21.body Electrical

DAIHATSU Technician >> Body Electrical
Body Electrical
Body Electrical
The body electrical components consist of electrical parts that are attached to the
vehicle body.
Basic composition
1.Wire harness
2.Switches and relays
3.Lighting system
4.Combination meter and gauges
5.Wipers and washers
6.Air conditioning
1
Wire harness
1.Wire harness
2
Switches and relays
2.Switches and relays
3
Lighting system
3.Lighting system
4
Combination meter and gauges
4.Combination meter and gauges
5
Wipers and washers
5.Wipers and washers
6
Air conditioning
6.Air conditioning
7
Wire Harness
Wire Harness
The wire harnesses are divided into the following groups that facilitate the
connections among the electrical components of a vehicle:
Wires and cables
Connecting parts
Circuit protecting parts, etc.
REFERENCE:
Body ground
8
Body ground
Return to previous page
Body ground
In a vehicle, the negative terminal of every electrical device and the negative
terminal of the battery are connected to the sheet metal of the vehicle body in
order to form an electric circuit.
The connection of the negative terminals to the body is called a "body ground".
The body ground minimizes the number of wire harnesses that are used.
9
Wires and Cables
Wires and Cables

Three main types of wires and cables are used on a vehicle.
To protect them, wiring protective parts are used:
1: Low-voltage wires
A type of wire that is widely used on automobiles, it consists of a wire element
and insulation.
2: Shielded cables
A type of cable that is designed to protect it self from external interference, it is
used in the following areas: Radio antenna feeder cables, ignition signal lines,
oxygen sensor signal lines, etc.
3: High-tension cords
A type of cord that is used as a part of the ignition system of a gasoline
engine. This cord consists of a conductor (core wire) covered with a thick
rubber insulator that prevents the high voltage from leaking.
4: Wiring protective parts

Protective parts cover or bind wires and cables, or secure them to other parts in
order to protect the wiring harness from damage.
10
Connecting Parts
Connecting Parts
To facilitate their connection, the wire harnesses are concentrated in a few

sections of the vehicle:
1. Junction blocks (J/B)
A junction block is a part in which the connectors for an electric circuit are
grouped together.
Generally, it consists of the following: Printed circuit boards, fuses, relays, circuit
breakers, and other devices.
2. Relay block (R/B)

Although very similar to a junction block, a relay block does not have printed
circuit boards or other centralized connecting functions.
1: Engine room J/B or R/B

2: Relays
3: Fuses and fusible link
11
Connecting Parts
3. Connectors
The function of the connectors, which are used between wire harnesses or
between a wire harness and an electric component, is to provide
electrical connections.
There are two types of connectors: Wire-to-wire connector, wire-to-component
connector.
Connectors are divided into male and female types, depending on the shape of
their terminals. Connectors also come in various colors.
4. Junction connector
The function of a junction connector is to connect terminals of the same group.
5. Grounding bolts
The grounding bolts are used for grounding the wire harnesses and electric
components to the vehicle body. Unlike ordinary bolts, the surfaces of these bolts
are painted green to prevent oxidation.
12
Circuit Protecting Parts
Circuit Protecting Parts
Circuit protecting parts protect circuits from the excessive current that flows
when a wire or an electronic/electric component is shorted.
1: Fuses
A fuse is installed between a fusible link and an electrical device. When a current
that exceeds a prescribed amperage flows through the circuit of an individual
electrical device, the fuse melts to protect the circuit.
Two types of fuses are used:

1:Blade type and cartridge type.
2: Fusible links
A fusible link is installed inline between the power source and an electrical
device through which a current with a large amperage flows. If an excessive
current flows as a result of the wire harness shorting with the body, the fusible
link melts to protect the wire harness.
Two types of fusible links are used:
Cartridge type and link type.
REFERENCE:
Types of fuses and fusible links
13

