferred from component to
component.
This symbol is a standard symbol for earths.
On the circuit diagrams some earths are shown as eyelets
with the description of Earth-**** next to it, the earths also
comply with the 4 digit C number. An example of this is
shown below.
=Anode Cathode
Anode Cathode
LED Colour
Arrow Symbol
indicating light
emission
Wiring and Circuit Protection (18.01)
Electric Distribution/Electronic Control (18.00)
May 2007 Workshop Manual 18-1-11
Maintenance
Forward Harness-Renew
Removal
1. Disconnect vehicle battery.
2. Remove LH headlamp (see Workshop Manual procedure 17.01.AB Headlamp Assembly - LH -
Renew).
3. Remove RH headlamp (see Workshop Manual procedure 17.01.BB Headlamp Assembly - RH -
Renew).
4. Release grommet from body, feed harness from inside of vehicle.
5. Disconnect multiplugs (x2) LH and RH side repeaters.
6. Disconnect multiplugs (x2) LH and RH pad wear indicators.
7. Disconnect multiplug (x2) LH and RH wheel speed sensors.
8. Disconnect multiplugs (x2) LH and RH air flow meters.
9. Disconnect multiplugs (x2) LH and RH headlamp bulb
monitoring resistors.
10. Remove nuts (x6) securing LH and RH earth leads to body (x6).
11. Remove screws (x4) LH and RH harness plate to body and release harness from plate.
12. Remove screen washer reservoir (see Workshop Manual procedure 01.16.DA Reserv oir and Motor Assembly -
Windshield Wash - Renew).
13. Remove fusebox (see Workshop Manual procedure 18.01.KD Fuse Box - Engine Bay - Renew).
14. Disconnect multiplug (x1) purge valve.
15. Disconnect multiplug (x1) ABS modulator.
16. Disconnect multiplug (x1) load level sensor.
17. Disconnect multiplugs (x4) forward harness to cabin harness.
18. Remove wiper motor and linkage (see Workshop Manual procedure 01.16.BA Linkage Assembly - Wiper
- Renew).
19. Remove cross member fr ont latch mounting (see
Workshop Manual procedure 01.14.BD Latch Assembly
- Hood - Renew).
20. Remove nuts (x2) securing earth leads to body (x2).
21. Disconnect multiplug (x1) heated front windshield.
22. Disconnect multiplug PAS sensor.
23. Disconnect multiplugs (x2) A/C compressor. 24. Disconnect multiplug (x1) horn.
25. Release forward harness to engine harness multiplug
(x1) from inner wing and di sconnect multiplugs (x2).
26. Disconnect multiplug (x2) cooling fans.
27. Disconnect multiplug (x1) ambient air temperature sensor.
28. Disconnect multiplugs (X2) crash sensors.
29. Release harness clips (70) and remove harness.
Installation
1. Layout harness around engine bay, feed harness into cabin area and secure grommet.
2. Secure forward harness clips (x70) to body.
3. Connect multiplug (x2) LH and RH side repeaters.
4. Connect multiplug (x2) LH and RH pad wear indicators.
5. Connect multiplugs (X2) LH and RH wheel speed sensors.
6. Connect multiplugs (x2) LH and RH air flow meters.
7. Connect multiplugs (x2) LH and RH headlamp bulb
monitoring resistors.
8. Position earth leads (x6), install and torque tighten nuts (x6).
9. Secure harness to plates (x2) and install plates to body.
10. Connect multiplug (x1) purge valve.
11. Install washer reservoi r (see Workshop Manual
procedure 01.16.DA Reservoir and Motor Assembly -
Windshield Wash - Renew).
12. Install fuse box (see Workshop Manual procedure 18.01.KD Fuse Box - Engine Bay - Renew).
13. Connect multiplug (x1) ABS connector.
14. Connect multiplug (x1) load level sensor.
15. Disconnect multiplug (x4) forward harness to cabin harness.
16. Connect multiplug (x1) heated front screen.
17. Connect multiplug (x1) PAS sensor.
18. Connect multiplugs (x2) A/C.
19. Connect multiplug (x1) horn
20. Position earth leads (x2), install and torque tighten nuts (x2).
21. Secure forward harness multiplug (x1) to inner wing and connect multiplugs (x2).
22. Connect multiplug (x2) cooling fans.
23. Connect multiplug (x1) am bient air temperature sensor.
24. Connect multiplugs (X2) crash sensors.
25. Install cross member front latch mounting 01.14.BD Latch Assembly - Hood - Renew).
26. Install wiper motor and linkage (see Workshop Manual procedure 01.16.BA Linkage Assembly - Wiper -
Renew).
