1700_3.pdf

hapter 7. Electrical system

Wiring and fuses

7 (8 Ä)

Left-hand front lamp (side marker light)

Right-hand front lamp (side marker light)

Number plate light

Side marker warning light

The electrical system is of the single-wire negative earth

type. The vehicle basic wiring diagram is illustrated in Fig.7-1.

Most electrical circuits are powered when the ignition is

switched on. Regardless the ignition switch position, the follow-

ing functions are available: horn, stoplight, cigarette lighter, inte-

rior lamps, inspection lamp, hazard warning flashers, exterior

lighting and main beam.

Most of the vehicle electrical circuits are protected by fuses,

which are located beneath the facia, at the left-hand side of the

steering column (Fig.7-2). There are no fuses for battery charg-

ing, ignition and engine start-up (starter and alternator) circuits,

main/dipped beam relay. Extra fuses 11, 12, 14, 16 are provided

in the additional fusebox to be used for alternative vehicle speci-

fications.

Before renewing a blown fuse, isolate and remedy the cause.

Before attempting to diagnose any electrical fault, refer to Table

7-1 to study the relevant wiring diagram protected by a failed

fuse.

8 (8Ä)

Right-hand rear lamp (side marker light)

Left-hand rear lamp (side marker light)

Instrument panel illumination

Heater control illumination lamp

Cigarette lighter illumination

Switch illumination

9 (16Ä)

Direction indicators and indicators hazard relay

(hazard flashers mode)

Tailgate heating element and switch-on relay

(contacts)

10 (16Ä)

Horn

Inspection lamp socket

Interior lamps

Tail lights (stop lamp bulbs)

13 (8Ä)

Tail lights (fog lamps)

Headlight wiper motors at start-up and

when wiper arms pass initial position

Headlight wiper relay (contacts)

Headlight washer motor

Table 7-1

Fuse-protected circuits

15 (16Ä) Cigarette lighter

________________________________________

* Pre-1996 vehicles were fitted with a voltmeter (protected by fuse No2) instead

of the relevant warning light in the instrument cluster.

Fuse No

Circuit protected

1 (16 Ä)

Heater blower motor

Headlight wiper relay (winding) and headlight wiper

motors at all wiper positions, except initial

Heated tailgate relay (winding)

Tailgate wipe/wash motors

Windscreen washer motor

In all wiring diagrams, covered by chapter ÇElectrical sys-

temÈ, the letters are used to denote the respective colour code:

the first letter stays for the wire colour ñode, while the second let-

ter - for the tracer colour code (Table 7-2).

2 (8 Ä)

Windscreen wiper relay and motor

Direction indicators and indicators flasher relay

(turn indication mode)

Direction indicator warning light

Tail lights (reversing lamp)

Alternator winding (at engine start-up) and

low battery warning light*

Differential lockup warning light

Relay and handbrake-on warning light

Low brake fluid warning light

Oil pressure warning light

Coolant temperature gauge

Low fuel gauge and fuel reserve warning light

Tachometer

Table 7-2

Fuse colour codes

Letter

Colour

White

Blue

Yellow

Green

Brown

Orange

Red

Pink

Grey

Black

WARNING. Always disconnect the battery negative lead

when making repairs on the vehicles or its electrical system.

When replacing fuses or checking wiring, never use fuses

other than those specified for a particular vehicle model as

it may damage current tracks in the fuse and relay box.

3 (8Ä)

Left-hand headlight (main beam)

Main beam warning light

4 (8 Ä)

Right-hand headlight (main beam)

5 (8 Ä)

Left-hand headlight (dipped beam)

6 (8 Ä)

Right-hand headlight (main beam)

135

Fig.7-1. Electrical system of VAZ-21213 vehicle:

1 - left-hand front headlamp; 2 - headlights; 3 - left-hand headlamp wiper motor; 4 - horn; 5 - fuel cutoff solenoid; 6 - idle switch; 7 - headlight washer motor; 8 - right-hand

headlight wiper motor; 9 - right-hand front headlamp; 10 - side repeaters; 11 - battery; 12 - heater motor; 13 - heater motor complimentary resistor; 14 - differential lockup

warning light switch; 15 - windscreen wiper relay; 16 - starter motor; 17 - windscreen wiper motor; 18 - alternator; 19 - windscreen washer motor; 20 - fuel cutoff solenoid

control unit; 21 - spark plugs; 22 - ignition distributor; 23 - spark control module; 24 - ignition coil; 25 - temperature gauge sender unit; 26 - oil pressure warning light sender;

