Electronic and computer controlled systems  course 673 technician handbook

Electronic & Computer Controlled Systems Course 673 Technician Handbook © 2009 Toyota Motor Sales, U.S.A., Inc TOYOTA Technical Training All rights reserved This book may not be reproduced or copied, in whole or in part by any means, without the written permission of Toyota Motor Sales, U.S.A., Inc Revision Date: June 22, 2009 Tai ngay!!! Ban co the xoa dong chu nay!!! Table of Contents 673 Electronic & Computer Controlled Systems Objectives Final Student Performances a Section 1: Diagnostic Techniques and Tools Course Menu Section Topics Electronic Control Units How ECUs Work Logic Function Simple ECU Inputs Voltage ON/OFF (Switch) Input Variable Voltage Input 10 Variable Resistance Input 11 Pulse Pattern Input 12 Simple ECU Outputs 13 Transistors as Switches 13 Pulse Width Modulation 14 Duty Cycle 15 Power-Side Control 16 Self Diagnosis 17 Differences in Self-Diagnosis 17 ECU Memory 19 Types of ECU Memory 19 Customization 20 Initialization 21 Why Initialize? 21 Section 2: Overview of Multiplex Communication Section Topics Why Use Multiplexing Applications of Multiplexing Benefits of Multiplexing Multiplexing ECU Communication Signaling Between ECUs Communication Protocols Multiplex Topology Ring Topology Two Opens in a Ring Network Open in a Star Network Open in a Bus Network Single Wire vs Twisted-Pair Advantage of Twisted-Pair Wiring 23 24 24 24 25 26 27 28 29 30 31 32 33 34 35 Section 3: Signals & Waveforms Section Topics Electronic Communication Types of Waveforms Waveform Measurements Amplitude 37 38 38 39 39 Technical Training i Table of Contents 673 Electronic & Computer Controlled Systems Frequency 40 Pulse Width 41 Duty Cycle 42 Section 4: Measuring Signals Section Topics The Oscilloscope PC Oscilloscopes Basic Operation Oscilloscope Scales Repair Manual Suggested Scales Repeating vs Changing Patterns Capturing Waveforms Scope Pattern Comparison The Effect of Scale Trigger Function Other Trigger Uses Advanced DVOM Features MIN/MAX Recording Peak MIN/MAX Relative Delta Frequency Measurement Duty Cycle Worksheet: DVOM Set-up & Advance Features Instructor Demo: Using DVOM Resistance Setting 43 44 45 46 47 48 49 50 51 52 53 54 55 55 55 55 56 56 57 58 Section 5: Using a PicoScope™ Section Topics Introduction to PicoScope™ Connecting the Leads PicoScope Features Auto Voltage Scale Auto Setup Manual Voltage Scale Settings Manual Time Scale Settings Turning the Trigger On Setting the Trigger Start and Stop Capturing Horizontal Zoom Rulers Sample Rate Displaying Two Channels Separating the A-B Traces Printing, Saving and Sending Patterns Worksheet: In-class PicoScope: Basic Set-up Worksheet: Using DVOM & PicoScope Instructor Demo: PicoScope & Power Window Circuit 59 60 60 61 61 61 62 62 63 64 65 66 67 69 70 71 72 73 74 74 ii Technical Training Table of Contents 673 Electronic & Computer Controlled Systems Section 6: Using an Inductive Clamp Section Topics The Inductive Clamp Polarity Current Rating Preparation for Use Converting Measurements to Amps Amp Clamp Applications Diagnosing Short Circuits and Parasitic Draw Diagnosing Motor Faults with an Oscilloscope Worksheet: Inductive Current Clamp I: Measurement & Conversion Worksheet: Inductive Current Clamp II: A/C Blower Motor Section 7: Multiplex Circuit Diagnosis Section Topics 83 Additional Properties of MPX Protocols 84 Communication Direction 85 Transmission Timing 86 Collision Detection 87 Data Casting 88 Sleep Mode 89 Wakeup Function 89 Body Electronics Area Network 90 Local Interconnect Network 91 LIN Characteristics 91 LIN Replacing BEAN 91 LIN Gateway Function 92 Controller Area Network 93 Terminating Resistors 93 Audio Visual Communication-Local Area Network 94 AVC-LAN Protocol 95 Gateway ECU 96 CAN Gateway ECU 96 Summary of Gateway ECU Functions 97 CAN Gateway ECU Functions 98 Transmit/Receive