XJ 8W - 01 GENERAL INFORMATION 8W - 01 - 1 8W-01 GENERAL INFORMATION INDEX page pageDESCRIPTION AND OPERATION INTERMITTENT AND POOR CONNECTIONS . . . . 5 SYMBOLS . . . . . . . . . . . . . . . . . . . . . ......... 3 TROUBLESHOOTING TESTS . . . . . . . . . . . . . . . . 6 ELECTROSTATIC DISCHARGE (ESD) TROUBLESHOOTING WIRING PROBLEMS . . . . . 6 SENSITIVE DEVICES . . . . . . . . . . . . . . . . . . . . 5 SERVICE PROCEDURES HOW TO USE THIS GROUP . . . . . . . . . . . . . . . . 1 WIRING REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . 7 SECTION IDENTIFICATION . . . . . . . . . . . . . . . . . 1 TERMINAL/CONNECTOR REPAIR-MOLEX CONNECTOR/GROUND LOCATIONS . . . . . . . . . . 1 CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . 7 SPLICE LOCATIONS . . . . . . . . . . . . . . . . . . . . . . 1 TERMINAL/CONNECTOR REPAIR—THOMAS NOTES, CAUTIONS, and WARNINGS . . . . . . . . . 1 AND BETTS CONNECTORS . . . . . . . . . . . . . . . 8 WIRE CODE IDENTIFICATION . . . . . . . . . . . . . . . 2 CONNECTOR REPLACEMENT . . . . . . . . . . . . . . 8 CIRCUIT IDENTIFICATION . . . . . . . . . . . . . . . . . . 3 CONNECTOR AND TERMINAL REPLACEMENT . . 9 CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TERMINAL REPLACEMENT . . . . . . . . . . . . . . . . . 9 TAKE OUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 DIODE REPLACEMENT . . . . . . . . . . . . . . . . . . . 10DIAGNOSIS AND TESTING SPECIAL TOOLS TROUBLESHOOTING TOOLS . . . . . . ......... 5 WIRING/TERMINAL . . . . . . . . . . . . . . . . . . . . . . 11DESCRIPTION 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 electricalcircuits in a clear, simple fashion and to make trou- CONNECTOR/GROUND LOCATIONSbleshooting easier. Components that work together Section 8W-90 contains connector/ground locationare shown together. All electrical components used in illustrations. The illustrations contain the connectora specific system are shown on one diagram. The feed name (or number)/ground number and componentfor a system is shown at the top of the page. All identification. Connector/ground location charts inwires, connectors, splices, and components are shown Section 8W-90 reference the illustration number forin the flow of current to the bottom of the page. Wir- components and 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 connectorscircuit is shown. In addition, all switches, compo- are identified using the name/number on the Dia-nents, and modules are shown in the at rest posi- gram pages.tion with the doors closed and the key removedfrom the ignition. SPLICE LOCATIONS If a component is part of several different circuits, Splice Location charts in Section 8W-70 show theit is shown in the diagram for each. For example, the entire splice, and provide references to other sectionsheadlamp 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 thethe chime warning system. It is important to real- general location of the splices in each harness. Theize that no attempt is made on the diagrams to illustrations show the splice by number, and providerepresent components and wiring as they a written location.appear on the vehicle. For example, a shortpiece of wire is treated the same as a long one. NOTES, CAUTIONS, and WARNINGSIn 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 orSECTION IDENTIFICATION components operate to complete a particular circuit. Sections in Group 8W are organized by sub-sys- They are also used to indicate different conditionstems. The sections contain circuit operation descrip-
8W - 01 - 2 8W - 01 GENERAL INFORMATION XJDESCRIPTION AND OPERATION (Continued)that may appear on the vehicle. For example, an WIRE CODE IDENTIFICATIONup-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 thecould prevent making an error that may damage the main circuit, gauge of wire, and color. The color isvehicle. 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 ofgeneral warnings that should be followed any time avehicle is being serviced.WARNING: ALWAYS WEAR SAFETY GLASSES FOREYE PROTECTION.WARNING: USE SAFETY STANDS ANYTIME A PRO-CEDURE REQUIRES BEING UNDER A VEHICLE.WARNING: BE SURE THAT THE IGNITION SWITCHALWAYS IS IN THE OFF POSITION, UNLESS THEPROCEDURE REQUIRES IT TO BE ON.WARNING: SET THE PARKING BRAKE WHENWORKING ON ANY VEHICLE. AN AUTOMATIC Fig. 1 Wire Code IdentificationTRANSMISSION SHOULD BE IN PARK. A MANUALTRANSMISSION SHOULD BE IN NEUTRAL.WARNING: OPERATE THE ENGINE ONLY IN AWELL-VENTILATED AREA.WARNING: KEEP AWAY FROM MOVING PARTSWHEN THE ENGINE IS RUNNING, ESPECIALLY THEFAN AND BELTS.WARNING: TO PREVENT SERIOUS BURNS, AVOIDCONTACT WITH HOT PARTS SUCH AS THE RADIA-TOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATA-LYTIC CONVERTER, AND MUFFLER.WARNING: DO NOT ALLOW FLAME OR SPARKSNEAR THE BATTERY. GASES ARE ALWAYSPRESENT IN AND AROUND THE BATTERY.WARNING: ALWAYS REMOVE RINGS, WATCHES, Fig. 2 Wire Color Code ChartLOOSE HANGING JEWELRY, AND LOOSE CLOTH-ING.
