Classroom Manual Automotive Electricity And Electronics Fifth Edition Barry Hollembeak Australia • Canada • Mexico • Singapore • Spain • United Kingdom • United States for Today’s Technician™: Automotive Electricity and Electronics, 5th Edition Barry Hollembeak Vice President, Career and Professional Editorial: Dave Garza Director of Learning Solutions: Sandy Clark Executive Editor: David Boelio © 2011 Delmar, Cengage Learning ALL RIGHTS RESERVED No part of this work covered by the copyright herein may be reproduced, transmitted, stored, or used in any form or by any means graphic, electronic, or mechanical, including but not limited to photocopying, recording, scanning, digitizing, taping, Web distribution, information networks, or information storage and retrieval systems, except as permitted under Section 107 or 108 of the 1976 United States Copyright Act, without the prior written permission of the publisher Managing Editor: Larry Main Senior Product Manager: Matthew Thouin Editorial Assistant: Jillian Borden Vice President, Career and Professional Marketing: Jennifer McAvey Marketing Director: Deborah S Yarnell Marketing Manager: Katie Hall Associate Marketing Manager: Mark Pierro Production Director: Wendy Troeger Production Manager: Mark Bernard Content Project Manager: Cheri Plasse For product information and technology assistance, contact us at Professional Group Cengage Learning Customer & Sales Support, 1-800-354-9706 For permission to use material from this text or product, submit all requests online at cengage.com/permissions Further permissions questions can be e-mailed to permissionrequest@cengage.com Library of Congress Control Number: 2010923010 ISBN-13: 978-1-4354-7008-8 ISBN-10: 1-4354-7008-7 Art Director: Benj Gleeksman Delmar Maxwell Drive Clifton Park, NY 12065-2919 USA Cengage Learning is a leading provider of customized learning solutions with office locations around the globe, including Singapore, the United Kingdom, Australia, Mexico, Brazil and Japan Locate your local office at: international.cengage.com/region Cengage Learning products are represented in Canada by Nelson Education, Ltd For your lifelong learning solutions, visit delmar.cengage.com Visit our corporate website at cengage.com Notice to the Reader Publisher does not warrant or guarantee any of the products described herein or perform any independent analysis in connection with any of the product information contained herein Publisher does not assume, and expressly disclaims, any obligation to obtain and include information other than that provided to it by the manufacturer The reader is expressly warned to consider and adopt all safety precautions that might be indicated by the activities described herein and to avoid all potential hazards By following the instructions contained herein, the reader willingly assumes all risks in connection with such instructions The publisher makes no representations or warranties of any kind, including but not limited to, the warranties of fitness for particular purpose or merchantability, nor are any such representations implied with respect to the material set forth herein, and the publisher takes no responsibility with respect to such material The publisher shall not be liable for any special, consequential, or exemplary damages resulting, in whole or part, from the readers’ use of, or reliance upon, this material Printed in the United States of America X X 12 11 10 Contents Preface vi Chapter Introduction to Automotive Electrical and Electronic Systems • Introduction • Why Become an Electrical System Technician? • The Role of Electricity in the Automobile • Introduction to the Electrical Systems • Summary 14 • Terms to Know 14 • Review Questions 15 • Multiple Choice 15 Chapter Basic Theories .17 • Introduction 17 • Basics of Electron Flow 17 • Electricity Defined 20 • Electrical Laws 24 • Types of Current 27 • Electrical Circuits 28 • Kirchhoff ’s Laws 39 • Capacitance 41 • Magnetism Principles 43 • Theory of Induction 46 • EMI Suppression 47 • Summary 48 • Terms to Know 48 • Review Questions 49 • Multiple Choice 49 Chapter Electrical and Electronic Components 51 • Introduction 51 • Electrical Components 51 • Electronic Components 59 • Circuit Protection Devices 70 • Circuit Defects 75 • Summary 78 • Terms to Know 78 • Review Questions 79 • Multiple Choice 80 Chapter Wiring and Circuit Diagrams 82 • Introduction 82 • Automotive Wiring 82 • Wiring Diagrams 93 • Summary 104 • Terms to Know 105 • Review Questions 105 • Multiple Choice 106 Chapter Automotive Batteries 108 • Introduction 108 • Conventional Batteries 110 • Maintenance-Free Batteries 115 • Hybrid Batteries 117 • Recombination Batteries 118 • High-Voltage Batteries 120 • Ultra-Capacitors 125 • Battery Terminals 125 • Battery Ratings 126 • Battery Cables 127 • Battery Holddowns 128 • Summary 129 • Terms to Know 130 • Review Questions 131 • Multiple Choice 131 Chapter Starting Systems and Motor Designs 133 • Introduction 133 • Direct-Current Motor Principles 133 • Dc Motor Field Winding Designs 138 • Starter Drives 142 • Cranking Motor Circuits 144 • Starter Control Circuit Components 144 • Cranking Motor Designs 152 • AC Motor Principles 156 • Integrated Starter Generator 161 • Summary 163 • Terms to Know 163 • Review Questions 164 • Multiple Choice 165 Chapter Charging Systems .166 • Introduction 166 • Principle of Operation 167 • AC Generators 169 • AC Generator Circuits 179 • AC Generator Operation Overview 180 • Regulation 183 • Charging Indicators 191 • AC Generator Design Differences 193 • HEV Charging Systems 201 • Summary 205 • Terms to Know 206 • Review Questions 206 • Multiple Choice 207 Chapter Lighting Circuits 208 • Introduction 208 • Lamps 209 • Headlights 210 • Headlight Switches 214 • Concealed Headlights 217 • Flash to Pass 220 • Exterior Lights 220 • Interior Lights 235 • Summary 237 • Terms to Know 237 • Review Questions 238 • Multiple Choice 239 iii Contents Chapter Introduction to the Body Computer 240 • Introduction 240 • Computer Functions 240 • Analog and Digital Principles 241 • Microprocessor 245 • Computer Memory 245 • Information Processing 248 • High-Side and Low-Side Drivers 253 • Outputs 254 • Summary 257 • Terms to Know 257 • Review Questions 258 • Multiple Choice 259 Chapter 10 Computer Inputs .260 • Introduction 260 • Thermistors 261 • Pressure Sensors 264 • Position and Motion Detection Sensors 268 • Switch Inputs 277 • Feedback Signals 279 • Summary 279 • Terms to Know 280 • Review Questions 281 • Multiple Choice 281 Chapter 11 Vehicle Communication Networks 283 • Introduction 283 • Multiplexing Communication Protocols 284 • Multiplexing Systems 286 • Supplemental Data Bus Networks 297 • Summary 302 • Terms to Know 302 • Review Questions 303 • Multiple Choice 304 Chapter 12 Advanced Lighting Circuits 305 • Introduction 305 • Computer-Controlled Concealed Headlights 305 • Computer-Controlled Headlight Systems 307 • Automatic On/Off with Time Delay 309 • Automatic Headlight Dimming 313 • Headlight Leveling 318 • Adaptive Headlights 318 • Daytime Running Lamps 320 • Adaptive Brake Lights 322 • Illuminated Entry Systems 323 • Instrument Panel Dimming 324 • Fiber Optics 326 • Lamp Outage Indicators 327 • Summary 331 • Terms to Know 331 • Review Questions 332 • Multiple Choice 332 Chapter 13 Instrumentation and Warning Lamps 334 • Introduction 334 • Electromechanical Gauges 335 • Quartz Analog Instrumentation 339 • Gauge Sending Units 341 • Digital Instrumentation 342 • Head-Up Display 349 • Travel Information Systems 350 • Warning Lamps 353 • Summary 355 • Terms to Know 355 •Review Questions 355 • Multiple Choice 356 Chapter 14 Accessories 358 • Introduction 358 • Horns 359 • Windshield Wipers 363 • Computer-Operated Wipers 374 • Intelligent Windshield Wipers 375 • Washer Pumps 376 • Blower Motor Circuits 379 • Electric Defoggers 382 • Power Mirrors 383 • Power Windows 386 • Power Seats 389 • Memory Seats 392 • Power Door Locks 394 • Automatic Door Locks 398 • Keyless Entry 399 • Antitheft Systems 404 • Immobilizer Systems 407 • Electronic Cruise Control Systems 409 • Electronic Sunroof Concepts 412 • Electronic Heated Windshield 417 • Vehicle Audio Entertainment Systems 422 • DVD Systems 428 • Hands-Free Cellular Telephone 429 • Navigation Systems 430 • Summary 431 • Terms to Know 431 • Review Questions 432 • Multiple Choice 433 Chapter 15 Passive Restraint Systems 434 • Introduction 434 • Passive Seat Belt Systems 435 • Air Bag Systems 438 • Air Bag Deployment 444 • Air Bag Warning Lamp 445 • Passenger-Side Air Bags 445 • Hybrid Air Bag Types 446 • Multistage Air Bag Deployment 447 • Side-Impact Air Bags 448 • Air Bag On/Off Switches 450 • Seat Belt Pretensioners 453 • Inflatable Knee Blockers 454 • Occupant Classification Systems 454 • Summary 459 • Terms to Know 460 • Review Questions 460 • Multiple