Automotive Technologies

Student Workbook

AURETR009 – Install vehicle lighting and wiring systems

TAFE - 2021

Version 3.1 09/2021

Acknowledgements

This Unit Guide has been prepared by TAFE Lecturers.

It is intended for TAFE students only.

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This unit outline has been created by TAFE for educational purposes.

Any third party content contained in the unit outline is copied with permission of the copyright owner or under Statutory License VB of the
Copyright Act 1968.
th
Cover Images from © https://pixabay.com/en/photos/?q=automotive accessed 27 January 2016

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Apart from any use as permitted under the Copyright Act 1968, no part may be reproduced without the prior written permission of

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Disclaimer:
While every effort has been made to ensure the accuracy of the information contained in this publication, no guarantee can be given
that all errors and omissions have been excluded. No responsibility for loss occasioned to any person acting or refraining from action as
a result of the material in this publication can be accepted by TAFE.
AURETR009 – Install vehicle lighting and wiring systems

Name:

Student Workbook

AURETR009
Install vehicle lighting and
wiring systems

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Student Workbook Index

Description Page
Student Instructions 4
External Links 5
Assessment Information 7
Theory Questions
Questions 9

Learning Exercises
Driving lights task 15
Incandescent to LED conversion project 16

Driving lights diagram 18

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Student Instructions

This Student Workbook contains all of the specific information, theory questions and
practical task instructions to prepare for the assessments in these units.

Refer to your lecturer for assessment dates and times.

The information required to complete the theory questions in this book can be found from
the following recommended sources:

 Wiring and Lighting (Textbook or eBook)

 Lecturer delivery
(Presentations, videos, handouts, demonstrations, class discussions)

 Further research
(Workshop manuals, textbooks, magazines, PC programs, websites, Apps,
Industry experience and contacts)

Refer to the recommended information source at the beginning of each theory question
section.

If you have any questions regarding the theory questions please ask.

The information required to complete the practical tasks in this book will be from a
combination of theory knowledge, experience, research and lecturer demonstration.

Practical tasks are covered at the rear of this workbook.

Student eLinks

SM TAFE My Campus Student Password Reset

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Install vehicle lighting and wiring systems - Links

Australian Design Rules WA Vehicle Licensing Publications

https://www.infrastructure.gov.au/ https://www.transport.wa.gov.au/licensing/
vehicles/design/ licensing-publications-by-topic.asp

Vehicle safety standards Narva Catalogue - Globes

https://www.transport.wa.gov.au/ https://view.publitas.com/bwi/narva-catalogue-
licensing/vehicle-safety-and-standards.asp 2019-20/page/153

Hella Tech World – lighting

https://www.hella.com/techworld/uk/
Technical/Automotive-lighting-209/ Hella Electrical and Lighting Catalogue
https://www.hella.com/MicroSite/ePaper/
HELLA_Australia_Universal_products_catalogue/
#p=1

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Road Traffic (Vehicle Standards)

Rules 2002 Australian Design Rules
http://www.austlii.edu.au/au/legis/ http://www.infrastructure.gov.au/roads/motor/
wa/consol_reg/rtsr2002308/ design/adr_online.aspx

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Assessment Information

Student Learning Resources

Provided by South Metro TAFE
South Metro TAFE Student Workbook.
Computer access, internet access and student account with data
storage. Workshop manuals (hardcopy and electronic), applicable
tools and equipment.
Required by student
Electronic pdf reader - required to access PDF eResource Eg. Your own
laptop, tablet or e-Reader
Textbook or eBook – printed or PDF on ereader
Appropriate stationary and study equipment.
Appropriate work wear and PPE – trousers, work shirt, steel cap boots,
safety glasses..

Assessment guidelines
Method Requirement
Written or verbal exam questions to assess aspects of competency that
Theory cannot be demonstrated during either practical task. Must answer all
correctly.
23 Questions with 2 Attempts
1st and 2nd attempts contain short answer questions

AURETR009 Install vehicle lighting and wiring

Practical Install one of the following low voltage (LV) lighting and wiring systems in a
non-controller area network databus (CAN-bus) system in a vehicle, vessel
Task 1
or piece of machinery, different to the system and vehicle used in
assessment 2
• Trailer lights and wiring harness
• Driving lights and wiring harness
• Side clearance lamp
• High-mount rear brake lamp
• Ascent strip light emitting diode (led) lamp
Practical Install the following low voltage (LV) lighting and wiring system in a non-
controller area network databus (CAN-bus) system in a vehicle, vessel or
Task 2
piece of machinery, different to the equipment used in assessment 1

• Filament lamp to led lamp replacement.

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Notes

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Questions
1. Select four items of PPE essential to WHS that should be worn when working on vehicle
lighting and wiring systems within TAFE live work areas.

□ Earmuffs □ Steel cap boots

□ Drill cotton clothing □ High visibility vest
□ Respirator □ Safety glasses
□ Leather apron □ Wide brim hat
□ Sunscreen □ Gloves

2. When testing circuit components using an oscilloscope, multimeter or test light why it is
important to use specialised back probing pins or spoons?

