BODY ELECTRICAL DIAGNOSIS COURSE AGENDA

BODY ELECTRICAL DIAGNOSIS COURSE AGENDA BODY ELECTRICAL DIAGNOSIS COURSE AGENDA BODY ELECTRICAL DIAGNOSIS COURSE AGENDA BODY ELECTRICAL DIAGNOSIS COURSE AGENDA BODY ELECTRICAL DIAGNOSIS COURSE AGENDA BODY ELECTRICAL DIAGNOSIS COURSE AGENDA BODY ELECTRICAL DIAGNOSIS COURSE AGENDA BODY ELECTRICAL DIAGNOSIS COURSE AGENDA BODY ELECTRICAL DIAGNOSIS COURSE AGENDA BODY ELECTRICAL DIAGNOSIS COURSE AGENDA BODY ELECTRICAL DIAGNOSIS COURSE AGENDA BODY ELECTRICAL DIAGNOSIS COURSE AGENDA BODY ELECTRICAL DIAGNOSIS COURSE AGENDA BODY ELECTRICAL DIAGNOSIS COURSE AGENDA BODY ELECTRICAL DIAGNOSIS COURSE AGENDA BODY ELECTRICAL DIAGNOSIS COURSE AGENDA BODY ELECTRICAL DIAGNOSIS COURSE AGENDA

BODY ELECTRICAL DIAGNOSIS COURSE - AGENDA Body Electrical Diagnosis Course L652 Course Agenda Lesson Day 1.00 1.10 Time Duration 9:00 9:10 10:10 10:25 10 60 15 60 11:25 12:25 1:25 1:55 2:25 3:25 60 60 30 30 60 90 2.10 8:30 90 2.20 2.25 10:00 11:00 12:00 1:00 2:00 3:00 4:00 60 60 60 60 60 60 60 8:30 10:30 11:00 12:00 1:00 2:00 3:30 3:45 120 30 60 60 60 90 15 75 1.20 1.30 1.40 1.49 1.50 Description Introduction Review of Basic Electrical Theory Break Introduction to EWD Worksheets 2-1 and 2-2 Following Current Flow in a Circuit Lunch Using Electrical Diagnosis Tools The Six-Step Diagnosis Troubleshooting Plan Using Repair Manual Worksheets Day 2.30 2.35 2.40 Open Circuit Diagnosis Worksheet 2-4 Right Hand Mirror Does Not Go UP or DOWN Short Circuit/Parasitic Load Diagnosis On-Car/Simulator Short & Parasitic Load Diagnosis Lunch High Circuit Resistance Diagnosis On-Car/Simulator High Resistance Diagnosis Feedback Problem Diagnosis Review Day 5.00 6.00 6.00 6.00 6.00 6.00 LEXUS Course L 652 - Body Electrical Diagnosis Rotations/Body Electrical Multiplexing Introduction Rotations/Multiplexing Worksheets Lunch Rotation/Body Electrical or Multiplexing Worksheets Rotation/Body Electrical or Multiplexing Worksheets Break Review and Final Test OVERVIEW ES 300 Body Electrical Simulator Instructor Information Overview The ES 300 Body Electrical Simulator is a TMC produced training aid designed for use in body electrical courses Nearly all body electrical systems from an ES 300 are fully operational, and can be used to teach both system operation theory and diagnosis The relative position of all parts (including wire harness routing) are approximately the same as on an actual vehicle Fault Switches • For convenience in the classroom, a set of twenty fault switches are provided Sixteen of the switches are pre-programmed with faults The following circuits have built-in “fault switches” for in-class practice of troubleshooting techniques: Interior Light Heater Blower Motor Horn CD / Radio Headlight Taillight Power Window Combination Meter Remote Control Mirror Turn Signals Wireless Door Lock • These circuits illustrate the major types of electrical problems encountered on the vehicle: Open, short-toground/parasitic load, high resistance, and feedback, with varying difficulty levels for each problem (see table) The fault for each circuit is activated by moving the appropriate fault switch to the UP position LEXUS Course L 652 - Body Electrical Diagnosis LEXUS BODY ELECTRICAL SIMULATOR INFORMATION LEXUS Course L 652 - Body Electrical Diagnosis LEXUS BODY ELECTRICAL SIMULATOR INFORMATION LEXUS Course L 652 - Body Electrical Diagnosis LEXUS BODY ELECTRICAL SIMULATOR INFORMATION LEXUS Course L 652 - Body Electrical Diagnosis LEXUS BODY ELECTRICAL SIMULATOR INFORMATION LEXUS Course L 652 - Body Electrical Diagnosis LESSON OBJECTIVES SUMMARY Body Electrical Diagnosis Course L 652 Summary of Lesson Objectives Lesson 1.00 Objectives Instructor introduction to technicians Complete attendance records Introduce technicians to program goals, and objectives Familiarize technicians with technician handbook Lesson 1.10 Objectives Technician will know what subjects the L 652 course will be covering Through this review of L 622 course materials, the technician will be able to demonstrate an understanding of the following concepts: • Voltage • Amperage • Resistance • An electrical circuit • Series circuit theory • Parallel circuit theory Familiarize the technicians with EWD wiring diagram symbols Lesson 1.20 Objectives After completing this section, the technician will be able to: Find and use each of the sections of the EWD Given a system circuit diagram in the EWD: • Identify each of the symbols used on the system diagram • Understand the meaning