electrical systems electronic systems diagnosis student guide COURSE CODE: 34S19T0 ORDER NUMBER: FCS-13450-REF IMPORTANT SAFETY NOTICE Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles, as well as the personal safety of the individual doing the work This manual provides general directions for accomplishing service and repair work with tested, effective techniques Following them will help assure reliability There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual doing the work This manual cannot possibly anticipate all such variations and provide advice or cautions as to each Accordingly, anyone who departs from instructions provided in this manual must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods, tools or parts As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS Each one is there for a specific purpose NOTES give you added information that will help you to complete a particular procedure CAUTIONS are given to prevent you from making an error that could damage the vehicle WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury The following list contains some general WARNINGS that you should follow when you work on a vehicle • • • • • • Always wear safety glasses for eye protection Use safety stands whenever a procedure requires you to be under the vehicle Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure Set the parking brake when working on the vehicle If you have an automatic transmission, set it in PARK unless instructed otherwise for a specific service operation If you have a manual transmission it should be in REVERSE (engine OFF) or NEUTRAL (engine ON) unless instructed otherwise for a specific service operation Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide Keep yourself and your clothing away from moving parts when the engine is running, especially the fan and belts • • • • To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler Do not smoke while working on the vehicle To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle Tie long hair securely behind your head Keep hands and other objects clear of the radiator fan blades Electric cooling fans can start to operate at any time by an increase in underhood temperatures, even though the ignition is in the OFF position Therefore, care should be taken to ensure that the electric cooling fan is completely disconnected when working under the hood The recommendations and suggestions contained in this manual are made to assist the dealer in improving his dealership parts and/or service department operations These recommendations and suggestions not supersede or override the provisions of the Warranty and Policy Manual, and in any cases where there may be a conflict, the provisions of the Warranty and Policy Manual shall govern The descriptions, testing procedures, and specifications in this handbook were in effect at the time the handbook was approved for printing Ford Motor Company reserves the right to discontinue models at any time, or change specifications, design, or testing procedures without notice and without incurring obligation Any reference to brand names in this manual is intended merely as an example of the types of tools, lubricants, materials, etc recommended for use Equivalents, if available, may be used The right is reserved to make changes at any time without notice WARNING: MANY BRAKE LININGS CONTAIN ASBESTOS FIBERS WHEN WORKING ON BRAKE COMPONENTS, AVOID BREATHING THE DUST BREATHING THE ASBESTOS DUST CAN CAUSE ASBESTOSIS AND CANCER Breathing asbestos dust is harmful to your health Dust and dirt present on car wheel brake and clutch assemblies may contain asbestos fibers that are hazardous to your health when made airborne by cleaning with compressed air or by dry brushing Wheel brake assemblies and clutch facings should be cleaned using a vacuum cleaner recommended