Choice 461 iv Contents Chapter 16 Vehicles with Alternative Power Sources 463 • Introduction 463 • Electric Vehicles 463 • Hybrid Vehicles 465 • 42-Volt Systems 470 • Fuel Cells 476 • Summary 483 • Terms to Know 483 • Review Questions 484 • Multiple Choice 485 Glossary .487 Index 515 v Preface Thanks to the support the Today’s TechnicianTM series has received from those who teach automotive technology, Delmar Cengage Learning, the leader in automotive related textbooks, is able to live up to its promise to provide new editions of the series every few years We have listened and responded to our critics and our fans and present this new updated and revised fifth edition By revising this series on a regular basis, we can respond to changes in the industry, changes in technology, changes in the certification process, and to the ever-changing needs of those who teach automotive technology We also listened to instructors when they said something was missing or incomplete in the last edition We responded to those and the results are included in this fifth edition The Today’s TechnicianTM series, by Delmar Cengage, features textbooks that cover all mechanical and electrical systems of automobiles and light trucks Principally the individual titles correspond to the certification areas for 2009 areas of ASE (National Institute for Automotive Service Excellence) certification Additional titles include remedial skills and theories common to all of the certification areas and advanced or specific subject areas that reflect the latest technological trends This new edition, like the last, was designed to give students a chance to develop the same skills and gain the same knowledge that today’s successful technician has This edition also reflects the changes in the guidelines established by the National Automotive Technicians Education Foundation (NATEF) in 2008 The purpose of NATEF is to evaluate technician training programs against standards developed by the automotive industry and recommend qualifying programs for certification (accreditation) by ASE Programs can earn ASE certification upon the recommendation of NATEF NATEF’s national standards reflect the skills that students must master ASE certification through NATEF evaluation ensures that certified training programs meet or exceed industry-recognized, uniform standards of excellence The technician of today and for the future must know the underlying theory of all automotive systems and be able to service and maintain those systems Dividing the material into two volumes, a Classroom Manual and a Shop Manual, provides the reader with the information needed to begin a successful career as an automotive technician without interrupting the learning process by mixing cognitive and performance learning objectives into one volume The design of Delmar’s Today’s TechnicianTM series was based on features that are known to promote improved student learning The design was further enhanced by a careful study of survey results, in which the respondents were asked to value particular features Some of these features can be found in other textbooks, while others are unique to this series Each Classroom Manual contains the principles of operation for each system and subsystem The Classroom Manual also contains discussions on design variations of key components used by the different vehicle manufacturers It also looks into emerging technologies that will be standard or optional features in the near future This volume is organized to build upon basic facts and theories The primary objective of this volume is to allow the reader to gain an understanding of how each system and subsystem operates This understanding is necessary to diagnose the complex automobiles of today and tomorrow Although the basics contained in the Classroom Manual provide the knowledge needed for diagnostics, diagnostic procedures appear only in the Shop Manual An understanding of the underlying theories is also a requirement for competence in the skill areas covered in the Shop Manual vi Preface A coil ring—bound Shop Manual covers the “how-to’s.” This volume includes step-by-step instructions for diagnostic and repair procedures Photo Sequences are used to illustrate some of the common service procedures Other common procedures are listed and are accompanied with fine line drawings and photos that allow the reader to visualize and conceptualize the finest details of the procedure This volume also contains the reasons for performing the procedures, as well as when that particular service is appropriate The two volumes are designed to be used together and are arranged in corresponding chapters Not only are the chapters in the volumes linked together, the contents of the chapters are also linked This linking of content is evidenced by marginal callouts that refer the reader to the chapter and page that the same topic is addressed in the other volume This feature is valuable to instructors Without this feature, users of other two-volume textbooks must search the index or table of contents to locate supporting information in the other volume This is not only cumbersome, but also creates additional work for an instructor when planning the presentation of material and when making reading assignments It is also valuable to the students, with the page references they also know exactly where to look for supportive information Both volumes contain clear and thoughtfully selected illustrations Many of which are original drawings or photos specially prepared for inclusion in this series This means that the art is a vital part of each textbook and not merely inserted to increase the numbers of illustrations The page layout, used in the series, is designed to include information that would otherwise break up the flow of information presented to the reader The main body of the text includes all of the “need-to-know” information and illustrations In the wide side margins of each page are many of the special features of the series Items that are truly “nice-to-know” information such as simple examples of concepts just introduced in the text, explanations or definitions of terms that are not defined in the text, examples of common trade jargon used to describe a part or operation, and exceptions to the norm are explained in the text This type of information is placed in the margin, out of the normal flow of information Many textbooks attempt to include this type of information and insert it in the main body of text; this tends to interrupt the thought process and cannot be pedagogically justified By placing this information off to the side of the main text, the reader can select when to refer to it Highlights of this Edition—Classroom Manual Upon opening the covers of the 5th Edition of Today’s Technician Automotive Electricity and Electronics, you will immediately notice the use of colored photos and illustrations that greatly enhance the visual quality of the text and the learning experience of the student The text layout has also been improved for easier reader comprehension Not only does the textbook have a fresh look, the text of the 5th Edition was updated throughout to include the latest developments Although chapter 16 covers details associated with alternate powered vehicles, all pertinent information about hybrid vehicles is included in the main text that concerns relative topics For example, the discussion of batteries in Chapter includes coverage of HEV batteries and ultra-capacitors Chapter now includes AC motor principles and the operation of the integrated starter/generator Chapter includes the HEV charging system including regenerative braking and the DC/DC converter The flow of basic electrical to more complex electronic systems has been maintained Rearrangement of chapters has been utilized to enhance this flow and reduce redundancy vii Preface Chapter introduces the student to the automotive electrical and electronic systems with a general overview This chapter emphasizes the interconnectivity of systems in today’s vehicles, and describes the purpose and location of the subsystems, as well as the major components of the system and subsystems The goal of this chapter is to establish a basic understanding for students to base their learning on All systems and subsystems that are discussed in detail later in the text are introduced and their primary purpose described The second chapter covers the underlying basic theories of electricity and now includes discussion of Kirchoff ’s laws This is valuable to the student and the instructor because it covers the theories that other textbooks assume the reader knows All related basic electrical theories are covered in this chapter Chapter applies those theories to the operation of electrical and electronic components, and Chapter covers wiring and the proper use of wiring diagrams Emphasis