Today's Technician: Automotive Electricity and Electronics, Classroom and Shop Manual Pack, Spiral bound Version

1507 Pages·2017·168.18 MB·English

by  Barry Hollembeak

C L A S S R O O M
M A N U A L
For Automotive Electricity and Electronics
SEVENTH EDITION
Barry Hollembeak
Australia • Brazil • Mexico • Singapore • United Kingdom • United States
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Today’s Technician™: Classroom Manual © 2019, 2015 Cengage Learning
for Automotive Electricity and Electronics,
WCN: 02-300
Seventh Edition
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Barry Hollembeak
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Printed in the United States of America
Print Number: 01 Print Year: 2017
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CONTENTS
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vi
CHAPTER 1 Introduction to Automotive Electrical
and Electronic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Terms to Know 1 • Introduction 1 • Why Become an Electrical System Technician? 2 •
The Role of Electricity in the Automobile 2 • Introduction to the Electrical Systems 3 •
Summary 15 • Review Questions 15
CHAPTER 2 Basic Theories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Terms to Know 17 • Introduction 17 • Basics of Electron Flow 18 • Electricity Defined 20 •
Electrical Laws 25 • Types of Current 28 • Electrical Circuits 28 • Kirchhoff’s Laws 41 •
Magnetism Principles 43 • Theory of Induction 47 • Photovoltaics 49 • EMI Suppression 49 •
Summary 49 • Review Questions 50
CHAPTER 3 Electrical and Electronic Components . . . . . . . . . . . . . . 52
Terms to Know 52 • Introduction 53 • Electrical Components 53 • Electronic Components 64 •
Circuit Protection Devices 75 • Circuit Defects 80 • Summary 84 • Review Questions 85
CHAPTER 4 Wiring and Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . 87
Terms to Know 87 • Introduction 87 • Automotive Wiring 87 • Summary 110 • Review
Questions 111
CHAPTER 5 Automotive Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Terms to Know 113 • Introduction 113 • Conventional Batteries 115 • Maintenance-Free
Batteries 121 • Hybrid Batteries 123 • Recombination Batteries 123 • High-Voltage Batteries
125 • Ultra-Capacitors 131 • Battery Terminals 132 • Battery Ratings 132 • Cranking Amps
133 • Battery Cables 134 • Battery Holddowns 135 • Summary 136 • Review Questions 137
CHAPTER 6 Starting Systems and Motor Designs . . . . . . . . . . . . . . . . . . 140
Terms to Know 140 • Introduction 140 • Direct-Current Motor Principles 141 • DC Motor
Field Winding Designs 145 • Starter Drives 149 • Cranking Motor Circuits 150 • Starter
Control Circuit Components 151 • Cranking Motor Designs 160 • AC Motor Principles
164 • Integrated Starter Generator 170 • Start/Stop Systems 171 • Summary 175 • Review
Questions 176
CHAPTER 7 Charging Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Terms to Know 178 • Introduction 178 • Principle of Operation 179 • AC Generators 181 •
AC Generator Circuits 192 • AC Generator Operation Overview 193 • Regulation 195 •
AC Generator Output Ratings 206 • Charging Indicators 207 • HEV Charging Systems 210 •
DC/DC Converter 213 • Summary 214 • Review Questions 215
iii
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iv
CHAPTER 8 Introduction to the Body Computer . . . . . . . . . . . . . . . . . . . 217
Terms to Know 217 • Introduction 217 • Computer Functions 218 • Analog and Digital
Principles 219 • Microprocessor 223 • Computer Memory 223 • Information Processing 226 •
High-Side and Low-Side Drivers 231 • Outputs 232 • Summary 236 • Review Questions 236
CHAPTER 9 Computer Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Terms to Know 238 • Introduction 239 • Thermistors 240 • Pressure Sensors 243 • Position
and Motion Detection Sensors 248 • Photo Cells 258 • Switch Inputs 261 • Feedback Signals
263 • Summary 264 • Review Questions 265
CHAPTER 10 Vehicle Communication Networks . . . . . . . . . . . . . . . . . . . . 267