The blade type fuses and the cartridge type fusible links are color-coded in
accordance with their capacity.
14
Circuit breakers
Circuit breakers
A circuit breaker is used for protecting a circuit with a large amperage load that
cannot be protected by a fuse, such as power windows,
a defogger, blower motor, etc.
When a current that exceeds the rated amperage flows, a bimetal element in the
breaker generates heat and expands to break the circuit.
Even if the current is below the rated amperage, if current flows repeatedly within
a short or long period, the temperature of the bimetal rises to break the circuit.
Unlike a fuse, a circuit breaker can be reused when its bimetal is reset.
Circuit breaker has two types as shown in the left illustration: the automatic reset
type which is reset automatically, and the manual reset type which is reset
manually.
15
Description
Switches and relays open and close electric circuits in order to turn the lights
ON/OFF, as well as to operate the control systems.
1: Switches
Some switches are operated manually, while others operate automatically by
sensing a pressure, oil pressure, or temperature.
2: Relays
Relays enable ON/OFF with a small current of electric circuits which need a
large current.
When relays are used, the circuits which needs a large current can be simplified.
3: Battery
REFERENCE:
The types of switches and relays
16
Switches and Relays
The types of switches and relays
Switches directly operated by hand
1:
a. Rotary switches
b: Push switches
c: Seesaw switches
d: Lever switches
2: Switches operated by changes in temperature or electrical current
e: Temperature detection switches
f: Current detection switches, etc.
3: Switches operated by changes in fluid levels
4: Relays
g: Electromagnetic relay
h: Hinge type switching relay
17
Rotary switch
a. Rotary switches
18
Push switches
b: Push switches
19
Seesaw switches
c: Seesaw switches
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Lever switches
d: Lever switches
21
Temperature detection switches
2: Switches operated by changes in temperature or electrical current

e: Temperature detection switches
22
Current detection switches etc.
f: Current detection switches, etc.
23
Switches operated by change in fluid levels
3: Switches operated by changes in fluid levels
24
Electromagnetic relay
4: Relays
g: Electromagnetic relay
25
Hinge type switching relay
h: Hinge type switching relay
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Lighting System
The lighting system is installed for driving safety.
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Headlight
Headlights cast their beams forward to ensure the driver's field of vision
during nighttime driving. They can be switched to cast high beams (aimed
upward) and low beams (aimed downward).
They also inform other vehicles or pedestrians of your vehicle's presence.
Some models are equipped with daytime running lights that remain ON at
all times to alert other vehicles of the presence of this vehicle. A headlight
cleaner to clean the headlight lenses is also provided on some models.
The following types of headlights are available:

The sealed beam type in which the bulb and the lens are integrated; and
The semi-sealed beam type in which the bulb can be replaced
independently.
REFERENCE:
•Headlight replacement
28
Sealed-beam headlights
Sealed-beam headlights
This is a type in which the bulb, reflector, and lens are integrated.
REFERENCE:
29
Conventional type
Conventional type
This is a type in which the bulb can be replaced. Two types of bulbs are
used:
Ordinary bulb type
Quartz-halogen bulb type
REFERENCE:
30
Headlight replacement
Headlight replacement
Since a quartz-halogen bulb gets hotter than a ordinary bulb while it is
used, the bulb will be broken if oil or grease adheres to the surface.
Furthermore, the salt in human perspiration can stain the quartz. For these
reasons, hold the flange portion when replacing the bulb to prevent fingers
from touching the quartz.
1: Flange
2: Bulb surface
31
Other Lights
Outside illumination
1. Taillights
2. Stoplights (Brake lights)
3. Turn signal lights
4. Hazard warning lights
5. Back-up lights
6. Clearance lights (Position lights)
7. License plate lights
8. Front & rear fog lights
REFERENCE:
•Types of bulbs
32
Tail light
1. Taillights
At night or in a tunnel, taillights inform the vehicles behind of the presence
of this vehicle.
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Stoplights (Brake lights)
2. Stoplights (Brake lights)