is on using the diagrams to determine how the system works and how to use the diagram to isolate the problem The chapters that follow cover the major components of automotive electrical and electronic systems, such as batteries, starting systems and motor designs, charging systems, and basic lighting systems This is followed by chapters that detail the functions of the body computer, input components, and vehicle communication networks From here the student is guided into specific systems that utilize computer functions Current electrical and electronic systems are used as examples throughout the text Most of these systems are discussed in detail This includes computer-controlled interior and exterior lighting, night vision, adaptive lights, instrumentation, and electrical/electronic accessories Coverage includes intelligent wiper, immobilizer, and adaptive cruise control systems to name a few Chapter 15 details the passive restraint systems currently used Jack Erjavec Highlights of this Edition—Shop Manual Like the Classroom Manual, the Shop Manual has a new layout with color photographs and illustrations The Shop Manual was updated to match current trends Service information related to the new topics covered in the Classroom Manual is included in this manual In addition, several new photo sequences were added The purpose of these detailed photos is to show students what to expect when they perform the same procedure They also help familiarize students with a system or type of equipment they may not be able to encounter at their school Although the main purpose of the textbook is not to prepare someone to successfully pass an ASE exam, all the information required to so is included in the textbook To stress the importance of safe work habits, Chapter is dedicated to safety, and has been updated to include general HEV safety As with the Classroom Manual, HEV system diagnosis is included within the main text This provides the student with knowledge of safe system diagnosing procedures so they know what to expect as they further their training in this area Included in this chapter are common shop hazards, safe shop practices, safety equipment, and the legislation concerning and the safe handling of hazardous materials and wastes Chapter covers special tools and procedures This chapter now includes the use of isolation meters and expanded coverage of scan tools In addition, a section on what it entails to be an electrical systems technician has been added This section covers relationships, completing the viii Preface work order and ASE certification Another section was added to emphasize the importance of proper diagnostic procedures Chapter leads the student through basic troubleshooting and service This includes the use of various test equipment to locate circuit defects and how to test electrical and electronic components Chapter provides experience with wiring repairs along with extended coverage and exercises on using the wiring diagrams The remainder of the chapters has been thoroughly updated Redundancy between the Classroom Manual and the Shop Manual has been reduced; the only time theory is discussed again is if it is necessary to explain the diagnostic results or as an explanation of the symptom The Shop Manual is cross-referenced to the Classroom Manual by the use of marginal notes This provides the benefit to the student of being able to quickly reference the theory of the component or system that they are now working with Currently accepted service procedures are used as examples throughout the text These procedures also served as the basis for new job sheets that are included in the Shop Manual chapters ix System main relay (SMR) Used to connect and disconnect the power source of the high-voltage system in an HEV Relé principal del sistema del (SMR o RPS) Se usa para conectar y desconectar la fuente de potencia del sistema de alto voltaje en un VHE Tachometer An instrument that measures the speed of the engine in revolutions per minute (rpm) Tacómetro Instrumento que mide la velocidad del motor en revoluciones por minuto (rpm) Thermistor A solid-state variable resistor made from a semiconductor material that changes resistance as a function of temperature Termistor Un resistor variable de estado sólido, fabricado a partir de material semiconductor que cambia la resistencia en función de la temperatura Test light Checks for electrical power in a circuit Luz de prueba Verifica la potencia eléctrica en un circuito Three-coil gauge A gauge design that uses the interaction of three electromagnets and the total field effect upon a permanent magnet to cause needle movement Calibrador de tres bobinas Calibrador disado para utilizar la interacción de tres electroimanes y el efecto inductor total sobre un imán permanente para producir el movimiento de la aguja Three-minute charge test A reasonably accurate method for diagnosing a sulfated battery for use on conventional batteries Prueba de carga de tres minutos Método bastante preciso en baterías convencionales para diagnosticar una batería sulfatada Throttle position sensor (TPS) Sensor used to modify the pulse width calculation based on position of the throttle plate and the rate of change of the throttle plate Sensor de posición del acelerador (TPS, por sus siglas en inglés) Sensor que se utiliza para modificar el cálculo de la amplitud del pulso sobre la base de la posición de la placa del acelerador y el índice de cambio de la placa del acelerador Timer control A potentiometer that is part of the headlight switch in some systems It controls the amount of time the headlights stay on after the ignition switch is turned off Control temporizador Un potenciómetro que es parte del conmutador de los faros en algunos sistemas Controla la cantidad del tiempo que quedan prendidos los faros después de apagarse la llave del encendido Tin Process of applying solder to the tip of the soldering iron to provide better heating control Estaño El proceso de aplicar soldadura en la punta de un hierro soldador para dar mejor control al calor Tire pressure monitoring (TPM) system A safety system that notifies the driver if a tire is underinflated or overinflated Sistema de monitoreo de presión de las llantas (TPM, por su sigla en inglés) Un sistema de seguridad que informa al conductor si una llanta está muy inflada o poco inflada Torque converter A hydraulic device found on automatic transmissions It is responsible for controlling the power flow from the engine to the transmission; works like a clutch to engage and disengage the engine’s power to the drive line Convertidor de par Un dispositivo hidraúlico en las transmisiones automáticas Se encarga de controlar el flujo de la potencia del motor a la transmisión; funciona como un embrague para embragar y desembragar la potencia del motor la flecha motríz Trimotor A three-armature motor 720 Trimotor Es un motor de tres armaduras Trouble codes Output of the self-diagnostics program in the form of a numbered code that indicates faulty circuits or components Trouble codes are two or three digital characters that are displayed in the diagnostic display if the testing and failure requirements are both met Códigos indicadores de fallas Datos del programa autodiagnóstico en forma de código numerado que indica los circuitos o los componentes defectuosos Dichos códigos se componen de dos o tres carácteres digitales que se muestran en el visualizador diagnóstico si se llenan los requisitos de prueba y de falla Troubleshooting The diagnostic procedure of locating and identifying the cause of the fault It is a step-by-step process of elimination by use of cause-and-effect Detección de fallas Procedimiento diagnóstico a través del cual se localiza e identifica la falla Es un proceso de eliminación que se lleva a cabo paso a paso por medio de causa y efecto TVRS An abbreviation for television-radio-suppression cable TVRS Una abreviación del cable de supresíon del televisión y radio Two-button diagnostics The buttons on the instrument panel that, when pressed in the right combination, place the module into self-test mode Diagnósticos de dos botones Estos son los botones que aparecen en el panel de instrumentos, los cuales al presionarlos en la combinación correcta, ponen el módulo en estado de autoprueba Two-coil gauge A gauge design that uses the interaction of two electromagnets and the total field effect upon an armature to cause needle movement Calibrador de dos bobinas Calibrador diseñado para utilizar la interacción de dos electroimanes y el efecto inductor total sobre una armadura para generar el movimiento de la aguja U-codes Diagnostic trouble codes assigned to the vehicle communication network Códigos en U Códigos de fallo de diagnóstico asignados a la red de comunicación del vehículo Vacuum distribution valve A valve used in vacuum-controlled