Professional Documents
Culture Documents
Always wear safety glasses for eye protection. Use safety stands whenever a procedure requires you to be under the vehicle. Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure. Set the parking brake when working on the vehicle. If you have an automatic transmission, set it in PARK unless instructed otherwise for a specific service operation. If you have a manual transmission it should be in REVERSE (engine OFF) or NEUTRAL (engine ON) unless instructed otherwise for a specific service operation. Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide. Keep yourself and your clothing away from moving parts when the engine is running, especially the fan and belts.
To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. Do not smoke while working on the vehicle. To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle. Tie long hair securely behind your head. Keep hands and other objects clear of the radiator fan blades. Electric cooling fans can start to operate at any time by an increase in underhood temperatures, even though the ignition is in the OFF position. Therefore, care should be taken to ensure that the electric cooling fan is completely disconnected when working under the hood.
The recommendations and suggestions contained in this manual are made to assist the dealer in improving his dealership parts and/or service department operations. These recommendations and suggestions do not supersede or override the provisions of the Warranty and Policy Manual, and in any cases where there may be a conflict, the provisions of the Warranty and Policy Manual shall govern. The descriptions, testing procedures, and specifications in this handbook were in effect at the time the handbook was approved for printing. Ford Motor Company reserves the right to discontinue models at any time, or change specifications, design, or testing procedures without notice and without incurring obligation. Any reference to brand names in this manual is intended merely as an example of the types of tools, lubricants, materials, etc. recommended for use. Equivalents, if available, may be used. The right is reserved to make changes at any time without notice. WARNING: MANY BRAKE LININGS CONTAIN ASBESTOS FIBERS. WHEN WORKING ON BRAKE COMPONENTS, AVOID BREATHING THE DUST. BREATHING THE ASBESTOS DUST CAN CAUSE ASBESTOSIS AND CANCER. Breathing asbestos dust is harmful to your health. Dust and dirt present on car wheel brake and clutch assemblies may contain asbestos fibers that are hazardous to your health when made airborne by cleaning with compressed air or by dry brushing. Wheel brake assemblies and clutch facings should be cleaned using a vacuum cleaner recommended for use with asbestos fibers. Dust and dirt should be disposed of in a manner that prevents dust exposure, such as sealed bags. The bag must be labeled per OSHA instructions and the trash hauler notified as to the contents of the bag. If a vacuum bag suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government approved toxic dust purifying respirators. OSHA requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians concerned with performing brake or clutch service should be present in the area. Copyright 2002 Ford Motor Company Produced and Coordinated by Technical Support Operations Ford Customer Service Division October, 2002
CUSTOMER EXPECTATIONS
Customer Expectations: Service
Fix It Right The First Time, on Time. Both service advisors and technicians are important players when it comes to Expectation #3. Why Customers tell us Fixing It Right The First Time, on Time is one of the reasons they would decide to return to a dealer to buy a vehicle and get their vehicles serviced. Technician Training It is our goal to help the technician acquire all of the skills and knowledge necessary to Fix It Right The First Time, on Time. We refer to this as competency. Technicians Role Acquire the skills and knowledge for competency in your specialty via: New Model STST Self Study Self Study FordStar Broadcasts FordStar Broadcasts Ford Multimedia Training (FMT) Instructor Led
Instructor Led
The Benefits The successful implementation of expectations means: Satisfied customers Repeat vehicle sales Repeat service sales Recognition that Ford and Lincoln/Mercury technicians are the Best in the Business
TABLE OF CONTENTS
TABLE OF CONTENTS COURSE INTRODUCTION ..............................................COURSE INTRODUCTION1 DAY ONE.............................................................................................................DAY ONE1 Agenda ...................................................................................................................Day One3 Students Objectives ..............................................................................................Day One4 Prerequisite Review ...............................................................................................Day One5 Workstation 1.......................................................................................................Day One15 Workstation 2.......................................................................................................Day One27 Workstation 3.......................................................................................................Day One35 Workstation 4.......................................................................................................Day One51 Homework ...........................................................................................................Day One69 DAY TWO ..........................................................................................................DAY TWO1 Agenda .................................................................................................................. Day Two3 Students Objectives ............................................................................................. Day Two4 Workstation 1........................................................................................................ Day Two5 Workstation 2...................................................................................................... Day Two25 Workstation 3...................................................................................................... Day Two35 Workstation 4...................................................................................................... Day Two45 Homework .......................................................................................................... Day Two65 DAY THREE ..................................................................................................DAY THREE1 Agenda ................................................................................................................ Day Three3 Students Objectives ........................................................................................... Day Three4 Instructor-led Demonstration.............................................................................. Day Three5 Workstation 1...................................................................................................... Day Three9 Workstation 2.................................................................................................... Day Three15 Workstation 3.................................................................................................... Day Three21 Workstation 4.................................................................................................... Day Three25 Homework ........................................................................................................ Day Three35 DAY FOUR....................................................................................................... DAY FOUR1 Agenda .................................................................................................................. Day Four3 Students Objectives ............................................................................................. Day Four4 Workstation 1........................................................................................................ Day Four5 Workstation 2...................................................................................................... Day Four11 Workstation 3...................................................................................................... Day Four17 Instructor-led Demonstration.............................................................................. Day Four23
October, 2002
Table of Contents i
TABLE OF CONTENTS
ii Table of Contents
October, 2002
COURSE INTRODUCTION
COURSE INTRODUCTION
October, 2002
Course Introduction 1
COURSE INTRODUCTION
ELECTRICAL SYSTEMS CURRICULUM PATH
Basic Electrical Theory and Operation 34S11W0 Battery Starting and Charging System Theory and Operation 34S12W0 Electrical Diagnostic Tools and Testing 34S13M0 Basic Electrical Diagnosis 34S14T0 (5 Days) Electronic Theory and Operation 34S15W0 Understanding Electronic Systems 34S16M0 New Generation Star Tester Operation 34S17W0 Basic Worldwide Diagnostic Tool Operation 34S18M0 Electronic Systems Diagnosis 34S19T0 (4 Days) Networks and Multiplexing System Operation and Diagnosis 34S20W0 Antitheft Systems Operation and Testing 34S21W0 Entertainment and Navigation Systems Operation and Testing 34S22W0 Speed Control System Operation and Testing 34S23W0 SRS Operation and Testing 34S24W0 Advanced WDS Tool Operation 34S25W0
Planned Training Pathway Ford Motor Company has identified the skills and knowledge necessary to meet the curriculum goals in the Electrical Systems specialty. The Planned Training Pathway is a series of courses designed to provide you with these skills and knowledge. The chart above illustrates the courses in this curriculum. Description The Electrical Systems Curriculum consists of sixteen courses. The web-based courses and FMT courses are self-paced training programs. The Classroom course is hands-on and is facilitated by an instructor. The information in the Web, FMT, and Classroom courses are designed to prepare you to successfully complete the instructor led course. You are currently in course seven of the Electrical Systems Curriculum, Electronic Systems Diagnosis.