These signal lights inform the vehicles behind that the brakes have been
applied. Ordinarily, the stoplights share the same light housing as the
taillights, and illuminate brighter.
34
Turn signal lights
3. Turn signal lights

These signal lights inform other vehicles in the vicinity that this vehicle is
making a right or left turn or that its direction of travel has changed.
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Hazard warning lights
4. Hazard warning lights

These signal lights inform other vehicles in the vicinity that this vehicle has
made an emergency stop or has parked.
36
Back-up lights
5. Back-up lights
These signal lights illuminate to when driving in reverse. They also
illuminate at night.
37
Clearance lights (Position lights)
6. Clearance lights (Position lights)

At night, these lights inform other vehicles in the vicinity of the position and
the width of this vehicle.
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License plate lights
7. License plate lights

These lights make the license plate numbers visible at night.
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Front & rear fog lights
8. Front & rear fog lights

These auxiliary indicator lights are used under poor visibility conditions
such as fog or rain.
Rear fog lamp position is differ depend on driver’s seat position.
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Type of bulbs
Type of bulbs
1: Single-end bulbs
2: Wedge-base bulbs
3: Double-end bulbs
HINT:
Be careful when replacing bulbs because each method is different. Check
the marking so as not to install the wrong wattage bulb.
41
Single-end bulbs
Single-end bulbs
a: Single-filament single-end bulbs
Used as bulbs for turn signal or back-up light.
b. Double-filament single-end bulbs
Used as bulbs for tailight or stoplight. Two filaments of different wattage
are attached.
Replacement:
Push the bulb toward the socket to unlock the base cap pins from the
socket notches, turn the bulb and pull it out to remove it. Reverse the bulb-
removing steps to install a new bulb.
42
Wedge-base bulbs
Wedge-base bulbs
a: Single-filament wedge base bulbs
Used as bulbs for turn signal light or back-up light, etc.
b: Double-filament wedge base bulbs
Used as bulbs for taillight or stoplight. Two filaments of different wattage
are attached.
Replacement:
Just pull the bulb out using your fingers and push in a new one.
43
Double-end bulbs
Double-end bulbs
Used as bulbs for dome light or courtesy light.
Replacement:
Push to open one of the two socket terminals and pull the bulb out. To
install a new bulb, place one end of the bulb in a socket terminal hole, and
push the other end in other hole.
HINT:
Be careful when replacing bulbs because each method is different. Check
the marking so as not to install the wrong wattage bulb.
44
Inside illumination
Inside illumination
1: Instrument panel lights
Illuminate to make the meters and gauges visible at night.
Illuminate when the headlight dimmer switch is turned one step.
2: Interior light (Dome/Room light)

Generally, this light is located in the center of the ceiling, or upper inside
rearview mirror.
The switch for this light usually has the following 3 settings:
"ON" to remain lit.
"OFF" to remain off.
"DOOR" to illuminate only when a door is opened.
45
Combination Meters and Gauges
The combination meters and gauges consists of meters, gauges, warning

lights, and indicator lights to show the information needed by the driver for
safe driving.
46
Meters and Gauges
The following meters and gauges indicate, through the movement of their
needles, the pieces of information that change constantly.
1: Tachometer
2: Speedometer
3: Water temperature gauge
4: Fuel gauge (w/ fuel level warning light)
Some models are also equipped with the following meter and gauge.
5: Oil pressure gauge

6: Voltmeter
47
Tachometer
Tachometer
Indicates the number of rotation of the engine per minute
48
Speedometer
Speedometer
Indicates the current vehicle speed: km/h or mile/h. There is also an
odometer and a trip meter that indicate the driven distance.
49
Water temperature gauge
Water temperature gauge

Indicates the temperature of the coolant water of the engine.
50
Fuel gauge (w/ fuel level warning light)
Fuel gauge (w/ fuel level warning light)

Indicates the volume of remaining fuel.
51
Oil pressure gauge
Oil pressure gauge

Indicates the circulation pressure of the engine oil.
52
Voltmeter
Voltmeter
Indicates the voltage generated by the alternator
53
Warning Lights
These warning lights illuminate in the following situations:

To alert the driver that a system has a malfunction or requires
replenishment or replacement.
To ensure safe driving.
Red and orange bulbs are used, depending on the urgency or the priority
of the information.
1: ABS warning light

(ABS-equipped vehicles only)
2: Brake fluid level warning light
3: Multifunction indicator lamp
4: Discharge warning light
5: Seat belt warning light
6: Open door warning light (Doom light glows when switch turn to door
position)
7: Airbag warning light (Airbag-equipped vehicles only)
8: Low fuel level warning light
9: Low oil pressure warning light
10: Fuel sedimenter warning light
(Only for the diesel vehicles)
11: Glow-plug warning light
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59
60
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62

63

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Indicator Lights
These lights illuminate to inform the driver that the respective device is
operating, after the driver has operated a switch or a lever. Blue, green,
and orange bulbs are used, depending on the purpose.
1: Turn signal and hazard warning indicators

2: A/T shift lever indicator light (automatic transmission vehicles only)
3: High-beam indicator
4: Overdrive off indicator light
5: Others
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1: Turn signal and hazard warning indicators
66
2: A/T shift lever indicator light (automatic transmission vehicles only)
67
3: High-beam indicator
68
4: Overdrive off indicator light
69
Wipers and Washers
Wiper motor and linkage Wiper arm and blade
Washer fluid reservoir Front washer nozzle
Rear wiper arm and blade Rear washer nozzle
Rear wiper motor
Wipers ensure the visibility of the driver by wiping the rain or dirt from the
front or rear windshield.
A windshield washer sprays washer fluid to remove dirt or oil that cannot
be removed by the wipers alone.
Wiper functions
•Speed function
Switches the wiper speed between HI and LO.
•Intermittent function
Operates the wipers intermittently at the LO speed. There is also a type in
which the intervals can be adjusted in several steps.
•Mist function
Operates the wipers once when the switch is operated.
•Auto park function
Regardless of the position of the wipers during operation, turning the
switch to OFF returns the wipers to their park position.
•Washer-linked function
Automatically operates the wipers when the washer switch is turned ON
for a few seconds.
70
Wipers
Wipers
The wiper system consists of a wiper switch, wiper motor, wiper linkage,
wiper arm, and wiper blade.
1: Wiper switch
Turns the wipers ON/OFF and changes their speeds.
2: Wiper motor
This motor produces the power to operate the wipers.
3: Wiper linkage
Changes the rotational movement of the wiper motor into a reciprocal
movement and operates both right and left wipers in unison.
4: Wiper arm
Applies a constant pressure to the wiper blade against the windshield
surface, in addition to transmitting the movement to the wiper blade.
5: Wiper
This is the portion that wipes the windshield glass. The rubber insert of the
wiper blade must be replaced periodically.
71
Washers
The windshield washer system consists of a washer fluid reservoir, washer

motor, hose, washer nozzle, and washer fluid.
1: Washer fluid reservoir
Stores washer fluid.
2: Washer motor
A compact motor that pumps washer fluid and sprays it through the
washer nozzles. Generally, it is mounted below the washer fluid reservoir.
3: Hose
Transports washer fluid from the reservoir to the nozzles.
4: Washer nozzle
A spout that sprays washer fluid. It contains check valves that prevent the
fluid from flowing back into the reservoir. The spraying angle of the nozzle
can be changed.
5: Washer fluid
A type of fluid that removes dirt from the windshield glass. When the glass
surface is dry, this fluid helps to protect the rubber blade of the wiper and
the glass surface from damage. In winter, use the fluid with a low
solidifying point to prevent its freezing.
72
Air Conditioning
Air conditioning regulates the temperature of the vehicle interior. It

functions as a dehumidifier, in addition to its heating and cooling
temperature regulation functions.
Air conditioning also helps to remove obstructions such as frost, ice, and
condensation from the interior and exterior surfaces of the windows.
73
Air Conditioning
Air conditioner consists from following part.

