Electrical System Zones and Connnectors

The entire electrical system is divided into a number of zones. Every such zone is a sub-system, which is a complete cable harness that supplies different electrical components. An electrical zone is in turn connected to the rest of the electrical system by a few large connectors. The sub-systems can in certain cases be pre-installed and then tested prior to factory assembly. Through having a few large cable harnesses, fewer connection points are ensured, which reduces the number of possible sources of faults.

ELECTRICAL ZONE
Connections To (example):
Battery Battery, body ground, engine ground and starter motor 30-supply.

Engine Headlights, cleaner, alarm, outside
compart- temperature sensor, data link
ment connector, Motronic 1.8 control module, vacuum pump for the cruise control system. Contains the main fusebox and the relay and fusebox.

Engine Injectors, ignition coils, throttle position sensor, mass airflow sensor, knock sensor, ignition discharge module, idle air control valve, starter motor, alternator.

ABS Hydraulic modulator, ABS control module, ABS sensor, alarm horn.

Dashboard Combined instrument, switches on control panel, radio
Heater Climate controls, blower motor, resistor/power stage, alarm diode-solar sensor.

Passenger Switches on the tunnel, ignition switch,
compart- wiper lever, horn, courtesy lighting, tank
ment fittings, speed sensor, SRS, antenna cable, electrical operation and heating of front seats. Contains the fusebox and the central relay module.

Doors Power windows and rear view mirrors, central locking, speakers and warning lights.

Ceiling Interior lights, power sunroof.

Parcel Centrally located brake light, defroster,
shelf trunk lighting.

Rear end Tail lights, rear bulb failure sensor, trunk lighting and interval relay on station wagons, license plate light and central locking module on sedans.

On station wagons there is a further electrical zone that is connected to the components in the tailgate

Wiring
New Connectors
The connectors between the cable harnesses are new, although the previous types of components are the same. The new connectors are available in three different sizes for small, large and medium currents as well as a mixture of these that are called hybrid connectors. It is the large connectors that are opened and closed with a screw. When the screw is in the correct position, it is released and produces a clicking sound to acknowledge that the connector is correctly connected. The hybrid connector is 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-and fusebox for the join between the engine compartment wiring and the engine wiring.

A further new connector type is found for beam adjustment and with the alarm switch for the hood.

Cable Terminals And Branching Points
The cable terminals in the new connectors are attached in a new and more reliable way with plastic locking tongues instead of in cable terminals. Some of the wiring branching points ("splices") are also new. These look like normal connectors but contain short-circuit terminals.
NOTE In one and the same branching point certain connections may be made to ground while others are made to battery voltage.

Other Modifications
- To protect and hold the cable harness, cable conduits are used to a greater extent than before, above all on the engine-and passenger compartment harnesses.
- Separate grommets in the firewall have been added intended for cable routing via accessory installation (holes with a plug on the right-hand side and a hole with a "snorkel" on the left-hand side for left-hand drive. On right-hand drive cars. only holes with a plug on the right-hand side