2 Course Introduction
October, 2002
COURSE INTRODUCTION
Course Overview This course has been designed to include both lecture and hands on activities. Students will have several opportunities to practice what they learn in the form of workstations. Audience Profile This course is designed for any Ford, Lincoln and Mercury service technician who wants to start their certification process in any specialty as well as those who wish to be certified in Electrical Systems. Course Prerequisites All students must have completed the first eight courses in the curriculum prior to enrolling in this course. Students who do not show passing credit in their STARS planners for the previous courses should not be admitted to this class. Their presence will slow down the course flow, as well as monopolize valuable instructor time.
z z z z z z z z
Basic Electrical Theory and Operation (Web) Battery Starting and Charging System Theory and Operation (Web) Electrical Diagnostic Tools and Testing (FMT) Basic Electrical Diagnosis (Classroom) Electronic Theory and Operation (Web) Understanding Electronic Systems (FMT) New Generation Star Tester Operation (Web) Basic Worldwide Diagnostic System Tool Operation (FMT)
October, 2002
Course Introduction 3
COURSE INTRODUCTION
Course Objectives The objectives of this course are to enable you to: z Use the SSCC (Symptom-to-System-to-Component-to-Cause) diagnostic process relating to electronic concerns. z Use special tools and service equipment associated with electronic diagnosis and repair. z Use all service publications in their available formats and to obtain needed information for diagnosis. z Perform diagnostic test procedures. z Perform repair procedures. Number Of Days This course has been designed to span a four-day period. Number Of Students This course has been designed to include up to twelve students. Course Requirements To meet the requirements of this course, you must satisfactorily complete the hands-on posttest and achieve a score of 80% or higher on the written post-test. Both tests will both be administered on the last day of class.
4 Course Introduction
October, 2002
DAY ONE
DAY ONE
October, 2002
Day One 1
DAY ONE
2 Day One
October, 2002
ACTIVITY
TIME
Introduction
8:30 am to 8:45 am
8:45 am to 10:15 am
Break
10:15 am to 10:30 am
Lecture
10:30 am to 11:30 am
Lunch
11:30 am to 12:30 pm
Workstations
12:30 pm to 4:00 pm
4:00 pm to 4:30 pm
October, 2002
Day One 3
CONTENT
4 Day One
October, 2002
PREREQUISITE REVIEW
October, 2002
Day One 5
2. What is an input?
3. What is an output?
6 Day One
October, 2002
Inputs
Module
Direct Outputs
Indirect Outputs
Cause:
Diagnostic Strategy: Inspection and verification Retrieve DTCs. Monitor PIDs Active Commands
October, 2002
Day One 7
8. What is the difference between direct module outputs and indirect module outputs?
9. Why should you determine how an electronic system operates before diagnosing it?
8 Day One
October, 2002
13. What does Output State Control (Active Commands) allow you to do?
BEC603-A/VF
October, 2002
Day One 9
BEC603-A/VF
17. What are some of the input devices that produce analog DC signals?
10 Day One
October, 2002
BEC603-A/VF
19. What are some of the input devices that produce analog AC signals?
October, 2002
Day One 11
12 Day One
October, 2002
25A
65
DG C101F C101M
65
DG
65
S110 65 DG 65 DG 65 DG 65 DG ENGINE COMPARTMENT FUSE BOX WINDSHIELD WIPER SPEED RELAY WINDSHIELD WASHER PUMP MOTOR RELAY
W/BK
12V
LO M RUN PARK
HI
BK/W C119 WINDSHIELD WASHER PUMP MOTOR 0V S104 SEE GROUNDS G102
61
Y/R
28
C233
WASHER PUMP CONTROL
16
15
PARK SENSE
57
BK
57
SEE GROUNDS
G101
19
RETURN 14 10
C234 O
51 K W
INT. #4
BEC550-B/VF
October, 2002
Day One 13
14 Day One
October, 2002
WORKSTATION 1
October, 2002
Day One 15
16 Day One
October, 2002
October, 2002
Day One 17
6. When using the NGS, why should you always write down Continuous DTCs before clearing them?
7. When clearing Continuous DTCs, why should you use the NGS as opposed to disconnecting the battery?
Press button 7 CLEAR and follow on-screen directions to clear Continuous Codes.
