NOTE: The descriptions and specifications contained in this manual were in effect at the time this manual was approved for printing. International Truck and Engine Corporation reserves the right to change specifications or design without notice and
without incurring any obligation.
S08311
p
3-1
Introduction
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 f use to various components is given in cell 13 “Power Distribution”. Full
representation of the ground connections are shown in cell 10 “Grounds”.
Switch Positions (2)
Hot in run
F2.6
5A
C270a31
LB/BK1405
See page
13−8
11C220a
1
4
VT939
15
VT939
7
2
Central Junction Box (CJB)
(14A067)
13−4
12
16
C220a
DG603
C1019
27
DG603
15
1
6
Instrument cluster (10849)
1) Traction control
12) ABS
62−3
4
3
8
LG/YE530
S200
LG/YE530
G104
5
Data Link Connector (DLC)
(14489)
2
See page
14−3
S157
TN/OG914
3
SCP +SCP −
11C135
C25110
See page
14−3
S156
PK/LB915
ABS control
module (2C219)
151−5
7
Within the schematic, all switches, sensors and relays are shown “at rest”
(as i f 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.
p
Component Referencing (4)
Each component on a schematic has a reference to the component location
view or the page where it is shown completely. It is located to the right of
each component.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the r ight hand side of each component.
Any notes that describe switch positions or operating conditions follow the
name. Descriptions of the internals of the component are also included here.
The page where the component appears in full is listed in the Index. The
base part number for a component is listed in parentheses next to or under a
component. These part numbers will appear any place the component name
appears i n the publication.
Internal Name and Function Identification Numbers (6)
Some components on each page have internal symbols with an
identification number l ocated to the right. You can identify the internal
symbol or function by finding the corresponding number under the
component name.
Introduction
3-2
Circuit Function Identifiers (7)
Some components without internal schematics use symbols or text to
describe the function of a circuit in a system.
p
3-3
Introduction
Fuse and Relay Information
Cell 11 “Fuse and Relay Information” contains a view of the fuse-/relay
box in which all fuses and relays are identified.
Fuse and Relay Numbering and Naming
Fuse and relay numbering and naming follow the indication of the fuse
panel cover. In addition, a prefix precedes the fuse number to facilitate
finding the fuse in the Component Location Charts, e.g. “F1.” precedes
Power Distribution Center fuses, and “F2.” precedes Central Junction Box
fuses.
Power Distribution
Cell 13 “Power Distribution” shows the current feed circuit. The current
path is shown from the battery to the ignition switch and to all fuses. It also
shows the circuits protected by each fuse. The circuit is traced from the fuse
to the component. All details (wires, splices, connectors) between the fuse
and t he first component are shown.
F1.12
F1.13
F1.14
F1.15
F1.1
F1.2
F1.3
F1.4
57 BK
F1.24
Battery
G1002
S130
Fusible Link A
1) 12 gauge
2) gray
S131
F1.20
10A
F1.21
20A
F1.23
Power
Distributi
on Center
(PDC)
F1.2
20A
DB/OG
Power
Distributio
nCenter
(PDC)
Instrument
cluster
60−1
Hot at all timesHot at all times
F1.1
30A
RDRD
932
C1041C1021C220
Headlamp,
right
85−1
932
Headlamp,
left
85−1
196
711
Introduction
p
3-4
Ground Distribution
Cell 10 “Grounds” contains the schematics that show the complete details
for each ground connection or main ground splice. This is useful in
diagnosing a problem affecting several components at once (poor ground
connection or ground splice). All details (wires, splices, connectors)
between the ground point and the components are shown. These ground
connection details are shown here in order to keep the individual cell
schematics as uncluttered as possible.
Headlamp,
right (13008)
85−2
C1041C162C152
21 1
BKBK5757BK57
Side lamp , left
front (13411)
92−1
22
BK
57
Fog lamp,
right front
(15200)
86−1
Headlamp,
left (13008)
85−2
C1021C1127
BK57
S102
BKBK
5757
2
Fog lamp,
front left
(15200)
86−1
Side lamp, right
front (13411)
92−1
C1126
G100
151−3
p
3-5
Introduction
Component and Connector Information
Cell 152 “Component Location Charts” helps the user find where the
various items depicted on the schematic can physically be found on the
vehicle. A brief written description of the location is given, along with a
reference t o the component location views.
