tle10_ia_automotive_q2_mod1_installingwiring_v3
tle10_ia_automotive_q2_mod1_installingwiring_v3
Technology and
Livelihood Education
Industrial Arts - Automotive Servicing
Quarter 2 - Module 1
Installing Wiring / Lighting System
Republic Act 8293, section 176 states that: No copyright shall subsist in any work
of the Government of the Philippines. However, prior approval of the government agency or
office wherein the work is created shall be necessary for exploitation of such work for profit.
Such agency or office may, among other things, impose as a condition the payment of
royalties.
Borrowed materials (i.e., electrical tape, pliers, screw, sealed beam, signal lights,
bulbs, wires, etc.) included in this module are owned by their respective copyright holders.
Every effort has been exerted to locate and seek permission to use these materials from
their respective copyright owners. The publisher and authors do not represent nor claim
ownership over them.
Management Team:
Chairperson: Arturo B. Bayocot, PhD, CESO III
Regional Director
Co-chairperson: Victor G. De Gracia, Jr., CESO V
Assistant Regional Director
This learning resource hopes to engage the learners into guided and
independent learning activities at their own pace and time. Furthermore, this
also aims to help learners acquire the needed 21st century skills while taking
into consideration their needs and circumstances.
In addition to the material in the main text, you will also see this box in the body
of the module:
As a facilitator you are expected to orient the learners on how to use this
module. You also need to keep track of the learners' progress while allowing
them to manage their own learning. Furthermore, you are expected to
encourage and assist the learners as they do the tasks included in the module.
The hand is one of the most symbolized part of the human body. It is often used
to depict skill, action and purpose. Through our hands we may learn, create and
accomplish. Hence, the hand in this learning resource signifies that you as a
learner is capable and empowered to successfully achieve the relevant
competencies and skills at your own pace and time. Your academic success lies
in your own hands!
This module was designed to provide you with fun and meaningful opportunities
for guided and independent learning at your own pace and time. You will be
enabled to process the contents of the learning resource while being an active
learner.
This module has the following parts and corresponding icons:
1. Use the module with care. Do not put unnecessary mark/s on any part of
the module. Use a separate sheet of paper in answering the exercises.
2. Don’t forget to answer What I Know before moving on to the other
activities included in the module.
3. Read the instruction carefully before doing each task.
4. Observe honesty and integrity in doing the tasks and checking your
answers.
5. Finish the task at hand before proceeding to the next.
6. Return this module to your teacher/facilitator once you are through with it.
If you encounter any difficulty in answering the tasks in this module, do not
hesitate to consult your teacher or facilitator. Always bear in mind that you
are not alone.
We hope that through this material, you will experience meaningful learning
and gain deep understanding of the relevant competencies. You can do it!
TABLE OF CONTENTS
Page
COVER PAGE
COPY RIGHT PAGE
TITLE PAGE
INTRODUCTORY MESSAGE
TABLE OF CONTENTS
What I Need to Know
What I Know
Lesson 1 – Checking continuity and condition of a combination switch/
Install wires leading to different lights and other relevant devices
causing improper grounding.
What I Need to Know 1
What I Know 2-3
What’s In 6-7
What’s New 7-9
What is It 10 - 14
What’s More 15 - 17
What I Have to Learned 17 - 18
What I Can Do 19
Post Assessment 20
Additional Activities 21
Answer Key 22
References 23
What I Need to Know
This module was designed and written with you in mind. It is here to help you master
Installing Wiring/Lighting System. The scope of this module permits it to be used in many
different learning situations. The language used recognizes the diverse vocabulary level of
students. The lessons are arranged to follow the standard sequence of the course. But the
order in which you read them can be changed to correspond with the textbook you are now
using.
1
What I Know
I can do
I I am this but I
cannot learnin need to
do this g how learn
COMPETENCY
yet. to do more
this. and
improve
.
Pre (1) Pre (2) Pre (3)
Uses and interpret the
schematic diagram.
Tests the
faults/defects
using appropriate tools.
Ensures the quality
of works.
Uses the tools/
materials and
equipment
appropriately.
Observes safety
measures in testing
and
interpreting
schematic diagram.
