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Automotive Electricity and Electronics PDF

647 Pages·2013·116.16 MB·English
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AUTOMOTIVE ELECTRICITY AND ELECTRONICS SECONDE DITION A1 Santini Retired, College of DuPage Glen Ellyn, Illinois DELMAR 4 a 0 CENGAGE Learning- - - - - - Australia * Brazil Japan Korea * Mexico * Singapore Spain United Kingdom United States - DELMAR .+ a 5 CENGAGE Learning. Automotive Electricity and Electronics, C,2 013 Delmar, Cengage Learning Second Edition ALL RIGHTS RESERVED. No part of this work covered by the copyright Al Santini herein may be reproduced, transmitted, stored, or used in any form or by any means graphic, electronic, or mechanical, including but not limited to Vice President, Editorial: Dave Garza photocopying, recording, scanning, digitizing, taping, Web distribution, Director of Learning Solutions: Sandy Clark information networks, or information storage and retrieval systems, except Executive Editor: Dave Boelio as permitted under Section 107 or 108 of the 1976 United States Copyright Managing Editor: Larry Main Act, without the prior written permission of the publisher. Senior Product Manager: Matthew Thouin Editorial Assistant: Courtney Troeger information and technology assistance, contact us at Cengage Learning Customer & Sales Support, 1-800-354-9706 Vice President, Marketing: Jennifer Baker For permission to use material from this text or product, Marketing Director: Deborah S. Yarnell submit all requests oriline at cengage.com/permissions Marketing Manager: Erin Brennan Further permissions questions can be e-mailed to Associate Marketing Manager: Jillian Borden [email protected] Production Director: Wendy Troeger Library of Congress Control Number: 201 1928574 Production Manager: Mark Bernard Senior Content Project Manager: Cheri Plasse ISBN-I3 : 978-1- 4283-9961 -7 ISBN-I0 : 1-4283-9961- 5 Delmar 5 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. To learn more about Delmar, visit www.cengage.com/delrnar Purchase any of our products at your local college store or at our preferred online store www.cengagebrain.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 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

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