Online Instructor’s Manual

to accompany

Diagnosis and Troubleshooting of

Automotive Electrical, Electronic,

and Computer Systems

Fifth Edition

James Halderman

Prentice Hall

Upper Saddle River, New Jersey

Columbus, Ohio

__________________________________________________________________________________

Copyright © 2010 by Pearson Education, Inc., Upper Saddle River, New Jersey 07458.

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Instructors of classes using James Halderman’s, Diagnosis and Troubleshooting of Automotive

Electrical, Electronic, and Computer Systems, may reproduce material from the instructor’s

manual for classroom use.

10 9 8 7 6 5 4 3 2 1

ISBN-13: 978-0-13-506902-8

ISBN-10: 0-13-506902-5

iii

Instructor’s Resource Guide Table of Contents

Page Chapter 1 Service Information, Tools, and Safety 1

Chapter 2 Environmental and Hazardous Materials 4

Chapter 3 Electrical Fundamentals 6

Chapter 4 Electrical Circuits and Ohm’s Law 8

Chapter 5 Series Circuits 10

Chapter 6 Parallel Circuits 12

Chapter 7 Series-Parallel Circuits 15

Chapter 8 Digital Meters 20

Chapter 9 Oscilloscopes and Graphing Multimeters 22

Chapter 10 Automotive Wiring and Wire Repair 24

Chapter 11 Schematics and Troubleshooting 27

Chapter 12 Capacitance and Capacitors 29

Chapter 13 Magnetism and Electromagnetism 31

Chapter 14 Electronic Fundamentals 33

Chapter 15 Computer Fundamentals 36

Chapter 16 Batteries 38

Chapter 17 Battery Testing and Service 40

Chapter 18 Cranking System 43

Chapter 19 Cranking System Diagnosis and Service 45

Chapter 20 Charging System 48

Chapter 21 Charging System Diagnosis and Service 50

Chapter 22 Lighting and Signaling Circuits 53

Chapter 23 Driver Information and Navigation Systems 55

Chapter 24 Horn, Wiper, and Blower Motor Circuits 58

Chapter 25 Accessory Circuits 60

Chapter 26 Airbag and Pretensioner Circuits 63

Chapter 27 Audio System Operation and Diagnosis 65

Chapter 28 Network Communications and Diagnosis 67

Chapter 29 On-Board Diagnosis 69

Chapter 30 Computer Sensors 71

iv Page

Chapter 31 Ignition System Components and Operation 75

Chapter 32 Ignition System Diagnosis and Service 77

Chapter 33 Fuel Pumps, Lines, and Filters 80

Chapter 34 Fuel Injection Components and Operation 82

Chapter 35 Fuel Injection System Diagnosis and Service 84

Chapter 36 Vehicle Emission Standards and Testing 87

Chapter 37 Emission Control Devices Operation and Diagnosis 89

Chapter 38 Scan Tools and Engine Performance Diagnosis 92

Chapter 39 Hybrid Electric Vehicle Fundamentals 95

Chapter 40 Hybrid Electric Vehicle Safety Procedures 97

Chapter 41 Fuel Cells and Advanced Technology 100

1

CHAPTER 1

Service Information, Tools, and Safety

TASK SHEETS IN THE WORKTEXT: Page

Fire Extinguisher (Task not specified by NATEF) 1 Vehicle Hoisting (Task not specified by NATEF) 2 Safety Check (Task not specified by NATEF) 3 Work Order (A6-A-1) 4 Vehicle Service Information (A6-A-3) 5 Vehicle Service History (A6-A-3) 6 Technical Service Bulletins (A6-A-3) 7

VIN Code (A6-A-4) 8 Vehicle Safety Certification Label (A6-A-4) 9

High-Voltage Circuits Identification (A6-B-7) 10 Hybrid High-Voltage Disconnect (A6-A-18) 11

Temporary Disabling of an Airbag (A6-H-6) 12 CHAPTER OUTLINE:

Objectives

Key Terms Vehicle Identification Service Information Threaded Fasteners Hand Tools Basic Hand Tool List Tool Sets and Accessories Electrical Hand Tools Safety Tips for Using Hand Tools Hand Tool Maintenance Air- and Electric-Operated Tools Safety Tips for Technicians

