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Understanding the relays

Quick facts :

A little lament

Electrical problems can be sorted in two categories : "before relay" and "after relay". Relay themselves, as they connect two systems, are important places to look at when you investigate electrical issues. They can be faulty (not so frequent), but also they are normally placed in reachable location from where it is possible to test the wiring connections before they dig into the body of the car.
The "relay" section of the Workshop Manual (M10) does list some relays and their applications, but this is far from exhaustive. In my case for example, the relay box (right hand side of the bulkhead) only shows five relays, when they are supposed to be 6 according to the manual. Furthermore, the relays IDs listed in the WM table are not the actual one that I could find in my car.
Relays are fitted about everywhere in the car, so a thorough reading of the "good" wiring diagram is necessary, but here too, it is not enough. The relays locations are not given in the theoretical diagram, assuming that you were able to find the one that matches your car. Not mentioning the diverse modifications your car would have come through during the last decades... But let's not loose optimism

5 relays fitted in the printed circuit board (PCB) to be found in the relay box attached to the bulkhead, SY 1976

Possibles resources

The wiring diagram - Assuming that the wiring diagram (for RH car > VIN 13681 see page 274 of the Wiring Diagram part of the Workshop Manuals) is a good starting base but not the best possible, because this document as it is available on the Australian RR technical library is dated 1973. My car is 1976.
The Workshop Manual -
The relays IDs
The wires colours

Wiring Diagram

This document lists the following relays

SystemRelay name on WDDescriptionWiring
Starter motorStarter Relay(5 contacts, not marked) Operates the starter motor and solenoidBrown Cotton - White Green Plastic - White Yellow Plastic
ParkingAuto Park Relay(W1-W2 / C1-C2) Links the gear range selector switch and the ignition switchRed Yellow Cotton -> W1; Red Green Plastic -> W2; Black Brown Plastic -> C1
Warning lampsBreak Warning Lamp Test Relay(W1-W2 / C1-C2-C4)Green Plastic -> W1; Green Purple Plastic -> W2; Black -> C2; Yellow Green Plastic -> C4; White Green Plastic -> C1
Warning lampsFuel Warning Lamp Dimming Relay(W1-W2 / C3-C2) Linked to low fuel warning lamp and to fuse #7 Black Plastic -> W1; Red Plastic -> W2; Green Plastic -> C2; White Purple Plastic -> C3
Warning lampsCoolant Warning Lamp Test relay((W1-W2 / C2-C3) Linked to Fuel Warning Lamp Dimming Relay on W1-W2 and to Coolant Probe, Coolant Level AmplifierGreen Plastic -> W1; Green Purple Cotton -> W2; Blue Green Plastic -> C2; Blue Green Plastic -> C3
Stop LampsStop Lamp Relay(4-5-6 / 7-8) Linked to Stop Lamps; to Handbrake Micro Switch; to Stop Lamp Switch; to Dimming RelaysBlack -> 8; White Green Plastic -> 4; White Green Plastic -> 6; Purple White Plastic -> 5; White Blue Plastic -> 7
Hazard WarningHazard Warning Relay(W1-W2 / C1-C2x2linked-C4) C2 linked to Hazard Warning Flashing Unit; W1 same; W2 ground; C1 to Direction Indicator Flasher Switch; C4 sameGreen Brown Plastic -> W1; Black -> W2; Green Red cotton -> C1; Green Blue cotton -> C2
Direction Indicators, Stop LampsDimming Relay(W1-W2 / 1-4 / 2-5 / 3-6 / 7-8 /9-10) linked to Stoplamp Switch; to rear, front, flashers and repeaters; W1 to hazard flasher unit and switch; W2 to ignition switchGreen Brown Plastic -> W1; Red Blue Cotton -> W2; Purple White Plastic -> 7,8,9,10 and 1; Green Black Cotton -> 2; Black White Cotton -> 3; White Purple Plastic -> 4; Green Red Cotton -> 5; Green White Cotton -> 6
HoodHood Relay(W1-W2 / C1-C2) linked to Hood SwitchWhite Cotton -> W1; Blue Brown Cotton -> W2; Green Plastic -> C1
Head LampsHead Lamp Flash Relay(W1-W2 / C1-C2) W1 linked to Head Flash Switch; W2 to fuse 5; C3 to Dip Switch then Head Lamp Safety RelayBrown Blue Plastic -> W1; White Cotton -> W2; Blue White Plastic -> C3
Head LampsHead Lamp Safety Relay(4 contacts, not marked) Connected to Dip Switch, to Head Safety Cut Out, to Main Beam Warning Lamp, to (L) and (R) Head LampsBlue White Plastic; Blue Red Plastic; Blue White Cotton
HornHorn relay(W1-W2 / C2-C3) W1 linked to horn button; C2 to fuse 3; C1 to hornsPurple Black Plastic -> W1; Purple Cotton -> C2; Purple Yellow Plastic -> C3
Blower motorBlower Motor Relay(W1-W2 / C2-C3) linked to Blower SwitchGreen Black Cotton -> W1; Green Cotton -> W2; Yellow Plastic -> C2 and C3
Radio and TapeRadio / Tape Change Over Relay PCContacts 1 to 12Purple Blue cotton; Slate Blue Plastic; Black
Speed RegulatorSpeed Regulator Relay(W1-W2 / C2-C3) Connects to RegulatorBlack -> W1 and C2; White Purple Plastic -> W2; Purple White Cotton -> C3
Air conditioningWater Tap Relay 1(W1-W2 / C1-C2-C3) to Water Tap ActuatorWhite Red Plastic -> W1; Yellow Purple Plastic -> W2; White Purple Plastic -> C1; Green Plastic -> C2; White Yellow Plastic -> C3
Air conditioningWater Tap Relay 2(W1-W2 / C2-C3) to Compressor Clutch; to Heater SwitchBlack -> W1; White Blue Plastic -> W2; Yellow Purple Plastic -> C2 White Red Plastic -> C3
SeatsElectrically Operated Seats relays (LH)(4 contacts, not marked); 2 symmetrical relays between motor and switchBlack Yellow Plastic / Black Blue Plastic
SeatsElectrically Operated Seats relays (RH)(4 contacts, not marked); 2 symmetrical relays between motor and switchGreen Blue Plastic / Green Red Plastic

