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Understanding Euro Wiring Diagrams PDF
Understanding Euro Wiring Diagrams PDF
European
DIN Wiring BY KARL SEYFERT
European wiring diagrams may look
strange and incomprehensible. But they’re
not so tough to understand when the
underlying standards are explained.
O
ver the years, I’ve ignore the differences of language and
heard many explana- culture, isn’t it still a difficult problem
tions for why some for a European manufacturer to build
technicians choose not vehicles in a different country like the
to work on European U.S.? To oversimplify the challenges
vehicles. For some, it’s involved, how do you get an American
based on their desire to work only on assembly line to crank out parts for a
vehicles built within our borders. For European car? The answer is stan-
others, the choice may be based on the dards. Standards have been an integral
belief that European cars are just too part of the automotive world since the
“foreign” and their systems too unusual earliest days of the automotive assem-
or exotic to easily understand. bly line. Standardization of parts al-
In today’s automotive economy, it has lowed automakers to transform their
Fig. 1
become increasingly difficult to hold businesses from a one-at-a-time propo-
onto these attitudes. Many cars sold in sition to a many-at-a-time operation. world, as long as it conforms to the
this country by European (and Asian) In this country, the Society of Auto- same set of standards.
manufacturers are actually assembled motive Engineers (SAE) is responsible In Europe, the most widely recog-
right here in the U.S. This blurs the for maintaining order by establishing nized organization responsible for es-
conventional definition of an imported many of the standards that apply to au- tablishing and publishing automotive
vehicle. At the same time, many “Amer- tomobile manufacturing. When you standards is called Deutsches Institut
ican” cars are actually assembled out- pick a bolt for a domestic vehicle out of für Normung e.V. Standards estab-
side our borders, further confusing the the bolt bin, chances are the standards lished by this organization are often re-
accepted definition of a domestic car. and specifications concerning its ferred to as DIN standards.
Auto manufacturing is truly a global thread pitch and hardness were origi- DIN standards have been estab-
enterprise, with all of the major manu- nally defined by SAE. Thanks to stan- lished for a multitude of things, includ-
facturers conducting business in sever- dardization, that bolt should thread in- ing many outside the automotive
al countries simultaneously. Even if we to any nut made anywhere in the world, but we’ll limit the focus of this
38 April 2003
Fig. 2 Fig. 3
article to the DIN standards for auto- always represents a direct connection to
motive wiring. Why wiring? Because
WIRE COLORS the battery positive terminal. And ter-
that’s the one thing I’ve heard the most English DIN (German) minal 50 is always battery positive with
techs complain about when it comes to Black . . . . . . . . . . . . . . . . . . . . .Sw the key ON or in the CRANK position.
Blue . . . . . . . . . . . . . . . . . . . . . .Bl
working on European vehicles. For Brown . . . . . . . . . . . . . . . . . . . .Br
some, it’s the layout of the electrical Green . . . . . . . . . . . . . . . . . . . . .Gn Wire Color Codes
components throughout the vehicle. Gray . . . . . . . . . . . . . . . . . . . . . .Gr Before we get into some actual DIN
For others, it’s understanding the Orange . . . . . . . . . . . . . . . . . . .Or wiring diagrams, a word about wire
Pink . . . . . . . . . . . . . . . . . . . . . .Rs
wiring diagrams that map out the posi- Purple . . . . . . . . . . . . . . . . . . . .Vi
color codes. Most wiring diagrams
tion and operation of all those systems Red . . . . . . . . . . . . . . . . . . . . . . .Rt you’re likely to come across will have
and components. The diagrams may Turquoise . . . . . . . . . . . . . . . . . .Tk already been translated into English.
look strange and incomprehensible. White . . . . . . . . . . . . . . . . . . . . .Ws Wire colors in those diagrams should
Yellow . . . . . . . . . . . . . . . . . . . .Ge
But when you understand the underly- be labeled with abbreviations you’ll be
ing system and standards that were able to understand. But just in case
used to design the vehicles and the dia- many of the common terminal desig- you run across a diagram with the orig-
grams, it’s not as tough as it first seems. nations described under DIN 72 552. inal wiring color codes, use the “Wire
Some of the more obscure numbers, Colors” key at left to sort things out. By
Terminal Designations which refer to components on trailers, the way, color codes for electrical
DIN standard 72 552 establishes the heavy-duty trucks and such, have been wiring are defined in DIN 47 002.