concealed headlight systems It controls the direction of vacuum to various vacuum motors or to vent Válvula de distribución al vacío Válvula utilizada en el sistema de faros delanteros ocultos controlado al vacío Regula la dirección del vacío a varios motores al vacío o sirve para dar salida del sistema Vacuum fluorescent display (VFD) A display type that uses anode segments coated with phosphor and bombarded with tungsten electrons to cause the segments to glow Visualización de fluorescencia al vacío Tipo de visualización que utiliza segmentos ánodos cubiertos de fósforo y bombardeados de electrones de tungsteno para producir la luminiscencia de los segmentos Valve body A unit that consists of many valves and hydraulic circuits This unit is the central control point for gear shifting in an automatic transmission Cuerpo de la válvula Una unedad que consiste de muchas válvulas y circuitos hidráulicos Esta unedad es el punto central de mando para los cambios de velocidad en una transmisión automática Variable resistor A resistor that provides for an infinite number of resistance values within a range Resistor variable Resistor que provee un número infinito de valores de resistencia dentro de un margen Vehicle Identification Number (VIN) A number that is assigned to a vehicle for identification purposes The identification plate is usually located on the cowl, next to the left upper instrument panel Limitador de tensión Conectado por el red de resistores de un regulador de tensión Determina si el campo recibirá alta, baja o ninguna tensión Controla la tensión de campo durante el tiempo indicado de carga Número de identificación del vehículo Número asignado a cada vehículo para fines de identificación Por lo general, la placa de identificación se ubica en la bóveda, al lado del panel de instrumentos superior de la izquierda Voltage output test Used to make a quick determination about whether or not the charging system is working properly If the charging system is operating correctly, then check for battery drain Vehicle lift points The areas that the manufacturer recommends for safe vehicle lifting They are the areas that are structurally strong enough to sustain the stress of lifting Puntos para elevar el vehículo Áreas específicas que el fabricante recomienda para sujetar el vehículo a fin de lograr una elevación segura Son las áreas del vehículo una estructura suficientemente fuerte para sostener la presión de la elevación Vehicle module scan A special function of the scan tools that will query all of the modules on the bus to respond and then list those that did reply Explorador del módulo del vehículo Función especial de los instrumentos de exploración que cuestionarán a todos los módulos en el bus para que respondan, y luego harán una lista de aquellos que respondieron Volatile A substance that vaporizes or explodes easily Prueba de salida del voltaje Se usa para determinar en forma rápida si el sistema de carga está trabajando correctamente Si el sistema de carga está funcionando correctamente, entonces revíselo todo para saber si hay algún drenaje en la batería Voltage regulator Used to control the output voltage of the AC generator, based on charging system demands, by controlling field current Regulador de tensión Dispositivo cuya función es mantener la tensión de salida del generador de corriente alterna, de acuerdo a las variaciones en la corriente de carga, controlando la corriente inductora Voltmeter A test meter used to read the pressure behind the flow of electrons Voltímetro Instrumento de prueba utilizado para medir la presión del flujo de electrones Warning light A lamp that is illuminated to warn the driver of a possible problem or hazardous condition Volátil Sustancia que se evapora o explota facilidad Luz de aviso Lámpara que se enciende para avisarle al conductor sobre posibles problemas o condiciones peligrosas Volatility The tendency for a fluid to evaporate quickly or pass off in the form of a vapor Watt The unit of measure of electrical power, which is the equivalent of horsepower One horsepower is equal to 746 watts Volatilidad La tendencia de un fluido a evaporarse rápidamente o disiparse en forma de vapor Watio Unidad de potencia eléctrica, equivalente a un caballo de vapor 746 watios equivalen a un caballo de vapor (CV) Volt The unit used to measure the amount of electrical force Wattage A measure of the total electrical work being performed per unit of time Voltio Unidad práctica de tensión para medir la cantidad de fuerza eléctrica Voltage The difference or potential that indicates an excess of electrons at the end of the circuit the farthest from the electromotive force It is the electrical pressure that causes electrons to move through a circuit One volt is the amount of pressure required to move one amp of current through one ohm of resistance Tensión Diferencia o potencial que indica un exceso de electrones al punto del circuito que se encuentra más alejado de la fuerza electromotriz La presión eléctrica genera el movimiento de electrones a través de un circuito Un voltio equivale a la cantidad de presión requerida para mover un amperio de corriente a través de un ohmio de resistencia Voltage drop A resistance in the circuit that reduces the electrical pressure available after the resistance The resistance can be either the load component, the conductors, any connections, or unwanted resistance Cda de tensión Resistencia en el circuito que disminuye la presión eléctrica disponible después de la resistencia La resistencia puede ser el componente de carga, los conductores, cualquier conexión o resistencia no deseada Voltage drop test Determines if the battery, regulator, and AC generator are all operating at the same potential Prueba de la cda de tensión en el voltaje Determina si la batería, el regulador, y el generador de corriente alterna AC están todos funcionando al mismo potencial Voltage limiter Connected through the resistor network of a voltage regulator It determines whether the field will receive high, low, or no voltage It controls the field voltage for the required amount of charging Vataje Medida del trabajo eléctrico total realizado por unidad de tiempo Waveform The electronic trace that appears on a scope; it represents voltage over time Forma de onda La trayectoria electrónica que aparece en un osciloscopio; representa la tensión a través del tiempo Weather-pack connector An electrical connector that has rubber seals on the terminal ends and on the covers of the connector half to protect the circuit from corrosion Conectador resistente a la intemperie Conectador que tiene sellos de caucho en los extremos de los bornes y en las cubiertas de la parte del conectador para proteger el circuito contra la corrosión Wet fouling A condition of a spark plug in which it is wet with oil Engrase húmedo Una condición de la bujía en la cual se moja de aceite Wheatstone bridge A series-parallel arrangement of resistors between an input terminal and ground Flexing of the disc the resistors are laid upon changes their value Puente Wheatstone Una disposición en serie paralela de resistores entre un terminal de entrada y la tierra La flexión del disco en el que están colocados los resistores cambia su valor Wiring diagram An electrical schematic that shows a representation of actual electrical or electronic components and the wiring of the vehicle’s electrical systems Esquema de conexciones Esquema en el que se muestran las conexiones internas de los componentes eléctricos o electronicos reales y las de los sistemas eléctricos del vehículo Wiring harness A group of wires enclosed in a conduit and routed to specific areas of the vehicle 721 Cableado preformado Conjunto de alambres envueltos en un conducto y dirigidos hacia áreas específicas del vehículo Workplace hazardous materials information systems (WHMIS) Canadian equivalent to MSDS sheets Sistemas de información acerca de los materiales peligrosos en el área de trabajo (SIMPAT o WHMIS) Equivalente canadiense a las hojas de datos de la seguridad de un material Worm gear A type of gear whose teeth wrap around the shaft The action of the gear is much like that of a threaded bolt or screw 722 Engranaje de tornillo sin fin Un tipo de engranaje cuyos dientes se envuelven alrededor del vástago El movimiento del engranaje es muy parecido a un perno enroscado o una tuerca Wye connection A type of stator winding in which one end of the individual windings are connected at a common point The structure resembles the letter “Y.” Conexión Y Un tipo de devanado estátor en el cual una extremidad de los devanados individuales se conectan en un punto común La estructura parece la letra “Y.” Index A ABS See antilock brake systems (ABS) accumulator, 27 AC generators See also charging systems component testing, 296–299 diodes (rectifier bridges), 297–298 diode