27 - inspection lamp socket; 28 - brake fluid level warning light switch; 29 - headlight wipe/wash relay; 30 - rear window heating relay; 31 - main beam relay; 32 - dipped

beam relay; 33 - ignition switch relay; 34 - starter motor relay; 35 - complimentary fuse box; 36 - main fuse box; 37 - indicators flasher relay; 38 - reversing light switch; 39

136

- stop light switch; 40 - cigarette lighter; 41 - exterior light switch; 42 - heater controls illumination; 43 - rear fog light switch; 44 - rear window heating switch; 45 - heater

motor switch; 46 - rear window wipe/wash switch; 47 - hazard warning flasher switch; 48 - ignition switch; 49 - instrument lighting switch; 50 - windscreen wiper switch; 51

- switch, windscreen washer & headlamp wipe/wash; 52 - horn switch; 53 - direction indicator switch; 54 - headlight switch; 55 - choke warning light switch;

56 - choke warning light; 57 - door courtesy light switches; 58 - interior lights; 59 - rear window washer motor; 60 - instrument cluster; 61 - handbrake warning light switch;

62 - fuel level and fuel reserve gauge sender unit; 63 - rear lights; 64 - number plate light; 65 - rear window wiper motor; 66 - rear window heating element;

Ä - pin assignment in steering column combination switch connector

137

Dry-storage battery - putting into operation

Fig.7-2. Fuses

The vehicles are factory-fitted with ready-to-use batteries, i.e.

batteries filled with electrolyte and fully charged.

Replacement batteries can be supplied dry, without elec-

trolyte. In order to operate such battery, first remove any provi-

sional plugs or masking tape. Then using a funnel (made of glass

or acid-resistant plastic), slowly fill the battery with electrolyte (at

25¡) of 1.28 g/cm 3 for normal climates or 1.23 g/cm 3 for tropics.

All procedures required to activate the battery should be per-

formed at the ambient temperature of (25±10) ¡ .

Allow 20 minutes for the internal plates and separators to sat-

urate well in electrolyte. Then check the battery voltage without

loads.

The battery is ready for use when its voltage reading is at

least 12.5 volts. At values below 12.5 volts but over 10.5 volts, the

battery should be recharged to the output voltage which is spec-

ified by the manufacturer. The battery is rejected when the volt-

age is equal or below 10.5 volts.

The saturation of internal plates and separators normally

results in a lower electrolyte level. Therefore, top up the battery

with electrolyte of the original specific gravity before refitting it to

the vehicle.

Always re-charge the battery after it is filled with electrolyte in

the event:

- the battery will be initially operated in heavy duty conditions,

in cold weather, at frequent engine starts, etc.;

- the battery has been stored for over 12 months from the

date of manufacture.

Battery

Specification

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55Ä, maintenance-free

Maximum voltage,volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Maximum capacity (at 20-hour

discharge rate and initial electrolyte

temperature of (27±2)¡, ampere-hour . . . . . . . . . . . . . . . . . . . . . 55

20-hour discharge amps rate . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.75

Cold start amps rating (with running starter motor

and electrolyte temperature of -18¡) . . . . . . . . . . . . . . . . . . . . . . 255

Fault diagnosis

Cause

Remedy

Battery discharge in operation

1. Alternator drivebelt slipping

2. Battery surface dirty

3. Damaged insulation in electrical

equipment system (discharge rate

exceeds 11 mÄ with loads discon-

nected)

4. Too many accessories fitted by

vehicle owner

5. Alternator faulty

6. Electrolyte contaminated

1. Adjust belt tension

2. Clean battery surface

3. Locate battery leak and remedy

the situation

Electrolyte level - checking

Electrolyte level in all battery cells must be maintained

between the ÇMINÈ ÇMAXÈ marks on the translucent battery

case. Never try to use the battery with the electrolyte level below

the ÇMINÈ mark.

In the course of vehicle operation the electrolyte level gradu-

ally decreases due to water evaporation. Only distilled water

should be used to top up the battery.

If spillage is suspected to be the cause for low electrolyte

level, always add electrolyte of the same specific gravity as that

remaining in the battery cell. When overfilled, remove excessive

electrolyte using an ebony-tipped rubber bulb.

