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Note 4

Note 5

Note 6

Note10

Note 14

Note 16


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DC resistance between battery and ECU should be minimised to avoid volt drops at a peak current of approximately 10Amps. A value of 40mOhms (total) is recommended. The splice should be as close to the ECU as possible. All power supply lines must insure disconnects do not occur for longer than 400us. DC resistance between battery and ECU should be minimised to avoid volt drops at a peak current of approximately 20Amps. A value of 40mOhms (total) is recommended. LOCAL Ground connection should be made within 200mm of ECU to conform with CISPR 25 recommendations. The splice should be made as close to the ECU as possible. Minimum wire thickness is to be 8AWG. Combustion noise sensor connections should be made with screened wire. Total capacitance not exceeding 450pF. Under no circumstances should the screen be connected to chassis. The screen should be continuous and in-line connectors avoided. The screen should start and finish as close as possible i.e. < 50mm.Vehicle variations should be minimised. For screen definition, see EMC Recommendation Table CPS wires should be twisted together throughout their length. A minimum of 33 twists per metre. Twist should start and finish as close to connectors as possible i.e. < 50mm. For twisted definition, see EMC Recommendation Table. All RPS wires should be twisted together throughout their length. A minimum of 33 twists per metre. Twist should start and finish as close to connectors as possible i.e. < 50mm. Harness length should less than 2 metres. For twisted definition, see EMC Recommendation Table. All RPS wires must insure disconnects do not occur for longer than 40 us. Injector wires should be twisted together throughout their length. A minimum of 33 twists per metre. Twist should start and finish as close to connectors as possible i.e. < 50mm. Total DC resistance should be between 100 and 200mOhms at 20OC. All injector pairs should be within 15mOhms of each other. For twisted definition, see EMC Recommendation Table. Where fitted SCP wires should be twisted together throughout their length. A minimum of 33 twists per metre. Twist should start and finish as close to connectors as possible i.e. < 50mm. For twisted definition, see EMC Recommendation Table Where fitted CAN wires should be twisted together throughout their length. A minimum of 33 twists per metre. Twist should start and finish as close to connectors as possible i.e. < 50mm.This feature is only required for development. For twisted definition, see EMC Recommendation Table. The positive feed to higher current inductive loads (where applicable IMV, SOST and EGR) should, ideally, be separately connected to the battery in order to avoid inductive load currents in the ECU supply connection. These wires should be as short as possible. See Diagram 1 (Below) CID wires must insure disconnects do not occur for longer than 10 us.

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ECU Ground(2) Power R ela y Drive Key S ens e Injector (1-4) High S ide Drive Injector (1-4) Low S ide Drive Inlet Metering Va lve S upply Inlet Metering Va lve Drive R ail Pres s ure S ens or S upply R ail Pres s ure S ens or S ens e R ail Pres s ure S ens or R eturn Cra nks ha ft Angular S ens or S ens e Cra nks ha ft Angular S ens or R eturn Camsha ft Angula r S ensor S upply Camsha ft Angula r S ensor S ens e Camsha ft Angula r S ense R eturn Accelerometer S ens or S ense Accelerometer S ens or R eturn Accelerometer S ens or S creen

< 500 m A DC A few m A DC < 26.5 A ins tanta neously < 26.5 A ins tanta neously 1.2 A DC 1.2 A DC 15 m A DC A few m A DC 15 m A DC A few m A DC A few m A DC 20 mA DC (typical va lue) A few m A DC 20 mA DC (typical va lue) < 1 mA < 1 mA ?

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Feature Power Hold Relay Cooling Fan Relay Cooling Fan Relay Glow plug Control Condenser fan Relay A/C Clutch Relay Battery Vehicle speed sensor

Component Part Number Customer Specified Customer Specified Customer Specified Customer Specified Customer Specified Customer Specified Customer Specified Customer Specified

JMC ref.

Connector Part Number

Terminal Part Number

Pin out function coil coil coil coil ref 2 2 2 2

ECU 9 80 81 113 79

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Customer Specified

Customer Specified

VPWR VSS
RTN

B2

Cylinder head temperature

Prt No 15336564

B5

B7

Cruise ctrl Decel Set-switch Cruise ctrl resume-switch Cruise ctrl Accel/set-switch Cruise ctrl on/off-switch Cruise ctrl safety contact-switch Combustion Noise Sensor

Customer Specified

Bosch 1 928 403 698 (2 pole, coding 1) Delphi 15397337 Customer Specified

929 939-3 0.5mm1.0mm JPT tin plated delphi 1534 4661 Customer Specified

CHT CHTRTN

SUPPLY 1 SIG 3 GND 2 2 1

51 36 75 101 102 67 50 31 17 18 45 46

Delphi 25348219

Delphi connector 15397337 Bosch 1 928 403 698 (2 pin, coding 2/3)

Tyco Junior Power Timer 2.7/2.9mm Wide x 0.77/0.83mm Thick 2-929-939-1 Brass Terminals Gold Plated Delphi No 1542 6999
Tyco Junior Power Timer Delphi 15426999