of the labels that are used with those symbols • Apply basic current flow theory to diagram the path of current flow through the circuit Know how to apply the information in the EWD within the 6-step troubleshooting plan Lesson 1.25 Objectives After completing this worksheet: The technician will have demonstrated the use of all the sections of the EWD during a "typical" diagnostic process Applied the concepts covered in lesson 1.1 on an actual system circuit diagram Demonstrated an understanding of the symbols used on the system circuit diagram Lesson 1.30 Objectives After completing this section, the technician will be able to: Use the System Outline section of the EWD when available Configure the switches/relays to the appropriate position for the operating condition Follow the current flow path from the B+ source to ground in example EWD circuits Apply "what-if" problem simulation scenarios to the circuit LEXUS Course L 652 - Body Electrical Diagnosis LESSON OBJECTIVES SUMMARY Lesson 1.40 Objectives In this section the technician will demonstrate the ability to: Use the system outline section of the EWD Configure the switches/relays to the appropriate position for the operating condition Follow the current flow path from the B+ source to ground Determine the amount voltage that should be measured at given test points Apply "what-if" problem simulation scenarios to the circuit After completing this section, the technician will be able to: Use a voltmeter and measure voltage drops and open circuit voltage in a circuit • Understand what an acceptable voltage drop is • Understand the concept of what creates a voltage drop • Understand the proper way to connect a voltmeter in a circuit • Know how to use a voltmeter for continuity check only • Understand the voltmeter's application in diagnostics Use an ammeter to measure current flow • Use a series type ammeter • Use a inductive type ammeter • Understand the concept of parasitic load • Be able to apply parallel circuit current rules • Understand the ammeter's application in diagnostics Use an ohmmeter to measure the resistance of a component • Understand the need for circuit isolation when using an ohmmeter • Understand the ohmmeter's application in diagnostics Use a jumper wire properly for circuit diagnosis Apply basic circuit theory concepts with the use of an EWD on vehicle circuits Lesson 1.49 Objectives After completing this section, the technician will be able to: Implement the 6-step diagnostic process on a typical body electrical problem Properly verify an electrical problem Use defined techniques to analyze the related symptoms Isolate and correct the trouble using the EWD and electrical diagnostic tools Perform wire, connector, and harness repairs according to proper procedures LEXUS Course L 652 - Body Electrical Diagnosis LESSON OBJECTIVES SUMMARY Lesson 2.10 Objectives After completing this section, the technician will be able to: Successfully diagnose an open circuit problem in an electrical circuit Apply the step diagnostic process Learn the diagnostic strategy for diagnosing an open circuit problem in which the entire circuit is inoperative Learn the diagnostic strategy for diagnosing an open circuit problem in which part of the circuit is still functional Apply basic circuit theory concepts with the use of an EWD on vehicle circuits Lesson 2.20 Objectives After completing this section, the technician will be able to: Successfully diagnose a high resistance electrical circuit problem Apply the step diagnostic process for this type of problem Locate a high resistance problem in the ground circuit Locate a high resistance problem in the B+ circuit Apply basic circuit theory concepts with the use of an EWD on vehicle circuits Lesson 2.25 Objectives After completing this section, the technician will have: Successfully diagnosed high circuit resistance problems Practiced and applied the step diagnostic process on these problems Extensively used the EWD support sections to locate electrical/wiring components and determine power flow from the fuses and junction blocks Used the EWD System Circuit Diagrams to trace the path of current flow through circuits Lesson 2.30 Objectives After completing this section, the technician will be able to: Diagnose a short-to-ground in an electrical circuit Diagnose an unwanted parasitic load problem Apply the step diagnostic process for each of these problems Use the EWD to determine circuit power distribution through the various