18 Day One
October, 2002
a. After codes are cleared, press CANCEL to return to the previous menu. TECHNICIAN B: Use the NGS during this workstation. 9. Use the NGS to perform the ON-DEMAND Self Test. a. Select ON-DEMAND SELF-TEST and press TRIGGER. b. Press START. c. Follow on screen directions. d. Carefully observe the system being tested for changes during the on-demand self-test. Briefly explain what happens to the systems outputs during the On-Demand Self-Test.
10. Use the table below to record any DTCs received during the On-Demand Self-Test. DTC DEFINITION
October, 2002
Day One 19
13. Using the wiring diagram provided, list below the components and or circuits that could be the cause of the On-Demand DTC(s).
20 Day One
October, 2002
October, 2002
Day One 21
16. Move the fault switch to position B. View each of the PIDs on the NGS while operating the corresponding component and write your results below. NOTE: If a PID is not available write N/A. PIDs IGN_R WASH_SW WPMODE 17. Move the fault switch back to position A. View each of the PIDs on the NGS while operating the corresponding component and write your results below. NOTE: If a PID is not available write N/A. PIDs IGN_R WASH_SW WPMODE 18. Based on the PID values above, your understanding of systems operation and the wiring diagram provided, list below the circuits or components that are the potential cause of the concern. READINGS READINGS
22 Day One
October, 2002
Switch Position High Low Interval One OFF e. Press TRIGGER to start recording. NOTE: The NGS is recording your actions.
f. Operate the wipers in the High, Low, and Interval 1 positions. g. Wait ten seconds and press TRIGGER again. NOTE: The recording is complete.
October, 2002
Day One 23
20. Use the scroll knob to place the cursor at the trigger point (0.0) in the picture below. A T will appear when you reach the trigger point. Label the NGS with the WP_MODE values on the left of the screen. Label the NGS with the time values at the bottom of the screen. Draw the graph as it appears on the NGS.
WPMODE
0.0
BEC113-A/VF
a. Press CANCEL to exit graphing function. b. Press button 7 TABLE. This is a table displaying the PID information. c. Turn the scroll knob to see the wiper mode change. NOTE: You can use the PLAY, REWIND and FORWARD buttons. 21. Did the wiper mode PID change after the trigger point? YES NO
24 Day One
October, 2002
23. Reset the workstation a. Press CANCEL several times to return to the main menu. b. Select VEHICLE AND ENGINE SELECTION. c. Highlight DESELECT VEHICLE and press TRIGGER (this will erase the vehicle from NGS memory). d. Turn off the ignition switch and unplug the NGS. e. Move the fault switch to position A to prepare the workstation for the next group.
October, 2002
Day One 25
26 Day One
October, 2002
WORKSTATION 2
October, 2002
Day One 27
2. What happens if you undock accidentally? (DO NOT COMPLETE THIS STEP)
3. How does the WDS receive its power to keep its internal battery running when not docked?
28 Day One
October, 2002
5. List below the components of the system identified in question four using the EVTM /Wiring Diagram manual. Inputs Module Direct Outputs Indirect Outputs
October, 2002
Day One 29
a. Follow the instructions on the screen to connect the Data Link Cable to the vehicle. Select the CONTINUE icon to proceed. The key must be in the RUN position. b. Wait while the PTU establishes communication with the Powertrain Control Module (PCM). The vehicle specification screen will appear. NOTE: Respond to any additional information questions if necessary. c. If the vehicle information is correct, select YES. d. Use the keypad to enter the VIN number (if required), repair order (RO) number and odometer reading. Select the CONTINUE icon to proceed. e. Once the WDS has identified the vehicle. Select the TOOLBOX icon. f. Select SELF TEST from the menu, then select the CONTINUE icon. g. Select ELECTRICAL from the menu, and then select the system that is appropriate to the symptom on the repair order. h. Follow the instructions on the screen, then select the CONTINUE icon to proceed. Observe the vehicle while the test is being performed. 7. What do you observe happening to the vehicle?
30 Day One
October, 2002
NOTE: Touch each DTC to view a definition of each code. 9. From the codes above list below the DTC(s) and definition(s) related to the concern.
10. What pinpoint test in the Workshop manual would help you diagnose this concern? (DO NOT PERFORM THE PINPOINT TEST.)
Pinpoint Test:
October, 2002
Day One 31
a. Select EXIT from the Pinpoint Menu and then select the CONTINUE icon. b. Repair the fault by placing fault switch in position B. c. Rerun Self Test by selecting the RETEST icon. 12. List DTCs retrieved. DTC TYPE (check one) DTC ODDTCs CMDTCs CLEARED CMDTCs
32 Day One
October, 2002
a. b. c. d.
To exit the test, select the MENU icon in the upper RH corner of the screen. Select exit. Select continue Select the LOG VIEWER icon in the lower LH corner of the screen.
a.