Safety in Lifting (Hoisting) a Vehicle Jacks and Safety Stands Drive-On Ramps Electrical Cord Safety Jump Starting and Battery Safety Fire Extinguishers Fire Blankets First Aid and Eye Wash Stations Hybrid Electric Vehicle Safety Issues Summary Review Questions Chapter Quiz

ANSWERS TO REVIEW QUESTIONS: 1. List three precautions that must be taken whenever hoisting (lifting) a vehicle. (Text page 28) a. Center the weight of the vehicle on the hoist. b. Raise the vehicle about one foot and check that it is stable. c. Do not look away when raising or lowering the vehicle. 2. Describe how to determine the grade of a fastener, including how the markings differ between fractional and

metric bolts. (Text page 6) The higher the grade of a fastener, the higher the number or the number of lines on the head. 3. List four items that are personal protective equipment (PPE). (Text page 25) Safety glasses, protective gloves, bump cap, and safety shoes are four items of personal safety equipment. 4. List the types of fire extinguishers and their usage. (Text page 32) Three types of fire extinguishers include water, CO2, and dry chemical. 5. Why are wrenches offset 15 degrees? (Text page 9) Wrenches are offset 15 degrees to allow for clearance around the fastener and to allow the wrench to be moved when in tight areas. 6. What are the other names for a line wrench? (Text page 10) Other names for a line wrench include flare-nut, wrench, fitting wrench, or tube-nut wrench.

2 7. What are the standard automotive drive sizes for sockets? (Text page 10) Standard automotive drive sizes for sockets include ¼ in., 3/8 in., and ½ in. 8. Which type of screwdriver requires the use of a hammer or mallet? (Text page 14) An impact type screwdriver. 9. What is inside a dead-blow hammer? (Text page 15) A dead-blow hammer contains lead shot inside a metal container surrounded by a plastic or rubber covering. 10. What type of cutter is available in left and right cutters? (Text page 17) Aviation snips. ANSWERS TO CHAPTER QUIZ:

1. The correct location for the pads when hoisting or jacking the vehicle can often be found in the ________. (Text page 28) a. Service manual b. Shop manual c. Owner's manual d. All of the above X 2. For the best working position, the work should be ________. (Text page 29) a. At neck or head level b. At knee or ankle level c. Overhead by about 1 foot d. At chest or elbow level X 3. A high-strength bolt is identified by ________. (Text pages 6-7) a. A UNC symbol b. Lines on the head X c. Strength letter codes d. The coarse threads 4. A fastener that uses threads on both ends is called a ________. (Text page 4) a. Cap screw b. Stud X c. Machine screw d. Crest fastener 5. When working with hand tools, always ________. (Text page 10) a. Push the wrench – don’t pull toward you b. Pull a wrench – don’t push a wrench away from you X 6. The proper term for Channel Locks is ________. (Text page 17) a. Vise Grips b. Crescent wrench c. Locking pliers d. Multigroove adjustable pliers X 7. The proper term for Vise Grips is ________. (Text page 17) a. Locking pliers X b. Slip-joint pliers c. Side cuts d. Multigroove adjustable pliers 8. Two technicians are discussing torque wrenches. Technician A says that a torque wrench is capable of tightening a fastener with more torque than a conventional breaker bar or ratchet. Technician B says that a torque wrench should be calibrated regularly for the most accurate results. Which technician is correct? (Text page 10)

a. Technician A only b. Technician B only X c. Both Technicians A and B d. Neither Technician A nor B

39. What type of screwdriver should be used if there is very limited space above the head of the fastener? (Text page 14) a. Offset screwdriver X b. Stubby screwdriver c. Impact screwdriver d. Robertson screwdriver 10. What type of hammer is plastic coated, has a metal casing inside, and is filled with small lead balls? (Text page 15) a. Dead-blow hammer X b. Soft-blow hammer c. Sledge hammer d. Plastic hammer

4

CHAPTER 2

Environmental and Hazardous Materials TASK SHEETS IN THE WORKTEXT: Page Material Safety Data Sheet (MSDS) (None specified) 13

CHAPTER OUTLINE:

Objectives

Key Terms Occupational Safety and Health Act Hazardous Waste

Resource Conservation and Recovery Act (RCRA)

Clean Air Act Material Safety Data Sheets (MSDSs) The Dangers of Exposure to Asbestos Asbestos OSHA Standards Asbestos EPA Regulations Asbestos Handling Guidelines Used Brake Fluid

Used Oil Disposal of Used Oil Used Oil Storage

Solvents Solvent Hazardous and Regulatory Status Used Solvents Coolant Disposal Lead-Acid Battery Waste Battery Hazardous and Regulatory Status Battery Handling and Storage Fuel Safety and Storage Airbag Handling Used Tire Disposal Air-Conditioning Refrigerant Oil Disposal Summary Review Questions Chapter Quiz

ANSWERS TO REVIEW QUESTIONS 1. List five common automotive chemicals or products that may be considered hazardous materials. (Text page 48)

Five common automotive chemicals that may be considered hazardous include: throttle body cleaner, brake cleaner, gear lube, used engine oil, and coolant.