Terms to Know 267 • Introduction 267 • Multiplexing Communication Protocols 268 •
Multiplexing Systems 271 • Network Architecture 281 • Supplemental Data Bus Networks
283 • Summary 288 • Review Questions 289
CHAPTER 11 Lighting Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Terms to Know 291 • Introduction 292 • Lamps 292 • Headlights 294 • Headlight Switches
301 • Automatic On/Off with Time Delay 307 • Automatic Headlight Dimming 310 •
Headlight Leveling System 316 • Adaptive Headlights 317 • Daytime Running Lamps 320 •
Exterior Lights 322 • Interior Lights 335 • Instrument Cluster and Panel Lamps 339 • Fiber
Optics 341 • Lamp Outage Indicators 343 • Summary 346 • Review Questions 347
CHAPTER 12 Instrumentation and Warning Lamps . . . . . . . . . . . . . . . . . 350
Terms to Know 350 • Introduction 350 • Electromechanical Gauges 351 • Quartz Analog
Instrumentation 355 • Gauge Sending Units 357 • Digital Instrumentation 359 • LCD
Monitors 366 • Head-Up Display 368 • Travel Information Systems 369 • Warning Lamps
370 • Summary 374 • Review Questions 374
CHAPTER 13 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
Terms to Know 377 • Introduction 377 • Horns 378 • Horn Circuits 380 • Windshield
Wipers 382 • Electromagnetic Field Wiper Motor Circuits 384 • Computer-Operated
Wipers 391 • Intelligent Windshield Wipers 393 • Washer Pumps 394 • Blower Motor
Circuits 396 • Electric Defoggers 399 • Power Mirrors 402 • Power Windows 405 • Power
Seats 409 • Memory Seats 411 • Climate-Controlled Seats 413 • Power Door Locks 415 •
Automatic Door Locks 418 • Keyless Entry 420 • Antitheft Systems 420 • Electronic Cruise
Control Systems 424 • Electronic Sunroof Concepts 430 • Summary 435 • Review Questions 436
CHAPTER 14 Radio Frequency and Infotainment Systems . . . . . . . . . . . . 439
Terms to Know 439 • Introduction 439 • Radio Frequency Generation 440 • Receiving
Radio Frequencies 442 • Remote Keyless Entry 443 • Tire Pressure Monitoring System 447 •
Immobilizer Systems 450 • Speakers 454 • Infotainment Systems 455 • Telematics 462 •
Summary 465 • Review Questions 467
CHAPTER 15 Passive Restraint and Vehicle Safety Systems . . . . . . . . . . . 469
Terms to Know 469 • Introduction 470 • Passive Seat Belt Systems 470 • Air Bag Systems
473 • Common Components 474 • Air Bag Deployment 480 • Air Bag Warning Lamp 480 •
Passenger-Side Air Bags 481 • Hybrid Air Bag Types 481 • Multistage Air Bag Deployment
483 • Side-Impact Air Bags 483 • Air Bag On/Off Switches 486 • Seat Belt Pretensioners 487 •
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v
Inflatable Knee Blockers 489 • Occupant Classification Systems 490 • ACM Overview 494 •
Active Headrests 497 • Vision Systems 497 • Ultrasonic Sensors 498 • Park Assist Obstacle
Detection 501 • Lane Departure Warning 503 • Rollover Mitigation System Overview 504 •
Summary 505 • Review Questions 507
CHAPTER 16 Vehicles with Alternative
Power Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
Terms to Know 509 • Introduction 509 • Electric Vehicles 510 • Hybrid Vehicles 512 •
42-Volt Systems 517 • Fuel Cells 522 • Summary 529 • Review Questions 530
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .532
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .554
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PREFACE
Thanks to the support the Today’s Technician™ series has received from those who teach
automotive technology, Cengage, the leader in automotive-related textbooks and learning
solutions, 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 fans and have presented this new
updated and revised seventh edition. By revising this series on a regular basis, we can
respond to changes in the industry, in technology, in the certification process, and the
ever-changing needs of those who teach automotive technology.
We have also listened to instructors when they said that something was missing or
incomplete in the previous edition. We have responded to those and have included the
results in this seventh edition.