for use with asbestos fibers Dust and dirt should be disposed of in a manner that prevents dust exposure, such as sealed bags The bag must be labeled per OSHA instructions and the trash hauler notified as to the contents of the bag If a vacuum bag suitable for asbestos is not available, cleaning should be done wet If dust generation is still possible, technicians should wear government approved toxic dust purifying respirators OSHA requires areas where asbestos dust generation is possible to be isolated and posted with warning signs Only technicians concerned with performing brake or clutch service should be present in the area Copyright © 2002 Ford Motor Company Produced and Coordinated by Technical Support Operations Ford Customer Service Division October, 2002 CUSTOMER EXPECTATIONS Customer Expectations: Service Make it convenient to have my vehicle serviced at your dealership The Service Advisor should demonstrate a genuine concern for my service needs Fix it right the first time Complete servicing my vehicle in a Provide me with a clear and thorough explanation of the service performed Call me within a reasonable amount of time after my service visit to ensure that I'm completely satisfied Be responsive to questions or concerns I bring to your attention timely and professional manner Expectation “Fix It Right The First Time, on Time.” Both service advisors and technicians are important players when it comes to Expectation #3 Why Customers tell us “Fixing It Right The First Time, on Time” is one of the reasons they would decide to return to a dealer to buy a vehicle and get their vehicles serviced Technician Training It is our goal to help the technician acquire all of the skills and knowledge necessary to “Fix It Right The First Time, on Time.” We refer to this as “competency.” Technician’s Role Acquire the skills and knowledge for competency in your specialty via: New Model STST – Self Study – Self Study – FordStar Broadcasts – FordStar Broadcasts – Ford Multimedia Training (FMT) – Instructor Led – Instructor Led The Benefits The successful implementation of expectations means: – Satisfied customers – Repeat vehicle sales – Repeat service sales – Recognition that Ford and Lincoln/Mercury technicians are “the Best in the Business” TABLE OF CONTENTS TABLE OF CONTENTS COURSE INTRODUCTION COURSE INTRODUCTION–1 DAY ONE DAY ONE–1 Agenda Day One–3 Student’s Objectives Day One–4 Prerequisite Review .Day One–5 Workstation .Day One–15 Workstation .Day One–27 Workstation .Day One–35 Workstation .Day One–51 Homework Day One–69 DAY TWO DAY TWO–1 Agenda Day Two–3 Student’s Objectives Day Two–4 Workstation Day Two–5 Workstation Day Two–25 Workstation Day Two–35 Workstation Day Two–45 Homework Day Two–65 DAY THREE DAY THREE–1 Agenda Day Three–3 Student’s Objectives Day Three–4 Instructor-led Demonstration Day Three–5 Workstation Day Three–9 Workstation Day Three–15 Workstation Day Three–21 Workstation Day Three–25 Homework Day Three–35 DAY FOUR DAY FOUR–1 Agenda Day Four–3 Student’s Objectives Day Four–4 Workstation Day Four–5 Workstation Day Four–11 Workstation Day Four–17 Instructor-led Demonstration Day Four–23 Electronic System Diagnosis October, 2002 Table of Contents – i TABLE OF CONTENTS ii – Table of Contents October, 2002 Electronic System Diagnosis COURSE INTRODUCTION COURSE INTRODUCTION Electronic Systems Diagnosis October, 2002 Course Introduction – COURSE INTRODUCTION ELECTRICAL SYSTEMS CURRICULUM PATH Basic Electrical Theory and Operation 34S11W0 Battery Starting and Charging System Theory and Operation 34S12W0 Electrical Diagnostic Tools and Testing 34S13M0 Basic Electrical Diagnosis 34S14T0 (5 Days) Electronic Theory and Operation 34S15W0 Understanding Electronic Systems 34S16M0 New Generation Star Tester Operation 34S17W0 Basic Worldwide Diagnostic Tool Operation 34S18M0 