trio, 298 rotors, 296 stators, 297 current output testing, 275 diagnostic chart for, 309 diode pattern testing, 283–285 diode/stator test, 282 disassembly, 290–295 full field tests, 275–281 inspection of components, 296 noises, 269 reassembly, 299 removal and replacement belt tension adjustment, 286–290 actuator tests, 368–370, 371–372, 489, 589, 607 scan tool, 369–370 activation test, 370 AC voltage, 119, 283, 299 air bag module, 25 air bag system diagnostic module (ASDM), 648 air bag systems cleanup procedure after deployment, 651 component replacement, 651–654 clockspring replacement, 652–654 module replacement, 651–652 defined, 25 diagnostic charts for, 671 inspecting, after accident, 651 retrieving fault codes, 645–646 safety and services warnings, 644–645 safety precautions with, 25–26 system check of, 644 system testing, 648–649 air gap, 410 air tools See pneumatic tools, safety issues with alarms See antitheft systems alcohol use, alternating current (AC) voltage, 50, 58–59, 119 aluminum wire repairs, 146 ammeters, 41, 42, 51–52 ampere, 41–42 amplifier test, 493 analog gauges, 539 analog meters, 45 analog ohmmeters, 50 analog signals, 120, 122 antennas, 615–617 antilock brake systems (ABS), 26–27 antitheft systems, 594–600 alarm sounds for no reason, 594 circuit schematic of, 595 controller test, 594–596 diagnostic charts for, 640 relay tests, 596 self-diagnostic tests, 594, 599–600 appearance, personal safety and, apprentices, 70 armature ground test, 252 armature short test, 252 asbestos, 22 exposure, 22 ASDM See air bag system diagnostic module (ASDM) ASE certification, 72–74 audio entertainment systems, 615–617 automatic door lock systems, 591–593 automatic headlight systems, 492–506 amplifier test, 493 photocell replacement, 494–4952 photocell test, 492–493 resistance assembly test, 496 SmartBeam diagnostics, 496–4503 automatic seat belt systems, 643–644 circuit schematic of, 643 drive motor assembly replacement, 644 automatic suspension systems, 201, 355 automatic wiper system, 577–579 automotive bulbs, 312 Automotive Service Excellence (ASE) certification, 72–74 average responding meters, 50 B back injuries, 6–7 backprobe, 48 back-up lights, 354 batteries, 185–214 See also charging systems battery drain test, 200–202 battery inspection, 187–189 charging the battery, 189–191, 679 computerized load-testing equipment, 200 diagnostic charts for, 225–227 general precautions, 186–187 high-voltage, 677–679 introduction to, 185–186 jumping the battery, 206–207 load testing, 200 723 maintaining and restoring memory functions, 191 memory function maintenance, 191 memory keepers, 66 recycling, 213 removal and cleaning, 202–206 safety precautions with, 23–24 selection of, 199 test series, 191–200 batter terminal test, 192 battery leakage test, 193 capacity test, 197–199 conductance testing, 200 open circuit voltage test, 196–197 state of charge test, 193–195 three-minute charge test, 199 BAT terminal, 24, 242, 244, 269 battery acid, 186 battery backups, 66 battery ECU, 208–209, 677–678 battery leakage test, 193 battery load testers, 200 battery stickers, 187 battery terminal test, 192 battery test equipment, 186 BCM See body control module (BCM) B-codes, 448 bearings, faulty, 269 belt tension sensors (BTSs), 656, 658 bimetallic gauges, 539 bipolar transistors, testing, 116–117 blade fuses, 104 blower motor service, 581–583 constantly operating fans, 583 ground side switches, 581 insulated switches, 581 resistor block, 581 body computer system See body control module (BCM) body control module (BCM), 355–375 computer system functions, 355–357 computer voltage supply and ground circuits, 358–363 concealed headlight system and, 487–491 entering diagnostics, 365–368 flashing the, 373–374 of instrument panel, 529 introduction to, 355–357 service precautions, 357 testing actuators, 368–369 trouble codes, 364, 366 visual inspection, 365 boots, brake lights, 330–334 brake systems See antilock brake systems (ABS) breakout boxes, 359, 407, 447 brighter-than-normal lights, 321 brush assembly checks, 251, 252 BTSs (belt tension sensors), 656–658 724 bus bar lead repair, 585 bus systems CAN bus diagnostics, 457–460 class A bus system diagnostics, 452–454 communication fault codes, 447–448 enhanced scan tool diagnostics, 462–463 failures, 448 ISO 9141–2 bus system diagnostics, 448–450 ISO-K bus system diagnostics, 450–451 J1850 bus system diagnostics, 454–456 LIN bus diagnostics, 460–462 C cable connections, for jump starts, 207, 256 Cadillac BCM trouble codes, 366 camera calibration procedure, 498–503 capacitance discharge sensor, 403 capacitors, 362 capacity test, 197–198 captured signals, 58 carbon monoxide, 13–14 cartridge fuses, 104 Caustic chemicals, CD systems, 616 ceramic fuses, 104 certification, ASE, 72–74 charge assist See jump assist charge rate, 190 charging systems, 267–310 AC generators component testing, 296–299 disassembly, 290–294 noises, 269 reassembly, 299 removal and replacement, 286–290 current output testing, 275, 276 diagnostic charts, 308–310 diode pattern testing, 283–285 diode/stator test, 282 field current draw test, 274–275 full field tests, 275–277 introduction to, 267–269 precautions, 269 regulator test, 282 requirement test, 286 safety, 24–25 troubleshooting, 270–272 voltage drop testing, 272–273 voltage output testing, 270–272 charging the battery, 189–191, 679–680 chokes, 362 Chrysler Collision Detection (CCD) multiplexing system, 452–454 cigarette smoking, 3, 25 circuit breakers, 100–101 circuit diagrams, reading, 154–158 circuit grounding, 48 circuit protection devices, 104–107 circuits, 96–97 ground, 100–101, 240–241 open, 96–97, 242–243 prove-out, 546–547 sensor return, 360–363 circuit test chart, 51 circuit testing with ammeter, 51–52 for defects, 96–97 ground circuit tests, 240–241 insulated circuit resistance test, 240 for opens, 96–97, 242–243 for shorts, 97–99 for short to ground, 100–101 solenoid circuit resistance testing, 242 CKP See crankshaft position sensor (CKP) class A bus system diagnostics, 452–454 clockspring replacement, 652–654 clothing, personal safety and, Code of Federal Regulations, 21 cold soak, 396 color codes, 154 combustible materials, storage of, 16 communication, with customers, 70 commutator tests, 252 compensation, 70 composite headlights aiming, 317–319 replacement, 312–317 compressed air, safety issues, computer-controlled lighting systems, 487–513 automatic headlight system diagnosis, 491–507 concealed headlight diagnosis, 487–491 daytime running lamps, 505–507 fiber optic diagnosis, 511 headlight systems, 489–491 illuminated entry lights, 507–510 introduction to, 487 computer-controlled wiper systems, 574 automatic system, 577–579 hi/low control circuit high, 577 hi/low control circuit low, 576–577 on/off control circuit high, 576 on/off control circuit low, 576 park switch input circuit high, 575–576 park switch input circuit low, 574–575 computer-driven instrumentation systems See instrument panels computerized load-testing equipment, 200 computer services, for service information, 66 computer systems See body control module (BCM) concealed headlights, 322, 487–491 conductance testing, 200 conductors of electricity, 2, 24 connector terminals repairing, 149–153 hard-shell connectors, 150–151 metri-pack connectors, 153 molded connectors, 150 weather-pack connectors, 151–152 continuity tester, 44 control assembly See electronic climate control panel (ECC) Controller Area Network (CAN) bus systems, 457–460 controller test, 594–596 converters, 680–681 copper wire repairs, 140–146 courtesy lights, 335–336, 339 crankshaft position sensor (CKP), 539 crimping, 140–142 crocus cloth, 252 cruise control systems, 599–610 component replacement, 609–610 servo assembly, 609–611 switch, 609 component testing, 607–609 dump valves, 609 servo assembly, 607–609 speed sensors, 609 continuously changing speeds diagnosis, 606, 607 DaimlerChrysler, 604 type 1, 604 type 2, 604–605 type 4, 604 diagnosing without trouble codes, 605–606 no operation, 606 simulated road test, 605–606 diagnostic charts for, 688 Ford, 602–603 General Motors, 599–602 type 1, 599–600 type 3, 600 type 4, 600–602 intermittent operation diagnosis, 607 no operation diagnosis, 606 self-diagnostics, 599–602 speed control electrical schematic, 608 curb height, 317–318 current, 95 current draw tests, 237–238 current output testing, 275 customer relations, 71 cycles, 53, 54, 59, 119 D DaimlerChrysler AC generators, 296 cruise control systems, 604 electromechanical clusters (MICs), 533–534 Darlington transistors, 116 D’Arsonval movement, 45–46 725 dash-mounted switches, 323–325, 574 data buses See bus systems data link connectors (DLC), 447 daytime running lamps, 505–507 DC/DC converter, 681 DC voltage, 53, 58–59 defogger diagnosis and repair, 584 Delco Remy starter, 247–249 demonstration mode, 498 diagnostic charts AC