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2026.06.17
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Complete Guide to Automotive Wiring Harnesses: Types of Automotive Wires and Automotive Cable Specifications | Taiwan Automotive Wiring Harness Manufacturer OEM/ODM
｜What Is an Automotive Wire Harness?
An automotive wire harness is an integrated wiring system composed of automotive wire, terminals, connectors, protective tubing, and shielding materials. Its primary function is to distribute power and transmit signals between
vehicle electronic modules.
Modern automotive wire harness systems are no longer simple wire assemblies, but highly engineered vehicle electrical architectures. A complete automotive wire harness design must consider current capacity, EMI protection, heat
resistance, waterproofing, mechanical strength, and long-term durability.
｜What are the most common types of wires and cables used in automobiles?
｜What Are Automotive Wire Harness and Automotive Wire? Roles and Importance in EV and Smart Vehicles Explained
｜What are the most common types of wires and cables used in automobiles?
Automotive wiring differs based on applicable international standards (such as Japanese JIS, German DIN, and American SAE). It must meet stringent operational and performance requirements, including high-temperature resistance,
excellent flexibility, and electromagnetic interference (EMI) resistance, to ensure stable and reliable vehicle electrical system performance.
Depending on insulation materials, structural design, and application requirements, FORTOP can provide automotive wire harnesses that comply with required temperature ratings and relevant standards according to customer specifications.
The following are common types of low-voltage automotive wiring harness wires:
|
|
Wire Type / Model |
Name |
Standard |
Temperature Rating |
Characteristics |
Application Range |
|
1 |
AVSS |
Japanese Thin Insulated Low-Voltage Wire |
Japanese (JASO/JIS) |
105°C |
．Thin-wall insulation design
．Lightweight and flexible
．Most widely used by Japanese automakers
．Small wire diameter, lightweight, and excellent flexibility
．helping reduce wiring harness space
|
Interior lighting, instrument panel power supply, and Japanese vehicle wiring harnesses |
|
2 |
AESSX |
Thin Cross-Linked Polyethylene Insulated Heat Resistant Low Voltage Wires |
Japanese (JASO/JIS) |
125°C |
．Cross-linked Polyethylene (XLPE) Insulation
．Suitable for high-temperature environments and electronic equipment wiring
．Uses cross-linked insulation material
．Superior heat resistance and durability compared to AVSS
|
Wiring harnesses, sensor leads, electronic circuits, and internal wiring of onboard equipment |
|
3 |
AV |
Standard Automotive Wire |
Japanese (JASO/JIS) |
85°C |
．Mature design and low cost
．Suitable for general low-voltage circuits
．Traditional low-voltage automotive wiring
．Simple structure and high reliability
|
Power cables, switch control wires, and general automotive wiring |
|
4 |
TXL / XLPE |
Thin Cross-Linked Polyethylene Wire |
US (SAE) |
125°C |
．Excellent heat, oil, and abrasion resistance
．Commonly used in ECU and engine compartment wiring harnesses
．Lightweight with excellent high-temperature and oil resistance
．Suitable for harsh operating environments
|
ECU wiring, engine compartment wiring, and grounding circuits |
|
5 |
GPT |
General Purpose Automotive Wire |
US (SAE) |
105°C |
．Excellent heat, oil, and abrasion resistance
．Commonly used in ECU and engine compartment wiring harnesses
．PVC insulation
．Lower cost and easy to process
|
Low-load circuits and general automotive wiring |
|
6 |
FLRY-A/B |
European Standard Wires (meeting IATF 16949 standards) |
German(DIN) / European (ISO 6722) |
105°C |
．Thin-wall design and lightweight construction
．Widely used in European vehicles and CAN Bus communication systems
．Complies with European ISO/DIN standards
．Small diameter and lightweight
．Type B offers greater flexibility
|
European vehicle wiring harnesses and CAN Bus communication lines |
｜What Are Automotive Wire Harness and Automotive Wire? Roles and Importance in EV and Smart Vehicles Explained
In today’s highly electronic automotive industry, automotive wire harness systems, automotive wire, and automotive wire types have become essential components of smart vehicles and EV systems. From ADAS advanced driver assistance
systems and onboard sensors to Automotive Ethernet and battery management systems (BMS), all electronic functions rely on high-quality automotive wire harness and automotive cable solutions for stable power and signal transmission.
Incorrect automotive wire harness or automotive wire selection may cause voltage drop, overheating, EMI interference, signal attenuation, and even vehicle safety risks. Therefore, understanding automotive wire types and automotive
wire harness design has become critical for OEMs and Tier 1 suppliers.
Accordingly,
FORTOP supports global automakers and Tier 1 customers by providing comprehensive one-stop OEM/ODM customized automotive wiring harness services, covering material selection, design, and manufacturing of automotive
wire harnesses.
｜FORTOP – Your Trusted Automotive Wiring Harness Partner
FORTOP is your reliable partner for high-quality automotive wiring harness solutions. With strong R&D capabilities and customized design expertise, we meet the evolving demands of next-generation Electric Vehicles (EV) and Advanced Driver Assistance Systems (ADAS).
｜FORTOP-Core Strengths
- Certified Expertise & Engineering Capability
Backed by an IATF 16949-certified team, we fulfill diverse customized automotive wiring harness requirements with precision and reliability.
- One-Stop Service
From co-design and engineering development to mass production, we provide comprehensive solutions for automotive wiring harnesses, EV harnesses, HEV harnesses, e-bike harnesses, and electric bus harnesses.
- Rapid Prototyping & Mass Production Support
Experienced in handling highly complex harness structures, we ensure fast lead times and stable production support
｜How to obtain a customized quotation for automotive wire harness?
If you are looking for a reliable manufacturer of customized automotive wire harness, please contactFORTOP. We provide automotive wire harness
solutions tailored to your requirements.
．https://www.fortop-wireharness.com/
