Introduction 1705c003 00 00p01 3-1 Note All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the schematic to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a schematic from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified. Complete Circuit Operation Each circuit is shown completely and independently in one cell. Other components which are connected to the circuit may not be shown unless they influence the circuit operation. Current Flow (1) Each cell normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the page to ground at the bottom of the page. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the schematics. A full representation of the power supply of a fuse or the power distribution from a fuse to various components is given in cell 13 Power Distribution . Full representation of the ground connections is shown in cell 10 Grounds . Switch Positions (2) Within the schematic, all switches, sensors and relays are shown at rest (as if the Ignition Switch were OFF). Splices (3) A dashed line indicates that the splice is not shown completely. A reference is given to the page where the splice appears in full. It is also listed in the Index. C270a 31 15 16 DG603 27 DG603 7 Central Junc- tion Box (CJB) (14A067) 13 4 F2.6 5A See page 13 8 11 C220a Instrument cluster (10849) 1)Traction control 12)ABS 62 3 1 12 4 VT939 15 VT939 C220a C1019 ABS control module (2C219) 151 5 2 TN/OG914 S157 3 C251 10 PK/LB915 S156 11C135 Data Link Con- nector (DLC) (14489) 8 LG/YE530 LG/YE530 G104 Hot in run 14 3 See page 14 3 See page 1 5 4 3 2 6 S200 7 SCP +SCP LB/BK1405 E-Series '04
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3-1 Introduction · 5-1 Connector Repair Procedures Troubleshooting wiring harness and connector hidden concerns The following illustrations are known examples of wiring harness,
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Introduction1705c003 00 00p01
3-1
Note
All wiring connections between components are shown exactly as they existin the vehicles. It is important to realize, however, that no attempt has beenmade on the schematic to represent components and wiring as theyphysically appear on the vehicle. For example, a 4-foot length of wire istreated no differently in a schematic from one which is only a few incheslong. Furthermore, to aid in understanding electrical (electronic) operation,wiring inside complicated components has been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one cell. Othercomponents which are connected to the circuit may not be shown unlessthey influence the circuit operation.
Current Flow (1)
Each cell normally starts with the component that powers the circuit, suchas a fuse or the ignition switch. Current flow is shown from the powersource at the top of the page to ground at the bottom of the page. In order toconcentrate on the essential parts, power supply and ground connections aresometimes simplified by a dashed line in the schematics. A fullrepresentation of the power supply of a fuse or the power distribution froma fuse to various components is given in cell 13 Power Distribution . Fullrepresentation of the ground connections is shown in cell 10 Grounds .
Switch Positions (2)
Within the schematic, all switches, sensors and relays are shown at rest(as if the Ignition Switch were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A referenceis given to the page where the splice appears in full. It is also listed in theIndex.
C270a31
15
16
DG603
27
DG603
7
Central Junc-tion Box (CJB)(14A067)13 4
F2.65A
See page13 8
11 C220a
Instrument cluster (10849)1)Traction control
12)ABS
62 31
12
4
VT939
15
VT939
C220a
C1019
ABS controlmodule (2C219)151 5
2
TN/OG914
S157
3
C25110
PK/LB915
S156
11C135
Data Link Con-nector (DLC)(14489)
8
LG/YE530
LG/YE530
G104
Hot in run
14 3See page
14 3See page
1
5
4
3
2
6
S200 7
SCP +SCP
LB/BK1405
E-Series '04
Symbols4-1
Distributed splice
Crossed wiring withoutconnection
Splice
Removable connection
Ground
Connector
Female connector
Male connector
Component with screwterminals
Connector attached tocomponent
Connector attached to com-ponent lead (pigtail)
Part of a component
Component case directly at-tached to metal part of vehicle(ground)
Entire component Resistor
Potentiometer (pressureor temperature)
Potentiometer (outside in-fluence)
Battery
Circuit breaker
Fuse
Heating element, Con-ductor loop
Positive Temperature Coef-ficient (PTC)
Twisted pair
E-Series '04
Connector Repair Procedures5-1
Troubleshooting wiring harness and connector hidden concerns
The following illustrations are known examples of wiring harness, splicesand connectors that will create intermittent electrical concerns. Theconcerns are hidden and can only be discovered by a physical evaluation asshown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminalsin their connections to the wiring harness. If those terminals need to bereplaced, they must be replaced with a gold plated terminal.
Terminal not properly seated
1=Locked terminal2=Male half3=Female half4=Seal5=Intermittent contact6=Unlocked terminal (Hidden by wire seal)7=Seal
Check for unlocked terminals by pulling each wireat the end of the connector.
