Chapter 28

Body-electrical systems

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-1
Figure 28.1 Principles of earth return and
insulated return electrical systems – arrows
show positive to negative current flow

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-2
Figure 28.2 Battery connections
A to alternator, B to ground on bodywork, C to solenoid, D to ground on
cylinder head Holden Ltd

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-3
Figure 28.3 Installation of a wiring
harness in the car body Holden Ltd

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-4
Figure 28.4 Location of the main wiring
harnesses of a station wagon Mitsubishi

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-5
Figure 28.5 Some of the main engine
harnesses and connectors
1 windscreen wiper, 2 injectors, 3 side turn-signal, 4 turn signal, 5 headlamp, 6 horn, 7
headlamp, 8 fan, 9 alternator, 10 air conditioner, 11 oil pressure, 12 fan, 13 headlamp,
14 horn, 15 windscreen washer, 16 side turn-signal Mitsubishi

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-6
Figure 28.6 Headlamp wiring harness
Holden Ltd

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-7
Figure 28.7 Simplified headlamp and
parking-lamp circuit

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-8
Figure 28.8 Basic lighting circuit diagram – the
headlamp switch terminals are identified as
B battery, P park lamp, R rear lamps, H headlamps, C stop lights, I instrument panel
lights Ford

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-9
Figure 28.9 Schematic electrical circuit of the exterior
lighting – the main components have borders with
dotted lines Ford

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-10
Figure 28.10 Various symbols used in
automotive electrical circuit diagrams

(continued)

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-11
Figure 28.10 Various symbols used in
automotive electrical circuit diagrams
(continued)

(continued)

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-12
Figure 28.10 Various symbols used in
automotive electrical circuit diagrams
(continued)

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-13
Figure 28.11 Example of a cable colour code
Hyundai

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-14
Figure 28.12 Portion of a body interior wiring
harness – it consists of cables and connectors
Holden Ltd

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-15
Figure 28.13 A combination switch mounted
on the steering column Ford

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-16
Figure 28.14 Relays are located at various
parts of a vehicle – these are examples

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-17
Figure 28.15 Relay schematics show that
relays can operate in a number of different
ways
1–2 coil terminals, 3–6 switch terminals

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-18
Figure 28.16 Types of fuses

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-19
Figure 28.17 A fusible link connected
into the electrical system Mitsubishi

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-20
Figure 28.18 External views of a four-cylinder
double overhead-camshaft engine

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-21
Figure 28.19 Construction of a cartridge-type
fusible link – the arrow shows the part of the
element that fuses Daihatsu

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-22
Figure 28.20 Location of blocks of fuses and
relays Ford

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-23
Figure 28.21 Contents of a power distribution
box in the engine compartment Ford

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-24
Figure 28.22 Interior block of fuses and
relays Ford

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-25
Figure 28.23 Types of bulb (the bulbs are not
drawn to the same scale)
(a) double filament with offset pins (b) single filament

(continued)

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-26
Figure 28.23 Types of bulb (the bulbs are not
drawn to the same scale) (continued)
(c) quartz halogen (d) festoon

(continued)

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-27
Figure 28.23 Types of bulb (the bulbs are not
drawn to the same scale) (continued)
(e) panel (f) capless panel (g) screw base

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-28
Figure 28.24 Parts of a headlamp assembly
with a quartz halogen bulb Ford

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-29
Figure 28.25 Sections through a headlamp
assembly Toyota

(continued)

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-30
Figure 28.25 Sections through a headlamp
assembly (continued) Toyota

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-31
Figure 28.26 Light rays from the filaments of
a bulb – full lines show high beam and dotted
lines show low beam

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-32
Figure 28.27 Headlamp rays
(a) conventional reflector and patterned lens Toyota

(continued)

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-33
Figure 28.27 Headlamp rays
(b) multi-reflector and clear lens Toyota

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-34
Figure 28.28 Gas discharge lamp
(a) operation (b) construction Volkswagen

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-35
Figure 28.29 The exterior lamps at the front of
a vehicle Mitsubishi

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-36
Figure 28.30 The exterior lamps at the rear of
a vehicle Daihatsu

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-37
Figure 28.31 Basic circuit for turn-signal
lamps
L lamps, B battery, E earth

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-38
Figure 28.32 Components that send signals
to and receive signals from a BEM Ford

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-39
Figure 28.33 Body electronic module
(a) BEM (b) location Holden Ltd

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-40
Figure 28.34 Comparison of conventional and
linear bus systems Bosch

(continued)

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-41
Figure 28.34 Comparison of conventional and
linear bus systems (continued) Bosch

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-42
Figure 28.35 CAN bus used with the
components of a diesel engine Bosch

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 28-43