Electrical system - electrical zones and connectors 960

Применимость

DoorRear endParcel shelf (4 door)DoorDoorABSBatteryEngine compartmentHybrid connectorEngine IDashboardHeaterPassenger compartmentRoofDoorThe electric system is divided up into a number of zones. Each electrical zone consists of a subsystem - a cable harness supplying various components. The electrical zone is connected to the rest of the electrical system by means of a few large connectors. The subsystems can, in certain cases be pre-installed and then tested prior to factory assembly. A small number of large cable harnesses means fewer connectors and fewer possible fault sources.

Electrical zone

Connections to (example):Battery Battery, body and engine ground and starter motor 30-supply. Engine compartment Headlamp, cleaner, alarm, outside temperature sensor, data link connector (DLC), horn, Motronic 1.8 control module, vacuum pump for cruise control. Contains main fuse box and integrated relay/fusebox. Engine Injector, ignition coils, throttle position (TP) sensor, mass air flow (MAF) sensor, knock sensor (KS), ignition discharge module (IDM), idle air control (IAC) valve, starter motor, generator (GEN). ABS ABS hydraulic modulator, ABS control module, ABS sensor, alarmhorn.Dashboard Combined instrument panel, switches on control panel, radio. Heater Climate control system, blower fan, blower fan resistor/power unit, alarm LED-sun sensor.Passenger compartment Switches on tunnel, ignition lock, horn, wiper stalk, courtesy lighting, fuel tank unit, vehicle speed sensor (VSS), SRS, antenna cable, front seat power and heating. Contains the fusebox and central relay box.Doors Power windows and door mirrors, central locking, loudspeakers and open door warning lamps.Roof Courtesy lighting, power sun roofParcel shelf Central brake light, defroster, cargo compartment lighting. Rear end Tail lamps, rear bulb failure warning sensor, cargo compartment lighting and intermittent wiper relay on 5 door, license plate lighting and central locking control module on 4 door. Station Wagons have an extra electrical zone connected to the components in the tailgate.

Wiring

New connectors

The connectors between the cable harnesses are new. Although the connections to the components are of the previous type. The new connectors are available in three sizes, for small, medium and large currents as well as a mixture of these which are called hybrid connectors. The large connectors are opened and closed with a screw. When the screw is in the correct position it is released and a "click" sound is heard which confirms that the connectors are correctly connected. The hybrid connectors are used for the 43-pin connector between the engine compartment and the passenger compartment as well as for the 55-pin connector in the relay/fusebox joining the engine cable harness with the engine compartment cable harness.A further new connector is found for beam adjustment and with the alarm switch for the hood.

Cable terminals and junction points

cable terminals in the new connectors are attached in a new more reliable way with plastic locking tongues instead of cable terminals. Some of the cabling junction points ("splices") are also new. These look like normal connectors but contain a short-circuit element.

Примечание: In one and the same junction point certain terminals may be connected to earth, while others are connected battery voltage.

Other modifications:

• Cable conduits have been more extensively used to protect and hold the cable harnesses, in particular the engine and passenger compartment harnesses.
• Separate grommets have been added to the firewall intended for cable routing via accessory installations (holes with plugs on right-hand side and holes with "snorkel" on left-hand side apply to left-hand drive cars. Right-hand drive only holes with plug on the right hand side).