E-Series'04
Wiring Harness Overview9-1
E-Series'04
Connector
Grommet
22
27
28
15
17
35
16
1442
1340
39
36
41
740
29
19
18
12
2110
9 24
3130
43
6
32
34
26
4
25
37
3
2
1
33
23
45
11
8
5
20
46
44
Grounds10-1
E-Series'04
Except stripped chassis,Except diesel; G100, G107
Fuel rail cutoffvalve26-9
26-10
26-10
22-1,23-2,24-1,26-10
C12581
BK57
A/C clutchfield coil54-3
C1001
BK57
A/C Compressorclutchdiode54-3
BK57
S1051
S1053
S143
Windshieldwasherpumpmotor(17618)81-3
C1372
BK 57
C1341
Blower motorresistor54-2
C12283
BK57
C17525
G107
C1254
S1069
3
C12542
C100975
875 BK/LB
875 BK/LB
PowertrainControlModule (PCM)
NaturalGasVehicle (NGV)timer jumper
NaturalGasVehicle (NGV)module
(12A650)
G100
875 BK/LB
875 BK/LB
NaturalGas Vehicle
(NGV)
57 BK
57 BK
Seepage
2057 BK
10-5
X
Seepage
570 BK/WH
10-3
B
all others Natural Gas Vehicle (NGV)
Fuse and Relay Information11-1
E-Series '04
Battery Junction Box (BJB) (14A003)
Horn relay C1006
Starter relay C1001 (Diesel)*Trailer tow relay, left turn C120
PCM power relay C1016
Trailer tow relay,parking lamp C1199
Blower motor relay C1011
Trailer tow relay,battery charge C1200
Fuel pump relayC1051
Fuel Injector Control Module (FICM)power relay C1235 (Diesel)
Alternative Fuel ControlModule (AFCM) diode C1319(Natural Gas Vehicle (NGV))
Trailer tow relay,reversing lamp C1178
F1.6 F1.5
F1.4 F1.3
F1.14 F1.13 F1.12 F1.11 F1.10 F1.9 F1.8 F1.7
F1.22 F1.21F1.20 F1.19 F1.18 F1.17 F1.16 F1.15
F1.23F1.24
F1.26F1.27
F1.25
F1.28
F1.1
Accessory delay relay C1002*Trailer tow relay, right turn C119
PCM power diode C1018
*Stripped chassis
Charging System12-1
E-Series '04
Except Diesel
C102aC102b
WH/BK4
21G107
C1100a
Battery(10655)151-8
BK2057
Generator
C102cB+3
1 2
Fusiblelink A
12 gaugeYellow
Fusiblelink B
12 gaugeYellow
YE303YE 303
YE303YE 303
S1008
YE37
BK/OG38
OG/LB35
OG/LB35
LG/RD904
Battery Junc-
Instrument cluster8) Charge indicator18) Battery voltage gauge41) Microprocessor
3)Speed control off5)Set/accelerate8)Coast9)Resume
2200680
Horn/CigarLighter44-1
HotinRun
F2.6
10A
CentralJunctionBox(CJB)(14A068)13-15
X
WH/LB294
LB/BK151
Hornswitch
Airbagslidingcontact(14A664)44-2
18
C218b2
DG/OG848
DG/OG848
C1226
C21917
LB/BK151
5
LB/BK151
Seethispage
Speedcontrol
servo(9C735)
151-2
VPWR SIG
RTN
7
Seepage
Seethispage
120
13-15
X
32 5
0
8
VREF
S124
Illumination
Illumination
? ??
71-2
71-2
CoolingFan33-1
C176c46
F2.2230A
13-4
13-4
YG/BK554
C1158
BN/LG352
6
6
RD/OG229
1
151-9
DB228
4
BN/PK360
2 C1158
25-9
14 C176c22
VPWRFSS
CentralJunctionBox(CJB)(14A067)
PowertrainControlModule(PCM)(12A650)
PowertrainControlModule(PCM)(12A650)
Electronicfanclutch
Diesel
H
Seepage
Hotatalltimes
S1033
25-9
PCMpowerrelay
C1016
C1016
30
87
BatteryJunctionBox(BJB)(14A003)25-1
25-1
Seepage
S1057
25-6
5
RD361
E-Series'04
ShiftLock37-1
E-Series'04
F2.6
10A
Hot in run
CentralJunctionBox(CJB)(14A068)13-12 13-1413-15
S207
G202
BrakeshiftinterlockShiftlocksolenoid
Microprocessor151-21,151-22
BK57
F2.11
15A
Hotatall times
Seepage10-13
C200813
Brakepedalpositionswitch(13480)0)Brakepedal
depressed2)Normalposition
151-21 151-22
0
C2782
C2781
DG569
DG569
16
G207
C2008
2
S286
2
4
Strippedchassis
10-18
Strippedchassis
LG/RD10
C219
Seepage
S174
90-3
ExceptstrippedchassisStrippedchassis
S220
Seepage90-5
WH/LB29424 C219
Seepage
PowerDistribution
S124
13-15
13-12,13-14ExceptstrippedchassisStrippedchassis
WH/LB294
2)
4)
270
2
ABS42-1
E-Series '04
F1.11
60A
BatteryJunction Box(BJB)(14A003)13-8
Hot at alltimes
ABS controlmodule(2C219)151-2 151-3151-4
OG/YE532
2515
603DG
603DG
10
Brake fluid levelswitch (2L414)0)Normal
1)Low
151-2 151-3151-4
32
C124
57
1
BK
See page10-4
C135
530530
24
LG/YE
530LG/YE
G121 Diesel
S147
8
LG/YE
S149
10-6
C135
VBATT
S177
9
VBATT
OG/YE532
OG/YE532
1
Instrument cluster
7)ABS indicator41) Microprocessor