LEGEND:
20-Advance
17-19 -Proficient In this module, you will learn the first part of
installing wiring/lighting systems. We will be
13-16 -Approaching Proficiency discussing the process of installing and checking
8-12 -Developing the wiring/lighting system.
2
1-7 -Beginning
3
LESSON Checking continuity and condition of a combination switch
1
Install wires leading to different lights and other relevant
devices causing improper grounding
INTRODUCTION
4
What I Need to Know
Objectives
What I Know
ACTIVITY 1.1. TRACING WIRES OF TAIL LIGHT, HIGH BEAM AND LOW BEAM OF
COMBINATION SWITCH USING MULTI-TESTER
Automotive wires
Combination switch
TOOLS
Electrical pliers
Long nose pliers
Test light
Screwdrivers
EQUIPMENT
Battery 12volts
Multi-tester
Electrical mock-up/Vehicle
PROCEDURE:
4. Rotate the combination switch into 2 nd position and place the test prod to
(EL) or white and the other test prod to (H) or red. There must have a
reading of continuity.
5. Then place the test prod into (ED) or white with black tracer and the other
end of test prod to (HU) or red with yellow tracer. There must be a reading
of continuity, when operating into high position (push-down) or pass
position (pull-up).
6. Stay the test prod to (ED) or white with black tracer and the other test prod
place into (HL) or red with green tracer. When it is back to normal position,
there must have a reading continuity in the pointer.
7. Stay again the prod to (ED) or white with black tracer and the other end of
test prod will be placed on (HF) or red with white tracer. There must be a
reading of continuity in the screen, when operating in pass position(pull-
up).
6
What’s In |
ACTIVITY 1.2 CONNECTING HORN CIRCUIT
Automotive wires
TOOLS
Electrical pliers
Long nose pliers
Test light
Screwdrivers
EQUIPMENT
Battery 12volts
Electrical mock-up/Vehicle
Plan/Working Drawing:
7
PROCEDURE:
2. Connect a wire to the terminal of horn and other end of wire to the 87
terminal of horn relay. The other terminal of horn is connected to the
vehicle body that serve as ground.
3. Connect the 86 terminal of horn relay to the push button switch. The other
terminal of the push button switch is connected to the ground.
4. Splice the wires of 30 and 85 terminals of horn relay and connect them to
the fuse load terminal. Connect the other end of the fuse source terminal
to the IG or ACC terminal of the ignition switch.
5. From the B terminal of the ignition switch, connect a wire to the terminal of
the ammeter. The other terminal wire of the ammeter is connected to the
positive (B+) terminal of the battery.
6. Connect the negative terminal of the battery to the vehicle body that serve
as ground.
Reminder:
What’s New
ACTIVITY 1.3 CONNECTING TURN SIGNAL LIGHT AND HAZARD LIGHT CIRCUIT
Automotive wires
TOOLS
Electrical pliers
8
Long nose pliers
Test light
Screwdriver
EQUIPMENT
Battery 12volts
Electrical mock-up/Vehicle
Plan/Working Drawing:
PROCEDURE:
2. Connect wires to the lamp specified as turn signal lights/left and right
terminals of signal light switch. Connect the ground side of the signal
lights to the vehicle body.
3. Connect the center terminal of signal light switch to the (L) terminal of
electronics flasher relay.
9
5. Connect a wire from the fuse box to the ACC terminal of the ignition
switch.
.
6. Connect a wire from B terminal of the ignition switch to the positive
terminal of the battery through the ammeter (if available).
7. Connect the negative terminal of the battery to the vehicle body that
serve as ground.
Note: For safety purposes, negative cable of the battery must be removed
to avoid short-circuit of electrical connections. Check electrical
connections before reconnection of the battery negative cable.
8. Connect wires of the left and right terminals of the hazard light switch
to the left and right terminals of the signal light/switch.
9. Connect the wire of the hazard light switch center terminal to the
(L) terminal of flasher relay.
10.Connect the left terminal of hazard switch to left signal light and right
signal to the right terminal of hazard switch.