Charts 99 BEAN Signal 100 BEAN Diagnosis 101 Open Circuit 102 Short Circuit 103 Short Circuit Step 104 Short Circuit Step 105 Short Circuit Step 106 Short Circuit Step 107 Short Circuit Step 108 Short Circuit Step 109 Diagnosing a Large Network 110 Diagnosing with Techstream 111 Diagnosing a BEAN Open Circuit with an Oscilloscope 112 Technical Training 75 76 76 77 78 79 80 80 81 82 82 iii Table of Contents 673 Electronic & Computer Controlled Systems Section 8: Electronic Systems iv Worksheet: BEAN Network Diagnosis Instructor Demo: BEAN Operation and Diagnosis LIN Signal LIN Diagnosis Worksheet: A/C LIN Interface CAN Signal CAN Diagnosis Short Between CANH and CANL Short to B+ or Ground Opens CAN Bus Check Location of DLC3 Terminating Resistors Resistance Tests on CAN Circuits Worksheet: CAN Diagnosis Instructor Demo: CAN Resistance Test Precautions Worksheet: CAN Main Bus Faults Worksheet: CAN Sub Bus Diagnosis AVC-LAN Signal AVC-LAN Diagnosis AVC-LAN DTCs Worksheet: AVC-LAN Inspection Other Multiplex Circuits A/C Servo Motor Circuits BUS Connectors Pulse-Type Servo Motors Worksheet: A/C Bus Servo Motor Operation & Diagnosis 113 113 114 115 116 117 118 118 118 119 120 120 121 122 124 124 125 125 126 127 128 129 130 130 131 132 133 Section Topics Engine Immobilizer Function Engine Immobilizer Operation Key Code Registration Master Keys and Sub Keys Automatic Key Code Registration Watch for Error Codes Ending Automatic Registration Configuration in Earlier Models Configuration in Later Models Immobilizer Reset Immobilizer Reset Support Chart ECU Communication ID Registration Be Wary of Differences between Models Analyzing ECU Input and Outputs Transponder Signals Power and Ground Circuits Terminal Values and Conditions 135 136 137 137 138 139 139 139 140 141 142 143 144 145 146 147 148 149 Technical Training Table of Contents 673 Electronic & Computer Controlled Systems Appendix Transponder Key Amplifier Terminal Values ECM Terminal Values Worksheet: Immobilizer Power Distributor Protect Mode Mode Monitor Terminal Smart Junction Box (MICON) High Intensity Discharge (HID) Headlights Dynamic Laser Cruise Control Operation Laser Sensor Indicators Error/Cancellation Codes Constant Speed Control Decelerator Control Follow-Up Control Accelerator Control System Diagram Distance Control ECU Waveforms Laser Radar Sensor Waveforms 150 151 152 153 153 153 154 155 156 157 158 158 159 160 161 162 163 164 165 Appendix Transistors Transistor Types How a Transistor Works Transistor Switches Transistor Amplifiers Digital Circuits Analog-to-Digital Converter Logic Gates Normal CAN Signal CAN Shorts and Opens Short CANH to CANL Short CANH to B+ Short CANL to B+ Short CANH to Ground Short CANL to Ground Open in CANH or CANL (Main Bus) Open in CANH and CANL (Main Bus) BEAN Signals BEAN Short to Ground Normal BEAN, Dual Trace BEAN Open Circuit, Dual Trace 167 168 169 170 171 172 173 174 175 176 177 177 178 178 179 179 180 181 182 183 184 185 Worksheets Technical Training v Table of Contents 673 Electronic & Computer Controlled Systems This page intentionally left blank vi Technical Training Objectives 673 Electronic & Computer Controlled Systems Course 673 Electronic & Computer Controlled Systems Final Student Performances Terminal Objective (Terminal FSP) Given all of the applicable tools, equipment, and appropriate vehicles, the technician will be able to apply a number of diagnostic techniques to monitor and repair faults in advanced computer and electronic circuits Technician Objectives (FSPs) The technician will be able to: Research information related to: • The purpose and function of ECU terminals • Inputs & Outputs • Terminals of the ECU • Power & Ground points Identify inputs and outputs and determine how they affect ECU operation Differentiate between: • Pulse width & duty cycle • Frequency & duty cycle Identify the consequences of the