Select the CLOSE SESSION icon in the lower LH corner of the screen.
b. Select DELETE from the menu then select the CONTINUE icon to finish. c. Place fault switch in position A, turn off ignition, and disconnect all cables from the WDS and vehicle. d. Re-dock the WDS. e. To ensure the WDS is fully docked, the external power LED should be lit (green).
October, 2002
Day One 33
34 Day One
October, 2002
WORKSTATION 3
October, 2002
Day One 35
2. What type of switch is used in the circuit below? A. Power side switch B. Ground side switch 3. Trace the power flow through the circuit below using colored markers. Use red to indicate power, blue for power-side switched circuits, green for ground-side switch circuits, and black for ground.
12V
V
C D
BEC100-A/VF
B: Module D: Lamps
36 Day One
October, 2002
V
C D
BEC100-A/VF
B: Module D: Lamps
October, 2002
Day One 37
FE-32
OPEN
CLOSED
12V
FE-30
FE-34
B+
INTERIOR LAMPS
B+
D-A CPU
POS SW SENSE
COLLECTOR MEMORY
SIGNAL RETURN
BEC101-E/VF
6. What type of signal does this input produce? A. Digital DC B. Analog DC C. Digital AC D. Analog AC Disconnect the jumper leads from the circuit boards.
38 Day One
October, 2002
October, 2002
Day One 39
9. What type of switch is used in the circuit below? A. Power side switch B. Ground side switch 10. Trace the power flow through the circuit below using colored markers. Use red to indicate power, blue for power-side switched circuits, green for ground-side switch circuits, and black for ground.
12V
BEC102-A/VF
B: Module
11. What will the voltage readings be with the module's internal voltmeter (V) connected as shown when the external input switch is opened and closed? Switch Open Switch Closed
40 Day One
October, 2002
12V
FE-34
GND SW SENSE A-D V CPU B+
D-A
FE-32
OPEN
POS SW SENSE
COLLECTOR MEMORY
CLOSED
SIGNAL RETURN
SINGLE SWITCH BOARD
BEC103-E/VF
13. What type of signal does this input produce? A. Digital DC B. Analog DC C. Digital AC D. Analog AC Disconnect the jumper leads from the circuit board.
October, 2002
Day One 41
42 Day One
October, 2002
B+
Power to CPU
Input
15. Will the module turn the lamp on or off when it sees the following input signals? INPUT OPEN CLOSED OUTPUT
October, 2002
Day One 43
17. Is the relay in this circuit acting as a power side switch or a ground side switch? A. Power side switch B. Ground side switch 18. Is the output transistor in this circuit acting as a power side switch or a ground side switch? A. Power side switch B. Ground side switch 19. Trace the power flow through the circuit below using colored markers. Use red to indicate power, blue for power-side switched circuits, green for ground-side switch circuits, and black for ground.
12V
12V
B+
Power to CPU
Input
44 Day One
October, 2002
12V
12V
B+
Power to CPU
Input
October, 2002
Day One 45
Input Closed=Relay ON
FE-33
COMMON
CLOSED
12V
RELAY
N/O
N/C
FE-34
GND SW SENSE A-D V CPU POS SW SENSE V COLLECTOR MEMORY B+
B+
FE-30
D-A
INTERIOR LAMPS
SIGNAL RETURN
BEC107-E/VF
46 Day One
October, 2002
24. Why is it important to know the difference between direct and indirect outputs?
October, 2002
Day One 47
See page 1316 37 C144 294 S228 20 WH/LB P113 Auxiliary relay box 3 994
See page 1316 S232 20 WH 294 1 422 ABS 2 C1290 Y274 4x2 center axle disconnect solenoid 1 145 2 C1290 20 GY/BK 1 605 4 C1291 20 RD C1046 20 WH/LB 294 3 2 S120 20 WH/LB C1046 C1291 Y275 4x4 center axle disconnect solenoid
5 779 14 BN
2 976
18 145 22 GY/BK
15 605 7
14
C201c 22 GY C192
783 21 1
20 GY C110
5 2
C110 C3146 A257 Transfer case assembly 9) Magnetic clutch coil 15116, 15117, 15118
784 14
20 LB/BK C175 A147 Powertrain Control Module (PCM) (12A650) 2210, 2310, 2410, 2510
22 2
0 1 2
C1177 N628 4x4 High/Low indicator switch 0 1 2 0) Low 1) High 2) 4x2 15116, 15117, 15118
BEC907-A/VF
Turn off the power supply and DMM. Disconnect all wires and return Workstation 1 to its original condition and complete the last activity at your desks.
48 Day One
October, 2002
October, 2002
Day One 49
50 Day One
October, 2002
WORKSTATION 4
October, 2002
Day One 51
Thermistors are variable resistors that change resistance when temperature changes. They provide temperature information to a module in the form of an analog DC signal. Thermistors are made of a special resistive material that is very sensitive to changes in temperature. In most thermistors, as temperature increases, the resistance of the thermistor decreases. As temperature decreases, thermistor resistance increases. This change of resistance is used in a voltage divider circuit to produce an analog DC voltage that indicates temperature. This analog voltage begins as five volts, which passes through a current limiting resistor inside the module and then is wired to the external thermistor. Thermistors are two-wire sensors that are part of a voltage divider circuit. The voltage supply and current limiting resistor are internal to the module. The wire from the current limiting resistor to the thermistor is called the signal wire. This is where the module monitors the analog DC voltage signal created by the change in temperature. The wire from the thermistor to ground is known as signal return.
