Automotive Electricity and Electronics

647 Pages·2013·116.16 MB·English

AUTOMOTIVE ELECTRICITY
AND ELECTRONICS
SECONDE DITION
A1 Santini
Retired, College of DuPage
Glen Ellyn, Illinois
DELMAR
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Automotive Electricity and Electronics, C,2 013 Delmar, Cengage Learning
Second Edition
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Printed in the United States of America
1 2 3 4 5 6 7 14 13 12 11
Automotive Electricity and Electronics, 2nd Edition, detailed reading assignments that students will find
has been written to fill a void in post-secondary text- easier to digest. These shorter chapters can be taught in
books. Many books lack the required breadth or depth almost any order, allowing instructors to pick and choose
needed to cover this complex subject, and oRen text- the material that best reflects the depth, direction, and
books reproduce only factory circuits, which dates the pace of their individual classes.
material and the book. For this reason, I have generally This title features an art-intensive approach to suit
avoided specific specialized circuits, and instead con- today’s visual learners-images drive the chapters.
centrated on component testing from a generic stand- From drawings to photos, you will find more art to
point. Because we frequently find the same component better understand the systems, parts, and procedures
on a variety of vehicles, the testing procedure can be under discussion. Look also for helpful graphics in
universal-plus this approach greatly enhances the features like You Should Know and Interesting Fact
student’s ability to comprehend the material. that draw attention to key points.
But the real strength of this text is its ability to teach, The text starts off with a section on safety and
in a logical sequence, transferable skills, fiom the fun- communication, which stresses safe work practices,
damentals to more advanced procedures. The knowledge tool competence, and familiarity with workplace “soft
that will be needed to repair tomorrow’s vehicles is skills” such as customer communication and the roles
rooted in the basics, and this text begins with an educa- necessary to succeed as an automotive technician.
tion in those essential skills. Circuit design, various ap- From there, learners are ready to tackle the technical
plicable laws, wiring principles, and a hands-on practical material in successive sections, ultimately leading
approach in the use of test equipment have all been in- them to the real test-an ASE practice exam in the
corporated. This means that the automotive electricity Appendix. Finally, in addition to the many revisions
student will develop a strong foundation to build upon in that have brought the content up-to-date, look for these
the remainder of the text, which covers batteries, starting, new featureshpdates to the second edition of Auto-
charging, ignition (both distributed and distributorless), motive Electricity and Electronics:
and accessories. On-vehicle testing is also stressed w Two-color illustrations and text design to
throughout the book, especially the use of digital multi- enhance the presentation of the chapter material
meters, scanners, and digital storage oscilloscopes. w All new content on battery testing (see Chapter 31)
Finally, an emphasis has been placed on readability w A full chapter devoted to coil-on-plug ignition
in this text.’Most students will find it easy to com- systems (Chapter 52)
prehend, and the relaxed style of writing should im- w All new Chapter 53: Diagnosing and Servicing
prove the enjoyment of a basic electricity class. If the Coil-&-Plug Ignition Systems
students’ first exposure to our industry is a positive rn An enhanced supplements package designed to
experience, I believe those students will become the engage students and help instructors easily and
technicians of the future that our industry needs. effectively prepare for time in the classroom
A1 Santini and shop
ORGANIZATION AND FEATURES
SUPPLEMENTS
OF THE SECOND EDITION
Instructor R ~ u l c e s
In Automotive Electricity and Electronics, you’ll
notice several differences from a traditional textbook. An Instructor Companion Site is available to in-
First, a large number of short chapters divide complex structors and includes the following components:
material into chunks. Instructors can give tight, rn Chapter presentations in PowerPoint
xix
A searchable Image Library with all of the pho- The author and publisher wish to thank the fol-
tos and illustrations from the text lowing instructors for their valuable feedback during
Customizable chapter test banks in ExamView the development of this textbook:
NATEF task correlation chart
Brian Blackburn
Golden West College
Workbook Huntington Beach, CA
John Eichelberger
The Workbook to accompany Automotive Elec-
St. Philip’s College
tricity & Electronics, 2nd Edition, is designed to re-
San Antonio, TX
inforce the chapter material through various written
activities and review questions. Job sheets are also Patrick English
included in all applicable chapters, offering step-by- Ferris State University
step procedures for common diagnostic and repair Big Rapids, MI
procedures related to the vehicle’s electrical and George Hritz
electronic systems. College of Marin
Kentfield, CA
ACKNOWLEDGMENTS
ABOUT THE AUTHOR
Many individuals have helped with this text. To
mention all would fill several pages. I have retired Al Santini has been involved in automotive edu-
from full-time teaching at the College of Wage in cation for over 40 years. He is semiretired and is
Glen Ellyn, Illinois, and am thankful that it was the currently teaching technician seminars. Before retire-
kind of community college where not only students ment, he taught automotive electricity and electronics
could learn, but instructors were also encouraged to for 22 years at the College of Wage in Glen Ellyn,
create positive student-oriented activities, such as this Illinois. He has also taught at an area vocational center
text. Mike Gustafson from OEM Tools has been very and a local high school.