27. Install LH headlamp (see Workshop Manual procedure
17.01.AB Headlamp Assembly - LH - Renew).
28. Install RH headlamp (see Workshop Manual procedure 17.01.BB Headlamp Assembly - RH - Renew).
29. Connect vehicle battery.
Repair Operation Time (ROT)
Warning
To prevent damage to elec trical components, always
disconnect the vehicle battery when working on the
vehicle's electrical system. The earth lead (- ve) must be disconnected first and reconnected last.
Wiring and Circuit Protection (18.01)
Electric Distribution/Electronic Control (18.00)
May 2007 Workshop Manual 18-1-15
4. Disconnect battery.
5. Cut cable ties securing pipes and wires to cylinder (see Fig. 2).
6. Release clips securing hall effect sensors to cylinder,
disconnect sensors and remove cylinder.
7. Release fir tree clip and cab le tie securing pipes and
harness to roof frame.
8. Attach string to cylinder end of both pipes to aid installation.
9. Feed pipes through to tonneau area by carefully guiding through roof mechanism and re lease string (see Fig. 3).10. Cut cable ties securing pipes and wires to cylinder (see
Fig. 4).
11. Release clips securing hall effect sensors to cylinder, disconnect sensors and remove cylinder.
12. Release fir tree clip and cable tie securing pipes and harness to roof frame.
13. Attach string to cylinder end of both pipes to aid
installation.
14. Feed pipes through to tonneau area by carefully guiding through roof mechanism and release string (see Fig. 5).
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Wiring and Circuit Protection (18.01)
Electric Distribution/E lectronic Control (18.00)
18-1-16 Workshop Manual May 2007
15. Remove lower cover RH (screw x1) (see Fig. 6).
16. Cut cable ties securing pipes and wires to cylinder (see
Fig. 7).
17. Release clips securing hall e ffect sensors to cylinder and
disconnect sensors. 18. Remove cable ties securing
pipes/harness to roof frame
(see Fig. 8).
19. Remove screws securing P- clips and strap to frame and
release harness.
20. Remove screw of pipe/harness keeper plate, loosen other and release pipe.
21. Attach string to cylinder end of harness to aid installation.
22. Feed harness through to tonneau area by carefully guiding through roof mechanism and release string (see
Fig. 9).
23. Disconnect heated rear windscreen multiplug.
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Wiring and Circuit Protection (18.01)
Electric Distribution/E lectronic Control (18.00)
18-1-18 Workshop Manual May 2007
29. Remove harness/pipe retaining clips (x3) LH side (see
Fig. 14).
30. Cut cable tie securing valve to bracket (see Fig. 15).
31. Release valve from support bracket, the bracket may need bending slightly. 32. Disconnect multip
lug (see Fig. 16).
33. Cut cable ties securing pipe s to cylinder.
34. Release clips securing hall effect sensors to cylinder, disconnect sensors and remove cylinder (see Fig. 17).
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Wiring and Circuit Protection (18.01)
Electric Distribution/Electronic Control (18.00)
May 2007 Workshop Manual 18-1-21
10. Move tonneau well liner ar ound lower cylinder fixing
and motor casing and secure velcro
11. Install trim clip and positi on tonneau lining stiffening
rod.
12. Install Hall sensors and secure with clips.
13. Secure pipes/wires to cylinder with cable ties.
14. Connect multiplug.
15. Install valve to support bracket, reposition bracket.
16. Install cable tie securing valve to bracket. Ensure no pipes or wiring will foul roof mechanism.
17. Install harness/pipe retaining clips (x9) behind ROPS units.
18. Install harness/pipe re taining clips LH (x2).
19. Install harness/pipe re taining clips RH (x3).
20. Feed harness into passenger compartment and connect multiplugs (LH).
21. Feed harness into passenger compartment, connect multiplugs and secure to body (RH).
22. Connect multiplug (RH).
23. Connect HRW multiplug.
24. Attach pipes to guide string, feed harness through roof frame and remove string.
25. Position Hall sensors to cyli nder and secure with clips.
26. Secure pipes and wires to cylinder with cable ties
27. Install p-clips and strap to harness and secure to frame with screws.
28. Install harness under keeper plate, install and tighten screws
29. Install new clips securi ng pipes to roof frame.
30. Install lower cover.
31. Attach pipes to guide string, feed harness through roof frame and remove string.
32. Position Hall sensors to cyli nder and secure with clips.
33. Secure pipes and wires to cylinder with cable tie.
34. Install new clips securi ng pipes to roof frame.
35. Attach pipes to guide string, feed harness through roof frame and remove string.
36. Position Hall sensors to cyli nder and secure with clips.
37. Secure pipes and wires to cylinder with cable tie.
38. Install new clips securi ng pipes to roof frame.
39. Connect battery.
40. Install Quarter trim LH (see Workshop Manual procedure 01.05.CS Panel Assembly - Quarter Trim
Lower - LH - Renew).