12V
Volt Reg 5V
C
Thermistor Signal T
Signal Return
BEC108-A/VF
B: Module
52 - Day One
October, 2002
DIRECTIONS: In this workstation you will use a Digital Multimeter and the WDS Oscilloscope to measure the input signals produced by a Thermistor circuit, a Potentiometer circuit and a Variable Reluctance Sensor circuit. You will also learn how to identify these devices in a Wiring Diagram. TECHNICIAN A: Perform steps 1 4. 1. Using the DMM, measure the resistance of the thermistor.
2. While monitoring the resistance of the thermistor, warm the tip of the thermistor with your fingers. What happens to the resistance? A. Resistance increases B. Resistance decreases C. Resistance stays the same
12V
FE-24
REF
FE-21
B+
THERMISTOR SIGNAL
SIG RTN
SIGNAL
VREF
POTENTIOMETER SIGNAL
POTENTIOMETER THEMISTOR
SIG RTN
BEC114-A/VF
October, 2002
Day One 53
54 - Day One
October, 2002
A231 Remote Climate Control (RCC) module 7 788 10 20 RD/OG 15 470 5 20 PK/BK 23 790 15 20 WH/OG 6 468 9 C228 20 BN C219 14 788 22 RD/OG S221 790 22 WH/OG 468 1 22 BN 218 2 A112 Generic Electronic Module (GEM) (14B205) C201b 592 22 WH/VT C287 B241 470 10 788 20 RD/OG P78 Integrated control panel S206 See page 105 G200 26 20 PK/BK C263 470 20 PK/BK 15121 5 398 C287 20 BK/YE
C198 B203
C233 B206
(19E702) 1511
(19C734) 15120
BEC903-B/VF
October, 2002
Day One 55
Signal
Signal Return
BEC109-A/VF
A: Potentiometer (Input)
B: Module
56 - Day One
October, 2002
TECHNICIAN B: Perform steps 8 11. 8. Measure and record the resistance of the potentiometer between "VREF" and "Signal Return" 9. Measure and record the resistance of the potentiometer between "Signal" and "Signal Return" 10. With the DMM still connected, turn the potentiometer through the full range of motion. Record the readings at each of the following positions: A. At rest B. travel C. Full travel
October, 2002
Day One 57
11. Connect the potentiometer to the Voltage Divider Input board as shown and measure voltage between the "Potentiometer Signal" and "Signal Return" terminals. Record the readings at: A. Rest B. travel C. Full travel V V V
12V
FE-24
REF
FE-21
B+
THERMISTOR SIGNAL
SIG RTN
SIGNAL
VREF
POTENTIOMETER SIGNAL
POTENTIOMETER THEMISTOR
SIG RTN
BEC110-D/VF
12. What type of signal does a potentiometer produce? A. B. C. D. Digital DC Analog DC Digital AC Analog AC
58 - Day One
October, 2002
29
C270b
1303 Radio
298 12
22 VT/OG
832
20 LB/PK 833 20 TN
914
10 VBATT
3 SCP +
SCP
20
22
21
C228
436
20 RD/LG
437
20 YE/LG
438
20 RD/WH
250
20 OG
249
20 DB/LG
ATX902-A/VF
October, 2002
Day One 59
A Variable Reluctance Sensor (VRS) produces an analog AC signal. It uses magnetism to generate its voltage signal. Variable reluctance sensors are used to provide position and speed information. By monitoring the frequency of the signal, the module determines speed. Higher frequency indicates higher speed. A variable reluctance sensor consists of a toothed trigger wheel called a reluctor (indicator) and a sensor, which is made of a permanent magnet with a coil of wire wrapped around it. This sensor is located at a specific distance from the reluctor (indicator). This distance is called an air gap.
BED304-A/VF
60 - Day One
October, 2002
12V
FE-23
LOW
MED HIGH
SIGNAL B+
OFF
VRS +
VRS
BEC111-B/VF
October, 2002
Day One 61
16. Use the DMM to measure frequency. a. Adjust the dial to the AC voltage position. b. Press and hold the yellow button in the center of the dial until it beeps (one beep then two quick beeps). c. The meter will now read AC frequency. What is the unit of measure for frequency?
Record the VRS frequency at each speed setting. Low Med High Hz Hz Hz
62 - Day One
October, 2002
T
BEC112-A/VF
October, 2002
Day One 63
T
BEC112-A/VF
64 - Day One
October, 2002
TECHNICIAN C: Perform step 19. 19. Set the motor speed to high. Watch the yellow trace on the WDS and draw a picture of the trace in the chart below.
T
BEC112-A/VF
20. When motor speed increases the AC voltage: A. Increases B. Decreases C. Stays the same 21. When motor speed increases the frequency: A. Increases B. Decreases C. Stays the same
October, 2002
Day One 65
22. What type of signal is associated with a VRS? A. B. C. D. Digital DC Analog DC Digital AC Analog AC
VREF
A147 Powertrain Control Module (PCM) (12A650) 6 84 20 DG/WH C143 B44 136 2 C175 18 DB/YE C193 B110 9 359
85 282 20 DB/OG
970 2
C1064
C143
359
20 GY/RD
359
20 GY/RD
C180 B41
C180
359
20 GY/RD
359
20 GY/RD
359
20 GY/RD S104
20 GY/RD
C1073 B230
359
20 GY/RD
359
20 GY/RD
359
20 GY/RD S112
See page 244 3 925 20 WH/YE 2 359 C1073 20 GY/RD 359 F 20 GY/RD
63
91
BEC904-A/VF
Turn off the DMM and Power Supply. Remove leads from the VRS/Hall board (FE23).
