CHAPTER 4

AUTOMOTIVE
ELECTRICAL SYSTEMS
AND CIRCUITS

LEARNING OUTCOMES
Understand

the electrical systems approach

Understand

electrical wiring, terminals, and

switching
Understand

circuit diagram and symbols

Understand

vehicle smart wiring system

ELECTRICAL SYSTEMS
APPROACH

System is a word used to describe a collection of related components,

which interact as a whole. Modern vehicle is a very complex system. It is
split into sub and sub-sub-systems on many level that aid both its design
and construction.

Vehicle system
o

Mechanical Engine and transmission

Electrical

Considering the electronic control unit (ECU) of the system as the control
element, and looking at its inputs and outputs, is the recommended
approach.

VEHICLE SYSTEM

Vehicle electrical system is mainly classified into two

types:
Open

loop

Input
Closed

Input

Control

Output

loop

Control

Output

OPEN LOOP SYSTEM

An open loop system is designed to give the required

output whenever a given input is applied.

No feedback is required for the open loop system to

operate.

As an example of an open loop system would be the

electrical circuit of the vehicle headlight.

CLOSE LOOP SYSTEM

A closed loop system is identified by a feedback loop. It can

be described as a system where there is possibility of applying
corrective measures if the output is not quite what is desired.

The feedback loop is due the fact that the output from the
system, i.e., temperature is also an input to the system.

The feedback from the system is very important in order to

control the temperature of the cabin.

As an example vehicle automatic temperature control system.

ELECTRICAL WIRING, TERMINALS,

AND SWITCHING
Cables Construction

Cables used for motor vehicle applications are almost always

copper strands insulated with PVC.

Copper, beside its very low resistivity of about 1.7 x10 -8m,
has ideal properties such as ductility and malleability.

This makes it the natural choice for most electrical

conductors PVC as the insulation is again ideal, as it not only
has very high resistance, the order of 10 15m, but is also
very resistant to petrol, oil, water and other contaminants.

Colour Code and Terminal

As seems to be the case for any standardization, a

number of colour code and terminal designation systems
are in operation.

Ford Motor Company now uses a circuit numbering and

wire identification system.

The system was developed to assist in vehicle

development and production processes.

However, it is also very useful to help the technician

with fault-finding.

FORD COLOUR CODE

BRITISH STANDARD COLOUR

CODES

EUROPEAN COLOUR CODES

TERMINAL DESIGNATION

HARNESS DESIGN

Harnesses are bundles of

wires that are grouped
together in plastic tubing,
wrapped with tape or molded
into a flat strip

Types of harness
o PVC wound harness
o PVC tube and tape harness

When deciding on the layout of a wiring loom

within the vehicle, many issues must be
considered.
Some of these are as follows.

1)
2)
3)
4)
5)
6)
7)
8)

Cable runs must be as short as possible.

Wire colour and gauge
The loom must be protected against physical
damage.
The number of connections should be kept to a
minimum.
Modular design may be appropriate.
Accident damage areas to be considered.
Production line techniques should be considered.
Access must be possible to main components and
sub-assemblies for repair purposes.

HARNESS LAYOUT

PRINTED CIRCUITS

The printed circuit is

used almost universally
on the rear of the
instrument pack and
other similar places.

This allows these

components to be
supplied as complete
units and also reduces
the amount and
complexity of the
wiring in what are
usually cramped areas.

FUSES AND CIRCUIT BREAKERS

FUSE

The simple definition of a fuse is that it is a deliberate weak link in the

circuit.

If an overload of current occurs then the fuse will melt and disconnect the
circuit before any serious damage is caused.