CNS CNSRTN

1 2

B8

Crank position

Delphi 10456604

Delphi connector 15397337 Bosch 1 928 403 698 (2 pole, coding 1) Delphi connector 12059595 Packard 12059595 FCI half shroud with ribs 211PC022S5049 FCI half shroud with ribs 211PC032S7061

B9

Camshaft Identification Sensor

Delphi 25353641

B10 B11

Fuel temperature Rail pressure

2-929 939-1 0.5mm2-1.0mm2 JPT Gold plated Gold Terminals 15366078 and lock 12052845 Seal 12048086 FCI 211CC2S1160 AMP MCP sensor 1,5 Gold 929027-1 or FCI 211CC2S1243 Tyco Junior Power Timer 2-929 939-1 0.5mm2-1.0mm2 JPT Gold plated Tin plate Delphi prt No 12048074 seal 12048086 lock 12052845 Delphi 12103881

VRSVRS+

2 1

82 90

VCC O/P GND FTS FTSRTN FRP FRP5V FRPRTN APP1 O/P APP2 O/P APP1 (+) APP2 (+) APP1 (-) APP2 (-) MAP MAP5V MAPRTN

1 3 2 1 2 1 3 2 4 1 3 2 5 6 4 3 1

111 103 104 109 110 25 6 26 71 32 72 51 53 70 99 108 100

B12

Pedal position (BOSCH pedal)

BOSCH 280 B00 379 2003-12-04/02

JPT 928-403-204

B13

Manifold Air Pressure Sensor

09373269

Delphi connector 12129946 type 102 (GT 15397396)

B15

B16

Water in Fuel Sensor

Delphi RFW-2038

AMP 282110-1 (TERM) AMP 880811-2 (BOOT) AMP 281934-3 (SEAL)

+12V O/P GND

1 2 3

40 14

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12129596

Delphi 12162197 (GT 15335987 PA6 30%) 15355319 PBT 20% AMP 282087-1

IMAT IMAT

2 1

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Y8

Y7

Y6

Y5

Y4

X1

L2 L4 L5

L1

S1 S2 S3 S4 S5 S6 S7 S8 A2

Check engine lamp

Inlet metering valve

Corporate diagnostic Connector J1962

Fuel injector #CYL2

Fuel injector #CYL3

Fuel injector #CYL4

Fuel injector #CYL1

A/C Request Switch A/C Pressure Switch A/C Temperature Switch Key-switch Brake Pedal switch B00 Cruise Control Brake Switch Clutch Switch Provisional Cruise Control Clutch Switch ECU

Glow plug lamp Cruise control lamp Water in fuel

TBC

TBC

TBC

TBC


AMP 179631-2 FCI 240 PC024 S8014. FCI 240 PC024 S8014. FCI 240 PC024 S8014. FCI half shroud 211PC022S1049 FCI 240 PC024 S8014.

AMP 1355771-1 AMP 1355773-1 Alternative assy # 0-1452826-1

AMP 776001

FCI 211CC2S1460

Gold plated contacts FCI: 6000 1534 seals 6099 3928 Gold plated contacts FCI: 6000 1534 seals 6099 3928 Gold plated contacts FCI: 6000 1534 seals 6099 3928 Gold plated contacts FCI: 6000 1534 seals 6099 3928

AMP 1326028-5 AMP 1326032-4

GROUND ISO K - Line +12V CAN high CAN low VPWR IMV INJ-H INJ-L

INJ-H INJ-L

INJ-H INJ-L

INJ-H INJ-L


4 7 16 6 14 1 2 1 2 1 2 1 2 1 2

62 23 60 20

118 120

118 121

117 115

35 54 73 87 117 114

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u 0 /   y z / { y{ z 1 u} v 
EMC Recommendation Table Screened Wire Screened cable construction shall be of foil tape spirally wrapped and lapped (50% minimum exposure at the connectors. The shield terminates to the associated modules power return within 300 mm of the modules power return pin The drain wire shall be equal to or greater than 18 AWG. Screen should be continuous through out its length. In line connectors should be avoided. Shield should terminate no further than 50mm from the connector. Twisted Wires Minimum twist rate of 30 twists per 1m. One twist is 180-degree rotation. Twists should be continuous through out its length, and should terminate no more than 50 mm from connector. Twisted wires shall be terminated in adjacent terminals located away from power and return connections. Starter Motor Battery Feed Wires The starter motor wire shall be routed at least 250 mm from all variable reluctance sensors and wiring. Eg RPS, CNS, Injectors (This list is not exhaustive). Alternator B+ Wires Module Mounting General Wiring Wires must not be routed within 100 mm of components and circuits which are particularly susceptible to AC magnetic fields. Eg RPS, CNS, injectors (This list is not exhaustive) The module should be mounted parallel to a chassis plane and close to the chassis plane. All wiring lengths should be as short as possible. All sensors wiring lengths should be less than 2 metres. All inductive loads should have wire lengths of less than 2 metres. Power feeds to inductive loads should be kept separate from module power. All wiring should be kept as close to the chassis plane as possible. Circuits can be characterised and grouped, i.e switched, power and data.

/

Continuous lengths of wire (in one plane) should be no greater than 1 metre. Harness should not contain un-terminated wires. Return wires should maximise surface area to minimise skin effects at high frequency.

2

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