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elec12 Using the Electrical Wiring Diagram.pdf

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ELEC12 USING THE ELECTRICAL WIRING DIAGRAM
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Body Electrical Diagnosis - Course L652 1 1. IntroducethefeaturesofeachEWDsection. 2. ExplainhowtousetheSystemCircuitDiagram 3. ExplainhowtheSystemCircuitDiagramworkswiththe additionalsupportsectionsintheEWD. 4. ShowhowtoapplytheSystemCircuitDiagramsandsupport sectionsinthediagnosticprocess 5. Explainandpracticetheprocessoftracingcurrentflowina circuit. Section 2 Using the Electrical Wiring Diagram Learning Objectives:Section 2 2 LEXUS Technical TrainingUsing the Electrical Wiring Diagram Body Electrical Diagnosis - Course L652 3 Oneofthekeystoaquickandsuccessfulelectricaldiagnosisiscorrectly usingthe LexusElectricalWiringDiagramorEWD .TheEWDis notjustabookofwiringdiagrams,butan informationresourcefor anythingelectrical onthevehicle.EverythingfromconnectorIDand locationtowhatcircuitssharesplicepointsisincludedinthismanual. Becausethereissomuchinformation,ittakesalittlepracticetolearn whereitislocated,andwhateachoftheEWDsymbolsandindividual sectionscantellyou.Wewilltakeadetailedlookatallofthese features,andhowtousethemindiagnosinganelectricalproblem. Asyoufollowyourinstructor’stour“oftheEWDSections,itis recommendedthatyouusethe actualEWD,insteadofthis TechnicianHandbook .Thisway,youwillbegettingafeel“forthe actualtoolthatyouhaveatyourdealership. Sections of the EWD (Through 1998 MY) The EWD is an invaluable tool when diagnosing an electrical problem. Knowing where specific information is, and the “system” that the book uses helps to speed up the diagnostic process. Introduction NOTESection 2 4 LEXUS Technical Training Sections of the EWD (Starting 2000 MY) Starting in the 2000 Model Year, the EWD sections have been rearranged and some new sections have been added. WiththelargenumberofpagesandsectionsintheEWD,thefastest waytofindthewiringdiagramorinformationyouneedistousethe TableofContents . Therearetwotableofcontentsthatareavailable.Oneisonthetitle pageofthebook.Thislistsallofthesections(1998MY=A-K; 2000MY=A-M)andalsohasan alphabeticallist ofallthe System CircuitDiagrams locatedinSectionI.Thesewiringdiagramsarethe heart“oftheEWD,andtheplacetostartwhendiagnosingan electricalproblem.ThereisalsoalistingofeachSystemCircuit DiagramonthefirstpageofSectionI. The Table of ContentsUsing the Electrical Wiring Diagram Body Electrical Diagnosis - Course L652 5 Table of Contents The Table of Contents is found on the title page of the EWD. A second table of contents for just the System Circuit Diagrams is found at the beginning of Section I (Section H starting with 1999 MY).Section 2 6 LEXUS Technical Training TheEWDisbuiltaroundtheuseofthe SystemCircuitDiagrams (SectionIthrough1998MY,SectionHstartingwith1999MY).These wiringdiagramsprovidecircuitroadmaps“forindividualcircuitsor systemsonthevehicle.You’llfindthattherearealotofadvantagesto usingthistypeofdiagramovertheold-style“ overallwiringdiagrams . w MoreInformation Thereisalotofwritteninformation(suchascomponentIDs)on eachdiagramthatworkswiththe supportmaterials/other Sectionsinthemanual.Also,thesymbolsthatareused graphicallygiveyouinformationaboutcomponents,connectors,or wires.UnderstandingthefullmeaningofthesymbolsandID callouts“willsaveyoutimewhentryingtolocateoridentifythese componentsonthecar. w EasiertoUse Everydiagramshowsonlyonesystematatime.Theparallel connectionstoothercircuitscanbetracedusingPowerSourceand GroundPointsections.Tracingcurrentflowthroughthecircuitis alsoeasierbecausethe powerisatthetop andthe groundisat thebottom ofeachpage. w PrintedinColor Becausethediagramsareprintedincolor,identifyingthewires shownonthewiringdiagraminthevehicleharnessoratthe connectorsisaloteasier. System Circuit Diagrams The entire EWD is built around the System Circuit Diagram. Every number, letter, shape, and shading on the diagram tells you information that can help you to locate or identify components on the car faster. Section I System Circuit Diagrams AdvantagesUsing the Electrical Wiring Diagram Body Electrical Diagnosis - Course L652 7 Watch for Asterisks*, (Parenthesis), and the Title at the Top These small notes will make a big difference! These marks alert you to different wiring or connections based upon model, engine type, California, Federal, or Canadian specificationsSection 2 8 LEXUS Technical Training Oneach SystemCircuitDiagram ,thereisalotofinformationthat