2. List five precautions to which every technician should adhere when working with automotive products and chemicals. (Text pages 55-56)

Five precautions to which every technician should adhere when working with automotive products and chemicals include wearing: safety glasses, safety shoes, a bump cap, protective gloves, and long sleeves to help protect the skin.

ANSWERS TO CHAPTER QUIZ 1. Hazardous materials include all of the following except ________. (Text page 48) a. Engine oil b. Asbestos c. Water X d. Brake cleaner 2. To determine if a product or substance being used is hazardous, consult ________. (Text page 48) a. A dictionary b. An MSDS X c. SAE standards d. EPA guidelines 3. Exposure to asbestos dust can cause what condition? (Text page 48) a. Asbestosis b. Mesothelioma c. Lung cancer d. All of the above are possible X

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4. Wetted asbestos dust is considered to be ______________. (Text page 49) a. Solid waste X b. Hazardous waste c. Toxic d. Poisonous 5. An oil filter should be hot drained for how long before disposing of the filter? (Text page 51) a. 30 to 60 minutes b. 4 hours c. 8 hours d. 12 hours X 6. Used engine oil should be disposed of by all except the following methods. (Text page 50) a. Disposed of in regular trash X b. Shipped offsite for recycling c. Burned onsite in a waste oil-approved heater d. Burned offsite in a waste oil-approved heater 7. All of the following are the proper ways to dispose of a drained oil filter except ______. (Text page 51) a. Sent for recycling b. Picked up by a service contract company c. Disposed of in regular trash d. Considered to be hazardous waste and disposed of accordingly X 8. Which act or organization regulates air-conditioning refrigerant? (Text page 48) a. Clean Air Act (CAA) X b. MSDS c. WHMIS d. Code of Federal Regulations (CFR) 9. Gasoline should be stored in approved containers that include what color(s)? (Text page 54) a. A red container with yellow lettering b. A red container X c. A yellow container d. A yellow container with red lettering 10. Used brake fluid can be considered hazardous because __________. (Text page 50) a. It contains polyglycol b. It is water soluble c. It has absorbed metals from the brake system X d. It has absorbed asbestos from the brake system

6

CHAPTER 3

Electrical Fundamentals

TASK SHEETS IN THE WORKTEXT: Page Electrical Circuits (Task not specified by NATEF) 14

CHAPTER OUTLINE:

Objectives Key Terms Electricity

Sources of Electricity Summary Review Questions Chapter Quiz

REVIEW QUESTIONS AND ANSWERS: 1. Define electricity. (Text page 63)

Electricity is the movement of electrons from one atom to another. 2. Define ampere, volt, and ohm. (Text pages 66-67)

An ampere is the unit of the amount of current flow; a volt is a unit of electrical pressure and an ohm is a unit of electrical resistance.

3. List three materials that are conductors and three materials that are insulators. (Text pages 64-65) Conductors include steel, iron, copper, aluminum, mercury, brass, and all other metals.

4. List four sources of electricity. (Text page 68) Sources of electricity include friction, heat, light, pressure, and chemistry.

CHAPTER QUIZ QUESTIONS AND ANSWERS: 1. An electrical conductor is an element with __________ electrons in its outer orbit. (Text page 64) a. Less than 2 b. Less than 4 X c. Exactly 4 d. More than 4 2. Like charges ________. (Text page 64) a. Attract b. Repel X c. Neutralize each other d. Add 3. Carbon and silicon are examples of ________. (Text page 66) a. Semiconductors X b. Insulators c. Conductors d. Photoelectric materials 4. Which unit of electricity does the work in a circuit? (Text page 67) a. Volt b. Ampere X c. Ohm d. Coulomb