10
What is it
TERMINAL
COLOR T H EL ED HU HL HF
CODE (Y/W) (R) (W) (WB) (RY) (RG) (RW)
SWITCH
CONDITION
OFF
ONE STEP ● ●
TWO STEP ● ● ●
HEADLIGHT HI ● ●
HEADLIGHT LO ● ●
HEADLIGHT PASS ● ● ●
LEGEND---------------------------------------------------------------------COLORCODE
H HEADLIGHTTERMINAL-------------------------------------------------- RED
T PARK, TAILTERMINAL---------------------------------------------------YELLOW/WHITE
ED GROUND FORDIMMERSWITCH-----------------------------------------WHITE/BLACK
HF PASSBEAMTERMINAL---------------------------------------------------------RED/WHITE
HU HIGHBEAMTERMINAL------------------------------------------------------RED/YELLOW
HL LOWBEAMTERMINAL--------------------------------------------------------RED/GREEN
11
TO
FUS
TO E
FUS
E 86
HEAD
86
TAIL LIGHT
& 87
PARK RELAY
87 LIGHT 30
30 RELAY
85 85
HF
H LIGHT
T CONTRO
L HL
SWITCH
DIMMER
SWITCH
EW HU
EL
HEAD
LIGHT
TAIL
LIGHT
PARK LIGHT
PLATE
LIGHT
PARK LIGHT
HEAD
LIGHT
TAIL
LIGHT
12
TERMINAL
COLOR TL TB TR B1 F B2
SWITCH CODE (GB (GW (GY (GB (G (GO
CONDITION ) ) ) ) ) )
● ● ● ●
RIGHT
● ●
NEUTRAL
● ● ● ●
LEFT
● ● ● ●
HAZARD
LEGEND---------------------------------------------------------------------COLORCODE
TB COMMON TURNSIGNALSWITCH----------------------------------------GREENWHITE
TR TURNRIGHTTERMINAL-------------------------------------------------GREENYELLOW
TL TURNLEFTTERMINAL------------------------------------------------------GREENBLACK
F BATTERY OFFLASHERRELAY------------------------------------------------GREENRED
B1 BATTERY OFHAZARDSWITCH--------------------------------------------GREENBLUE
B2 FLASHERRELAYFUSE---------------------------------------------------GREENORANGE
Fig. 29 A schematic diagram of horn circuit with relay.
(http://www.google.com.ph)
All the current has to flow through the vehicle’s metal frame and/or body to
return to the negative (-) side of the battery, there are many locations and
connections that can cause high resistance for the entire circuit.
Most cars have ground wires connecting the negative (-) side of the battery
to the car’s body. Remember, all current flowing to any part of the body will
ground to the body, and since the negative (-) battery cable connects to the
engine, there must be an electrical connection between the engine block and the
body. The body is usually electrically insulated from the engine because of the
following rubber insulators.
Lights, horns or other electrical accessories may not operate correctly (or
not at all) if body ground wires are loose or corroded. Transmission and other
drive line problems can also be caused by loose or missing engine to body ground
wires. If these wires are not properly connected, current could flow through dirt
and moisture under the car then through the transmission as it tries to return to
the negative (-) side of the battery.
This current (up to 35A) flows through the drive shaft and transmission.
This current can arc or spark across the transmission bearings and U-joints.
Always check the condition and tightness of all ground wires and do not fail to
reconnect the wires attached to the valve covers and other engine and body
locations.
Soldering lead
Safety glasses
Soldering iron
Electrical tapes
Wire terminal
Wires
TOOLS
Philip screwdrivers
Standard screwdrivers
Electrical pliers
Wrenches (socket and ratchet)
Soldering gun
EQUIPMENT
Battery (12volts)
Electrical mock-up/Vehicle
PROCEDURE:
Automotive wiring could be damaged and will need repair during the
lifetime of a vehicle. You can repair wiring in multiple ways; though it is important
to follow industry standards on the proper way of repairing damaged wiring.
Under this standard, the way of doing it is to solder the broken pieces together to
create a strong bond that is equal to the strength of new wiring.
1. Put on the safety glasses. Disconnect the positive and negative battery
cables from the vehicle's battery using the socket and ratchet.