Electronic Systems Diagnosis 34S19T0 (4 Days) Networks and Multiplexing System Operation and Diagnosis 34S20W0 Antitheft Systems Operation and Testing 34S21W0 Entertainment and Navigation Systems Operation and Testing 34S22W0 Speed Control System Operation and Testing 34S23W0 SRS Operation and Testing 34S24W0 Advanced WDS Tool Operation 34S25W0 Advanced Electronic Systems Diagnosis 34S26T0 (4Days) Planned Training Pathway Ford Motor Company has identified the skills and knowledge necessary to meet the curriculum goals in the Electrical Systems specialty The Planned Training Pathway is a series of courses designed to provide you with these skills and knowledge The chart above illustrates the courses in this curriculum Description The Electrical Systems Curriculum consists of sixteen courses The web-based courses and FMT courses are self-paced training programs The Classroom course is hands-on and is facilitated by an instructor The information in the Web, FMT, and Classroom courses are designed to prepare you to successfully complete the instructor led course You are currently in course seven of the Electrical Systems Curriculum, Electronic Systems Diagnosis – Course Introduction October, 2002 Electronic Systems Diagnosis COURSE INTRODUCTION Course Overview This course has been designed to include both lecture and hands on activities Students will have several opportunities to practice what they learn in the form of workstations Audience Profile This course is designed for any Ford, Lincoln and Mercury service technician who wants to start their certification process in any specialty as well as those who wish to be certified in Electrical Systems Course Prerequisites All students must have completed the first eight courses in the curriculum prior to enrolling in this course Students who not show passing credit in their STARS planners for the previous courses should not be admitted to this class Their presence will slow down the course flow, as well as monopolize valuable instructor time z Basic Electrical Theory and Operation (Web) 34S11W0 z Battery Starting and Charging System Theory and Operation (Web) 34S12W0 z Electrical Diagnostic Tools and Testing (FMT) 34S13M0 z Basic Electrical Diagnosis (Classroom) 34S14T0 z Electronic Theory and Operation (Web) 34S15W0 z Understanding Electronic Systems (FMT) 34S16M0 z New Generation Star Tester Operation (Web) 34S17W0 z Basic Worldwide Diagnostic System Tool Operation (FMT) 34S18M0 Electronic Systems Diagnosis October, 2002 Course Introduction – COURSE INTRODUCTION Course Objectives The objectives of this course are to enable you to: z Use the SSCC (Symptom-to-System-to-Component-to-Cause) diagnostic process relating to electronic concerns z Use special tools and service equipment associated with electronic diagnosis and repair z Use all service publications in their available formats and to obtain needed information for diagnosis z Perform diagnostic test procedures z Perform repair procedures Number Of Days This course has been designed to span a four-day period Number Of Students This course has been designed to include up to twelve students Course Requirements To meet the requirements of this course, you must satisfactorily complete the hands-on posttest and achieve a score of 80% or higher on the written post-test Both tests will both be administered on the last day of class – Course Introduction October, 2002 Electronic Systems Diagnosis WORKSTATION – DAY FOUR WORKSTATION NGS ON-BENCH DATA DIAGNOSIS Generic Electronic Module 765 22 YE/BK 761 1 57 22 YE/RD 657 Door ajar switch, left front 1) Door closed 2) Door open 20 BK 57 576 22 RD/BK Door ajar switch, right front 1) Door closed 2) Door open 22 GY/RD C18 Door ajar switch, right rear 1) Door open 2) Door closed 20 BK 57 57 C19 Door ajar switch, liftgate 1) Door closed 2) Door open 20 