generators, 309 batteries, 226–227 burned fusible links, 184 burned or defective connectors, insulation, or conductors, 184 charging systems, 308–309 diodes, 309 electrical accessories, 633–642 electrical opens, 137 headlights, 350–351, 523 high-resistance problems, 137 hybrid electric vehicle (HEV) systems, 688 instrument panels, 558–559 lighting systems, 350–354, 523–524 multiplexing systems, 486 sensor diagnostic routines, 441–445 shorts, 137 starting systems, 264–265 voltage regulation, 309 diagnostics See also troubleshooting approach to, 74 cause-and-effect approach to, 149 importance of, 74 diagnostic tools See test equipment diagnostic trees, 68 diagnostic trouble codes (DTCs), 63, 364–365 diesel fuel, 16–17 digital instrument panel cluster display, 647 digital multimeters (DMMs), 46 digital signals, 120–122 digital storage oscilloscopes (DSOs), 58, 117–122 screen, 118–119 selecting voltage and time base, 119 trigger and trigger slope, 119–120 types of voltage signals, 120–121 user-friendly, 121 digital volt/ohmmeters (DVOMs), 46 additional functions of, 53–54 reading, 54–55 dim lights, 321–322 dimmer/brighter-than-normal lights, diagnostics, 321 dimmer switches, testing and replacement of, 326–329 diode pattern testing, 283–285 diodes diagnostic chart for, 309 testing, 114–115, 297–298 726 diode/stator test, 282–285 DLC See data link connectors (DLC) door locks, 591 automatic, 591–593 remote keyless entry systems, 593 drain test, 200–202 dress, personal safety and, drive belts, 268–269 loose, 269 drug use, DSOs See digital storage oscilloscopes (DSOs) DTCs See diagnostic trouble codes (DTCs) dual ramping, 394 dual range See dual ramping dual resolution See dual ramping dump valves, 609 duty cycle, 53, 122, 369 DVOMs See digital volt/ohmmeters (DVOMs) E eddy currents, 534 EEPROM chips, 373 EIC See electronic instrument cluster (EIC) electrical accessories, 561–618 antitheft systems, 594–596 audio entertainment systems, 615–617 blower motor service, 581–583 computer-controlled, 574–577 diagnostic charts for, 633–642 electric defoggers, 584–586 heated windshields, 612–615 horn diagnosis, 562–566 horn sounds continuous sound, 565 poor sound quality, 565 systems with relay, 562–564 systems without relay, 564–565 immobilizer systems, 596–599 introduction to, 561–562 memory seats, 589–591 power door locks, 398, 591 power seats, 589 power windows, 587–589 remote keyless entry systems, 593 sunroofs, 611–612 video entertainment systems, 615–617 windshield washer system service, 579–581 wiper system service, 566–574 dash-mounted switch, removal and installation, 574 faulty park switch, 569–571 intermittent wiper system diagnosis, 571 no operation in one speed only, 567 no wiper operation, 568–569 slower than normal wiper speeds, 569 steering column-mounted switch, removal and installation 574 wiper motor removal and installation, 572–573 electrical components testing and replacing, 108–113 relays, 108–112 stepped resistors, 112 switches, 108–110 variable resistors, 112–113 electrical diagram/schematics, 139 reading, 154–158 electrical disturbances, 57 electrical noise, 53, 57 electrical opens See open circuits electrical requirement, testing for, 286 electrical system safety, 23–27 air bags, 25–26 antilock brake systems (ABS), 26–27 batteries, 23–24, 25 charging system, 24–25 starting system service, 24 electrical systems technician, working as a, 70–75 work order completion, 72 electrical test equipment See test equipment electrical troubleshooting and service basic, 95–122 introduction to, 95 process of, 139–140 test equipment for, 43–66 testing and replacing electrical components, 108–113 testing circuit protection devices, 104–107 testing diodes, 114–115 testing for circuit defects, 96–101 testing for voltage drop, 101–103 testing transistors, 116–117 using DSO, 117–122 electric cooling fans, safety and, 6, 14 electric current, 41 electric defogger diagnosis and service, 584–586 bus bar lead repair, 585 grid wire repair, 585 electricity, conductors of, 2, 43 electromagnetic gauges, 539 electromagnetic interference (EMI), 358, 361 electromechanical clusters (MICs), self-test, 533 electromotive force (EMF), 41 electronic climate control panel (ECC), 366, 529, 599, 647 electronic clusters, self-test, 534 electronic cruise control systems See cruise control systems electronic gauges, 543–544 electronic instrument cluster (EIC) diagnosis of, 529–531 function diagnostic mode, 529–530 imports, 531–533 prove-out display, 529 special test mode, 531 electronic service precautions, 357–358 electronic sunroofs, 611–612 electrostatic discharge (ESD), 357–358 straps, 357 employer-employee relations, 70–71 entertainment systems, 615–617 entry lights, 507–510 environmental data, 392 Environmental Protection Agency (EPA), 20 equipment safety, 7–8 eye injuries, eye protection, 3–4 eyewash fountains, F face shields, fail soft action, 357 false wipes See automatic wiper system fan motor service, 581–583 fast charging, 190 fault codes, 364, 447–448, 645–648 See also trouble codes Cadillac BCM trouble code, 366–368 feedback, 97, 338 fiber optic diagnosis, 511 field coil testing, 251 field current draw test, 274–275 fire blanket, 17 fire extinguishers types, 14 use of, 17 fire hazards, 14–18 first-aid kits, flammable fumes, 15 flash a computer, 373–374 flash code, 364 retrieval, 646–648 flashers, 334 flat rate system, 70 floor jacks, safe use of, 9–12 floor-mounted switches, 329 floor stands, 9–12 footwear, Ford AC generators, 290–295, 296–299 air bag flash codes, 647–648 electronic clusters, 534 integrated vehicle speed control (IVSC) systems, 602–603 free speed test, 244–245 free spin test, 244, 256 freeze frame, 392 data, 676 frequency, 53, 59, 121–122 signal, 54 fuel gauges, 542–543 fuel level senders, 535, 545 full fielding, 275 test, 275–282 727 functional test, of AHS (automatic headlight systems), 492 fuses, 104–108, 149 blown, 335, 488 determining current flows through, 202 fusible links, 104–107, 148–149 G gasoline containers, 16 as fire hazard, 14–16 gauges See also instrument panels analog, 539 bimetallic, 539 defined, 539 diagnosis of conventional, 539–543 electromagnetic, 539 electronic, 543–544 failure of multiple, 541–543 failure of single, 540–541 fuel, 542–543 Gauss, 100–101 sending units, 544 Gauss gauge, 100–101 gear reduction starters, 249–250 gel cell batteries, recharging, 191 General Motors (GM) AC generators, 275, 277 BCMs, 529 cruise control systems, 599–611 flash code retrieval, 646–647 heated windshield system, 613 generator drive belts, 268–269 generators, 24–25 See also AC generators; charging systems glitches, 57–58 gloves, 4–5 grids, 584 grid wire repair, 585–586 ground circuits, 240–242, 358–362 ground straps, 154 ground wires, 50 H hair, long, Hall-effect sensors, 416–417, 439 hand protection, 4–5 hand tools, safety issues, hard codes, 364 hard-shell connectors, 150–151 Hazard Communication Standard, 18 hazard lights, 354 hazardous materials, 18–23 hazardous waste, 20–21 headlight aiming pads, 318, 319 headlights, 312–322 728 aiming, 317–321 composite, 319–321 sealed-beam, 318–319 automatic headlight system diagnosis, 492–503 concealed, 322–323, 487–489 daytime running lamps, 505–507 diagnostic charts for, 350–351, 523–524 dimmer- or brighter-than normal, 321–322 dimmer switch testing and replacement, 326–329 HID lamp and ballast service, 315–317 replacement, 312–317 switch testing and replacement, 312–317 testing computer-controlled, 489–491 types of, 312 heated windshields, 612–615, 641 heat shrink tubes, 142 heavy objects, lifting, hertz, 53 HEV inverter/converter, 299–300 HID lamp and ballast service, 315–317 high beam camera calibration, 500–502 High-efficiency particulate-arresting (HEPA), 22 vacuum cleaner, 22 high-resistance problems, 95, 101–102, 137 high-voltage batteries, 679–680 high-voltage electronic control unit (HV ECU), 676–677 high-voltage service plugs, 675–676 high-voltage systems See hybrid electric vehicle (HEV) systems history data information, 676 hoist pads, 12–13 hoists, safe use of, 12–13 Honda air bag systems, 648–649 horn diagnosis, 562–566 continuous sound, 565–566 diagnostic charts, 634 no horn operation, 562–565 poor sound quality, 565 hotline services, 70 HV battery service, 207–210 high-voltage charging, 210–22 hybrid electric vehicle (HEV) systems diagnostic charts for, 688 high-voltage battery service, 677–680 high-voltage service plugs, 30–31, 675–676 insulated glove integrity test, 30 insulation tester, 55–56 introduction to, 673 inverter/converter assembly, 680–681 safety precautions with, 673–675 self-diagnosis capabilities, 676–677 system main relay (SMR), 682 hydrometer battery, 188 testing batteries with, 193–194 hydrostatic lock, 234 Hypalon, 148 I IAR See integral alternator/regulator (IAR) system illuminated entry actuator, 507 illuminated entry lights, 355, 507–510 