junction blocks and junction connectors Apply basic circuit theory concepts with the use of an EWD on vehicle circuits Lesson 2.35 Objectives After completing this section, the technician will have: Successfully diagnosed short-to-ground/excessive parasitic load circuit problems Practiced and applied the step diagnostic process on these problems Extensively used the EWD support sections to locate electrical/wiring components and determine power flow from the fuses and junction blocks Used the EWD System Circuit Diagrams to trace the path of current flow through circuits LEXUS Course L 652 - Body Electrical Diagnosis LESSON OBJECTIVES SUMMARY Lesson 2.40 Objectives After completing this section, the technician will be able to: Successfully diagnose an electrical feedback circuit problem Apply the step diagnostic process for this type of problem Diagnose a feedback problem in a lighting circuit Diagnose a feedback problem in a general body electrical circuit Apply basic circuit theory concepts with the use of an EWD on vehicle circuits Lesson 5.00 Objectives After completing this section, the technician will be able to: Accurately diagnose open circuit problems Diagnose parasitic load problems Diagnose short to ground problems Diagnose high resistance problems Diagnose feedback problems This section will also: Provide feedback on what the technician has learned from the course Enhance the technicians' confidence in their electrical diagnostic ability Lesson 6.00 Objectives After completing this section, the technician will be able to: Define multiplexing and serial data Explain the need for standard Retrieve trouble codes (DTCs) from a multiplexing system Diagnose a simple system fault in a multiplexing system LEXUS Course L 652 - Body Electrical Diagnosis 10 MULTIPLEXING SYSTEMS 13 The effectiveness of your diagnosis then depends on how well you are able to interpret what really needs to be done in this situation Your Diagnostic tester gives you a place to start Once you have the code for the general area of the fault, you then have a direction The easy thing about multiplexing is that you are frequently dealing with only one wire That wire is either sending a signal or it is not The break out for system failure looks something like this: B Assume that the Remote Mirrors will not operate ID2 B B 22 BP1 B-W IU2 SB 12 A I19 A , I20 B INSTRUMENT ECU SB B IU4 11 ID2 IC2 T9 MPX2 TILT AND MPX1 TELESCOPIC ECU 25 MPX2 R30 REMOTE CONT MPX1 MIRROR ECU 13 L B-W 17 L If the Main control unit in the LAN system is OK then the problem is in a local unit or in a wire or in a connector If they then ECU or Body LAN or Instrument Panel ECU is “probably OK” The next step involves removing various connectors and checking the continuity between them in addition to a visual inspection of the harness and connectors R BP1 B-W Do other components on the BUS circuit operate? 11 B-W 10 MPX1 P24 POWER MPX2 SEAT ECU 11 IC2 L Another trick that might be helpful is to use a jumper wire across a local control unit For example, if you jump T / Pin #8 to T9 Pin #3 and then send a signal to move one of the remote control mirrors and the mirror operates you have established that the L wire between T9 and R30 has continuity You may also have determined that the Tilt and Telescopic ECU has an internal problem Body Electrical Diagnosis - Course L652 297 DOOR Rear Door Lock Condition Wireless Door Lock Wireless Door Unlock Body FCU DOOR 23 – 28 12 – 17 12 DOOR 23 24 13 14 25 26 15 16 17 27 Driver Door ECU M M Front Passenger Door ECU M 28 Driver Door Lock Motor M Passenger Door Lock Motor Rear Door Lock Motors 14 You can see that Multiplexing requires some degree of detective work and also the use of the hand held tester for retrieval of codes and for testing various actuators Based on multiplexing designs we’ve discussed so far, take a look at the diagram below and see if you can answer some questions The diagram comes from an NCF for the 1995 LS 400 15 Which inputs communicate along a one way path to the Body ECU? 16 Which lines communicate the signals from the Driver’s Door ECU to the Body ECU? 298 Lexus Technical Training MULTIPLEXING SYSTEMS 17 Which unit would communicate the condition of a locked passenger door? 18 If a signal is sent from a wireless door lock to “Lock Doors” which unit receives and sends that message? 