isgiventoyouthroughtheuseofdifferentsymbols,colors,numbers, andletters.Understandingthemeaningbehindeachoftheseisvery importanttoeffectivelyusetheEWD. Besidesbeingshownincolor,wirecolorsarealsoindicatedbyan alphabeticalcodenexttoeachofthewires.Thefirstletterrepresents thebasicwirecolor,andthesecondletterindicatesthecolorofthe stripe“onthewire. w BlueWires Asyoulookatthelistbelow,notethatthecolor blueispresentedby theletter L“toseparateitfromtheletter B“usedtoidentifyblack“. Alsonotethatthereisnolightblue“wiredesignationusedinLexus wiringharnesses.Ifitisanyshadeofblue,itsconsidered blue(L) . w ComponentPigtails“ Thewirecolorsofcomponentpigtails“(suchasonanigniter) are notshownintheEWD .ThecolorsintheEWDrepresentthe vehicleharnessuptowhereitisconnectedtothecomponent. w SilverBandsontheWireInsulation Onsomewiresyouwillfindsmallsilverbands“.Thesebands(which arenotshownonthewiringdiagram)indicatethatthewireusesa PVCinsulation .Thisinsulationislighterinweightandthinner thanthenormalinsulation,makingthewirediameterappearsmaller thanitactuallyis.(Maylooklikea20ga.wireontheoutside,butis reallya16ga.whenthewirestrandsareexamined) Wire Identification Wires are identified by color and by the letters next to the wire. The letter that follows the “-” is the stripe on the wire. Note that the color BLUE is represented by the letter “L”. B = Black BR = Brown G = Green GR = Grey L = Blue LG = Light Green Y = Yellow SB = Sky Blue O = Orange P = Pink R = Red V = Violet W = White Understanding the System Circuit Diagram Wire ColorsUsing the Electrical Wiring Diagram Body Electrical Diagnosis - Course L652 9 Junction blocksareusedtodistributepowerandgroundtothe differentcircuits.Ajunctionblockjoinsthecircuitsusinglayersof insulated,solidmetalplates,eliminatingtheneedformanyadditional splices,andimprovingreliability. w GreyShading Everyjunctionblockshownonthewiringdiagramishighlighted withgreyshading.Ifthereismorethanonejunctionblockshown inasinglediagram,adifferentgreyshadingmaybeusedforeach JunctionBlock. w IDNumbers ConnectionstotheJ/Bareindicatedwithanoval.TheJ/Bnumber andtheconnectornumberareinsidetheoval,withpinnumberjustto theleft.UsetheseIDnumberswiththe JunctionBlockandWire HarnessConnectorlocationtable inthesupportsectionwhich followseachwiringdiagram.Thistablehasa writtendescriptionof wheretheJ/Bislocated,andapagenumberin SectionFRelay LocationswhereacompletediagramoftheJ/Bislocated. Junction Blocks Junction Blocks are shown with grey shading. The oval indicates the J/B number, connector number, and pin number. Use the ID number on the location table to find where the J/B is located on the vehicle. Junction Blocks Key FeaturesSection 2 10 LEXUS Technical Training A relayblock actsasacentrallocationforrelays,harness-to-harness connectors,andfuses.AlthoughsimilarinappearancetoaJunction Block,relayblocksaredifferentbecausetheydonothaveinternal circuitsinsidetodistributepowerorground,likeajunctionblock. w IDNumbers TheIDnumberinanoval(similartoaJ/B),tellsyouwhichRelay Blocktherelayislocatedin.Theconnectortoeachrelayis identifiedonlybytherelaythatitisconnectedto(thereisno individualconnectornumberasonaJ/B).NotethattheRelay BlockIDnumbersequenceisintegratedintothesamesequenceas theJunctionBlockIDs. w NoShading RelayBlocksarenotshadedonthediagramlikeaJunctionBlock. w LocationontheVehicle ThelocationofaRelayBlockcanbefoundbymatchingtheID numberonthe RelayBlocklocationtable inthesupportsection thatfollowseachsystemcircuitdiagram.Thiswilldirectyoutoa diagramoftherelayblocklocatedin SectionF oftheEWD. Relay Blocks A relay block is indicated by “ovals” at the wire connection (with no grey shading). ID the proper connector by the relay it is connected to. Use the Relay Location Table and Section F to find the relay on the vehicle. Relay Blocks Key FeaturesUsing the Electrical Wiring Diagram Body Electrical Diagnosis - Course L652 11 Allloads,relays,switches,ECU-typecontrollers,capacitors(noisefilters) andisolationdiodesaretreatedascomponentpartsinthecircuit. w IDNumbers EachcomponentconnectorhasanIDnumber. ThisIDnumber usuallybeginswiththefirstletterofthenameofthe component.