XJ 8W - 01 GENERAL INFORMATION 8W - 01 - 3DESCRIPTION AND OPERATION (Continued)CIRCUIT IDENTIFICATION All circuits in the diagrams use an alpha/numericcode to identify the wire and its function (Fig. 3). Toidentify which circuit code applies to a system, referto the Circuit Identification Code Chart. This chartshows the main circuits only and does not show thesecondary 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 in-line connectors by number, and component connectors by name. If a component has two or more connectors they will be identified as C1, C2, C3...etc. This sections also provides terminal numbering, cir- cuit 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. SYMBOLS Various symbols are used throughout the Wiring Diagrams. These symbols can be identified by refer- ring to the symbol identification chart (Fig. 5). Fig. 3 Circuit IdentificationCONNECTORS Connectors shown in the diagrams are identifiedusing the international standard arrows for male andfemale terminals (Fig. 4). A connector identifier isplaced next to the arrows to indicate the connectornumber (Fig. 4).
8W - 01 - 4 8W - 01 GENERAL INFORMATION XJDESCRIPTION AND OPERATION (Continued) Fig. 5 Symbol Identification
XJ 8W - 01 GENERAL INFORMATION 8W - 01 - 5DESCRIPTION AND OPERATION (Continued)ELECTROSTATIC DISCHARGE (ESD) SENSITIVE CAUTION: Most of the electrical components usedDEVICES 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 resistancethe following procedures to reduce the possibility of between two points of a circuit. Low or no resistanceelectrostatic charge build up on the body and inad- in a circuit means good continuity.vertent discharge into the component. If it is notknown whether the part is ESD sensitive, assume CAUTION: - Most of the electrical components usedthat 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 adling the part. This should be repeated while han- 10-megohm or greater impedance. In addition, makedling 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 probingground 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 insertpacking 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 thevehicle. Fig. 7 Probing Tool Fig. 6 Electrostatic Discharge Symbol INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are causedDIAGNOSIS AND TESTING by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause aTROUBLESHOOTING 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 seatedare 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 fullynect two points of a circuit. It can be used to bypass seated into the connector/component and locked inan open in a circuit. position • Dirt or corrosion on the terminals. Any amountWARNING: NEVER USE A JUMPER WIRE ACROSS of corrosion or dirt could cause an intermittent prob-A LOAD, SUCH AS A MOTOR, CONNECTED lemBETWEEN 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 causingcuit. Always connect the black lead to a known good a short to groundground and the red lead to the positive side of the • Wiring broke inside of the insulationcircuit.
8W - 01 - 6 8W - 01 GENERAL INFORMATION XJDIAGNOSIS AND TESTING (Continued)TROUBLESHOOTING TESTS Before beginning any tests on a vehicles electricalsystem 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 aknown good ground (Fig. 8). (2) Connect the other lead of the voltmeter to theselected test point. The vehicle ignition may need tobe 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 thecircuit being tested. Low or no resistance means good TROUBLESHOOTING WIRING PROBLEMScontinuity. When troubleshooting wiring problems there areTESTING 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 arelamp 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.
XJ 8W - 01 GENERAL INFORMATION 8W - 01 - 7DIAGNOSIS 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, wherethe problem most likely is occurring and where thediagnosis will continue. (4) Isolate the problem area. (5) Repair the problem. (6) Verify proper operation. For this step check for Fig. 11 Wire Repairproper 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 securelyin place to prevent damage to the insulation. (1) Disconnect battery negative cable (2) Remove 1 inch of insulation from each end ofthe wire. (3) Place a piece of heat shrink tubing over oneside of the wire. Make sure the tubing will be longenough to cover and seal the entire repair area. (4) Spread the strands of the wire apart on eachpart of the exposed wire (example 1). (Fig. 11) (5) Push the two ends of wire together until thestrands of wire are close to the insulation (example2) (Fig. 11) (6) Twist the wires together (example 3) (Fig. 11) (7) Solder the connection together using rosin coretype solder only. Do not use acid core solder. Fig. 12 Molex Connector Repair
8W - 01 - 8 8W - 01 GENERAL INFORMATION XJSERVICE 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, asnecessary. 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 6742TERMINAL/CONNECTOR REPAIR—THOMAS ANDBETTS CONNECTORS (1) Disconnect battery. (2) Disconnect the connector from its mating half/component. (3) Push in the two lock tabs on the side of theconnector (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)Fig. 14 Thomas and Betts Connector Lock Release Tabs (4) Insert the probe end of special tool 6934 intothe back of the connector cavity (Fig. 15). (5) Grasp the wire and tool 6934 and slowlyremove the wire and terminal from the connector. (6) Repair or replace the terminal. Fig. 17 Connector Locking Wedge (7) Install the wire and terminal in the connector.Fully seat the terminal in the connector.