immobilizer systems, 596–599, 641 impedance multimeters, 357 information codes, 676–677 injury prevention See safety instrument cluster lights, 351, 352 instrument panels BCM diagnostics, 529 conventional gauge diagnosis, 539–543 diagnostic charts, 558–559 electronic gauge diagnosis, 543–544 gauge sending units, 544 introduction to, 527–528 removal, 528 self-diagnostics, 529–534 speedometers, 534–539 tachometers, 539–540 trip computers, 547 warning lamps, 544–547 instrument voltage regulator (IVR), 539, 556–557 insulated circuit resistance test, 240 insulating gloves, 675 integral alternator/regulator (IAR) system, 274–275 full field testing, 278–279 integrated vehicle speed control (IVSC) systems, 602–603 interior lights, 335–338 courtesy lights, 335–337 instrument cluster and panel lights, 338 intermittent codes, 364 intermittent wiper system diagnosis, 571–572 inverter, 680 inverter/converter assembly, 680–681 ISO 9141-2 bus system diagnostics, 448–450 ISO-K bus system diagnostics, 450–451 IVR See instrument voltage regulator (IVR) J jack stands, 9–10 J1962 breakout box (BOB), 447 J1850 bus system diagnostics, 454–456 jewelry, Job sheets active speed sensor circuit diagnosis, 437–438 air bag system safety, 661–662 antitheft system operation testing, 629–630 automatic headlight system, 515–516 automatic high-beam systems, 521–522 battery cleaning and inspection, 217–218 battery conductance tester usage, 223–224 battery removing, cleaning, and installation, 219–220 battery service and diagnosis hybrid vehicle, 226–227 BCM.flashing, 379–381, 387–388 BCM-controlled headlight system, 517–519 CAN bus system diagnosis, 479–482 capacity testing, battery, 221–222 charging system circuit testing, 307–310 circuit protection and PTCs operation, 425–426 circuit protection devices testing, 129–130 clockspring replacement and centering, 667–668 component locator, usage, 173–174 copper wires soldering, 183–184 current draw of starter motor, 261–262 diode testing, 133–134 DMM testing, magnetic induction sensor, 431–432 drive belts inspection, 303–304 driver squib circuit open fault diagnosis in air bag system, 663–665 DSO usage on sensors and switches, 135–137 electronic cruise control system testing, 627–628 electronic instrument cluster, 555–556 engine coolant temperature sensor testing, 421–423 fire hazard inspection, 37 fuel gauge checking, 551–552 hall-effect sensors, 439–440 headlight aiming equipment, 349–350 headlight switch, checking, 347–348 hybrid safety, 39–40, 685–688 immobilizer key programming, 631–633 ISO 9141-2 Bus system diagnosis, 467–469 ISO-K Bus system diagnosis, 471–472 J1850 Bus system diagnosis, 473–477 lab scope testing, magnetic induction sensor, 433–434 lighting systems diagnosis, 345–346 LIN Bus system diagnosis, 483–485 magnetoresistive sensor tester building of, 435–436 meter symbol interpretation, 85 OCS (Occupant Classification System) validation procedure, 669–670 ohmmeter, 91–93 Ohm’s law calculation, 79–83 oil pressure warning light circuit, 553–554 open circuit testing, 125 output testing, charging system, 305–306 potentiometer testing, 429–430 pressure switch analysis, 427–428 rear window defogger testing, 625–626 scan tool usage, 383–385 shop safety survey, 35–36 short to ground testing, 127–128 starting system circuit testing, 263–265 switches testing, 131–132 test light usage, 87 voltmeter usage, 89–90 windshield, 621–624 wiring diagram, 171–172, 177–182 jump assist, 214 jumper wires, 43, 96, 108 jump starts, 206–207 729 K keyless entry systems, 589, 641 knock sensor, 406 KOEO (key on engine off ), 602, 603 KOER (key on engine running), 602, 603 L lab scopes, 56–62, 236–237 testing actuators with, 371–373 lamp sequence check, 589–590 LEDs, testing, 115 Lifting heavy objects, vehicles, 8–13 lift points, 10–12 lighting circuits, 311–342 brake lights, 330–333 dimmer switch testing and replacement, 326–329 flashers, 334 headlights, 312–322 aiming, 317–321 concealed, 322–323 dimmer- or brighter-than normal, 321–322 replacement, 312–317 switch testing and replacement, 323–326 interior lights, 335–338 introduction to, 311–312 taillight assemblies, 329–334 turn signals, 330–333 lighting systems complexity, 338–341 computer-controlled, 489–491 automatic headlight system diagnosis, 492–503 concealed headlight diagnosis, 487–489 daytime running lamps, 505–507 headlight systems, 489–491 illuminated entry lights, 507–510 introduction to, 487 diagnostic charts for, 350–354, 523–524 live air bag modules, 644 live module, 644 load testers/testing, 197, 270 local interconnect network (LIN) bus systems, 460–462 locking tangs, 151, 152 logic probes, 44–45 long hair, M magnetic induction sensors, 410 magnetic pickup speed sensors, 537–538 magnetoresistive (MR) sensors, 410 material safety data sheets (MSDS), 19–20 maxi-fuses, 104 memory functions, maintaining and restoring, 191 memory keepers, 66 See also battery backups 730 memory seats, 562, 589–591, 639 metri-pack connectors, repairing, 153 mileage readings, 536 molded connectors, 149, 150 MSDS See material safety data sheets (MSDS) multifunction switches, 326–327 multimeters, 45–56 additional functions of, 53–54 ammeters, 51–52 analog meters, 45–46 digital, 46–47 ohmmeters, 50–51 reading, 54–55 trigger level of, 53 voltmeters, 47–50 multiplexing systems, 447–463 CAN bus diagnostics, 457–460 class A bus system diagnostics, 452–454 communication fault codes, 447–448 diagnostic charts for, 486 enhanced scan tool diagnostics, 462–463 introduction to, 447 ISO 9141-2 bus system diagnostics, 448–450 ISO-K bus system diagnostics, 450–451 J1850 bus system diagnostics, 454–456 LIN bus diagnostics, 460–462 multiplying coil, 274 N Negative temperature coefficient (NTC), 394 no-crank problems, 234, 242–244, 234, 242 noises, 53, 53, 57 from AC generators, 269 circuit, 362 no-load test, 244 normally open (NO) switches, 108 O occupant classification systems (OCSs), 655–658 Occupational Safety and Health Act, 20 Occupational Safety and Health Administration (OSHA), 18 occupational safety glasses, OCS service kits, 655 OCS validation test, 656 odometer mileage labels, 532 odometers, 536–538 ohm, 41 ohmmeters, 41, 50–51, 97 testing brush holders with, 252–253 testing bus system failures, 452–454 testing diodes with, 114–115 testing field coils with, 251 testing relays with, 111–112 testing stepped resistors with, 112 testing switches with, 108 testing variable resistors with, 112–113 oil disposal, 22 One-hand rule, 28 open circuits, 95 diagnostic chart for, 137 testing for, 96–97 open circuit test, 242–244 open circuit voltage test, 196–197 optical refractometer, 195 optical speed sensors, 538–539 optics test, 502 oscilloscopes, 56–62 controls, 60–62 digital storage oscilloscope (DSOs), 117–122 diode pattern testing with, 283–285 waveforms, 58–60 overloads, 104 overrunning clutch inspection, 253–254 P panel lights, 338 parasitic drain, 200 parking lamps, 350, 507 park switch, 569–371 passive restraint systems, 643–658 air bag systems, 644–645 automatic seat belt service, 643–644 diagnostic charts for, 671 introduction to, 643 occupant classification systems (OCSs), 655–658 pay systems, 70 peak, 119 peak-to-peak voltage, 119 personal safety, 2–7 alcohol and drugs and, dress and appearance and, with electric cooling fans, eye protection, 3–4 eyewash fountains, first-aid kits, hand protection, 4–5 lifting and, with rotating equipment, smoking and, when working with batteries, 186–187, 189 photocell resistance assembly, 496 photocells, 492 replacement, 493 testing, 493 piezoelectric sensors, 406 piezoelectric transducer, 406 piezoresistive construction, 400 piezoresistive sensor, 544 pinpoint tests, 603 pneumatic tools, safety issues with, polymer, 396 positive temperature coefficient (PTC), 394, 396 potentiometers, 113, 407–410 power door lock diagnosis, 591, 638 power seat diagnosis, 589, 636–637 power tools inspection of, safety issues, power window diagnosis, 587–588, 636 printed circuit board, removal, 528 PROM replacement, 358 protection devices See circuit protection devices protective gear eye protection, 3–4 hand protection, 4–5, 675 prove-out circuits, 546 prove-out displays, 529 pull to seat connectors, 153 pulse width, 53, 120, 121 pulse width modulation (PWM), 122 push to seat connectors, 153 Q quartz swing needle, 536–537 quick testing, 235–236 R radio frequency interference (RFI), 358, 616 radio systems, 615–617 rags, storage of dirty, 15, 17 rear window defogger, 355, 584–585 Rechargeable Battery Recycling Corporation (RBRC), 213 recharging See charging the battery rectifier bridge, testing, 298 refractometer, 195 regulator test, 282 relative compression testing, 238–239 relays system main relay (SMR), 682 testing, 108–112, 596, 597–598 remote keyless entry systems, 593 resistance, 95 See also voltage drop infinite, 50 low, 51 resistance assembly test, 496 resistance