66 - Day One
October, 2002
October, 2002
Day One 67
68 - Day One
October, 2002
HOMEWORK
October, 2002
Day One 69
GEM
SWITCHED TO GROUND
DRIVER'S DOOR AJAR SWITCH PASSENGER DOOR AJAR SWITCH LIFTGATE DOOR AJAR SWITCH SLIDING DOOR AJAR SWITCH DOOR HANDLE SWITCH WASHER FLUID LEVEL SWITCH REAR WINDOW DEFROST SWITCH SEAT BELT SWITCH OIL LEVEL SWITCH KEY-IN IGNITION SWITCH
RELAYS
WIPER HIGH/LOW SPEED RELAY WIPER DYNAMIC BRAKE/RUN RELAY WASHER PUMP RELAY SLIDING MEMORY RELAY REAR WINDOW DEFROST RELAY BATTERY SAVER RELAY INTERIOR LAMP CONTROL RELAY (DELAYED ACCESSORY) RELAY ONE-TOUCH-DOWN (DRIVER POWER WINDOW) RELAY
O I U N T P P U U T T S S
SWITCHED TO BATTERY
KEY-IN RUN SWITCH KEY-IN RUN/ACCY SWITCH KEY-IN START SWITCH HEADLAMP ON SWITCH WINDOW UP/DOWN SWITCH DOOR LOCK/UNLOCK SWITCH WIPER PARK SENSE SWITCH
INDICATOR LAMPS
DOOR AJAR LAMP SEAT BELT LAMP LOW WASHER FLUID LAMP LOW OIL LEVEL LAMP
ANALOG
BATTERY VEHICLE SPEED SIGNAL WINDOW CURRENT SENSE (HIGH/LOW) SIGNAL WIPER MODE SELECT WIPER INTERVAL DELAY
DLC
BEC980-A/VF
70 Day One
October, 2002
October, 2002
Day One 71
One of the greatest benefits DTC's allow us is the ability to detect system faults and report them. This is accomplished by an internal mechanism in the GEM that contains logic designed to observe a specific type of behavior, and if that behavior ventures outside of what the logic declares as "normal operation," the GEM will generate a Continuous DTC. The next time the technician requests information, the GEM will report the Continuous DTC(s). The most common conditions that would cause a DTC to be generated include: a circuit failure an open circuit a short circuit-to-ground a short circuit-to-battery DTC's also allow us to compare On-Demand Self-Test DTC's with Continuous DTC'S. If a DTC is detected during Continuous mode, but not during On-Demand Self-Test mode, then there is an intermittent fault (the failure existed once, but is now gone when On-Demand Self-Test is run). If a DTC is an On-Demand Self-Test code, there is a hard fault (an existing problem that can be isolated).
72 Day One
October, 2002
October, 2002
Day One 73
74 Day One
October, 2002
October, 2002
Day One 75
76 Day One
October, 2002
October, 2002
Day One 77
78 Day One
October, 2002
DAY TWO
DAY TWO
October, 2002
Day Two 1
DAY TWO
2 Day Two
October, 2002
ACTIVITY
TIME
8:30 am to 10:15 am
Break
10:15 am to 10:30 am
Lecture
10:30 am to 11:30 am
Lunch
11:30 am to 12:30 pm
Workstations
12:30 pm to 4:00 pm
4:00 pm to 4:30 pm
October, 2002
Day Two 3
DAY TWO
STUDENTS OBJECTIVES
Monitor and record PID values for the Intake Air Temperature Sensor and the Throttle Position Sensor. Determine which DTCs will be set when faults are inserted in a circuit. Use the datalogger function to monitor and record PID values. Use the WDS to view and capture information using the datalogger function. Use Active Commands to control outputs. Use the SSCC process and the active command function to diagnose a lighting concern. Describe voltage reference and the meter function of the NGS active command mode. Describe normal operation of Hall Effect sensors and phototransistors. Describe output signals used in electronic systems: Duty cycle Pulse width Analog input
CONTENT
PID values WDS datalogger function Active commands and Output State Controls Hall Effect sensors Phototransistors Duty cycle Pulse width Analog input
4 Day Two
October, 2002
WORKSTATION 1
October, 2002
Day Two 5
1. Use the table below and the wiring diagram to identify the IAT Signal and Signal Return wires for the Intake Air Temperature (IAT) sensor on the vehicle you are working on. Write the circuit number and wire color for each wire in the table. Circuit Number IAT SIG SIG RTN Wire Color
6 Day Two
October, 2002
NOTE: Use the 1 and 0 on the NGS keypad to move forward and back one screen at a time. Use 2 and 9 to move to the beginning and end of the screen. g. Select START 2. With no faults in the IAT circuit complete the table below with voltage at component and PID values.
VOLTAGE AT COMPONENT
VREF
PID VALUE
Signal
V
SIGNAL T
IAT Deg.
PCM
Signal Return
SIGNAL RETURN
BEC801-B/VF
IAT Volts
NOTE: Connect the negative DMM lead to the battery ground. 3. Warm the IAT with your finger while monitoring PIDs. Do any of the values change? YES NO
October, 2002
Day Two 7
PID VALUE
Signal
V
SIGNAL T
IAT Deg.