1: Heater
2: Cooler
3: Dehumidifier
REFERENCE:
•Refrigerant
74
Heater
Heater
Uses a heater core as a heat exchanger that heats the air. The coolant
that is heated by the engine enters the heater core, which heats the air
that flows from the blower fan.
75
Cooler
Cooler
Uses an evaporator as a heat exchanger that cools the air. When the air
conditioning switch is turned ON, the compressor engages and pumps the
refrigerant gas into the evaporator. As the refrigerant flows through the
evaporator, the evaporator absorbs the heat from the surrounding air, thus
cooling the air.
76
Dehumidifier
Dehumidifier
When the air conditioning switch is turned ON, the evaporator removes the
moisture in the air by condensing it into water. Thus, the air becomes drier
as a result of this dehumidifying function. Removed moisture is discharged
outside the vehicle.
77
Refrigerant
Refrigerant
Air conditioning cools the interior by absorbing the heat from the interior
and dissipating it to the exterior. The refrigerant is the medium that
transfers the interior heat to the exterior. Currently, a type of refrigerant
called "HCF-134a" (or R134a) is used.
Because the air conditioning operates with a refrigerant that is
compressed to a high pressure, the refrigerant could leak, necessitating
the periodic inspection of the refrigerant status.
HINT: Some vehicles have no sight glass.
78
Temperature Adjustment
Vehicle air conditioning uses both the heater core and the evaporator to
regulate the temperature in accordance with the opening of the air-mix
damper and the opening of the water valve. The air-mix damper and the
water valve operate in unison with the temperature selector of the control
panel.
1: Blower fan
2: Evaporator
3: Air-mix damper
4: Heater core
5: Temperature selector
79
HOT
1: Blower fan
2: Evaporator
3: Air-mix damper
4: Heater core
80
Cool
1: Blower fan
2: Evaporator
3: Air-mix damper
4: Heater core
81
Engine Immobilizer System
In this system, the engine ECU (Electronic Control Unit) in the vehicle
checks the ID of the chip that is integrated in the key to prevent the engine
from being started with an unregistered key.
1: Ignition key
2: Transponder chip
3: Transponder key coil
(ID code receiver)
4: Key cylinder
5: Transponder key amplifier
6: Engine ECU
7: Spark plug
8: Fuel injector
9: Injection pump
HINT:
There is an integrated type with transponder key amplifier and an engine
ECU.
A. Gasoline engine model

(Stop fuel injection/ignition)
82
SRS Airbags
SRS (Supplemental Restraint System) airbags

Together with the seat belts, the SRS airbags dampen the impact that is
applied to the occupant's face and head during a collision.
When the sensors detect a front or side impact, the center airbag sensor
assembly ignites the gas propellant to instantly inflate the airbag.
1: SRS drivers airbag

2: SRS passengers airbag
3: SRS side airbag
4: SRS curtain shield airbag
REFERENCE:
•Outline diagram
83
Outline diagram
Outline diagram
1: Front airbag sensor
2: Center airbag sensor assembly
3: Airbag
84
Question-1
Mark each of the following statements True or False:

Refer to
No. Question True or False
page
An electrical circuit formed by the body ground of a True False

vehicle consists of the negative terminals of the
1
individual electric devices and the negative terminal of
the battery that are connected to the body.
Because a halogen bulb reaches a high temperature True False

2 when it is lit, do not touch any areas other than glass
portion during a replacement.
Relays used on automobiles turn high-amperage circuits True False

3
ON/OFF by turning small-amperage circuits ON/OFF.
The tachometer in a combination meter indicates the True False

4
number of revolutions of the engine per minute.
The wiper arms of a wiper mechanism must be replaced True False