3. A. Why is it important to remove jewellery when working around high current systems?

B. What are 2 injuries that could potentially occur when working on these systems without
removing jewellery?

4. When installing trailer plug on modern vehicles why would a trailer module need to be
fitted?

5. When the stop lamp switch is operated on a normal passenger vehicle, the stop lamp or
brake light circuit will activate. This usually consists of one globe (or lamp) on the left and
right of the vehicle at the back and another lamp mounted in the middle of the back of the
vehicle, in a higher up location.

What is this middle, higher lamp called and what purpose does it serve?

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6. Complete the table below For a standard 7 pin flat or round trailer plug what colour wire
and what circuit is used for each pin?

pin Circuit Wire colour

1
2
3
4
5
6
7

7. What are 2 ways to determine the size (conductor cross section) of cable required to run an
electrical load without exceeding the permissible volt drop in the circuit?

a.

b.

8. If the brake light circuit on a 12v vehicle has 2 x 21w globe and 1x5w globe. What is the
current required for this circuit? (show working out)

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9. Using the formula required, calculate the required conductor cross section, on a circuit with
a. a length 10m
b. 0.2v allowable volt drop
c. Brake light circuit consuming 60watts of power @12v
Amps x Length x 0.0164
Conductor cross
Volt drop (allowable) section mm2

10. Using the wire size chart from the lighting and wiring unit resource book what automotive
wiring size cable would be required for the above brake light circuit?

11. After repairing or modifying vehicle lighting and wiring systems what post repair tests must
be conducted?

12.

Give 3 key factors to consider when selecting wires, crimp terminals and connectors for repair or

a.
b.
c.
fitting of components

13. The driving light diagram on p18, contains a key, also know as a legend, explain how this is
used to help interpret the diagram.

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14. Draw the symbols used to represent:

Globe

Switch

Fuse

H4 Plug

15. On the diagram below show four basic voltmeter connections you would make to check the
electrical integrity of this circuit if the lamp was dim?

16.

17.

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18. Complete the table below

Cable type Where is it used Why is it used for this type of circuit
3mm Tinned
multistrand

Twisted pair

Shielded wiring

4mm 7 core cable

2 B&S

2mm single core multi

strand

19. When removing and replacing vehicle electrical connectors or components what two key
points must be adhered to, according to manufacturer instructions?
a.
b. .

20. Give 3 key factors to consider when selecting wires, crimp terminals and connectors for
repair or fitting of components
a. .
b. .
c.

21. Ascent lighting is used on busses and coaches so passengers and staff can see at nighttime,
what type(a) of lighting is normally used for this application and why(b)?
a. .
b.

22. When crimping terminals to wires how do we test to ensure the terminal wont come off?
.

23. What are three key features of a good solder join?

a. .
b. .
c.

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Refer to the diagrams towards the back of the unit resource book and clearly label the marker
FRONT
lamps on the trailer above, showing colour of the lenses as they would be mounted for ADR
compliance.

SIDE TOP

REAR

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Learning Exercises
L1. Go to the workshop and locate a headlight wiring diagram for one of the workshop
vehicles.
Draw this diagram here, determine if this is negatively or positively switched, then add
the required components to install a set of driving lights(spotlights)

Now install driving lights in the vehicle researched above and test, once complete with
your lecturer.

Lecturer sign Date:

off
Wire the L.E.D. conversion board (Show all your test results and calculations)

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L2. As directed by your lecturer, test and replace a filament style lamp with LED lamp for
the indicators, on a vehicle or lighting board.

Use the worksheet below to guide you:

1. The regulations state that the flasher unit flash rate should be 90/ + or – 30 flashers
per minute.
2. Count the RH incandescent bulb flash rate
__________________________________
3. Remove the flasher unit, use an ammeter to measure and record the current draw
on the LH and RH flasher circuits. LH __________ amps and RH ___________
amps.
4. Subtract the LH LED current draw from the RH incandescent bulb current draw.
__________________________________________________________________
_____
This is the current draw/ load that must be put in parallel with the LH led flasher
circuit so the lamps will flash at the same rate as the RH incandescent bulbs.
5. Measure and record the battery voltage, ___________________________ volts.
(you will need this for your ohms law calculation)
6. Measure and record the resistance of each of the resistors R1 up to R10, record
these on page 2 of this sheet.
7. Use ohms law to calculate the current flow for each resistor R1 up to R10, record
on page 2.
8. Using the value of current draw in step 4 and the resistor current calculations you
will choose the most suitable resistor/s to be placed in parallel with the LH LED
flasher circuit. The current draw should be within 0.2 amp between the LH & RH
flashers. _________________________
9. Count the LH flasher rate it should be the same as the RH side. ______________

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Wire up LED conversion board. (Show all your results and calculation)

Battery voltage .

Use ohms law to calculate the current Current flow from

Resistance values flow in each resistor the calculation
R1 –

R2

R3

R4

R5

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What resistor will you use to load the LH LED lamps to have the same current draw
as the incandescent bulbs? ____________________________________________

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