Electricity and Electronics

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Herbert Tucker
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1 Advanced Automotive Electricity and Electronics James D. Halderman PEARSON Boston Columbus Indianapolis New York San Francisco Upper Saddle River Amsterdam Cape Town Dubai London Madrid Milan Munich Paris Montreal Toronto Delhi Mexico City Sao Paulo Sydney Hong Kong Seoul Singapore Taipei Tokyo

2 chapter 1 ELECTRICAL FUNDAMENTALS 1 " Objectives 1 Key Terms 1 Introduction 1 Electricity 1 How Electrons Move Through a Conductor 4 Units of Electricity 5 Sources of Electricity 7 Conductors and Resistance 8 Resistors 8 summary 9 review questions 10 chapter quiz 10 chapter 2 ELECTRICAL CIRCUITS AND OHM'S LAW 11 Objectives 11 Key Terms 11 Circuits 11 Circuit Fault Types 12 Ohm's Law 14 Watt's Law 15 SUMMARY 16 REVIEW QUESTIONS 17 CHAPTER QUIZ 17 Kirchhoff's Voltage Law 19 Series Circuit Laws 21 Series Circuit Examples 21 Parallel Circuits 22 Kirchhoff s Current Law 22 Parallel Circuit Laws 22 Determining Total Resistance in a Parallel Circuit 23 Parallel Circuit Examples 25 Series-Parallel Circuits 26 Solving Series-Parallel Circuit Problems 27 Series-Parallel Circuit Examples 27 SUMMARY 29 REVIEW QUESTIONS 29 CHAPTER QUIZ 29 chapter 4 CIRCUIT TESTERS AND DIGITAL METERS 31 Objectives 31 Key Terms 31 Fused Jumper Wire 31 Test Lights 32 Logic Probe 33 Digital Multimeters 33 Inductive Ammeters 37 Diode Check, Pulse-Width, and Frequency 38 Electrical Unit Prefixes 39 How to Read Digital Meters 40 SUMMARY 48 REVIEW QUESTIONS 48 CHAPTER QUIZ 48 chapter 3 SERIES, PARALLEL, AND SERIES-PARALLEL CIRCUITS 18 Objectives 18 Key Terms 18 Series Circuits 18 Ohm's Law and Series Circuits 18 chapter 5 OSCILLOSCOPES AND GRAPHING MULTIMETERS 49 Objectives 49 Key Terms 49 Types of Oscilloscopes 49 Scope Setup and Adjustments 50 Xii

3 DC and AC Coupling 51 Pulse Trains 51 Number of Channels 52 Triggers 53 Using a Scope 54 Graphing Multimeter 55 Graphing Scan Tools 55 summary 55 review questions 55 chapter quiz 56 summary 86 review questions 86 chapter quiz 86 chapter 8 BATTERIES 88 Objectives 88 Key Terms 88 Introduction 88 Battery Construction 88 chapter 6 AUTOMOTIVE WIRING AND WIRE REPAIR 57 Objectives 57 Key Terms 57 Automotive Wiring 57 Ground Wires 59 Battery Cables 59 Jumper Cables 59 Fuses and Circuit Protection Devices 60 Terminals and Connectors 65 Wire Repair 66 Electrical Conduit 69 summary 70 review questions 70 chapter quiz 70 How a Battery Works 90 Valve-Regulated Lead-Acid Batteries 91 Battery Ratings 92 Battery Service Safety Precautions 93 Battery Voltage Test 93 Battery Load Testing 94 Electronic Conductance Testing 95 Battery Charging 95 Battery Electrical Drain Testing 96 Hybrid Auxiliary Batteries 98 Jump Starting 98 Hybrid and Electrical Vehicle Batteries 98 Other High-Voltage Battery Types 101 Battery Comparison 103 summary 103 review questions 103 chapter quiz 104 chapter 7 WIRING SCHEMATICS AND CIRCUIT TESTING 71 Objectives 71 Key Terms 71 Wiring Schematics and Symbols 71 Schematics Symbols 72 Relay Terminal Identification 77 Locating an Open Circuit 80 Common Power or Ground 80 Circuit Troubleshooting Procedure 81 Locating a Short Circuit 82 Electrical Troubleshooting Guide 84 Step-by-Step Troubleshooting Procedure 85 chapter 9 CRANKING SYSTEM 105 Objectives 105 Key Terms 105 Cranking Circuit 105 Computer-Controlled Starting 106 Starter Motor Operation 107 How the Starter Motor Works 109 Gear-Reduction Starters 111 Starter Drives 112 Positive Engagement Starters 113 Solenoid-Operated Starters 114 summary 115 review questions 115 chapter quiz 115 contents xiii