XJ 8W - 01 GENERAL INFORMATION 8W - 01 - 9SERVICE PROCEDURES (Continued) (4) Position the connector locking finger away from (3) Cut off the existing wire connector directlythe terminal using the proper pick from special tool behind the insulator. Remove six inches of tape fromkit 6680. Pull on the wire to remove the terminal the harness.from the connector (Fig. 18) (Fig. 19). (4) Stagger cut all wires on the harness side at (5) Reset the terminal locking tang, if it has one. 1/2 inch intervals (Fig. 20). (6) Insert the removed wire in the same cavity on (5) Remove 1 inch of insulation from each wire onthe repair connector. the harness side. (7) Repeat steps four through six for each wire in (6) Stagger cut the matching wires on the repairthe connector, being sure that all wires are inserted connector assembly in the opposite order as was doneinto the proper cavities. For additional connector pin- on the harness side of the repair. Allow extra lengthout identification, refer to the wiring diagrams. for soldered connections. Check that the overall (8) Insert the connector locking wedge into the length is the same as the original (Fig. 20).repaired connector, if required. (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- Fig. 19 Terminal Removal Using Special Tool tems.CONNECTOR AND TERMINAL REPLACEMENT TERMINAL REPLACEMENT (1) Disconnect battery. (1) Disconnect battery. (2) Disconnect the connector (that is to be (2) Disconnect the connector being repaired fromrepaired) from its mating half/component. its mating half. Remove connector locking wedge, if required (Fig. 21).
8W - 01 - 10 8W - 01 GENERAL INFORMATION XJSERVICE PROCEDURES (Continued) (3) Remove connector locking wedge, if required(Fig. 21). Fig. 23 Terminal Removal Using Special Tool (12) Twist the wires together. Fig. 21 Connector Locking Wedge Tab (Typical) (13) Solder the connection together using rosin (4) Position the connector locking finger away core type solder only. Do not use acid core solder.from the terminal using the proper pick from special (14) Center the heat shrink tubing over the jointtool kit 6680. Pull on the wire to remove the terminal and heat using a heat gun. Heat the joint until thefrom the connector (Fig. 22) (Fig. 23). tubing is tightly sealed and sealant comes out of both ends of the tubing. (15) Insert the repaired wire into the connector. (16) Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. (17) Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. (18) Connect battery, and test all affected systems. DIODE REPLACEMENT (1) Disconnect the battery. (2) Locate the diode in the harness, and remove the protective covering. (3) Remove the diode from the harness, pay atten- tion to the current flow direction (Fig. 24). Fig. 22 Terminal Removal (5) Cut the wire 6 inches from the back of theconnector. (6) Remove 1 inch of insulation from the wire onthe harness side. (7) Select a wire from the terminal repair assem-bly that best matches the color wire being repaired. (8) Cut the repair wire to the proper length andremove 1 inch of insulation. (9) Place a piece of heat shrink tubing over oneside of the wire. Make sure the tubing will be longenough to cover and seal the entire repair area. (10) Spread the strands of the wire apart on eachpart of the exposed wires. (11) Push the two ends of wire together until the Fig. 24 Diode Identificationstrands of wire are close to the insulation.
XJ 8W - 01 GENERAL INFORMATION 8W - 01 - 11SERVICE PROCEDURES (Continued) (4) Remove the insulation from the wires in theharness. Only remove enough insulation to solder inthe new diode. (5) Install the new diode in the harness, makingsure current flow is correct. If necessary refer to theappropriate wiring diagram for current flow. (6) Solder the connection together using rosin coretype solder only. Do not use acid core solder. (7) Tape the diode to the harness using electricaltape making, sure the diode is completely sealedfrom the elements (8) Re-connect the battery, and test affected sys- Terminal Removing Tool 6932tems.SPECIAL TOOLSWIRING/TERMINAL Terminal Removing Tool 6934 Probing Tool Package 6807 Terminal Pick 6680
XJ 8W - 02 COMPONENT INDEX 8W - 02 - 3 8W-02 COMPONENT INDEXGENERAL INFORMATIONINTRODUCTION This section provides an alphabetical listing of allthe components covered in group 8W. For informationon system operation, refer to the appropriate sectionof the wiring diagrams.