problems, 95 sensor return circuits and, 360–363 testing for, 112–113 resistive shorts, 544 resistor block, 581 Resource Conservation and Recovery Act (RCRA), 21 RF sniffer tool, 617 rheostats, 112–113 right-to-know laws, 18–20 root mean square (RMS), 119 731 root mean square (RMS) meters, 50 rotating equipment, safety and, rotors, testing, 296–297 S safety, 1–31 electrical systems, 23–27 fire hazards and prevention, 14–18 with hazardous materials, 18–23 with hybrid systems, 673–675 introduction to, lifting vehicles, 8–13 personal, 2–7 running vehicles in shop, 13–14 tool and equipment, 7–8 safety goggles, safety stands, safe use of, 9–12 satellite radio systems, 617 scan tester diagnostics, 365–368, 594 scan tools, 62–65 communication between bus system and, 448–450 for DTC retrieval, 645–646 enhanced diagnostics, 462–463 flashing the BCM with, 373–374 sensor testing with, 373 vehicle module scans, 448 scopes See oscilloscopes sealed-beam headlights aiming, 312–314 replacement, 313–314 seat belt systems See automatic seat belt systems self-diagnostic tests for antitheft systems, 594 for BCM ATC-controlled systems, 529 for cruise control systems, 599–611 of hybrid systems, 676–677 self-powered continuity tester, 44 self-test input (STI) terminal, 603 sending units, gauge, 544 sensor diagnostic routines introduction, 391–392 intermittent faults, 392–393 magnetoresistive, 413–415 alternate , 415 position and motion detection sensors, 407– magnetic induction, 410–413 potentiometer testing, 407–410 pressure sensors capacitance discharge, 403 lab scope testing, 405 piezoelectric transducers, 406–407 switch, 397–400 wheatstone bridge and DMM testing, 400–402 temperature sensors and circuits PTC circuit protection devices, 396–397 thermistor circuits, 394–396 732 sensor dropout, 410 sensor return circuits, 360–363 sensors, testing, 394–397 service history tracking, 70 service information/manuals, 66–70 servo assembly, 607–609 servomotor, 603–604 shoes, short circuits, 95 testing for, 97–99 short to ground, 100–101 checking for, 100 Silicone/GXL, 148 simulated road tests, for cruise control systems, 605 sine waves, 50, 58–59 sinusoidal waves, 58 slow charging, 189 slow cranking, 230, 233 SmartBeam diagnostics, 496–503 camera calibration test and adjustment, 498–502 demonstration mode, 498 smoking, 3, 15 SMR See system main relay (SMR) soldering, 142–146 solderless connectors, crimping, 140–142 solenoid circuit resistance testing, 242 solvents, 17 disposal of, 22 spade fuses, 104 speaker problems, 616 special tools memory keepers, 66 service information/manuals, 66–70 static straps, 65–66 test equipment, 43–65 specifications, 67 specific gravity, measuring, 194 speedometer readings, 532 speedometers, 534 conventional, 534–536 diagnosis and repair, 534–539 electronic, 536–539 speed sensors, 410–415, 532–533 ABS wheel, 410, 433 magnetic pickup, 537–538 optical, 538–539 testing, 609 splice clips, 142 splices, 140, 142 square waves, 59 stabilize the battery, 196 starter/charging system tester, 235 starter motors component tests, 249–254 armature ground test, 252 armature short test, 252 brush inspection, 252–253 commutator tests, 252 field coil tests, 251 overrunning clutch inspection, 253–254 disassembly, 247–249 reassembly, 254–256 removal, 245–247 starter safety switches, 244 starter systems, 229–256 components, 229–230 diagnostic charts for, 231–233, 264–265 introduction to, 229–230 precautions, 230 safety, 24 starter motor component tests, 249–254 starter motor disassembly, 247–249 starter motor removal, 245–247 starter reassembly, 254–256 testing, 235–245 current draw tests, 237–238 free speed test, 244–245 ground circuit test, 240–242 insulated circuit resistance test, 240 lab scope tests, 236–237 open circuit test, 242–244 quick tests, 235–236 relative compression tests, 238–239 solenoid circuit resistance test, 242 troubleshooting, 230–235 starting/charging system testers, 267, 280 state of charge (SOC), 676 state of charge test, 193–195 static charges, 65 static electricity, 357, 529 static straps, 65–66 stators, testing, 282 steering column module (SCM), 460 steering column-mounted switches, 326, 329, 574 stepped resistors, testing, 112 stop lights See brake lights sulfated battery, 199 sulfation, 199 sulfuric acid, 188, 202–203 Sun Electrical Corporation VAT-40, 186 sunroofs, 611–612, 639–640 switches cruise control system, 609 dash-mounted, 323–326, 574 dimmer, testing and replacement, 326–329 floor-mounted, 329 Hall-effect, 416–417 headlight, testing and replacement, 3223–326 multifunction, 326, 329–330 power window, 587–589 steering column-mounted, 326, 329, 574 testing, 108 turn signal, 327–329, 330–334 wiper, 571–572, 574, 617 wiper park, 574–575 switch operational logic chart, 644 system main relay (SMR), 30, 682 T tachometers, 539 taillight assemblies, 329–334 tap splice connector, 142 Technical Service Bulletins (TSBs), 67 temperature sensor, overriding, 612 test equipment, 43–45 for batteries, 185–186 computerized load-testing equipment, 200 digital storage oscilloscope (DSOs), 117–122 J1962 breakout box (BOB), 447 jumper wires, 43 logic probes, 44–44 multimeters, 45–56 ohmmeters, 50–51 optical refractometer, 195–196 oscilloscopes, 56–62 potentiometers, 407–410 RF sniffer tool, 617 scan tools, 62–65, 369–371 self-powered continuity tester, 44 test lights, 44 voltmeters, 47–50 test lights, 44–45, 96 testing power windows with, 588 testing relays with, 108–112 testing for shorts with, 97–99 testing switches with, 108 thermistors, 394–396, 544 three-minute charge test, 199–200 throttle position sensor (TPS), 120, 408 tin, 585 tinning, 142 tool safety, 7–8 Toyota, air bag flash codes, 648 transistors, testing, 116–117 trickle charging, 190 trigger, 119 slope, 119–120 trip computers, 547 trouble codes, 139 for air bag systems, 645–648 BCM, 366–368 B-codes, 448 for cruise control systems, 599–605 for hybrid systems, 676 instrument panel, 529 U-codes, 448 troubleshooting See also diagnostic charts; electrical accessories defined, 139 electrical problems, 42–43 process of, 139–140 733 turn signals, 330–334, 353 turn signal switches, 327–334 twisted/shield wire repairs, 146–148 U U-codes, 447 V vapors, gasoline, 14 variable resistors, testing, 112–113 VAT-40, 267 vehicle identification number (VIN), 67, 367 vehicle lift points, 10–11 vehicle module scans, 448 vehicle safety on lifts and hoists, 8–13 while running in shop, 13–14 vehicle speed sensors (VSSs), 533, 410–411 ventilation systems, testing, 13 video entertainment systems, 615–617 VIN numbers, 67, 367 volatile substances, 16 voltage, 41, 95 AC, 50, 58–59, 119 DC, 58–59 peak-to-peak, 119 waveforms, 58–60 voltage drop, 47–50, 106 measuring, 192, 240–242 testing, 101–103, 272–273 of headlight system, 321 voltage output testing, 270–272 voltage regulation, diagnostic chart for, 309 voltage signals, types of, 120–122 voltage supply, diagnosis of computer, 358–363 voltmeters, 42, 43, 47–50, 106 See also oscilloscopes testing batteries with, 192–193 testing diodes with, 114 testing relays with, 108–112 testing stepped resistors with, 112 testing switches with, 109 testing variable resistors with, 113 testing voltage drop with, 101–103 volts, 41 734 W wages, 71 warning lamps, 527–528, 544–547, 557 for air bag systems, 645–648 waste disposal, 21–22 asbestos, 22 oil 22 solvents, 22 waveforms, 58–60, 120–122 weather-pack connectors, repairing, 151–152 wheatstone bridge, 400 wheels, blocking, 10 wheel speed sensors, 410, 411, 414–415 whining noises, 269 wiggle test, 58 Williams-Steiger Act, 20 window defogger, 584–585, 637 windshields, heated, 612–615 windshield washer system service, 579–581 wiper system service, 566–574 diagnostic charts, 634–635 intermittent wiper system diagnosis, 571–572 no operation in one speed only, 567–568 no wiper operation, 568–569 slow speed, 569 wiper circuit, two-speed, 568 wiper motor removal and installation, 572–574 wiper switch removal and installation, 574 wiper system schematic, three-speed, 567 wiper will not park, 569–571 wire repair, 140–148 aluminum, 146 copper, 140–142 twisted/shielded, 146–148 wires, checking for shorts, 51, 52 wiring diagrams, reading, 154–158 work order, 72 workplace hazardous materials information systems (WHMIS), 19 workplace relationships, 70–71 Z Zener diodes testing, 114–115 ... Introduction to Automotive Electrical and Electronic Systems • Introduction • Why Become an Electrical System Technician? • The Role of Electricity in the... an electric vehicle Like the electric vehicle, it uses an electric motor to supply torque to the drive wheels The difference is that the fuel cell produces and supplies electric power to the electric... Review Questions 49 • Multiple Choice 49 Chapter Electrical and Electronic Components 51 • Introduction 51 • Electrical Components 51 • Electronic Components 59 • Circuit Protection