19 Since the Driver’s Door ECU is responsible for locking its own door what kind of information is sent from the Body ECU? 20 Which fuse is common to all on board ECUs? Body Electrical Diagnosis - Course L652 299 Notes 300 Lexus Technical Training MULTIPLEXING SYSTEMS WORKSHEET 6-4 Multiplexing General Diagnosis Requirements: Repair Manual, Diagnostic Tester Take a look in the Repair Manual at the multiplexing circuits available on this vehicle Determine the location of a connector which is easy to access Check with your instructor if you are not certain Unplug the connector or back out a pin and check the operation of the system What has been disabled on your system? Connector and/or pin number Hook up the Diagnostic Tester and check for codes List any codes you find Do the codes accurately represent the component that has been disconnected? Explain If the code(s) listed were found on a customer's car, does the Repair Manual take you to the location of the problem? Explain Access the Active Test area of the system you are working on Select three or four of the functions you might need to check with this particular system malfunction List the ones you selected below Operate each of the functions you selected using the Active Test and make a note of the values displayed on the screen Item Value/Condition Body Electrical Diagnosis - Course L652 301 Are their any conclusions you can reach based on the operation or nonoperation of the system you are testing? List your observations 10 Can you conclude that the Body ECU is sending signals? Why ? 11 An interruption has been placed (your bug) in the lines which either power or communicate with your chosen system Are there any values you found in your Active Test which might lead you to look in the area of this interruption? Yes or No 12 Would you be able to discover anything further if you changed the criteria of the things you were looking for with the Diagnostic Tester? Example: I should have checked the 'up' movement instead of the 'down' 13 Return the vehicle to its original condition and erase any codes that may have been set Place the Diagnostic Tester and Repair Manual on the bench 302 Lexus Technical Training LEXUS BODY ELECTRICAL DIAGNOSIS Lexus Body Electrical Diagnosis - Post Test When taking a voltage measurement at a wiring harness connector of an electrical component you should a probe the connector terminals of the component side of the connector if it has been disconnected b probe the connector terminals from the wire side of the connector even if the connector has been disconnected c you can probe the connector terminals from which ever side is most accessible d none of the above To find where the ECM is located in the vehicle you should look at the: a Engine Control system diagram in the EWD b Relay Location section of the EWD c Wire Routing diagrams in the EWD d Trouble Shooting section in the EWD A technician is checking the dimmer switch in the illustration below with an ohmmeter In the FLASH position you should have continuity between terminals a 11 and 13 of connector E b 3, and f14 of connector E c 9, 12 and 14 of connector E d 3, 9, 12 and 14 of connector E Body Electrical Diagnosis - Course L652 303 Two technicians are discussing the effects on circuits of some fault conditions Technician A says that a circuit that is shorted to ground will have less resistance than it normally should Technician B says that a circuit that has a dirty connection will have less current flow than it normally should Who is right? a A only b B only c Both A and B d Neither A nor B The section of the Electrical Wiring Diagram manual that contains voltage and resistance values is the: a connector diagrams b wire routing diagrams c system diagrams d relay locations The voltmeter in the circuit below reads battery voltage, this reading indicates: a the fuse is blown b the switch is bad c the fuse is OK d the motor is not grounded Switch 304 Lexus Technical Training LEXUS BODY ELECTRICAL DIAGNOSIS The lamp in the circuit below glows dimly, the volt meter reads 12.6 volts Technician A says that high resistance in the circuit between the battery and the lamp could be the cause Technician B says that a poor ground connection at the lamp could be the cause 12 Who is right? a A only b B only Switch c Both A and B Light d Neither A nor B 8, The electrical symbol illustrated below represents: a a fusible link b a resistor c a fuse d a switch To check a ground wire for an open circuit, you could use a : a self-powered test light b ohmmeter c voltmeter d all of the above Body Electrical Diagnosis - Course L652 305 10 When replacing