following to the diagnostic process: • Initialization (Memory Loss) • Customization (CBEST) • Sleep mode vs normal operation Demonstrate proficient use of the advanced DVOM features • MIN/MAX function • Peak MIN/MAX function • Measure frequency • Measure duty cycle Apply advanced DVOM functions for quick diagnostic evaluations Practice using an Inductive Current Clamp with a DVOM to provide the ability to take current readings without breaking into a circuit Utilize an inductive Current Clamp to evaluate system operation & determine diagnostic strategy Practice conversion of voltage and amperage values to apply to inductive clamps that use conversion factors for sensitivity 10 Monitor AC blower motor current using a DVOM equipped with an inductive current clamp, and monitor current using an oscilloscope and inductive clamp Technical Training a Objectives 673 Electronic & Computer Controlled Systems 11 Properly set-up an oscilloscope • Auto features • Voltage & Time Scale Settings • Horizontal & vertical rulers • Trigger point • Horizontal & vertical zoom features 12 Apply the basic features of the oscilloscope used in combination with the Techstream Unit 13 Locate and back probe a dimmer-controlled interior lamp or LED, practice measuring Voltage (V), Hertz (Hz), and percentage values (%) using a DVOM, and use an oscilloscope to display the signal pattern 14 Set oscilloscope voltage and time settings appropriate to the circuit measured 15 Utilize oscilloscope patterns derived from a known good vehicle to verify normal system operation 16 Differentiate between different oscilloscope patterns 17 Use an oscilloscope to confirm proper operation vs a faulty circuit • Duty cycle • Frequency • Amplitude 18 Use an oscilloscope to identify intermittent faults 19 Capture, record, save and send oscilloscope waveforms 20 Identify Body Electronics Area Network topology and network operation 21 Perform fault diagnostics on a BEAN network 22 Identify Local Area Network topology and network operation 23 Monitor and diagnose the AC Control Assembly operation and LIN communication using Techstream, an oscilloscope and TIS 24 Identify Controller Area Network topology and network operation 25 Use an ohmmeter and an oscilloscope to observe CAN High and CAN Low; diagnose a short to ground and an open circuit on CAN High and CAN Low; and short CAN High to CAN Low to observe the results 26 Develop a strategy to diagnose a CAN Network fault using the EWD, a Techstream CAN Bus Check, and the information provided 27 Identify Audio Visual Communication-Local Area Network topology and network operation 28 Create, monitor and diagnose an AVC-LAN System amplifier malfunction using Techstream and an oscilloscope 29 Monitor AC bus and servo motor operation using Techstream DATA LIST and an oscilloscope to deduce communication problems with the AC System 30 Reference service literature to determine if immobilizer reset is supported on a vehicle 31 Use Techstream Data List to make determinations related to the ID Code of the transponder chip embedded in the ignition key of the Immobilizer System 32 Use an oscilloscope to observe Immobilizer System waveforms under varying conditions and compare them to those found in the Repair Manual b Technical Training Technician Handbook 673 Electronic & Computer Controlled Systems Transistor Amplifiers Keys to Operation • Voltage at the base regulates current flow through the transistor • A minimum voltage at the base is required to start current flow NPN Bipolar Transistor Amplifier Circuit 12V • Increasing the voltage at the base lowers transistor resistance and increases current flow through the collector-emitter Without Rc, voltage on the output line would always be 12v Rc Rb Input Line Amplified output signal voltage (phase shifted) Weak input signal voltage Transistor resistance varies with voltage applied to the base