PCM
Signal Return
SIGNAL RETURN
IAT Volts
BEC802-B/VF
5. Refer to the DTC Chart. What code will be set by the PCM with an open signal wire? A. P0112 B. P0113 C. No DTCs will be set DTC CHART P0112 - Intake Air Temperature (IAT) Circuit Low Input P0113 - Intake Air Temperature (IAT) Circuit High Input
Indicates the sensor signal is less than Self-Test minimum. The IAT sensor minimum is 0.2 volts or 121C (250F). Indicates the sensor signal is greater than Self-Test maximum. The IAT sensor maximum is 4.6 volts or -50C (-58F).
IAT V PID reading less than 0.2 volts with key ON and engine OFF or during any engine operating mode indicates a hard fault. IAT V PID reading greater than 4.6 volts with key ON and engine OFF or during any engine operating mode indicates a hard fault.
6. Warm the IAT with your finger while monitoring PIDs. Do any of the values change? YES NO If you answered yes, which ones?
8 Day Two
October, 2002
PID VALUE
Signal
V
SIGNAL T
IAT Deg.
PCM
Signal Return
SIGNAL RETURN
IAT Volts
BEC803-B/VF
8. Refer to the DTC Chart. What code will be set by the PCM? A. P0112 B. P0113 C. No DTCs will be set 9. Warm the IAT with your finger while monitoring PIDs. Do any of the values change? YES NO
October, 2002
Day Two 9
PID VALUE
Signal
V
SIGNAL T
IAT Deg.
PCM
Signal Return
SIGNAL RETURN
IAT Volts
BEC804-B/VF
11. Refer to the DTC Chart. What code will be set by the PCM? A. P0112 B. P0113 C. No DTCs will be set 12. Warm the IAT with your finger while monitoring PIDs. Do any of the values change? YES NO
10 Day Two
October, 2002
PID VALUE
Signal
V
SIGNAL T
IAT Deg.
PCM
Signal Return
SIGNAL RETURN
IAT Volts
BEC805-B/VF
14. Refer to the DTC Chart. What code will be set by the PCM? A. P0112 B. P0113 C. No DTCs will be set 15. Warm the IAT with your finger while monitoring PIDs. Do any of the values change? YES NO
October, 2002
Day Two 11
PID VALUE
Signal
V
SIGNAL T
IAT Deg.
PCM
Signal Return
SIGNAL RETURN
V
BEC806-B/VF
IAT Volts
17. Refer to the DTC Chart. What code will be set by the PCM? A. P0112 B. P0113 C. No DTCs will be set 18. Warm the IAT with your finger while monitoring PIDs. Do any of the values change? YES NO
12 Day Two
October, 2002
SIG RTN
Circuit Number
Wire Color
TP
Circuit Number
Wire Color
VREF
Circuit Number
Wire Color
DTC CHART If during key ON engine OFF P0122 - Throttle TP voltage is below a Position (TP) Circuit Low Input minimum calibrated limit, the test fails. If during key ON engine OFF P0123 - Throttle TP voltage is above Position (TP) Circuit High Input maximum calibrated limit, the test fails.
A TP PID (TP V PID) reading less than 3.42% (0.17 volt) in key ON engine OFF, continuous memory or key ON engine running indicates a hard fault. A TP PID (TP V PID) reading greater than 93% (4.65 volts) in key ON engine OFF, continuous memory or key ON engine running indicates a hard fault.
October, 2002
Day Two 13
PID VALUE
VREF
V
VREF
TP Mode
PCM
Signal
SIGNAL
SIGNAL RETURN
BEC808-B/VF
Signal Return
TP Volts V
21. Operate the TP sensor while monitoring PIDs. Do any of the values change? If you answered yes, which ones? YES NO
14 Day Two
October, 2002
PID VALUE
VREF
V
VREF
TP Mode
PCM
Signal
SIGNAL
SIGNAL RETURN
BEC809-B/VF
Signal Return
TP Volts V
23. Refer to the DTC Chart. What code will be set by the PCM? A. P0122 B. P0123 C. No DTCs will be set 24. Operate the TP sensor while monitoring PIDs. Do any of the values change? If you answered yes, which ones? YES NO
October, 2002
Day Two 15
PID VALUE
VREF
V
VREF
TP Mode
PCM
Signal
SIGNAL
SIGNAL RETURN
BEC810-B/VF
Signal Return
TP Volts V
26. Refer to the DTC Chart. What code will be set by the PCM? A. P0122 B. P0123 C. No DTCs will be set
27. Operate the TP sensor while monitoring PIDs. Do any of the values change? If you answered yes, which ones? YES NO
16 Day Two
October, 2002
PID VALUE
VREF
V
VREF
TP Mode
PCM
Signal
SIGNAL
SIGNAL RETURN
BEC811-B/VF
Signal Return
TP Volts V
29. Refer to the DTC Chart. What code will be set by the PCM? A. P0122 B. P0123 C. No DTCs will be set 30. Operate the TP sensor while monitoring PIDs. Do any of the values change? YES NO
October, 2002
Day Two 17
PID VALUE
VREF
V
VREF
PCM
TP Mode
Signal
SIGNAL
SIGNAL RETURN
BEC812-B/VF
Signal Return
TP Volts V
32. Refer to the DTC Chart. What code will be set by the PCM? A. P0122 B. P0123 C. No DTCs will be set 33. Operate the TP sensor while monitoring PIDs. Do any of the values change? YES NO
18 Day Two
October, 2002
PID VALUE
VREF
V
VREF
PCM
TP Mode
Signal
SIGNAL
SIGNAL RETURN
BEC813-B/VF
Signal Return
TP Volts V