BK 57 Door ajar switch, liftgate 1) Door closed 2) Door open 20 BK 20 BK G205 Hot at all times F2.26 10A C23 792 Door ajar lamp C23 20 TN/YE 10 792 Auxiliary relay box C21 Battery saver relay 1005 22 VT/OG 705 20 LG/OG Generic Electronic Module S220 20 LG/OG 1008 22 LG /OG C20 Generic Electronic Module C20 Generic Electronic Module 705 C21 C20 705 22 LG 20 TN/YE 53 20 LG /OG Instrument C20B panel dimming module 6) Off 7) On Auxiliary relay C22 box Interior lamp relay 705 20 LG/OG C22 20 BK/LB C24 C24 Glove box lamp 0) Glove box closed 1) Glove box open Interior lamp assembly 57 20 BK C24 G205 BEC700-D/VF 12 – Day Four October, 2002 Electronic Systems Diagnosis DAY FOUR – WORKSTATION WORKSTATION NGS ON-BENCH DATA DIAGNOSIS Diagnostic Situation: The door ajar light sometimes comes on while driving While verifying the concern, you note that the door ajar light comes on intermittently OASIS and service history show nothing about this concern, and your visual inspection reveals no obvious faults Identify the SYMPTOM and write on the space below What electronic module controls the door ajar light of this 95 Windstar? What SYSTEM was affected? The vehicle was road tested and PID data is stored in recorder area A Once the vehicle is moving, at what speed did the door ajar light first come ON? B When was the first time during the road test (in relation to when you pressed the TRIGGER) that the light came ON? What occurs at the same time, which may provide you with a clue to the cause of the concern? Electronic Systems Diagnosis October, 2002 Day Four – 13 WORKSTATION – DAY FOUR WORKSTATION NGS ON-BENCH DATA DIAGNOSIS What component(s) would you suspect of causing this concern? Were there times when the door ajar light came ON without a right rear door signal? NOTE: When repairing a fault, you should always try and determine the cause of the failure What would you next to determine the root cause of the concern? How much time was recorded before the TRIGGER? 10 How much time was recorded after the TRIGGER? 11 What is the total recording time? Exercise complete Please return workstation to its original condition for the next team 14 – Day Four October, 2002 Electronic Systems Diagnosis DAY FOUR – WORKSTATION WORKSTATION NGS ON-BENCH DATA DIAGNOSIS NOTES Electronic Systems Diagnosis October, 2002 Day Four – 15 WORKSTATION – DAY FOUR NOTES 16 – Day Four October, 2002 Electronic Systems Diagnosis DAY FOUR – WORKSTATION WORKSTATION Electronic Systems Diagnosis October, 2002 Day Four – 17 WORKSTATION – DAY FOUR WORKSTATION INTERIOR LIGHTING DIAGNOSIS Generic Electronic Module 765 22 YE/BK 761 1 57 22 YE/RD 657 2 Door ajar switch, left front 1) Door closed 2) Door open 20 BK 57 576 22 RD/BK Door ajar switch, right front 1) Door closed 2) Door open 22 GY/RD C18 Door ajar switch, right rear 1) Door open 2) Door closed 20 BK 57 57 C19 Door ajar switch, liftgate 1) Door closed 2) Door open 20 BK 57 Door ajar switch, liftgate 1) Door closed 2) Door open 20 BK 20 BK G205 Hot at all times F2.26 10A C23 792 Door ajar lamp C23 20 TN/YE 10 792 Auxiliary relay box C21 Battery saver relay 1005 Generic Electronic Module C21 705 20 LG/OG C20 S220 705 Generic Electronic Module 705 7 C22 1008 20 LG /OG C20B 20 LG/OG 22 LG /OG C20 Generic Electronic Module 53 705 20 LG/OG Instrument panel dimming module 6) Off 7) On Auxiliary relay box Interior lamp relay C22 20 BK/LB C24 C24 Glove box lamp n 0) Glove box closed 1) Glove box ope Interior lamp assembly 57 20 BK C24 G205 BEC712-A/VF 18 – Day Four C20 22 VT/OG 792 20 TN/YE 22 LG 20 TN/YE October, 2002 Electronic Systems Diagnosis DAY FOUR – WORKSTATION WORKSTATION INTERIOR LIGHTING DIAGNOSIS Wire the Interior lighting system as shown below The inputs have already been wired for you Operate the lighting system to verify the symptom What symptom is present? REAR DEFROST