supportive of my efforts. Not only do they sell and In addition to Automotive Electricity and Elec-
support some of the best automotive test equipment tronics, A1 has authored OBD II Functions, Monitors
available, but they are willing to help instructors learn and Diagnostic Techniques. He is an active member
how to improve their teaching., of the Illinois College Automotive Instructors As-
Last, I want to thank my wonderful family. My wife, sociation (ICAIA) and the North American Council
Carol, helped a great deal with this text, organizing all of Automotive Teachers (NACAT). When he is
the illustrations. Without her, you would not be reading not teaching, A1 enjoys sailing, camping, and bike
this. I thank her and love her more and more every day. riding.
.................................................
Preface xix
Safety and Communication ........................................ 1
SECTION 1
SECTION 2 Circuit Fundamentals and Basic Test Equipment ....................... 17
..............................................
SECTION 3 Vehicle Circuits 51
SECTION 4 Digital Storage Oscilloscope (DSO) Use ............................ 101
Electronic Fundamentals ....................................... 139
SECTION 5
Wiring Diagrams ............................................. 189
SECTION 6
SECTION 7 Batteries ................................................... 209
Starting Systems ............................................. 239
SECTION 8
SECTION 9 Charging Systems ............................................ 295
Ignition Systems ............................................. 337
SECTION 10
SECTION 11 Accessories ................................................. 449
..............................................
Appendix 497
........................................
Bilingual Glossary 501
.................................................
Index 509
iii
.................................................
Preface xix
................................
SECTION 1 SAFETY AND COMMUNICATION 1
CHAPTER 1 Safe Working Practices .......................................... 3
Introduction ...................................................... 3
Workclothes ..................................................... 3
Eye Protection .................................................... 3
The Air We Breathe and Noises We Hear ................................. 4
Fire Protection .................................................... 5
Material Safety Data Sheets ........................................... 5
'Battery Safety ..................................................... :6
summary ......................................................... 7
Review Questions ................................................... 7
CHAPTER 2 Working as an Electricity/Electronics Technician ........................ 9
Introduction ........: ............................................. 9
YourToolbox ..................................................... 9
Access to Wiring Diagrams and Repair Information ........................ 11
Communicating with the Customer ..................................... 11
Working around Air Bags ........................... ............... 11
Static Electricity ................................................... 13
summary ........................................................ 14
Review Questions ................................................. 14
.........