Cell 151 “Component Location Views” show the components and their
connecting wires as they can be found on the vehicle.
Cell 150 “Connector Views” show the views of the pins and/or cavities of
all connectors. The pin and cavity sides are shown separately as if the
connector were disconnected. The color of the connector housing is
indicated next to the connector number when available. The harness causal
number is located above the component name and below the connector
number or above the connector face itself. Wiring harness designations are
listed in cell 152 “Component Location Charts”. Circuit function charts are
located below each connector.
C150
(BK)
12A581
Wheel speed sensor, left front
(2C205)
PinCircuitCircuit Function
1522 (TN/BK)Wheel speed sensor, left front (2C205) −
2521 (TN/OG)Wheel speed sensor, left front (2C205) +
2
FEMALE
1
C1033
(BK)
(1) −
(2) 1102 (YE/LG)
12B637
42
31
FEMALE
14B102
2
1
MALE
(3) 359 (GY/RD)
(4) −
4
3
p
WARNINGS
!
D Always wear safety glasses for eye protection.
D Use safety stands whenever a procedure requires being under a
vehicle.
D Be sure that the Ignition Switch is always in the OFF position, unless
otherwise required by the procedure.
D Set the parking brake when working on any vehicle. An automatic
transmission should be in PARK. A manual transmission should be in
NEUTRAL.
D Operate the engine only in a well-ventilated area to avoid danger of
carbon monoxide.
D Keep away from moving parts, especially the fan and belts, when the
engine is running.
D To prevent serious burns, avoid contact with hot metal parts such as
the radiator, exhaust manifold, tail pipe, catalytic converter and muffler.
D Do not allow flame or sparks near the battery. Gases are always pres-
ent in and around the battery cell. An explosion could occur.
D Do not smoke when working on a vehicle.
D To avoid injury, always remove rings, watches, loose hanging jewelry
and avoid wearing loose clothing.
Introduction
3-6
Symbols4-1
Distributed splice
Crossed wiring without
connection
Splice
Removable connection
Ground
Connector
Female connector
Male connector
Entire componentResistor
Part of a component
Potentiometer (pressure
or temperature)
Component case directly attached to metal part of vehicle
(ground)
Component with screw
terminals
Connector attached to
component
Connector attached to component lead (pigtail)
Potentiometer (outside influence)
Battery
Fuse
Circuit breaker
Twisted pair
Positive Temperature Coefficient (PTC)
Heating element, Conductor loop
Symbols4
-2
Ignition coil assembly
Solenoid controlled valve
or clutch solenoid
Light emitting diode
(LED)
Capacitor
Variable capacitor
Coil
Hall sensor
Air bag sliding contact
(14A664)
Diode, current flows in
direction of arrow
Transistor
Bifilament lamp
Gauges
Antenna
Permanent magnet,
one−speed−motor
Permanent magnet,
two−speed−motor
Shield
Horn or speaker
Fusible link
Warning
!