Interior Lighting System FE-26 RELAY RF DOOR FE-27 LF DOOR AJAR AJAR 12V N/O N/C COMMON AJAR AJAR SLIDING DOOR AJAR DOOR AJAR SWITCHES COMMON COIL COIL LF DOOR RF DOOR SLIDE DOOR TAIL GATE N/O N/C DOOR AJAR DIRECT OUTPUTS FE-25 VSS CKT 70 B+ FE-30 LF DOOR BATT B+ RF DOOR INTERIOR LAMP SLIDING DOOR DOOR AJAR INTERIOR LAMPS LIFT GATE MODE SELECT BRAKE RUN INTERVAL WASH WIPTER SPEED BOARD WITH GLOVE BOX LAMP SIGNAL RETURN RELAY CONTROL PARK SWITCH GLOVE BOX LAMP INPUT GEM BOARD BEC400-D/VF Electronic Systems Diagnosis October, 2002 Day Four – 19 WORKSTATION – DAY FOUR WORKSTATION INTERIOR LIGHTING DIAGNOSIS What components or circuits could be causing the concern? Perform the needed diagnostic steps and record your actions and results in the spaces below Use another sheet of paper if necessary ACTIONS/TESTS 20 – Day Four RESULTS October, 2002 Electronic Systems Diagnosis DAY FOUR – WORKSTATION WORKSTATION INTERIOR LIGHTING DIAGNOSIS What is your diagnosis? What service actions would you take to resolve the concern? Diagnostic summary Fill in the blanks Symptom: System: Component: Cause: Workstation complete Return the workstation to its original condition Electronic Systems Diagnosis October, 2002 Day Four – 21 WORKSTATION – DAY FOUR NOTES 22 – Day Four October, 2002 Electronic Systems Diagnosis DAY FOUR – INSTRUCTOR LED DEMO INSTRUCTOR LED DEMONSTRATION Electronic Systems Diagnosis October, 2002 Day Four – 23 INSTRUCTOR LED DEMO – DAY FOUR INSTRUCTOR LED DEMO DIRECTIONS: Using the schematic below create a symptom by creating an open, short or high resistance in a circuit or component Based on what you already know, use the following schematic and DTC chart on the next page to identify a Component and Cause of the concern provided Hot in start or run Hot in run or acc F2.27 10A Hot in run F2.11 15A Hot at all times F2.32 10A F2.07 40A 85 P91 Central Junction Box (CJB) (14A068) 13–10, 13–13, 13–14, 13–15 Controls current flow to rear heated window switch, heated grid and heated mirrors when energized C2021 30 K1 Rear window defrost relay 151–48 86 C2021 87 F2.12 10A 16 VBATT C201a C201d A112 Generic Electronic Module (GEM) (14B205) 59–1, 59–2 C201b VBATT 11 C270b Provides rear defogger ON/OFF input to GEM 18 C270c 185 12 BK 186 12 BN/LB 186 wagon C438 12 BN/LB S416 938 20 BK/LG 1010 22 DB/OG 694 17 22 DG/VT 1.2kΩ manual A/C C2009 C402a P78 Integrated control panel C402b 57 12 BK R19 Rear window defrost grid (18C618) 151–29 151–41 EATC S402 57 12 C2009 20 BK 694 20 BK/YE G108 wagon C2009 C410 S203 S206 See page 10–7 See page 10–5 See page 10–11 10–12 G201 G200 G303 BEC901-A/VF 24 – Day Four October, 2002 Electronic Systems Diagnosis DAY FOUR – INSTRUCTOR LED DEMO INSTRUCTOR LED DEMO Rear Defrost - DTC Chart B 1347 Heated backlight relay circuit failure B 1345 Heated backlight input short to ground B 1349 Heated backlight relay short to battery Diagnostic Summary: Symptom: System: Component: Cause: Will your concern set a DTC? YES NO If you answered yes, which DTC would be set? Would you require the use of a scan tool to diagnose your concern? Electronic Systems Diagnosis October, 2002 Day Four – 25 INSTRUCTOR LED DEMO – DAY FOUR NOTES 26 – Day Four October, 2002 Electronic Systems Diagnosis ... Introduction October, 2002 Electronic Systems Diagnosis DAY ONE DAY ONE Electronic Systems Diagnosis October, 2002 Day One – DAY ONE – Day One October, 2002 Electronic Systems Diagnosis DAY ONE –... Four–23 Electronic System Diagnosis October, 2002 Table of Contents – i TABLE OF CONTENTS ii – Table of Contents October, 2002 Electronic System Diagnosis COURSE INTRODUCTION COURSE INTRODUCTION Electronic. .. BEC550-B/VF Electronic Systems Diagnosis October, 2002 Day One – 13 PREREQUISITE REVIEW – DAY ONE 14 – Day One October, 2002 Electronic Systems Diagnosis DAY ONE – WORKSTATION WORKSTATION Electronic