4)Low brake fluidlevel/park brakeindicator
60-2
C220b24
60 C219
512TN/LG
20
531DG/YE
531DG/YE
19
38
4
41
7
512TN/LG
512TN/LG
1733
37
36Strippedchassis
S199 Stripped chassis
10-16
Stripped chassisG114
ISO
C124
S1005
Diesel
S125 Stripped chassis
G100
G105
G105
0 1
VREF
VREF
VREFVREF
70LB/WH
Module CommunicationsNetwork14-1 14-2
Horn/CigarLighter44-1
E-Series'04
C1256Horn151-1
YE/LB
F1.515A
BatteryJunctionBox(BJB)(14A003)
460 YE/LB460
Hornrelay
BatteryJunctionBox(BJB)(14A003)13-5
3 1
5 2 C1006
S121
DB1
DB1
C1449
2 1
H o t a t a l l
times
Seepage13-5
F2.2620A
CentralJunctionBox(CJB)(14A068)13-5
LB/WH40
C21973
C2376
Cigarlighter,front(15055)0)Off1)On
C2031
10
1
Hotatall
times
S229
C20313
BK57
BK57
S207
Seepage10-13
Seepage44-2
Exceptstripped
chassis
Exceptstripped
chassis
C203b10
VehicleSecurityModule(VSM)(15K602)111-3
C21953
54 Strippedchassis
DB1
C218b1
A
Airbagslidingcontact(14A664)
YE/LG6
DB1
C23757
LB/WH40
YE/LB460
S1034
Withremotekeylessentry
13-5
151-21
C1256Horn151-1
1 C1256G202
S163
Seepage10-510-16
S197
G102
G115
Except stripped chassis
Late production Early production
C1006
Strippedchassis
Strippedchassis
AirBags46-1
E-Series'04
WarningThe belt and buckle assemblypretensioner is a pyrotechnic device.Never probe the connectors on the beltand buckle pretensioners. Doing socould result in belt and buckleassembly pretensioner or air bagdeployment and could result inpersonal injury. Always wear safetyglasses when servicing an air bagequipped vehicle and when handlinga belt and buckle assembly pretensioner.
CentralJunctionBox(CJB)(14A068)13-25
151-25
151-24151-24
60-2
Passengersafetybeltretractorpretensioner
Driversafetybeltretractorpretensioner
3 C323
Seepage
G204
10-10
C220b25
BN/LB85
7 C211
BN/LB85
3
4
4 C3134
BK57
Restraintscontrolmodule(14B321)
1082LB/BK
35 C310b36
Instrumentcluster HotinStart
orRun
RD/WH937
12
VBATT
C310a
2 1 C3006
2 1 C3135
1 2 C303
1080LG/BK1079LG/RD
1817
2 1
2 1
C3134
C323
WarningDo not attempt to diagnose ortroubleshoot air bag circuitry withoutconsulting the Workshop Manual.Improper troubleshooting couldcause the air bags to deployinadvertently, causing injury.
Component testing procedures are provided to determine whether a component is good or bad.
Testing information for each component includes a schematic, a view of the terminal locations and step-by-step test procedures. Terminallocations are identified by numbers or letters that may be on the component or next to it.
The component connector MUST BE REMOVED before testing. To test a single circuit within the component, select that circuit under thecolumn"Circuit to test". If you wish to test the complete component, perform all tests.
Connect the tester to the terminals shown in the second column and operate the component as shown in the third column.
Terminals
C1 C1
with molded pin numbering without molded pin numbering
1 2 3 4
5 6 7 8 9 10
1 2 3 4
5 6 7 8 9 10
Numbers molded on the component do not necessarily reflect harness side connector.
ComponentLocationViews151-1
E-Series'04
A
B
C
D
E
F
4 5321
C1043
G102
Park/turnlamp,rightfront(13411)
876
4 5321 876
A
B
C
D
E
FEnginecompartment,front
frontofvehicle
C144
G103
C1256
Horn
C177
CenterAirBagSensor
C1023
Park/turnlamp,leftfront(13411)
C132
Ambientairtemper-aturesensor(19E702)
C1285
Headlamp,right(13008)
C1041
C1284
Headlamp,left(13008)
C1021
C1030
DaytimeRunningLamps(DRL)module
14439
Vehicle Repair Location Charts160-1
E-Series '04
FCS-12128-04E-SERIES
Vehicle Repair Location Codes
TO PINPOINT THE ACTUAL VEHICLE LOCATION OF A REPAIR,THE VEHICLE REPAIR LOCATION CODE IS REQUIRED.For example, an "X" has been placed in the quadrant of thevehicle diagrams indicating the location of the repair. Seediagrams.LOCATION CODE, FOR THE EXAMPLE: A5/FU - (UNDER THEFLOOR OF DRIVER'S LEFT FOOT.)