4 chapter 10 CRANKING SYSTEM DIAGNOSIS AND SERVICE 116 Objectives 116 Key Terms 116 Starting System Troubleshooting Procedure 116 Voltage Drop Testing 117 Control Circuit Testing 119 Starter Amperage Test 119 Starter Removal 120 Starter Motor Service 120 Bench Testing 122 Starter Installation 122 Starter Drive-to-Flywheel Clearance 122 Starting System Symptom Guide 123 summary 128 Charging System Testing and Service 141 Drive Belt Inspection and Adjustment 142 Testing an Alternator Using a Scope 144 AC Ripple Voltage Check 144 Testing AC Ripple Current 145 Charging System Voltage Drop Testing 146 Alternator Output Test 147 Minimum Required Alternator Output 148 Alternator Removal 148 Alternator Disassembly 148 Testing the Rectifier 151 Reassembling the Alternator 151 Remanufactured Alternators 152 Alternator Installation 152 SUMMARY 159 REVIEW QUESTIONS 159 CHAPTER QUIZ 159 review questions 128 chapter quiz 128 chapter 11 CHARGING SYSTEM 129 Objectives 129 Key Terms 129 Principles of Alternator Operation 129 Alternator Construction 129 Alternator Overrunning Pulleys 129 Alternator Components and Operation 131 How an Alternator Works 132 Alternator Output Factors 135 Alternator Voltage Regulation 136 Alternator Cooling 137 Computer-Controlled Alternators 137 summary 139 review questions 140 chapter quiz 140 chapter 13 ELECTRONIC FUNDAMENTALS Objectives 161 Key Terms 161 Semiconductors 161 Summary of Semiconductors 162 Diodes 162 Zener Diodes 164 High-Voltage Spike Protection 164 Diode Ratings 166 Light-Emitting Diodes 166 Photodiodes 167 Photoresistors 167 Silicon-Controlled Rectifiers 167 Thermistors 168 Rectifier Bridges 168 Transistors 168 Field-Effect Transistors 170 Phototransistors 171 chapter 12 CHARGING SYSTEM DIAGNOSIS AND SERVICE 141 Objectives 141 Key Terms 141 Integrated Circuits 171 Transistor Gates 172 Operational Amplifiers 172 Electronic Component Failure Causes 173 How to Test Diodes and Transistors 174 Converters and Inverters 175 Electrostatic Discharge 176 XiV