(Thisisunlikethesplicepointsandharness-to-harness connectorswhichusethelettersE,I,andBtoindicateengine compartment,instrumentpanel,orbodywiringharnesslocation.) UsetheIDnumberwiththepartslocationtablethatfollowseach wiringdiagram.Thiswillreferyoutoaharnessconnectordiagram inSectionGwherethecomponentconnector’slocationisshown. Onlycomponentconnectorsareshowninthesystemdiagram. w LightBlue“Shading Partsarealwaysshadedinblue. w CommonConnectors When2partsorcircuitsuseacommonconnector(suchasthe headlightandturnsignalcircuitsusingthecombinationswitch connector)thec onnectornameusedintheSectionGWire Routingdiagram isshowninbracketsunderthecomponentname. Electrical Components/Parts All electrical components are shown with connector ID numbers, and light blue shading. If the connector it uses is also part of other circuits, the name called- out in the location diagram is listed in brackets. Components/ Parts Key FeaturesSection 2 12 LEXUS Technical Training Wheneverawireisconnectedtoanelectricalcomponent,the pin numberislistednexttoeachwire.Thesepinnumberscorrespondto theconnectordiagramsprovidedinthesupportsectionwhichfollows eachwiringdiagram. w ConnectorID Connectorsatthecomponentareidentifiedbythe component connectorIDnumber . w ConnectorColor Thecoloroftheconnectoris whiteunlessanothercolorislisted. w PinNumbering Connectorpinnumbersarealwaysshownfromthe matingsideof theconnector,nottheharness“sideoftheconnector.Ifyouare backprobingtheconnectorforavoltagecheck,rememberthatthe pinnumberingbecomesthemirrorofwhatispicturedinthe diagram. Usethewirecolorinthewiringdiagramtodoublecheck“thatyouare lookingatthecorrectpin. w DotintheConnector(whenavailable-EWDpre-2000MY) A w“intheconnectorcavityindicatesthatthecavityisusedbutby anothercircuit. w XintheConnector(whenavailable-EWDpre-2000MY) AnX“intheconnectorindicatesthatthecavityisempty. w Pinnumberingonmaleandfemaleterminals w Secondrownumberingbeginsbackunder#1 w MultipleConnectorsonaSingleComponent Iftherearemultipleconnectorsonasinglecomponent(suchason theTCCSECM),eachconnectorwillhaveanindividual parts/connectorID number,andwillalsobeidentifiedwitha letterinacircle “.Thisletterinacircleisusedasashorthand“ waytoIDtheconnectornexttoeachofthepins,andisalsousedon theconnectordiagramsthatfollowtheSystemCircuitDiagram. Pin Numbers and Connectors Key Features HINTUsing the Electrical Wiring Diagram Body Electrical Diagnosis - Course L652 13 Pin Numbering on the EWD Pin numbers are next to the wire. Use the component ID number to find the connector diagram which is part of the support section. The pin numbers are shown from the front or “mating” side of the connector, and not the harness side. If there is more than one connector for a single component, a letter is assigned as a “callout” for that connector.Section 2 14 LEXUS Technical Training A connectorjoiningwireharnesstowireharness or harness-to-harnessconnector“islocatedwithintheharness,andis notfoundatanindividualcomponent. w IDNumbers IDnumberswillbeginwithEforengine,Iforinstrumentpanel, andBforbody.UsetheIDnumbertofindtheconnectorinSection GoftheEWD. w ConnectorDiagrams Diagramsfortheseconnectorsarenotlocatedwiththecomponent connectorswhichfollowthewiringdiagram.Becausethese connectorsareusedinanumberofdifferentcircuits,allthe informationaboutthemislocatedin SectionG oftheEWD.The WireHarnessJoiningWireHarness locationtabledescribesthe locationandtellsyouthepagetoturntoforthelocationdiagram andconnector/pindetails. w MaleandFemaleTerminals Maleandfemaleterminalsideoftheharnessisshownbytheshape ofthesymbol.Maleterminalsshownwithsymbol: Wire Harness to Wire Harness Connectors Harness-to-harness connectors use a 3-digit ID number. Information on the connectors is located in Section G of the EWD. Connector Joining Wire Harness to Wire HarnessUsing the Electrical Wiring Diagram Body Electrical Diagnosis - Course L652 15 Locating a Harness-to- Harness Connector Use the ID number on the Location Table. Turn to the Section G page for pin numbering and a location diagram.Section 2 16 LEXUS Technical Training Asimplesingle-pole,single-throwswitchisrelativelyeasyto understandonawiringdiagram.However,iftheswitchisa multi-pole (hasmorethanonepinthatisbeingswitched),or gangtypeswitch (wherethemovementoftheswitchlevermovesanumberofswitches openorclosed),thesymbolusedonthewiringdiagramcanbemore difficulttounderstand. w SwitchesareshownintheNormalposition(Keyoffandout ofignition,doorsclosedbutnotlocked.) AllswitchesandrelaysareshownintheNormalpositionoratrest. Ifit’sarelay,youknowthattherelaycoilis notenergized“ . w Multi-poleSwitches Formulti-poleswitchessuchastheCombinationSwitch,orthe HeaterFanSwitch,theschematicsymbolisalittlemore complicated.Acircleandlineindicatewhichpinsareconnected togetherundereachofthedifferentswitchpositions.OntheHeater FanSwitch,abusbar“ismovedforeachswitchposition,changing thepinconnectionsinthes
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