Automobile fuses are available in three types:

o Glass cartridge
o Ceramic
o Blade type

CERAMIC TYPE FUSE

GLASS TYPE FUSE

BLADE TYPE FUSE

CIRCUIT BREAKER

Current flows from battery to the

other terminal through bi-metal strip

Bi-metal strip made of two different

metals which have different
coefficients of expansion

When the bi-metal heats up, one of

the metal will expand more than the
other

The metal that expand more tend to

bend upward and disconnect the
contacts

DIFFERENCES BETWEEN FUSES AND CIRCUIT

BREAKERS
FUSE

CIRCUIT BREAKER

Constructed of a fine tin

conductor inside a glass, plastic
or ceramic housing

Made of two different metal

(bimetallic)

Conductor melt and open the

circuit if excessive current flows
through the fuse

Bimetallic bends when heated by

excessive current result breaking
the connection

Fuse has to be replaced when it

is blows

Circuit breaker can be reset to

restore service

TERMINATION

Terminals are used to connect wires together or plug them into

components.

Types of terminal:
1) Ring
2) Fork
3) Pin
4) Flat blade
5) Hook blade
6) Cranked blade
7) Butt
8) Female push-on
9) Male push-on
10) Female fully insulated
11) Push-on adapter
12) Bullet

TYPES OF TERMINAL

SWITCHES

A simple definition of a switch is a device for breaking and

making the conducting path for the current in a circuit.

This means that the switch can be considered in two parts;

the contacts, which perform the electrical connection, and
the mechanical arrangement, which moves the contacts.

The characteristics the contacts require are simple:

Resistance to mechanical and
Low contact resistance.
No build up of surface films.
Low cost.

electrical wear.

TYPES OF SWITCHES

1)
2)
3)
4)

SPST Single Pole Single Throw

SPDT Single Pole Double Throw
DPST Double Pole Single Throw
DPDT Double Pole Double Throw

CIRCUIT DIAGRAM AND

SYMBOLS

SIMPLE CIRCUIT

The electrical pressure at any point in

an electrical system is called the
potential.

The potential difference (p.d.) is the

difference in electrical pressure
between two points in an electrical
system.

When two points of different p.d. are

joined together by an electrical
conductor an electric current will flow
between them.

DIRECTION OF CURRENT FLOW

By convention, electric current flows from high

potential (+, positive) to low potential (,
negative).

CONVENTIONAL CIRCUIT
DIAGRAM

The conventional type of diagram shows the electrical

connections of a circuit but makes no attempt to show
the various parts in any particular order or position.

Figure shows an example of this type of diagram.

LAYOUT OR WIRING DIAGRAM

A layout circuit diagram makes an attempt to show the main

electrical components in a position similar to those on the
actual vehicle.

Owing to the complex circuits and the number of individual

wires, some manufacturers now use two diagrams one to
show electrical connections and the other to show the actual
layout of the wiring harness and components.

Citron, amongst others, has started to use this system.

An example of this is reproduced in Figure below.

TERMINAL DIAGRAMS

A terminal diagram shows only the connections of the

devices and not any of the wiring.

The terminal of each device, which can be represented

pictorially, is marked with a code.

This code indicates the device terminal designation, the

destination device code and its terminal designation and,
in some cases, the wire colour code.

Figure below shows an example of this technique.

CURRENT FLOW DIAGRAM

Current flow diagrams are now very popular.

The idea is that the page is laid out such as to show

current flow from the top to the bottom.

These diagrams often have two supply lines at the top of

the page marked 30 (main battery positive supply) and15
(ignition controlled supply).

At the bottom of the page is a line marked 31 (earth or

chassis connection).

Figure 4.33 is a representation of this technique.

VEHICLE SMART WIRING

SYSTEM

Smart Wiring System/Multiplex technology involves only two cables.

One of them is able to carry all the signals in the system at the same
time. The other is the electrical cable, which carries the necessary
power.

These cables run around the entire car and are known as the databus.

The information travels in digital packages.

All the small network modules are able to recognize their signal for
action and do as they are told.

ADVANTAGES OF
SMART WIRING SYSTEM
The benefits of the multiplex system are considerable:

Fewer cables and connections in the car.

Improved reliability.

Communication between all the components.

Easier and improved opportunities for the retro-installation of electrical

functions

The system also has the benefit of self-diagnosis for all functions.
Diagnosis is easier, as is servicing. Any information about a fault or
malfunction is passed on to the driver by indicator lamps and a message
display in the instrument cluster.