5 SUMMARY 177 REVIEW QUESTIONS 177 CHAPTER QUIZ 177 chapter 16 LIGHTING AND SIGNALING CIRCUITS 203 chapter 14 COMPUTER FUNDAMENTALS 178 Objectives 178 Key Terms 178 Computer Fundamentals 178 Computer Functions 178 Digital Computers 180 Computer Input Sensors 182 Computer Outputs 182 summary 184 review questions 185 chapter quiz 185 Objectives 203 Key Terms 203 Introduction 203 Exterior Lighting 203 Bulb Numbers 204 Brake Lights 208 Turn Signals 209 Headlights 211 High-Intensity Discharge Headlights 213 LED Headlights 215 Headlight Aiming 215 Adaptive Front Lighting System 215 Daytime Running Lights 217 Dimmer Switches 217 Courtesy Lights 217 Illuminated Entry 219 chapter 15 CAN AND NETWORK COMMUNICATIONS 186 Objectives 186 Key Terms 186 Module Communications and Networks 186 Fiber Optics 219 Automatic Dimming Mirrors 219 Feedback 220 Lighting System Diagnosis 220 Lighting System Symptom Guide 221 summary 225 review questions 225 chapter quiz 225 Network Fundamentals 186 Module Communications Configuration 187 Network Communications Classifications 189 General Motors Communications Protocols 189 Ford Network Communications Protocols 192 Chrysler Communications Protocols 193 Controller Area Network 194 Honda/Toyota Communications 196 European BUS Communications 196 Network Communications Diagnosis 197 OBD-II Data Link Connector 200 SUMMARY 201 REVIEW QUESTIONS 201 CHAPTER QUIZ 202 chapter 17 DRIVER INFORMATION AND NAVIGATION SYSTEMS 226 Objectives 226 Key Terms 226 Dash Warning Symbols 226 Oil Pressure Warning Devices 229 Temperature Lamp Diagnosis 230 Brake Warning Lamp 230 Analog Dash Instruments 231 Network Communication 232 Stepper Motor Analog Gauges 232 Head-Up Display 234 Night Vision 234 Digital Electronic Display Operation 235 XV

6 Electronic Speedometers 237 Electronic Odometers 238 Electronic Fuel Level Gauges 240 Navigation and GPS 240 OnStar 242 Backup Camera 243 Backup Sensors 244 Lane Departure Warning System 245 Electronic Dash Instrument Diagnosis and Troubleshooting 246 Maintenance Reminder Lamps 246 summary 249 Electrically Heated Seats 277 Heated and Cooled Seats 278 Heated Steering Wheel 278 Adjustable Pedals 279 Outside Folding Mirrors 280 Electric Power Door Locks 280 Keyless Entry 281 Antitheft Systems 288 Electrical Accessory Symptom Guide 293 summary 297 review questions 297 chapter quiz 297 review questions 249 chapter quiz 249 chapter 18 HORN, WIPER, AND BLOWER MOTOR CIRCUITS 251 Objectives 251 Key Terms 251 Horns 251 Windshield Wiper and Washer System 253 Rain Sense Wiper System 260 Blower Motor 260 Electrical Accessory Symptom Guide 263 summary 264 review questions 264 chapter quiz 264 chapter 20 AUTOMATIC TEMPERATURE CONTROL SYSTEMS 299 Objectives 299 Key Terms 299 Automatic Temperature Control System 299 Sensors 299 Airflow Control 302 Actuators 303 Automatic HVAC Controls 305 Air Filtration 307 Automatic Climate Control Diagnosis 308 summary 310 review questions 310 chapter quiz 311 chapter 19 ACCESSORY CIRCUITS 265 Objectives 265 Key Terms 265 Cruise Control 265 Troubleshooting Cruise Control 266 Electronic Throttle Cruise Control 268 Radar Cruise Control 268 Precollision System 269 Heated Rear Window Defoggers 270 Heated Mirrors 271 HomeLink Garage Door Opener 272 Power Windows 272 Power Seats 275 chapter 21 AIRBAG AND PRETENSI0NER CIRCUITS 312 Objectives 312 Key Terms 312 Safety Belts and Retractors 312 Front Airbags 314 Airbag Diagnosis Tools and Equipment 317 Airbag System Service 319 Driver Side Airbag Module Replacement 320 Safety When Manually Deploying Airbags 321 Occupant Detection Systems 322 XVi