terminal numbering system that’s used intentionally omitted.
for any wiring diagram or vehicle When you’ve worked with DIN Circuit, Block &
wiring that conforms to DIN specifica- wiring for a while, you’ll begin to recog- Schematic Diagrams
tions. The terminal codes are not wire nize certain numbers that come into Description of an electrical system or
designations, as devices with differing play more often than others. For exam- circuit may begin with a circuit dia-
terminal codes can be connected to ple, a terminal 31 designation always gram. This is an idealized representa-
the opposite ends of a single wire. The refers to a direct connection to vehicle tion, rendered in the form of symbols
chart on pages 42 and 43 outlines ground and a terminal 30 designation to provide a quick overview of circuit
April 2003 39
Understanding European DIN Wiring
and device functions. The circuit dia- to see how the current flows through
gram illustrates the functional interre- the various sections of the circuit.
lationships and physical links that con- The diagram also includes informa-
nect various devices. These diagrams tion on terminal numbers, wire sizes
may also include illustrations and sim- and colors, connector sizes and a basic
plified design drawings, as needed. representation of the internal working
A block diagram is another simpli- of the gauges and sensors. The symbols
fied representation of a circuit, showing used to define the components also
only the most significant elements. It’s conform to DIN specifications. A key
40 April 2003
Understanding European DIN Wiring
to reach the load terminals. It also tells Let’s look at one more schematic dia- these more complicated schematic dia-
you which switching devices are used gram, this time the backup light circuit grams are assembled using the same
to control the ON or OFF state of the in Fig. 3 (page 39). Again, it’s a current basic building blocks and DIN conven-
circuit. The schematic diagram is laid flow diagram, with all of the circuit tions found in the simpler diagrams.
out so you can quickly find the parts of components laid out end to end. All of When you’re troubleshooting a specific
a circuit and test them. For example: the wires, connectors and other compo- circuit problem, learn to home in on
•If there’s no power at the coolant nents are clearly labeled and identified. the part of the circuit that’s involved,
thermo switch, the diagram shows that At the bottom of the diagram, note the and tune out all the clutter around it. If
fuse 1 is the source of power. circled numbers 7 and 8. These refer to necessary, make a disposable copy of
•If the fuse is good, the next step is the actual locations of the ground con- the diagram, then mark it up with col-
to check the connections between the nections indicated in the diagram. An ored pens or pencils until you under-
fuse and the thermo switch. accompanying vehicle diagram shows stand how the circuit works.
•The diagram shows two connec- you where the grounds are located.