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5. As temperature increases ________. (Text page 69) a. The resistance of a conductor decreases b. The resistance of a conductor increases X c. The resistance of a conductor remains the same d. The voltage of the conductor decreases 6. The __________ is a unit of electrical pressure. (Text page 67) a. Coulomb b. Volt X c. Ampere d. Ohm 7. Technician A says that a two-wire variable resistor is called a rheostat. Technician B says that a three-wire variable resistor is called a potentiometer. Which technician is correct? (Text page 70) a. Technician A only b. Technician B only c. Both Technicians A and B X d. Neither Technician A nor B 8. Creating electricity by exerting a force on a crystal is called _______________. (Text page 68) a. Electrochemistry b. Piezoelectricity X c. Thermoelectricity d. Photoelectricity 9. The fact that a voltage can be created by exerting force on a crystal is used in which type of sensor? (Text page 69) a. Throttle position (TP) b. Manifold absolute pressure (MAP) c. Barometric pressure (BARO) d. Knock sensor (KS) X 10. A potentiometer, a three-wire variable resistance, is used in which type of sensor? (Text page 70) a. Throttle position (TP) X b. Manifold absolute pressure (MAP) c. Barometric pressure (BARO) d. Knock sensor (KS)

8

CHAPTER 4

Electrical Circuits and Ohm’s Law

TASK SHEETS IN THE WORKTEXT: Page Electrical Circuits (Task not specified by NATEF) 15

CHAPTER OUTLINE:

Objectives Key Terms

Circuits Ohm’s Law

Watt’s Law Summary Review Questions Chapter Quiz

REVIEW QUESTIONS AND ANSWERS: 1. List the parts of a complete electrical circuit. (Text page 74)

The parts of a complete circuit include: the power source, the protection (fuse), the control (switch) power side conductor, electrical load, and return path.

2. Describe the difference between a short-to-voltage and a short-to-ground. (Text pages 74-75) A short-to-voltage involves a copper-to-copper connection whereas a short-to-ground involves a copper-to-steel connection.

3. Describe the difference between an open and a short. (Text pages 74) An open results in the stoppage of the flow of current in the circuit, whereas a short is a path of reduced resistance, which usually causes an increase in the flow of current through the circuit and may or may not cause a fuse to blow.

4. State Ohm's law. (Text page 76) Ohm’s Law states, “It requires one volt to push one ampere through one ohm of resistance.” 5. Explain what occurs to current flow (amperes) and wattage if the resistance of a circuit is increased because of a corroded connection. (Text page 78)

A corroded electrical connection results in increased unwanted resistance in the circuit. This increased resistance reduces the current (in amperes) as well as the voltage (amperes times volts) that are applied to the loads in the circuit.

CHAPTER QUIZ QUESTIONS AND ANSWERS: 1. If an insulated wire rubbed through a part of the insulation and the wire conductor touched the steel body of a vehicle, the type of failure would be called ________. (Text page 75) a. A short-to-voltage b. A short-to-ground X c. An open d. A chassis ground 2. If two insulated wires were to melt together where the copper conductors touched each other, the type of failure would be called ___________. (Text page 75) a. A short-to-voltage X b. A short-to-ground c. An open d. A floating ground

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3. If 12 volts are being applied to a resistance of 3 ohms, _______ amperes will flow. (Text page 77) a. 12 b. 3 c. 4 X d. 36 4. How many watts are consumed by a light bulb if 1.2 amperes are measured when 12 volts are applied? (Text page 78) a. 14.4 watts X b. 144 watts c. 10 watts d. 0.10 watt 5. How many watts are consumed by a starter motor if it draws 150 amperes at 10 volts? (Text page 78) a. 15 b. 150 c. 1500 X d. 15,000 6. High resistance in a circuit can cause ___________. (Text page 76) a. Dim lights b. Slow motor operation c. Clicking relays or solenoids d. All of the above X 7. If the voltage increases in a circuit, what happens to the voltage if the resistance remains the same? (Text page 78) a. It increases X

b. It decreases c. it remains the same d. It cannot be determined

8. If 200 amperes flow from the positive terminal of a battery and operate the starter motor, how many amperes will flow back to the negative terminal of the battery? (Text page 76) a. Cannot be determined b. Zero c. About one-half (about 100 amperes) d. 200 amperes X 9. What is the symbol for voltage used in calculations? (Text page 76) a. V b. E X c. EMF d. I 10. Which circuit failure is most likely to cause the fuse to blow? (Text page 75) a. Open b. Short-to-ground X c. Short-to voltage d. High resistance