7 Seat and Side Curtain Airbags 323 Event Data Recorders 324 summary 324 review questions 324 chapter quiz 325 chapter 22 TIRE PRESSURE MONITORING SYSTEMS 326 Objectives 326 Key Terms 326 Need for Tire Pressure Monitoring 326 Indirect TPMS 327 TREAD Act 328 Identifying a Vehicle with TPMS 329 TPMS Pressure Sensors 329 TPMS Sensor Operation 330 chapter 24 ELECTRIC POWER STEERING SYSTEMS 355 Objectives 355 Key Terms 355 Electric Power Steering Overview 355 EPS System Parts and Operation 355 Steering Shaft Torque Sensor 357 Steering Wheel Position Sensor 358 Power Steering Motor 358 Power Steering Control Module (PSCM) 358 EPS Diagnosis 358 Self-Parking System 359 Electro-Hydraulic Power Steering 359 summary 360 review questions 360 chapter quiz 360 TPMS Receiver 331 Direct TPMS Diagnosis 331 Installing a New Pressure Sensor 332 TPMS Diagnostic Tools 332 TPMS Sensor Activations 333 TPMS Relearn Procedure 333 TPMS Sensor Service Tools 333 summary 335 review questions 335 chapter quiz 335 chapter 25 ELECTRONIC STABILITY CONTROL SYSTEMS 362 Objectives 362 Key Terms 362 The Need for Electronic Stability Control 362 Federal Motor Vehicle Safety Standard (FMVSS) No Sine with Dwell Test 363 chapter 23 ELECTRONIC SUSPENSION SYSTEMS 337 Objectives 337 Key Terms 337 The Need for Electronic Suspensions 337 Electronic Suspension Controls and Sensors 337 Electronic Suspension System Actuators 343 Types of Electronic Suspension 344 Automatic Level Control (ALC) 350 Magneto-Rheological (MR) Suspension 351 Troubleshooting Rear Electronic Leveling Systems 352 summary 353 review questions 353 chapter quiz 353 Names of Various ESC Systems 364 ESC Sensors 364 Traction Control 366 ESC/TC Diagnosis 368 summary 368 review questions 369 chapter quiz 369 chapter 26 INTRODUCTION TO HYBRID VEHICLES 370 Objectives 370 Key Terms 370 Hybrid Vehicle 370 Electric Vehicles 370 XVi

8 Driving and Owning a Hybrid Electric Vehicle 372 Classifications of Hybrid Electric Vehicles 372 Belt Alternator Starter Systems 374 Common Features of Most Hybrids 377 Levels of Hybrid Vehicles 377 summary 378 review questions 379 chapter quiz 379 High-Voltage Safety Equipment 391 Electric Shock Potential 393 De-Powering the High-Voltage System 395 Collision and Repair Industry Issues 395 Moving and Towing a Hybrid 396 Removing the High-Voltage Batteries 397 Routine Service Procedures 398 SUMMARY 403 REVIEW QUESTIONS 403 chapter 27 REGENERATIVE BRAKING SYSTEMS 380 Objectives 380 > Key Terms 380 Introduction 380 Principles of Regenerative Braking 380 Types of Regenerative Braking Systems 382 Battery Charging During Regeneration 383 Regenerative Braking Systems 384 How the Regeneration System Deceleration Rates 387 Works 386 Engine Design Changes Related to Regenerative Braking 388 Servicing Regenerative Braking Systems 388 summary 389 review questions 389 chapter quiz 389 CHAPTER QUIZ 403 chapter 29 FUEL CELLS AND ADVANCED TECHNOLOGIES 405 Objectives 405 Key Terms 405 Fuel-Cell Technology 405 PEM Fuel Cells 407 Fuel-Cell Vehicle Systems 408 Hydraulic Hybrid Storage System 414 HCCI 414 Plug-In Hybrid Electric Vehicles 415 The Future for Electric Vehicles 415 Vehicle Charging 416 Wind Power 417 Hydroelectric Power 418 summary 419 review questions 419 chapter 28 HYBRID SAFETY AND SERVICE PROCEDURES 391 Objectives 391 chapter quiz 419 appendix NATEF TASK CORRELATION CHART 420 GLOSSARY 424 INDEX 440 Key Terms 391 High-Voltage Safety 391 xviii

Diesel Technology: Electrical and Electronic Systems

Diesel Technology: Electrical and Electronic Systems NATEF Crosswalk The following NATEF Electrical/Electronic Systems tasks (rev. 2001) are covered in this publication. The chart shows where each task