2. Place a piece of heat-shrink tubing over either side of the broken wire and
slide as far away from the break as possible.
Figure 1. Preparing wires for soldering
3. Trim back the remaining protective coating with the wire trimmers and
provide about an inch of bare wire on each end of the break, then overlap
and twist the wire together, creating a strong connection.
4. Heat up the soldering iron and solder over the twisted wire. When done
correctly the heat will cause the solder to wick into the wiring, creating a
strong joint. Allow to cool and provide a gentle tug to the wire to ensure a
good solder.
Figure 3. Soldering wires.
5. Slide the heat-shrink tubing up and over the bare wire joint and use the
heat gun to shrink the tubing, effectively creating an air-tight seal.
Automotive wires
Combination switch
TOOLS
Electrical pliers
Long nose pliers
Test light
Screwdrivers
EQUIPMENT
Battery 12volts
Electrical mock-up/Vehicle
PROCEDURE:
2. Connect the ground terminal of light control switch (EL) into ground of
vehicle.
3. The headlight terminal (H) is connected to the pass beam terminal (HF)
and connected to the headlight relay.
4. Connect the ground terminal of the dimmer switch (ED) into the ground of
vehicle.
.
5. The high beam terminal (HU) into the high beam of headlight.
6. The low beam terminal (HL) into the low beam of headlight.
8. Jump the wire of headlight relay (86) and (30) and connect to the fuse
terminal.
9. Connect terminal (T) of light control switch into terminal 85 of tail, and
park light relay.
10. The 87 terminal of tail, and park light relay into park light, plate light, and
taillight.
11. Jump the wire of tail, and park light relay (86) and (30) and connect to the
fuse terminal.
I can do this
I cannot do I am learning but I need to I can do this
this yet. how to do learn more and very well.
COMPETENCY this. improve.
Post (1) Post (2) Post (3) Post (4)
Crimps thewires
correctly.
Solders thewires
properly.
Checks the qualityof
works.
Uses thetools/materials
and equipment
appropriately.
Observes safety
measures in crimping
and solderinglead
terminals ofwires.
LEGEND:
20 - Advance
17 - 19 - Proficient
13 - 16 - Approaching Proficiency
8 - 12 - Developing
1 - 7 - Beginning
Post Assessment
Multiple Choice. Directions: This checklist determines your initial
level of knowledge and mastery about to
perform correct procedure for testing and
interpreting schematic diagram of lighting
system.
I can do
I am this but I I can
learnin need to do this
g how learn more very
COMPETENCY
to do and well.
this. improve.
Post (2) Post (3) Post (4)
Uses and interpretsthe
schematic diagram.
Tests thefaults/defects
using appropriatetools.
Ensures the quality of
works.
Uses the tools/ materials
andequipment
appropriately.
Observes safety
measures in testingand
interpreting schematic
diagram.
LEGEND:
20 - Advance
17 - 19 - Proficient
13 - 16 - Approaching Proficiency
8 - 12 - Developing
1 - 7 - Beginning
Additional Activities
I can do this
I am learning but I need to I can do this
how to do learn more and very well.
this. improve.
COMPETENCY Post (1) Post (2) Post (3)
Uses the two relays in
connecting headlights,
park, tail, and platelights
circuit.
Reads the circuitdiagram
of headlights, park,tail,
and plate lights circuit
correctly.
Connects the wires of
headlights, park, tail,and
plate lights correctly.
Uses thetools/materials
and equipment
appropriately.
Observes safetymeasures
in connecting wiresin
combination switches.
LEGEND:
20 - Advance
17 - 19 - Proficient
13 - 16 - Approaching Proficiency
8 - 12 - Developing
1 - 7 - Beginning
LEGEND:
20 - Advance
17 - 19 - Proficient
13 - 16 - Approaching
Proficiency
8 - 12 - Developing
1 - 7 - Beginning
Answer Key
REFERENCES:
Toyota Manual.
http://www.google.com.ph
http://www.autoshop101.com
http://www.wikihow.com.
http://auto.howstuffworks.com
www.autobatteries.com
www.electronics–symbols.com
www.intermotorimport.com
www.ehow.com