The Today’s Technician™ series features textbooks and digital learning solutions that
cover all mechanical and electrical systems of automobiles and light trucks. The individual
titles correspond to the ASE (National Institute for Automotive Service Excellence)
certification areas and are specifically correlated to the 2017 standards for Automotive
Service Technicians, Master Service Technicians, as well as to the standards for
Maintenance and Light Repair.
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.
Today’s Technician: Automotive Electricity & Electronics, 7e is 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 most recent changes in the guidelines estab-
lished by the National Automotive Technicians Education Foundation (NATEF).
The purpose of NATEF is to evaluate technician training programs against standards
developed by the automotive industry and recommend qualifying programs for certifica-
tion (accreditation) by ASE. Programs can earn ASE certification upon the recommenda-
tion 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 the future must know the underlying theory of all auto-
motive 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 objec-
tives into one volume.
The design of Cengage’s Today’s Technician™ 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 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 different vehicle manufacturers. It also looks into emerging technolo-
gies 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.
vi
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vii
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.
A spiral-bound Shop Manual delivers hands-on learning experiences with step-by-
step instructions for diagnostic and repair procedures. Photo Sequences are used to illus-
trate some of the common service procedures. Other common procedures are listed and
are accompanied with fine line drawings and color photos that allow the reader to visualize
and conceptualize the finest details of the procedure. This volume also contains the rea-
sons 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, but the contents of the
chapters are also linked. The linked content is indicated by marginal callouts that refer the
reader to the chapter and page where the same topic is addressed in the companion vol-
ume. This valuable feature saves users the time and trouble of searching the index or table
of contents to locate supporting information in the other volume. Instructors will find this
feature especially helpful when planning the presentation of material and when making
reading assignments.
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
art is a vital part of each textbook and not merely inserted to increase the number of
illustrations.
—Jack Erjavec
HIGHLIGHTS OF THE NEW EDITION—
CLASSROOM MANUAL
The text, photos, and illustrations in the seventh edition have been updated throughout
to highlight the latest developments in automotive technology. In addition, some chapters
have been combined. Although chapter 16 covers details associated with alternative pow-
ered 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 5 includes
coverage of HEV batteries and ultra-capacitors. Chapter 6 includes AC motor principles
and the operation of the integrated starter/generator. Chapter 7 includes the HEV charg-
ing system, including regenerative braking and the DC/DC converter.
The flow of basic electrical to more complex electronic systems has been maintained.
Chapters are arranged to enhance this flow and reduce redundancy.
Chapter 1 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 is
described. Chapter 2 covers the underlying basic theories of electricity and includes dis-
cussion of Ohm’s and Kirchhoff’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 3 applies those theories to the operation of electrical and electronic compo-
nents, and Chapter 4 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.
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Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it.
viii
The chapters that follow cover the major components of automotive electrical and
electronic systems, such as batteries, starting systems and motor designs, charging sys-
tems, 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. Chapter 15 details the passive restraint systems currently used.
HIGHLIGHTS OF THE NEW EDITION—SHOP MANUAL
Like the Classroom Manual, the Shop Manual is updated to match current trends. Service
information related to the new topics covered in the Classroom Manual is also included
in this manual. In addition, several new Photo Sequences are added. The purpose of these
detailed photos is to show students what to expect when they perform the same proce-
dure. They also help familiarize students with a system or type of equipment they may
not encounter at school. Although the main purpose of the textbook is not to prepare
someone to successfully pass an ASE exam, all the information required to do so is
included in the textbook.
To stress the importance of safe work habits, Chapter 1 is dedicated to safety, and
includes 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 equip-
ment, and the legislation concerning and the safe handling of hazardous materials and
wastes.
Chapter 2 covers special tools and procedures. This chapter includes the use of isola-
tion meters and expanded coverage of scan tools. In addition, a section on what it entails
to be an electrical systems technician is included. This section covers relationships, com-
pleting the work order, and ASE certification. Another section emphasizes the importance
of proper diagnostic procedures.
Chapter 3 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 4 provides experience with wiring repairs along with
extended coverage and exercises on using the wiring diagrams.
The remaining chapters have been thoroughly updated. The Shop Manual is cross-
referenced to the Classroom Manual by using marginal notes. This provides students the
benefit 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 serve as the basis for new job sheets that are included in the Shop
Manual chapters.
Copyright 2019 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s).
Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it.