SECTION 2 CIRCUIT FUNDAMENTALS AND BASIC TEST EQUIPMENT 17
CHAPTER 3 Voltage. Current. and Resistance .................................. 19
Introduction ..................................................... 19
Electricity ....................................................... 19
Voltage ........................................................ 19
Current ......................................................... 21
Wattage ........................................................ 22
Resistance ....................................................... 22
Insulators and Conductors ............................................ 25
Loads .......................................................... 26
Summary ........................................................ 27
Review Questions ................................................. 27
V
CHAPTER 4 Circuits .................................................... 29
Introduction ..................................................... 29
Circuit Components ................................................ 29
SeriesCircuits .................................................... 31
Parallel Circuits .................................................. 32
Series-Parallel Circuits .............................................. 35
Summary ....................................................... 36
Review Questions ................................................. 36
CHAPTER 5 Voltmeters .................................................. 38
Introduction ..................................................... 38
Purpose of the Voltmeter ............................................ 38
Connecting the Voltmeter ........................................... 39
Measuring Voltage Drop ............................................ 40
Interpreting Voltage Readings ........................................ 40
Summary ....................................................... 41
Review Questions ................................................. 41
CHAPTER 6 Ammeters ................................................... 43
Introduction ..................................................... 43
TypesofAmmeters ................................................ 43
Current Probes ................................................... 44
Summary ....................................................... 46
Review Questions ................................................. 46
CHAPTER 7 Ohmmeters .................................................. 47
Introduction ..................................................... 47
Reading and Interpreting Ohmmeter Readings ............................. 47
Continuity Testing ................................................. 49
Summary ....................................................... 50
Review Questions ................................................. 50
............................................
SECTION 3 VEHICLE CIRCUITS 51
CHAPTER 8 Circuits That Do Work ......................................... 53
Introduction ..................................................... 53
Circuit Components ................................................ 53
Summary ....................................................... 56
Review Questions ................................................. 57
CHAPTER 9 Analyzing Series Circuits ........................................ 58
Introduction ..................................................... 58
Wiring up a Series Circuit ........................................... 58
Voltage Division in a Series Circuit .................................... 59
Example I ..................................................... 60
Example 2 ..................................................... 60
Current Flow in a Series Circuit ....................................... 62
Summary ....................................................... 63
Review Questions ................................................. 63
vi
CHAPTER 10 Analyzing Parallel Circuits ...................................... 65
Introduction ..................................................... 65
Current Flow in a Parallel Circuit ...................................... 65
Resistance in a Parallel Circuit ........................................ 65
Voltage in a Parallel Circuit .......................................... 68
Summary ....................................................... 68
Review Questions ................................................. 69
CHAPTER 1 1 Series-Parallel Circuits .......................................... 70
Introduction ..................................................... 70
Series-Parallel Circuits .............................................. 70
Dashboard Dimmer Circuit .......................................... 73
Summary ....................................................... 74
Review Questions ................................................. 75
CHAPTER 12 Control Circuits .............................................. 76
Introduction ..................................................... 76
The Switch as a Control Device ....................................... 76
Relays as Control Devices ........................................... 76
Electronic Relay as a Control Device ................................... 79
Summary ....................................................... 81
Review Questions ................................................. 81
CHAPTER 13 Diagnosing Open Circuits ....................................... 83
Introduction ..................................................... 83
Using a 12-Volt Test Light .......................................... 83
Open-Circuit Diagnosis Using a 12-Volt Test Light .......................... 83
Diagnosing Open Circuits with a Voltmeter .............................. 87
Summary ....................................................... 89
Review Questions ................................................. 89
CHAPTER 14 Diagnosing Short Circuits ....................................... 91
Introduction ..................................................... 91
Short Circuits and Resistance ......................................... 91
Diagnosing a Short Circuit with a Short Detector .......................... 91
Diagnosing Short Circuits with Electronic Control .......................... 94
Summary ....................................................... 94
Review Questions ................................................. 95
CHAPTER 15 Servicing Open and Short Circuits ................................. 96
Introduction ..................................................... 96
Replacing a Component ............................................. 96
Replacinga Wire ................................................. 96
Repair Considerations .............................................. 96
Summary ....................................................... 98
Review Questions ................................................. 99
vii
.................