41. Install Quarter trim RH (see Workshop Manual procedure 01.05.CR Panel Assembly - Quarter Trim
Lower - RH - Renew).
42. Restore roof and tonneau to original positionTransaxle Harness-Renew
Removal
1. Remove RH Wheel arch liner (see Workshop Manual procedure 01.02.HB Wheel Arch Liner - Rear - RH -
Renew).
2. Remove rear undertray (see Workshop Manual procedure 01.02.PB Undertray - Rear - Renew).
3. Disconnect transaxle multiplug from body harness.
4. Release harness from RH wheel arch (clips x2).
5. Disconnect LH and RH pad wear sensor multiplug (X2).
6. Disconnect load le vel sensor multiplug.
7. Disconnect LH and RH AB S sensor multiplugs (x2)
8. Disconnect reverse light switch and release harness from transaxle (clips x2).
9. Release harness clips (x23) from subframe and toe control arms.
Installation
1. Secure harness clips (x23) to subframe and toe control arms.
2. Connect reverse light swit ch multiplug and secure
harness clips (x2) to transaxle.
3. Connect ABS sensors
4. Connect load level sensor.
5. Connect pad wear sensor multiplugs.
6. Connect transaxle multiplug and secure harness to wheel arch.
7. Install rear undertray (see Workshop Manual procedure 01.02.PB Undertray - Rear - Renew).
8. Install RH rear wheel arch liner (see Workshop Manual procedure 01.02.HB Wheel Arch Liner - Rear - RH -
Renew).
Repair Operation Time (ROT)
Warning
To prevent damage to electrical components, always disconnect the vehicle battery when working on the
vehicle's electrical system. The earth lead (- ve) must be disconnected first an d reconnected last.
Warning
Always connect the battery earth (- ve) terminal last.
Wiring and Circuit Protection (18.01)
Electric Distribution/Electronic Control (18.00)
May 2007 Workshop Manual 18-1-23
12. Remove nuts (x8) securing RH exhaust manifold to cylinder head, remove ma nifold (see Fig. 5).
13. Remove coil covers (x2).
14. Disconnect multiplugs (x8) to ignition coils (see Fig. 6).
15. Disconnect multiplug to VVT solenoids (x2).
16. Disconnect multiplugs (x8) to Injectors (see Fig. 7).17. Disconnect multiplug (x1) fu
el rail pressure sensor (see
Fig. 8).
18. Remove bolt (x1) purge valve pipe to RH support bracket.
19. Release engine harness from RH support bracket (clips x3).
20. Remove cam cover nut (x1) and bolts (x2) and remove RH support bracket.
21. Release heater hose from heater hose bracket.
22. Release vacuum pipe from heater hose bracket clips (x2).
23. Release harness from heater hose bracket clips (x3).
24. Remove cam covers nuts (x2) and release RH heater hose bracket.
25. Disconnect multiplug (x1) alternator (see Fig. 9).
Fig. 5
Fig. 6
Fig. 7
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Fig. 8
Fig. 9
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Wiring and Circuit Protection (18.01)
Electric Distribution/E lectronic Control (18.00)
18-1-24 Workshop Manual May 2007
26. Disconnect multiplugs (x2) oil pressure and temperature
switches (see Fig. 10).
27. Disconnect multiplug (x1) starter motor (see Fig. 11). 28. Disconnect multiplug (x1) cr
ankshaft sensor (see Fig.
12).
29. Release HEGO engine harn ess connections (x4) from
mounting brackets.
30. Release engine harness from clips (x10) and move harness aside.
31. Release VVT harness clip to cam cover.
32. Disconnect multiplug (x1) inlet air temperature sensor.
33. Disconnect multiplug (x1) throttle body.
34. Disconnect multiplug (x1) condenser.
35. Release engine harness from LH heater hose bracket.
36. Remove cam cover nut (x1) and bolts (x2) and remove
LH support bracket.
37. Release servo hose from bracket clip.
38. Release heater hose fr om heater hose bracket.
39. Remove cam covers nuts (x 2) and release heater hose
bracket.
40. Disconnect breather hose from manifold.
41. Remove bolts (x10) inlet manifold.
42. Release engine harness from clips (x15) and move harness aside.
43. Disconnect multiplugs (x2) from CMP sensors.
44. Disconnect multiplug (x1) air control valve solenoid
connection.
Fig. 10
Fig. 11
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Fig. 12
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