4. Disconnect new electrical con-

sumers

5. Check alternator

6. Charge battery, drain electrolyte,

flush, fill with new electrolyte and

recharge battery

7. Renew battery

8. Restore electrolyte level

7. Short-circuits between plates

8. Electrolyte level below top plate

edge

Electrolyte on battery cover

1. Too high electrolyte level caus-

ing spillage

2. Electrolyte leaks through frac-

tures in battery case

3. Electrolyte boiling due to

excessive alternator voltage

4. Electrolyte boiling through plate

sulfation

1. Replenish electrolyte as required

Battery charge level- checking

2. Replace battery

Always measure the battery charge with a hydrometer (are-

ometer) during servicing or in the event of the battery failed in

operation. At the same time measure the temperature in order to

account for temperature correlation (Table 7-3) of hydrometer

readings.

3. Replace alternator

4. Replace battery

138

Table 7-3

- when electrolyte is ÇboilingÈ. Wait to see bubbles rising to

the surface in the electrolyte, sampled with a hydrometer.

Temperature correction values to hydrometer readings

for measuring electrolyte density

Battery charging

Electrolyte temperature, ¡ Correction value, g/cm 3

-40 to -26 -0.04

-25 to -11 -0.03

-10 to +4 -0.02

+5 to +19 -0.01

+20 to +30 0.00

+31 to +45 +0.01

With electrolyte temperatures over 30¡, the correction value

is added to actual hydrometer readings. When electrolyte tem-

perature is below 20¡, the correction value is subtracted. The

correction value is not applied when electrolyte temperature is

within 20 to 30¡.

Once you have measured the electrolyte specific gravity in

each battery cell, determine the state of the battery charge using

Table 7-4. Withdraw the battery from the vehicle for re-charging

when it is discharged in excess of 25 percent in winter time or 50

percent in summer time.

When measuring electrolyte density, take care not to drip

electrolyte on the battery cover, case, body or other parts.

Electrolyte contains hazardous sulfuric acid which causes corro-

sion, current leaks, etc.

Do not measure the electrolyte specific gravity in the follow-

ing cases to exclude wrong readings:

- when the electrolyte level is not as required;

- when electrolyte is too hot or too cold; the optimum temper-

ature to measure electrolyte specific gravity is 15-27 ¡ ;

- immediately after the battery replenishment. Leave the bat-

tery for some time to let the electrolyte mix up; it may take up to

several hours if the battery has been fully discharged;

- after a number of start-up attempts. It is advisable to wait

until electrolyte in the battery cell is homogeneous in terms of

density;

Remove the battery from the vehicle and clean it carefully,

especially its top. Check the electrolyte level and replenish, if

applicable.

The battery is recharged at a rate of 5.5 amperes with the

caps undone. Charge the battery until intensive gas escape is

observed and consistent voltage and electrolyte specific gravity is

achieved within three hours. The electrolyte density of the

charged battery at 25 ¡ should be as shown in Table 7-4.

When recharging the battery, frequently check the electrolyte

temperature to keep it below 40 ¡ . When 40 ¡ is reached, then

either halve the charging current or stop recharging to cool the

battery down to 27 ¡ .

Stop charging the battery in case of intensive gas escape

from the battery cells and when the last three measurements

(taken hourly) show no changes in voltage and specific gravity.

If at the end of the recharging procedure the electrolyte spe-

cific gravity (after temperature correlation) differs from that spec-

ified, adjust it accordingly. In case of higher specific gravity,

remove some electrolyte and top up distilled water, while in case

of lower specific gravity - remove some amount of lower specific

gravity electrolyte and add some higher specific gravity elec-

trolyte (1.4 g/cm 3 ).

After the electrolyte specific gravity has been duly adjusted,

continue to charge the battery further 30 minutes for better elec-

trolyte mixing. Next disconnect the battery and after 30 minutes

check the electrolyte level in all cells.

When electrolyte is below the level required, pour in elec-

trolyte of the specific gravity which is recommended for that cli-

mate (Refer to Table 7-4). When electrolyte level is above that

required, remove excessive amount using a rubber bulb.

Table 7-4

Electrolyte specific gravity at 25¡, g/cm 3

Climate (average

Season

Fully discharged

Battery discharged

January temperature, ¡

battery

by 25%

by 50%

Very cold (from -50 to -30)

Winter

1.30

1.26

1.22

Summer

1.28

1.24

1.20

Cold (from -30 to -15)

All seasons

1.28

1.24

1.20

Moderate (from -15 to -8)

All seasons

1.28

1.24

1.20

Warm and damp (from 0 to +4)

All seasons

1.23

1.19

1.15

Hot and dry (from -15 to +4)

All seasons

1.23

1.19

1.15

139

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