tions—terminal 87 at the relay and pin The schematic diagrams used here DIN Relays
6 of the green 10-point connector. are admittedly on the basic side. When Suppose you’re diagnosing a relay in an
Voltage testing at these points will help the system involved is more complicat- electrical circuit. Perhaps the wiring di-
you determine where the break in the ed, several circuits may be included in agram shows only a square box, with no
circuit is located. the same diagram. Just remember, information about what’s going on in-
42 April 2003
Terminal Definition Terminal Definition
58 . . . . . . . . . .Side-Marker Lamps, Taillamps, License Plate Switching Relay
& Instrument Illumination 85 . . . . . . . . . .Output: Actuator (Negative Winding End or Ground)
Input: Actuator
58d . . . . . . . . .Rheostatic Instrument Illumination, Tail- & Side-Marker Lamps 86 . . . . . . . . . .Start of Winding
58L . . . . . . . . .Left 86a . . . . . . . . .Start of Winding or First Winding Coil
58R . . . . . . . . .Right, License Plate Lamps 86b . . . . . . . . .Winding Tap or Second Winding Coil
AC Generator (Alternator) Normally Closed (NC) Relay Contact & Changeover Contacts
(Magneto Generator) 87 . . . . . . . . . .Input
59 . . . . . . . . . .AC Voltage Output, Rectifier Input 87a . . . . . . . . .First Output (NC-Contact Side)
59a . . . . . . . . .Charging-Armature Output 87b . . . . . . . . .Second Output
59b . . . . . . . . .Taillamp Armature, Output 87c . . . . . . . . .Third Output
59c . . . . . . . . .Stop-Lamp Armature, Output 87z . . . . . . . . .First Input
87y . . . . . . . . .Second Input
61 . . . . . . . . . .Charge Indicator Lamp 87x . . . . . . . . .Third Input
Switches, Normally Closed (NC) Contacts & Changeover Contacts Generator/Alternator & Voltage Regulator
81 . . . . . . . . . .Input B . . . . . . . . .Battery Positive Terminal
81a . . . . . . . . .First Output on NC-Contact Side B . . . . . . . . .Battery Negative Terminal
81b . . . . . . . . .Second Output on NC-Contact Side (NO Contacts) D . . . . . . . . .Generator Positive Terminal
82 . . . . . . . . . .Input C . . . . . . . . .Generator Negative Terminal
82a . . . . . . . . .First Output DF . . . . . . . . . .Generator Field Winding
82b . . . . . . . . .Second Output DF1 . . . . . . . . .Generator Field Winding 1
82z . . . . . . . . .First Input DF2 . . . . . . . . .Generator Field Winding 2
82y . . . . . . . . .Second Input
Multiple-Position Switch Alternator
83 . . . . . . . . . .Input U, V, W . . . . . .Three-Phase Terminals
83a . . . . . . . . .Output (Pos. 1)
83b . . . . . . . . .Output (Pos. 2) Turn Signals (Turn-Signal Flasher)
83L . . . . . . . . .Output (Left) C . . . . . . . . . . .Indicator Lamp 1
83R . . . . . . . . .Output (Right) C0 . . . . . . . . . .Main Terminal Connection for Indicator Lamp Not
Connected to Turn-Signal Flasher
Current Relay C2 . . . . . . . . . .Indicator Lamp 2
84 . . . . . . . . . .Input: Actuator & Relay Contacts L . . . . . . . . . . .Left-Side Turn Signals
84a . . . . . . . . .Output: Actuators R . . . . . . . . . . .Right-Side Turn Signals
84b . . . . . . . . .Output: Relay Contacts
side the relay. Or maybe you need to mally closed (NC). In either case, the rule, apparently, as you may encounter
bench-test the relay or jumper the con- relay switch input is always connected relays where the polarities of terminals
nector but can’t see the wire colors. If to pin 30. Pin 30 not only designates 85 and 86 have been reversed.
the vehicle uses DIN standards, the re- the input to the relay switch, but in ac- How does DIN pin number informa-
lay will provide you with information cordance with DIN standards, we also tion help in the real world? By using pin
about its inner workings, just by looking know that it’s connected to battery pos- information, you may be able to reduce
at its terminal numbers. And for a more itive. The relay outputs on the other the amount of time spent with locator
thorough explanation, many DIN re- side of the relay switch are designated manuals. When you remove a relay or
lays even include a tiny schematic dia- either 87, 87a or 87b. look at a connector, you should be able
gram on the outside of the housing. The two remaining relay terminals to figure out how it works just by look-
Relays are electrically controlled are connected to the relay coil. Apply- ing at the pin assignments.
switches. The switch inside the relay ing current to the coil is what makes the
will be in one of two positions, de- relay close or open. According to DIN Visit www.motor.com to
pending on whether the electromag- standards, pin 85 should be connected download a free copy of this
netic relay coil is energized or deener- to ground (usually controlled by another article. Copies are also available
gized. In basic relays, there’s one input switch) and pin 86 should be connected by sending $3 for each copy to:
Fulfillment Dept., MOTOR Magazine,
and either one or two outputs. Relays to battery positive (usually protected by
5600 Crooks Rd., Troy, MI 48098.
are either normally open (NO) or nor- a fuse). This one is not a hard and fast
April 2003 43