SECTION 4 DIGITAL STORAGE OSCILLOSCOPE (DSO) USE 101
C HA PT E R 16 Digital Storage Oscilloscopes .................................... 103
Introduction .................................................... 103
Voltage Settings ................................................. 103
Time Settings ................................................... 105
Using Signal Finder ............................................... 106
Setting for AC or DC Voltage ....................................... 106
.....................................................
Input Leads 107
Summary ...................................................... 107
Review Questions ................................................ 107
CHAPTER 17 DSO Trigger and Slope ........................................ 109
....................................................
Introduction 109
Advantage of Using Trigger and Slope ................................. 109
Setting Trigger and Slope ........................................... 109
Using an External Trigger .......................................... 110
Examples ...................................................... 111
Summary ...................................................... 113
Review Questions ................................................ 114
CHAPTER 18 Reading and Interpreting a DSO Pattern ............................ 115
....................................................
Introduction 115
AC Signal ...................................................... 115
DC Signal ...................................................... 116
Variable Frequency ............................................... 117
Duty Cycle Patterns ............................................... 118
....................................................
Pulse Width 119
Summary ...................................................... 121
Review Questions ................................................ 121
CHAPTER 19 Using a Current Probe with a DSO ................................ 123
Introduction .................................................... 123
Why Use a Current Probe? ......................................... 123
Setting and Calibrating the Probe ..................................... 123
Setting up the DSO ............................................... 123
Connecting the Probe into the Circuit .................................. 124
Measuring a Nonpulsing Load ....................................... 125
Measuring a Pulsing Load .......................................... 126
Summary ...................................................... 128
Review Questions ................................................ 128
C H APT E R 2 0 Using the DSO’s Multiple-Trace Capability ......................... 130
....................................................
Introduction 130
Why Use Multiple-Trace Capability? .................................. 130
How to Set and Adjust Multiple Traces ................................ 130
Setting a Trigger ................................................. 132
Examples ....................................................... 132
Summary ...................................................... 136
Review Questions ................................................ 136
viii
...............................
SECTION 5 ELECTRONIC FUNDAMENTALS 139
CHAPTER 21 Solid-state Devices ........................................... 141
....................................................
Introduction 141
Conductors and Insulators ........................... .............. 141
The Diode ..................................................... 141
Transistors ..................................................... 144
Transistors as Amplifiers ........................................... 145
Transistors as Switches ............................................ 145
Precautions Necessary When Working on Electronics ...................... 146
Summary ...................................................... 146
Review Questions ................................................ 146
C HA PT E R 2 2 Electronic-Control Input Devices ................................. 148
Introduction .................................................... 148
.....................................................
Thermistors 148
Position Sensors ................................................. 150
The Switch as an Input Device ....................................... 151
summary ...................................................... 151
Review Questions ................................................ 152
C H APT E R 2 3 Diagnosing and Servicing Electronic-Control Input Devices .............. 153
....................................................
Introduction 153
Using a DMM to Test Inputs ........................................ 153
...................................................
Thermistors 153
Position Sensors ............................................... 153
Switches ..................................................... 153
Using a DSO to Test Inputs ......................................... 155
Position Sensors ............................................... 156
Introduction to a Scanner ........................................... 156
Using the Scanner to Test Inputs ..................................... 158
Thermistors ................................................... 158
Throttle Position Sensors ......................................... 158
Switches ..................................................... 159
Summary ...................................................... 159
Review Questions ................................................ 159
CHAPTER 24 Integrated Circuits as Input Devices ............................... 161
....................................................
Introduction 161
IC Protection ................................................... 161
Hall Effect Sensors ............................................... 161
Variable-Frequency Generators ....................................... 162
Photo Diode Sensors .............................................. 164
Summary ...................................................... 165
Review Questions ................................................ 165
CHAPTER 25 Diagnosing and Servicing ICs ................................... 167
....................................................
Introduction 167
Using a DSO to Test Input Sensors ................................... 167
HallEffect ................................................... 167
....................................................
Map Sensors 168
Optical Sensors ....... ........................................ 171
ix