What do you know about Low voltage
harnesses?
©Leoni
Introduction
A low voltage (LV) wire harness is an electrical assembly designed to transmit
low voltage power (typically below 50V) for various vehicle functions. The
harness bundles multiple cables, connectors, terminals, protective elements,
grommets, clips, and other components.
These harnesses are engineered to optimize wiring routing, reduce assembly
complexity, and ensure safe and electrical connections.
Depending on the application’s size and complexity, wire harnesses vary in
component count, length, and functionality.
Harness applications
Module Name Functions Example Components Wire Types / Signals
Front End Module Headlights, sensors, horn, LED DRLs, radar unit,
Power, LIN, CAN, PWM
(FEM) front fog lamps ambient light sensor
Instrument cluster, HVAC,
Touchscreen, push-button LV power, CAN, LIN, MOST,
Cockpit / Dashboard infotainment, start/stop,
start, climate control unit USB, Ethernet
buttons
Overhead lighting, sunroof, Dome lights, sunroof
Roof Module LIN, low current power
microphone, rain/light sensor motor, SOS button
Window lifts, door locks,
Mirror control, window CAN/LIN, power, speaker
Door Modules mirror adjustment, puddle
switches, speaker wires (twisted pair)
lights
MAF, MAP, knock sensor,
ECU, injectors, sensors, Shielded signal wires,
Engine Compartment cam/crankshaft position
starter, alternator twisted pairs, power
sensor
Chassis/Body Brake system, ABS, ESP, fuel Wheel speed sensor, brake CAN, twisted pair, shielded
Module tank sensor lights signal
Taillights, rearview camera, Park assist, reverse lamps,
Trunk/Rear Module Power, LIN, CAN
power liftgate electric tailgate actuator
Harness applications
© Car body Ex Peugeot/Stellantis
Wire and cable coding
Cross
Typical
Section Application Signal Type
Current
(mm²)
0.13 mm² ~2–3 A Sensor signals (e.g., air temp, rain/light sensors) Analog / digital signal
0.22 mm² ~4–5 A LIN bus, CAN-H/L, switches, logic signals Low-current digital
0.35 mm² ~6–8 A Door lock signal, dashboard switches, ECUs Signal / control
0.5 mm² ~9–10 A Headlamp control, small motors, sensors with higher load Signal / low power
0.75 mm² ~10–15 A Light power, power windows, relays LV power
1.0 mm² ~15–20 A Power mirrors, seat adjustment, blower motors LV power
1.5 mm² ~20–25 A Fuel pump, starter signal, wiper motors LV power
2.5 mm² ~25–30 A Heated seats, rear defroster, central locking motors Power
4.0 mm² ~35–40 A Air suspension, A/C compressor clutch, fan relays Power
6.0 mm² ~45–60 A Power distribution to ECUs, high-demand devices Power
10 mm² ~70–90 A Main battery feed (12V), power electronics Power
16 mm² ~100–120 A Starter cable (12V), small EV battery modules Power
25 mm² 120 – 150 A Battery to fuse box, high-demand ECUs, medium load grounding Power
Battery to starter motor, Alternator to battery, power to
35 mm² 150 – 180 A Power
junction/fuse box
Battery to powertrain harness, high power systems (Mild hybrid)
50 mm² 180 – 220 A Power
inverter), heavy load grounding
Wire and cable coding
In automotive low voltage (LV) wire harnesses, wire colors help identify the function,
polarity, and circuit type. These are typically defined by OEM specific standards, but the
following color conventions are widely used across the industry.
Color Meaning / Function
Black Ground / Earth
Red Battery positive (12V) / Unswitched power
Yellow Switched power (ignition-controlled)
Green Signal / control wires (e.g., indicators, wipers)
Blue Lighting circuits, diagnostics, or CAN-B
White Sensor signal or logic-level data
Brown Ground (used in European OEMs like VW/Audi)
Gray Interior lighting, optional circuits
Purple Diagnostic lines or optional accessories
© Chunbin
Orange Data bus (CAN, LIN, FlexRay, Ethernet)
Pink Optional equipment / control relays
Wire and cable coding
In two color wires, the base color indicates the main function, and the stripe color
indicates a secondary circuit or routing group.
Base / Stripe Typical Use Example of application
Ground variant / chassis return Used in engine or body
Black / White
path harness
Battery + (red) through lighting
Red / Blue Tail lights or interior lighting
© ebay (blue) circuit
Ignition-switched line to sensor Ignition system or ECU power
Yellow / Green
or ECU input
Headlamp or fog lamp
Blue / Red Lighting control via battery
control
Logic signal routed via control Window switch or module
White / Green
unit control
Orange / Black CAN High or CAN Low CAN Bus communication
Ground with logic return or
Brown / Red ECU signal ground
sensor reference
© prowireusa
Wire and Norm
Every wire and cable in an automotive system is designed for a specific electrical, thermal, and
mechanical application, following ISO standards or OEM specifications, below examples of
applications and norms.
Application Example Function
0.35 mm² twisted pair wire for CAN Low voltage data signal
Electrical
communication transmission
Silicone insulated 1.5 mm² wire rated up to High temp operation near
Thermal
200°C for engine bay harness exhaust and flexibility
6 mm² shielded cable with XLPE or PP
Mechanical Vibration and abrasion resistance
insulation routed under chassis
ISO 6722-1 : LV single-core cables up to 60 V and 600 V, for general automotive
ISO 19642 : High-voltage cable specs for HEV/EV applications (up to 1000 V)
ISO 14572 : High-temp single-core cables with thin insulation
ISO 16750-2 : Electrical loads and environmental testing for cables
ISO 21848: Requirements for electrical safety in hybrid/electric vehicles
LV112 / LV214 : Performance & testing of LV/HV cables (valid for German OEM’)
VW 60306 : Specification of conductor materials and constructions (for VW Group)
JASO D611 : Low Voltage Cables for Automobiles (Japaneese OEM’s)
SAE J1128 : Low Voltage Primary Cable (US OEM’s)…..
Coming Up Next
In the next post, I’ll dive deeper into connection systems specifications, applications
and accessories.
Stay tuned for deeper insights into automotive systems, wire harness technology,
and the industry!
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