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Today's Technician: Automotive Electricity & Electronics, 5th PDF

1298 Pages·2011·44.43 MB·English
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Classroom Manual for Automotive Electricity And Electronics Fifth Edition Barry Hollembeak Australia • Canada • Mexico • Singapore • Spain • United Kingdom • United States Today’s Technician™: Automotive Electricity © 2011 Delmar, Cengage Learning and Electronics, 5th Edition ALL RIGHTS RESERVED. No part of this work covered by the copyright herein Barry Hollembeak may be reproduced, transmitted, stored, or used in any form or by any means graphic, electronic, or mechanical, including but not limited to photocopying, Vice President, Career and Professional recording, scanning, digitizing, taping, Web distribution, information networks, Editorial: Dave Garza or information storage and retrieval systems, except as permitted under Director of Learning Solutions: Sandy Clark Section 107 or 108 of the 1976 United States Copyright Act, without the prior Executive Editor: David Boelio written permission of the publisher. Managing Editor: Larry Main Senior Product Manager: Matthew Thouin For product information and technology assistance, contact us at Editorial Assistant: Jillian Borden Professional Group Cengage Learning Customer & Sales Support, 1-800-354-9706 Vice President, Career and Professional For permission to use material from this text or product, Marketing: Jennifer McAvey submit all requests online at cengage.com/permissions. Further permissions questions can be e-mailed to Marketing Director: Deborah S. Yarnell [email protected]. Marketing Manager: Katie Hall Associate Marketing Manager: Mark Pierro Library of Congress Control Number: 2010923010 Production Director: Wendy Troeger ISBN-13: 978-1-4354-7008-8 Production Manager: Mark Bernard ISBN-10: 1-4354-7008-7 Content Project Manager: Cheri Plasse Art Director: Benj Gleeksman Delmar 5 Maxwell Drive Clifton Park, NY 12065-2919 USA Cengage Learning is a leading provider of customized learning solutions with offi ce locations around the globe, including Singapore, the United Kingdom, Australia, Mexico, Brazil and Japan. Locate your local offi ce 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 fi tness 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 1 2 3 4 5 X X 12 11 10 Contents Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi Chapter 1 Introduction to Automotive Electrical and Electronic Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 • Introduction 1 • Why Become an Electrical System Technician? 1 • Th e Role of Electricity in the Automobile 2 • Introduction to the Electrical Systems 2 • Summary 14 • Terms to Know 14 • Review Questions 15 • Multiple Choice 15 Chapter 2 Basic Theories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 • Introduction 17 • Basics of Electron Flow 17 • Electricity Defi ned 20 • Electrical Laws 24 • Types of Current 27 • Electrical Circuits 28 • Kirchhoff ’s Laws 39 • Capacitance 41 • Magnetism Principles 43 • Th eory of Induction 46 • EMI Suppression 47 • Summary 48 • Terms to Know 48 • Review Questions 49 • Multiple Choice 49 Chapter 3 Electrical and Electronic C omponents. . . . . . . . . . . . . . . .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 4 Wiring and C ircuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . .82 • Introduction 82 • Automotive Wiring 82 • Wiring Diagrams 93 • Summary 104 • Terms to Know 105 • Review Questions 105 • Multiple Choice 106 Chapter 5 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 6 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 7 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 Diff erences 193 • HEV Charging Systems 201 • Summary 205 • Terms to Know 206 • Review Questions 206 • Multiple Choice 207 Chapter 8 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 9 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 • Th ermistors 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 C ommunication 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 • Infl atable Knee Blockers 454 • Occupant Classifi cation Systems 454 • Summary 459 • Terms to Know 460 • Review Questions 460 • Multiple Choice 461 iv Contents Chapter 16 Vehicles with A lternative P ower 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 Th anks 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 fi fth edition. By revising this series on a regular basis, we can respond to changes in the industry, changes in technology, changes in the certifi cation 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 fi fth edition. Th e 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 certifi cation areas for 2009 areas of ASE (National Institute for Automotive Service Excellence) certifi cation. Additional titles include remedial skills and theories common to all of the certifi cation areas and advanced or specifi c subject areas that refl ect the latest technological trends. Th is 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. Th is edition also refl ects the changes in the guidelines established by the National Automotive Technicians Education Foundation (NATEF) in 2008. Th e purpose of NATEF is to evaluate technician training programs against standards developed by the automotive industry and recommend qualifying programs for certifi cation (accreditation) by ASE. Programs can earn ASE certifi cation upon the recommendation of NATEF. NATEF’s national standards refl ect the skills that students must master. ASE certifi cation through NATEF evaluation ensures that certifi ed training programs meet or exceed industry-recognized, uniform standards of excellence. Th e 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. Th e design of Delmar’s Today’s TechnicianTM series was based on features that are known to promote improved student learning. Th e 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. Th e Classroom Manual also contains discussions on design variations of key components used by the diff erent vehicle manufacturers. It also looks into emerging technologies that will be standard or optional features in the near future. Th is volume is organized to build upon basic facts and theories. Th e primary objective of this volume is to allow the reader to gain an understanding of how each system and subsystem operates. Th is 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.” Th is 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 fi ne line drawings and photos that allow the reader to visualize and conceptualize the fi nest details of the procedure. Th is volume also contains the reasons for performing the procedures, as well as when that particular service is appropriate. Th e 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. Th is 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. Th is 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. Th is 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. Th is means that the art is a vital part of each textbook and not merely inserted to increase the numbers of illustrations. Th e page layout, used in the series, is designed to include information that would otherwise break up the fl ow of information presented to the reader. Th e 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 defi nitions of terms that are not defi ned 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. Th is type of information is placed in the margin, out of the normal fl ow 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 justifi ed. 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. Th e 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 5 includes coverage of HEV batteries and ultra-capacitors. Chapter 6 now includes AC motor principles and the operation of the integrated starter/generator. Chapter 7 includes the HEV charging system including regenerative braking and the DC/DC converter. Th e fl ow of basic electrical to more complex electronic systems has been maintained. Rearrangement of chapters has been utilized to enhance this fl ow and reduce redundancy. vii Preface Chapter 1 introduces the student to the automotive electrical and electronic systems with a general overview. Th is 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. Th e 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. Th e second chapter covers the underlying basic theories of electricity and now includes discussion of Kirchoff ’s laws. Th is 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 components, 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. Th e 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. Th is 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 specifi c 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. Th is 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. Th e 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. Th e purpose of these detailed photos is to show students what to expect when they perform the same procedure. Th ey 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 do so is included in the textbook. To stress the importance of safe work habits, Chapter 1 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. Th is 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 2 covers special tools and procedures. Th is 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. Th is section covers relationships, completing the viii Preface work order and ASE certifi cation. Another section was added to emphasize the importance of proper diagnostic procedures. Chapter 3 leads the student through basic troubleshooting and service. Th is 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. Th e 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. Th e Shop Manual is cross-referenced to the Classroom Manual by the use of marginal notes. Th is provides the benefi t 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. Th ese procedures also served as the basis for new job sheets that are included in the Shop Manual chapters. ix

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