Workshop Manual

We refer to section 10 of the WM starting page M63. The point is to check whether the parts mentioned in the WM apply to my car, in order to check for alteration or even missing items.

My car (June 1976) can be considered as "late refrigerated" as to this manual reprinted in nov 1976. Refrigerate means equipped with AC.

This document mentions a relay box connecting relays to the wiring loom through a printed circuit board (PCB) and also relays fitted apart from the PCB, behind the front cover of the relay box

1- Behind and on top the relay box
Three types of regulators (also called alternator control units) were used from oldest to newest : Lucas RB340; Lucas 4TR going with alternator 11AC; and in my case a CAV Control box going with the C.A.V. 512 alternator.

There is also this relay which remains to identify (labelled 33222). It could be one of those three : Brake Pressure relay, Coolant Probe relay, Ignition Warning Lamp / Choke relay which are supposed to be standing under the relay box cover on older cars. :

There was also these two elements, mentioned in the WM : a choke thermal delay switch (Scintilla) a regulator capacitor
OK so everything is in place.

2- On the printed circuit
Left is how the WM locates the relays and right is my relay table
A is labelled 33298 - Alternator field
B 33269 - ?
C 33270(0) - Head Lamp, Safety ignition warning lamp and choke, Additional Water Tap and Rear Window Demister
D 33270(0)
E 33270(0)
You can notice that only the relay marked C matches...

The wiring loom

There are 5 connectors under to the PCB :

Two connections : Black cotton, Black plastic : black is GROUND
Three connections (plastic) : White Purple, Green (FUSED IGNITION CONTROLED), White Yellow
Three connections (plastic) : Blue, Blue Red (double)
Six connections (plastic) : Green black (double), Blue, White Purple, White Blue, Yellow Purple
Six connections : Black Purple (plastic), Purple Yellow (plastic), Purple (cotton) double, Blue Black ((plastic) double, Blue White (pl astic), White (cotton) double


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