Piezoelectric sensor
Lamp
Rotational sensor
Symbols4-3
Wire colors
BK
Black
BNBrown
BUBlue
DBDark blue
DGDark green
GNGreen
GYGray
LBLight blue
LGLight green
NANatural
OGOrange
PKPink
RDRed
SRSilver
TNTan
VTViolet
WHWhite
YEYellow
VREF
Reference voltage
PWR
VBATTVPWRSCP +SCP −
Switched power
signalsignalSignal return
Joint connector
Battery voltageSwitched or
+−
−
module voltage
SIG
RTN
Standard Corporate Protocol (SCP)
data +
Standard Corporate Protocol
(SCP) data −
ground
C1201
GY/RD359
C2003
ISO
Data bus ISO
9141 (K−line)
GroundsignalSignal returnSwitched
jumper
C2004
GY/RD359
C1202
Symbols4
-4
Hot in Start
or Run
910GY/BK
53C240
Circuit number
Pin number
F1.18
15A
See page
13-1
PK329
4C100
57
BK
G100
Power Distribution
Center (PDC)
(14A003)
Other circuits which share
fuse 18, but are not shown,
can be referenced in Power
Distribution
Wire insulation is one
color
Connector reference
number for component
location chart
Ground numbered for
reference to component
location chart
1C125
57BK
See page
10-1
G100
29−1
Transmission
Controls
Windshield wiper
motor (17508)
Other circuits which are also
grounded at G100, but are not
shown, can be referenced in
Grounds
GN/WH329
Wire insulation is one
color with another
color stripe (green
with white)
Reference to another
cell where circuit is
shown completely
359
359
3
GY/RD
GY/RD
Shorting bar
PK329
4C103
Two connections
(pins) in the
same connector
Dashed line indicates terminals
for the same connector
A choice bracket
shows wiring differences between models, countries or options
A
See page
46−2
See page
46−1
A
Cut wires referenced between pages. Arrows
show current flow from
power to ground.
F1.3
10A
Busbar
F1.14
10A
Symbols4-5
Indicates incomplete
internal bussing
Name of com-
Ignition switch
(11572)
3
C3003
12
0) Off
0
1) Acc
12
2) Run
3) Start
Switches that move together
Reference number indicates
12
switch position
Dashed line shows a mechanical connection between
switches
Normally open contact
When coil is energized,
switch is activated
ponent
Details about
component or
operation
Component connector number
non−serviceable components
Hot in Start or Run
Fuel pump relay
DG/YE238
LB/OG238
16
18
33
BK57
4
19
57
LB/RD19
C17517
C175
BK
C2012
Engine
Control
Module (ECM)
(12A650)
Hotatalltimes
F2.23
3A
720
RD/YE
C2205
6
C2204
See page
13−1
S100
LB/RD19
C1351
C1352
BK57
Fuse conditionRelays shown without a connector number are
Central Junction
Box (CJB)
Instrument cluster
6) Illumination
ABS control
module
(2C219)
Name of component
Details about component or
operation
Reference number for internal
component name
Referencetopagewhere
circuit is shown complete
Component connector number
Base service part number
Dashed line indicates terminals for the same connector
Wire insulation is one color
One pole, two position switch
12
G102
Ground numbered for reference to component location
chart
S101
See page
10−1
G101
Splice numbered for reference in component location
chart
Other circuits which are
also grounded at G100,
butarenotshown,canbe
found using the reference
The first digit of every connector, ground,
and splice number used in this publication references
its location within the vehicle.
The chart below describes the different sections of the vehicle, and lists the number associated
with each.
Symbols4
-6
Number
100−199
1000−1999
200−299
2000−2999
300−399
3000−3999
400−499
4000−4999
500−599left front door
600−699right front door
700−799left rear door
800−899right rear door
900−999A, B, C pillars Above door trim panel and
Location
front fascia, hood, front fenders, front axle, Engine compartment, Powertrain (including: axle/
differential/transmission/exhaust system)
Instrument Panel and Center Stack Console,
Steering wheel assembly, front kick panels,
cowl panel (body side)
From instrument panel to rear seat, A, B, C
pillars below door trim panel, center console
Troubleshooting wiring harness and connector hidden concerns
The following illustrations are known examples of wiring harness, splices
and connectors that will create intermittent electrical concerns. The
concerns are hidden and can only be discovered by a physical evaluation as
shown in each illustration.
NOTE: Several components, such as the ECM, utilize gold plated
terminals in t heir connections to the wiring harness. If those terminals need
to be replaced, they must be replaced with a gold plated terminal.
Lock may be displaced into an unlocked
position; pull on the connector to verify the lock.
Connector Repair Procedures5-3
Deformed (enlarged) female terminals
1= Enlarged
2= Normal
Any probe entering the terminal may enlarge the contact spring opening
creating an intermittent signal. Insert the correct mating terminal
(Location A) from the service kit and feel for a loose fit.
Electrical s hort inside the harness
1 =Solder coated wire to ground
2 =Harness protective tape
3 =Intermittent short
Solder coated wire pierced through the insulation of
another circuit