a piece of wire: Technician A says that if the length is increased, the diameter should also be increased Technician B says that a poor splice can result in lower current flow Who is right? a A only b B only c Both A and B d Neither A nor B 11 A fuse has blown twice in the same circuit Technician A says that the resistance and current flow are both too high Technician B says that a poor ground connection may be the cause Who is right? a A only b B only c Both A and B d Neither A nor B 306 Lexus Technical Training LEXUS BODY ELECTRICAL DIAGNOSIS 12 Two technicians are discussing the properties of parallel circuits Technician A says that adding more branches to a parallel circuit reduces total circuit resistance Technician B says that adding more branches to a parallel circuit increases the total curent in a circuit Who is right? a A only b B only c Both A and B d Neither A nor B 13 When testing a 1998 ES 300 for a parasitic load, an ammeter hooked in series as shown indicated a reading of 30 milliamps (.030mA) Ignition, lights, and accessories are OFF Technician A says that this is an excessive drain from the battery and further testing is required to find the fault Technician B says that this is a normal current draw, even with all the systems OFF Who is right ? a A only b B only c Both A and B d Neither A nor B Body Electrical Diagnosis - Course L652 307 14 During a quick check of starting performance, the engine cranks slowly and the headlights dim noticably Which of the following could cause the problem ? a An open in the starter control circuit b An open in the magnetic switch (solenoid) holdin coil c A melted fusible link d A discharged battery 15 A starter on an ES 300 is to be tested for current draw while cranking the engine Technician A says the battery’s state-of-charge and capacity must be tested before a valid starter test can be performed Technican B says that if the battery has less than 50% charge (specific gravity 1.190 or less) it cannot be used for a starter current draw test a A only b B only c Both A and B d Neither A nor B 16 During cranking with the ignition disabled, the voltage drop in the starter ground circuit should not exceed: a 0.0 volts b 0.2 volts c 1.5 volts d 12.0 volts 308 Lexus Technical Training LEXUS BODY ELECTRICAL DIAGNOSIS 17 When testing the starting system on an LS 400, you find that the starter will not crank and the magnetic switch does not “click” Referring to this diagram, this symptom could be causd by each of the following except: AM2 a a faulty neutral start switch Fuse ST 7.5A b an open magnetic switch hold-in coil Fusable Link c an open circuit between the magnetic switch and the ignition switch Neutral Start Switch AM2 30A MAIN 0.86R d an open in the starter ground circuit Starter Relay Contact Plate Terminal 30 Battery Terminal 50 M To Theft Deterrent ECU Starter 18 A voltage drop measurement: a requires the circuit to be operating while the test is being made b is exactly the same as an open circuit voltage measurement c cannot detect a circuit resistance problem d none of the above 19 With the battery voltage held constant at 12.6 V; if the circuit resistance goes DOWN: a the amperage in a circuit will go up b the amperage in a circuit will go down c the source voltage will increase to make up the difference d Both A and B Body Electrical Diagnosis - Course L652 309 20 During an alternator output test, you find that the output is zero amps and the voltage is 12 volts Your next step should be: a replace the regulator b full field the alternator and check the readings c remove the alternator for bench testing d test the battery 310 Lexus Technical Training LEXUS BODY ELECTRICAL DIAGNOSIS Technical & Body Training Development TEST: Lexus L 652 Body Electrical Diagnosis DATE: INSTR: _ LOCATION: NAME: _ SSN: _ DEALER CODE: _ Body Electrical Diagnosis - Course L652 311 ... 652 - Body Electrical Diagnosis LEXUS BODY ELECTRICAL SIMULATOR INFORMATION LEXUS Course L 652 - Body Electrical Diagnosis LEXUS BODY ELECTRICAL SIMULATOR INFORMATION LEXUS Course L 652 - Body Electrical. .. LEXUS Course L 652 - Body Electrical Diagnosis LEXUS BODY ELECTRICAL SIMULATOR INFORMATION LEXUS Course L 652 - Body Electrical Diagnosis LEXUS BODY ELECTRICAL SIMULATOR INFORMATION LEXUS Course. .. actual body electrical troubleshooting Tools of Electrical Diagnosis a Explanation and practice with major tools for electrical diagnosis: b LEXUS Course L 652 - Body Electrical Diagnosis 1) Electrical