Chapter 29

Body-electrical service

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-1
Figure 29.1 A headlamp installation with a quartz
halogen bulb Holden Ltd

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-2
Figure 29.2 Installing a quartz halogen bulb in a
headlamp Ford

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-3
Figure 29.3 Components of a headlamp assembly
for a passenger vehicle Ford

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-4
Figure 29.4 Handling a quartz halogen bulb
Mitsubishi

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-5
Figure 29.5 Aiming headlamps with an aiming
board

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-6
Figure 29.6 The centre of the headlamp is located
for aiming Daihatsu

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-7
Figure 29.7 Aiming board for headlamps with
quartz halogen bulbs – low beam is used

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-8
Figure 29.8 Headlamp aiming for high-beam bulb

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-9
Figure 29.9 Tail lamp assembly for a passenger
car Ford

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-10
Figure 29.10 Rear lamp assembly for a station
wagon Ford

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-11
Figure 29.11 Removing an interior lens
(a) small screwdriver in recess Mitsubishi

(continued)

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-12
Figure 29.11 Removing an interior lens (continued)
(b) protecting with a cloth Mitsubishi

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-13
Figure 29.12 Components of a side turn-signal
lamp Mitsubishi

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-14
Figure 29.13 Crimped connections
(a) Cable and crimped terminal (b) crimping pliers

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-15
Figure 29.14 The steps in making a soldered wire
connection

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-16
Figure 29.15 Examples of wire terminals
(a) slide-type crimp terminals (b) bullet connector (c) crimp and soldered
terminals

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-17
Figure 29.16 Checks that can be made on a
wiring harness Holden Ltd

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-18
Figure 29.17 Multipin connectors
(a) depress the tang to unlock (b) push the parts firmly together to lock
Hyundai

(continued)

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-19
Figure 29.17 Multipin connectors (continued)
(b) push the parts firmly together to lock Hyundai

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-20
Figure 29.18 Multipin connector
(a) removing a terminal (b) refitting the terminal Toyota

(continued)

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-21
Figure 29.18 Multipin connector (continued)
(b) refitting the terminal Toyota

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-22
Figure 29.19 Checking blade-type fuses with a
test lamp
(a) checking for a short circuit in the wiring (b) checking the fuse

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-23
Figure 29.20 Causes of a blown fuse
(a) thermal fatigue Hyundai

(continued)

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-24
Figure 29.20 Causes of a blown fuse (continued)
(b) excess current Hyundai

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-25
Figure 29.21 With a cartridge fusible link, a blown
element can be seen through the top Daihatsu

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-26
Figure 29.22 Checking a relay with an ohmmeter

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-27
Figure 29.23 Short circuit in a coil – fault
indicated at X

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-28
Figure 29.24 Ground circuit: coil wire is in
contact with the case – fault indicated at X

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-29
Figure 29.25 Open circuit – fault indicated at X

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-30
Figure 29.26 12 volt test lamp
(a) construction (b) test for voltage

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-31
Figure 29.27 Arrangement of a test lamp with a
light-emitting diode (LED)

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-32
Figure 29.28 Continuity tester
(a) construction (b) testing continuity of a connector (c) testing to earth

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-33
Figure 29.29 Using a voltmeter at a lamp
connector
1 test for voltage, 2 test for voltage drop

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-34
Figure 29.30 Using an ohmmeter to check the
resistance of a connector Hyundai

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-35
Figure 29.31 Using an ammeter to check the
current flow in a circuit

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-36
Figure 29.32 Digital and analog types of electrical
test instruments Toyota

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-37
Figure 29.33 An autoranging digital multimeter

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-38
Figure 29.34 Scan tool (diagnosis tester) and data
link connector (DLC) Holden
Ltd

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-39
Figure 29.35 General circuit checks

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Artwork t/a Automotive Mechanics Vol 2, 7r by May & Simpson 29-40