10

CHAPTER 5

Series Circuits

TASK SHEETS IN THE WORKTEXT: Page

Series Circuit Worksheet #1 (A6-A-5) 16 Series Circuit Worksheet #2 (A6-A-5) 17 Series Circuit Worksheet #3 (A6-A-5) 18

CHAPTER OUTLINE:

Objectives Key Terms Series Circuits Ohm’s Law and Series Circuits Kirchhoff’s Voltage Law

Series Circuit Laws Series Circuit Examples Summary Review Questions Chapter Quiz

REVIEW QUESTIONS AND ANSWERS: 1. What is Kirchhoff’s voltage law? (Text page 83)

Kirchhoff’s Voltage Law states, “The voltage around any closed circuit is equal to the sum (total) of the voltage drops across the resistances.”

2. What would current (amperes) do if the voltage were doubled in a circuit? (Text page 82) If the voltage was doubled, the current flow in amperes would also double assuming that the resistance in the circuit remains the same.

3. What would current (amperes) do if the resistance in the circuit were doubled? (Text page 82) If the resistance is doubled in a circuit, the current in amperes would decrease to one-half.

4. What is the formula for voltage drop? (Text page 83) The formula for determining voltage drop is E = I x R where the letter E represents the voltage drop, the letter I represents the current in amperes through the resistance (load), and the letter R represents the resistance of the load.

CHAPTER QUIZ QUESTIONS AND ASWERS: 1. The amperage in a series circuit is ________________. (Text page 85) a. The same anywhere in the circuit X b. Variable in the circuit due to the different resistances c. High at the beginning of the circuit and decreases as the current flows through the resistance

d. Always less returning to the battery than leaving the battery 2. The sum of the voltage drops in a series circuit equals the __________________. (Text page 83) a. Amperage b. Resistance c. Source voltage X d. Wattage 3. If the resistance and the voltage are known, what is the formula for finding the current (amperes)? (Text page 82) a. E = I × R b. I = E × R c. R = E × I d. I = E/R X

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4. A series circuit has three resistors of 6 ohms each. The voltage drop across each resistor is 4 volts. Technician A says that the source voltage is 12 volts. Technician B says that the total resistance is 18 ohms. Which technician is correct? (Text page 82)

a. Technician A only b. Technician B only c. Both Technicians A and B X d. Neither Technician A nor B

5. If a 12-volt battery is connected to a series circuit with three resistors of 2 ohms, 4 ohms, and 6 ohms, how much current will flow through the circuit? (Text page 82) a. 1 ampere X b. 2 amperes c. 3 amperes d. 4 amperes 6. A series circuit has two 10 ohm bulbs. A third 10 ohm bulb is added in series. Technician A says that the three bulbs will be dimmer than when only two bulbs were in the circuit. Technician B says that the current in the circuit will increase. Which technician is correct? (Text page 85)

a. Technician A only X b. Technician B only c. Both Technicians A and B d. Neither Technician A nor B

7. Technician A says that the sum of the voltage drops in a series circuit should equal the source voltage. Technician B says that the current (amperes) varies depending on the value of the resistance in a series circuit. Which technician is correct? (Text pages 88-85)

a. Technician A only b. Technician B only c. Both Technicians A and B X d. Neither Technician A nor B

8. Two light bulbs are wired in series and one bulb burns out (opens). Technician A says that the other bulb will work. Technician B says that the current will increase in the circuit because one electrical load (resistance) is no longer operating. Which technician is correct? (Text page 82)

a. Technician A only b. Technician B only c. Both Technicians A and B d. Neither Technician A nor B X

9. Four resistors are connected to a 12 volt battery in series. The values of the resistors are 10 ohms, 100 ohms, 330 ohms, and 470 ohms. Technician A says that the greatest voltage drop will occur across the 10 ohm resistor. Technician B says that the greatest voltage drop will occur across the 470 ohm resistor. Which technician is correct? (Text page 82)

a. Technician A only b. Technician B only X c. Both Technicians A and B d. Neither Technician A nor B

10. Three light bulbs are wired in series. A fourth bulb is connected to the circuit in series. Technician A says that the total voltage drop will increase. Technician B says that the current (amperes) will decrease. Which technician is correct? (Text page 82)

a. Technician A only b. Technician B only X c. Both Technicians A and B d. Neither Technician A nor B