Руководство How to Read Wiring Diagrams - Symbols, Layout and Navigation

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How to Read Wiring Diagrams
Self-Study Program
(для перевода используйте в браузере правую кнопку мыши -> "перевести на русский" )

Introduction
Wiring Diagram Overview, Layout
Navigation
Elements of a wiring diagram, Symbols, DIN 72 552
Introduction to Conductors, Wires, Wire colors, Wire sizes, Other Conductor descriptions
Connector Pin Assignments
Components
Layout
Practical Examples
Navigation 1, Navigation 2
Navigation 3, Navigation 4
Appendix A: Component Symbols
Appendix B: Wiring Connections
Appendix C: Component Codes and Wiring
Appendix D: DIN Standards.
Appendix E: Wiring Diagrams
Glossary

Course goals

This course will enable you to:
• Follow current from its power source to the Ground point quickly and accurately.
• Understand the symbols of common components and circuit designations used in Volkswagen Wiring Diagrams.
• Practice Wiring Diagram navigation through practical exercises and hands on examples.


Introduction

As today’s vehicles become increasingly complex, so does the job of the technician.
Wiring diagram navigation skills are critical to diagnosing and repairing today’s vehicle in a timely and accurate manner.

This Self Study Program is not intended to instruct the technician how the electrical system operates in a vehicle.
Given an understanding of electrical operation, this Self Study Program will introduce you to the skills necessary to read Volkswagen wiring diagrams.

In this program you will be exposed to all aspects of wiring diagrams, including:
• Commonly used symbols and their meanings
• Current tracks, including how to follow circuits between pages or diagrams
• Component identification
• DIN standards for terminal designations
• Wiring color codes and gauge (size)
• Terminal identification on both connectors and components

 

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Wiring Diagram Overview

Overview
Volkswagen wiring diagrams are a graphic representation of the actual vehicle wiring.
They are developed from the engineering drawings that are used to produce the wiring harness. A consistent set of symbols are used to represent the actual components and conductors.
Volkswagen electrical systems and wiring diagrams follow the German DIN (Deutsche Industrie Norm/Deutsches Institut für Normung) standards.
These standards are guidelines for manufacturing in Germany, similar to SAE (Society of Automotive Engineers) in the United States.

Layout
The layout of wiring diagrams is common to all Volkswagen vehicles. Called “Current Track” wiring diagrams, they show the power source at the top of the page and the Ground points at the bottom.
Situated vertically between power and Ground are the current tracks, which contain electrical components and conductors.
This current track layout simplifies the wiring diagram. Conductor symbols crossing where they do not connect is kept to a minimum.
Refer to the example on page 3 for the basic layout of the wiring diagram.

Central/relay panel
The central/relay panel is indicated in gray at the top of the wiring diagram page.
The central/relay panel includes common power circuits, such as battery power (30), ignition switched power (15), load reduction (75/X), and Ground (31).

Ground Connections
Ground connections are represented as a line at the bottom of the wiring diagram page, directly above the current track numbers.
All Ground connections, whether they occur as a splice in a harness, or the final Ground source, are numbered and identified in the wiring diagram.

Conductors and components
Between the central/relay panel and the vehicle ground at the bottom of the diagram are located the component symbols and conductors.
Components are marked with a component code listed in the legend.
Conductors are generally marked with wire color and size.

Current tracks
Individual current tracks are identified numerically along the base of the wiring diagram.
These numbers are used to find the continuation of a conductor. Where the system or circuit layout is complex, this continuation may be on the same page, or on a different page.
For example, the number 191 inside of the small box on page 3 indicates that the wire is continued on current track 191. Following straight down on the diagram, we see that this wire is on current track 5. If we were to navigate to current track 191, we would see the same color and size wire with a small box containing the number 5.

Legend
Below the current track numbers you’ll find a legend of the components (by component code) found in the specific diagram. This will often detail the location of a given component or connection.

 

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Navigation

Navigation in the wiring diagram is based around the use of the current track numbers.
You will generally start with the affected component and then follow the associated circuit from there, tracing Power, Ground, and signals that affect the component’s operation.

 

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Elements of a wiring diagram

In this section, we will look at how various symbols are used in a wiring diagram to represent the actual components on the vehicle.
Every circuit needs a minimum of the following to operate:
• Power supply
• Consumer (load)
• Ground
• Conductors (usually wire)
If any of these are missing, a complete circuit is broken and the consumer will not function. The ability to break down a circuit
into its individual parts is the key to being able to diagnose failures in the circuit.

Wiring diagrams incorporate many symbols used to illustrate a complete circuit.
These symbols can include:
• Current track numbers
• Components
• Terminal designations
• Conductors
• Connectors
Together these components make up a complete and accurate wiring diagram.

Symbols
Graphical representations called "symbols" are used to represent components and conductors in wiring diagrams.
The key to reading wiring diagrams is understanding the symbols.
These symbols are standardized, allowing quick recognition of various components.

DIN Standard 72 552
This standard applies to the terminal designations for circuits.
The purpose of the terminal designation system is to enable accurate connection identification from conductors (wires) to various components when diagnosis and repair is necessary.

Examples of DIN standards for terminal designations are shown below:
1 Ignition coil primary
4 Ignition coil secondary
15 Ignition switched, on and start
30 Battery +
31 Ground
31b Switched Ground
50 Starter control
75/X Load Reduction/Ignition switched on only

The terminal designations do not identify the wires, but the type of circuit.
For this reason, the designations are not placed on the wires in the diagram, but on the component.
Refer to Appendix D on page 36 for a more complete list of terminal standards.
Be aware that some abbreviations are used, and they may be abbreviations of German words.
For example, “GRA” is the abbreviation for “cruise control”, and VL is the abbreviation for “left front.

 

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Introduction to Conductors

The wiring harness and related components may contain many different types of conductors, including wires, internal connections, threaded connections, welded connections, push-on connectors, multiple point connectors and Ground.
The complete list of wiring connections and symbols is shown in Appendix B.

Wires
Wires are conductors that carry current to components, and are usually indicated by a solid line.
A wire shown as a dashed line in a wiring diagram indicates that the wire does not apply to all vehicles, and is noted in the wiring diagram legend.

Wire colors
Knowing the standards for wiring colors makes the job of reading and interpreting them easier.
Some of the common standards include wiring color for specific circuits, as well as the terminal designation.
For example:
Red . . . . . . . . . . . . . . . . . . . Battery +
Green. . . . . . . . . . . . . . . . . . Ignition (1)
Brown . . . . . . . . . . . . . . . . . Ground (31)
Yellow . . . . . . . . . . . . . . . . . Headlights (58)

Once the technician has an understanding of the color guides, the job of isolating systems becomes easier.
Wire colors are shown as abbreviations of the German word for the color.

The following list