5
periodically.
85
Question-2
Which one of the following statements is true about the

air conditioner of an automobile?
The heating function of the vehicle air conditioner uses an evaporator as the
1
heat exchanger for heating the air.
The cooling function of the vehicle air conditioner uses a heater core as the heat
2
exchanger for cooling the air.
After prolonged use, the refrigerant in the vehicle air conditioner diminishes.
3
Therefore, it is necessary to periodically check the refrigerant volume.
The automatic air conditioner of a vehicle automatically controls the cooling
4
function. However, the heating function must be controlled manually.
Refer to page
86
Question-3
Which one of the following statements is true about the

warning and indicator lights?
The high-beam indicator light illuminates when the headlight dimmer switch is
1
turned one notch.
2 The seat belt warning light illuminates when a door of the vehicle is opened.
The fuel level warning light illuminates when the level of the fuel in the fuel
3
tank is low.
The ABS warning light illuminates to alert other vehicles of the presence of this
4
vehicle.
Refer to page
87
Question-4
From the word group indicated below, select the

words that correctly correspond to the names of the
diagrams shown below.
a Oil pressure warning light

b Glow plug warning light
c Malfunction indicator lamp
d Brake fluid level warning light
e Discharge warning light
1 a b c d e 4 a b c d e
2 a b c d e 5 a b c d e
3 a b c d e - -
Click answer Click answer Refer to page
88
Congratulations! Your answer is correct.
Let’s try next question.
89
Sorry! You are wrong. Please practice more.
Let’s try again.
90
91
Let’s try again.
92
93
Let’s try again.
94
95
Let’s try again.
96
Close
97
Warning Lights
These warning lights illuminate in the following situations:

To alert the driver that a system has a malfunction or requires
replenishment or replacement.
To ensure safe driving.
Red and orange bulbs are used, depending on the urgency or the priority
of the information.

6: Open door warning light (Doom light glows when switch turn to door
position)
54

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DAIHATSU Technician >> Body Electrical

2.Switches and relays

4.Combination meter and gauges

5.Wipers and washers

Return to previous page

Wires and Cables

4: Wiring protective parts

To facilitate their connection, the wire harnesses are concentrated in a few

2. Relay block (R/B)

1: Engine room J/B or R/B

Circuit Protecting Parts

Two types of fuses are used:

Types of fuses and fusible links

Return to previous page

The types of switches and relays

Switches directly operated by hand

2: Switches operated by changes in temperature or electrical current

f: Current detection switches, etc.

3: Switches operated by changes in fluid levels

h: Hinge type switching relay

The lighting system is installed for driving safety.

The following types of headlights are available:

Return to previous page

2. Stoplights (Brake lights)

3. Turn signal lights

4. Hazard warning lights

6. Clearance lights (Position lights)

7. License plate lights

8. Front & rear fog lights

2: Interior light (Dome/Room light)

The combination meters and gauges consists of meters, gauges, warning

3: Water temperature gauge

4: Fuel gauge (w/ fuel level warning light)

5: Oil pressure gauge

Return to previous page

Water temperature gauge

Fuel gauge (w/ fuel level warning light)

Oil pressure gauge

Return to previous page

These warning lights illuminate in the following situations:

1: ABS warning light

1: ABS warning light

2: Brake fluid level warning light

3: Multifunction indicator lamp

4: Discharge warning light

5: Seat belt warning light

7: Airbag warning light (Airbag-equipped vehicles only)

8: Low fuel level warning light

9: Low oil pressure warning light

10: Fuel sedimenter warning light

11: Glow-plug warning light

1: Turn signal and hazard warning indicators

1: Turn signal and hazard warning indicators

2: A/T shift lever indicator light (automatic transmission vehicles only)

4: Overdrive off indicator light

Wiper motor and linkage Wiper arm and blade

Washer fluid reservoir Front washer nozzle

Rear wiper arm and blade Rear washer nozzle

Rear wiper motor

The windshield washer system consists of a washer fluid reservoir, washer

Air conditioning regulates the temperature of the vehicle interior. It

Air conditioner consists from following part.