35. Refer to the DTC Chart. What code will be set by the PCM? A. P0122 B. P0123 C. No DTCs will be set 36. Operate the TP sensor while monitoring PIDs. Do any of the values change? YES NO
October, 2002
Day Two 19
PID VALUE
VREF
V
VREF
PCM
TP Mode
Signal
SIGNAL
SIGNAL RETURN
BEC814-B/VF
Signal Return
TP Volts V
38. Refer to the DTC Chart. What code will be set by the PCM? A. P0122 B. P0123 C. No DTCs will be set 39. Operate the TP sensor while monitoring PIDs. Do any of the values change? YES NO
20 Day Two
October, 2002
PID VALUE
VREF
V
VREF
PCM
TP Mode
Signal
SIGNAL
SIGNAL RETURN
BEC815-B/VF
Signal Return
TP Volts V
41. Refer to the DTC Chart. What code will be set by the PCM? A. P0122 B. P0123 C. No DTCs will be set 42. Operate the TP sensor while monitoring PIDs. Do any of the values change? YES NO
October, 2002
Day Two 21
PID VALUE
VREF
V
VREF
PCM
TP Mode
Signal
SIGNAL
SIGNAL RETURN
BEC816-B/VF
Signal Return
TP Volts V
44. Refer to the DTC Chart. What code will be set by the PCM? A. P0122 B. P0123 C. No DTCs will be set 45. Operate the TP sensor while monitoring PIDs. Do any of the values change? YES NO
22 Day Two
October, 2002
PID VALUE
VREF
V
VREF
PCM
TP Mode
Signal
SIGNAL
SIGNAL RETURN
BEC817-B/VF
Signal Return
TP Volts V
47. Refer to the DTC Chart. What code will be set by the PCM? A. B. C. D. P0122 P0123 No DTCs will be set No communication
48. Operate the TP sensor while monitoring PIDs. Do any of the values change? If you answered yes, which ones? YES NO
Turn the ignition OFF and disconnect the NGS. Return Workstation to its original condition.
October, 2002
Day Two 23
24 Day Two
October, 2002
DAY TWO-WORKSTATION 2
WORKSTATION 2
October, 2002
Day Two 25
2. List below the components that may be the cause of the concern of the suspected faulty system using the EVTM /Wiring Diagram manual.
Inputs
Module
Direct Outputs
Indirect Outputs
26 Day Two
October, 2002
3. Perform a self-test on the Perimeter anti-theft security system that is at fault. List any DTCs related to the concern.
a. Select the TOOLBOX icon. b. Select DATALOGGER. c. Select CONTINUE (This will bring you to the System Identification screen which is represented by this icon) d. e. f. g. Select BODY. Select SECURITY. Select PERIMETER. Select CONTINUE.
October, 2002
Day Two 27
c. Select the KEY CODE, KEYPAD, and TNSMT_CMD PIDs NOTE: The selected PIDs are dark gray with white lettering. d. View the live data by pressing the CONTINUE icon. 7. What is the key code for this vehicle?
8. Use the vehicle key code to verify the customer concern. Was the customer concern verified? YES NO
28 Day Two
October, 2002
PID VALUES
Using the WDS to record PIDs. Prepare the WDS to make a recording. a. Select the MENU icon. b. Select CAPTURE SET-UP to view the buffer settings. c. Use the arrows to set the duration to 30 seconds. d. Press the CONTINUE icon. e. Press each button on the vehicle keypad. f. Press the DATA CAPTURE icon.
NOTE: Watch the status bar in the lower right hand corner of the screen. Wait for the recording to end, before proceeding to the next step.
October, 2002
Day Two 29
a. Return to live data display. b. Press the TNSMT_CMD PID to highlight the box around it.
d. e. f. g. h.
Select LOCK. Turn on the auto capture feature by selecting the AUTO CAPTURE button. Select Transition. Press the CONTINUE icon. Turn the ignition to the off position and remove the keys.
12. What happens to the PID when you press the UNLOCK button on the key fob?
13. What happens to the PID when you press the LOCK button on the key fob?
a. Press the PLAYBACK DISPLAY icon and view the recording. b. Use the arrow buttons at the bottom of the screen to move the cursor along the timeline.
14. How many seconds before 0 (Trigger Point) was the LOCK button pressed?
30 Day Two
October, 2002
b. Press the CONTINUE icon. 15. Approximately 5 seconds before the trigger point, what was the TNSMT_CMD PID value?
16. Approximately 5 seconds after the trigger point, what was the TNSMT_CMD PID value?
October, 2002
Day Two 31
NOTE: Notice the # sign next to the PID. This indicates that this output can be controlled.
f. Press the CONTROL ITEM ACTIVATE icon. 17. What symbol is now displayed in place of the # sign?
18. Press the CONTROL ITEM INCREMENT icon. What happened to the PID value?
32 Day Two
October, 2002
a. Press the CLEAR CONTROL ITEMS icon to allow the module to control the headlamps.
22. What option would you use to save the recordings? (Do not perform this step)
a. Select DELETE SESSION. b. Select CONTINUE. Return the workstation back to its original condition.
October, 2002
Day Two 33
34 Day Two
October, 2002
WORKSTATION 3
October, 2002
Day Two 35
1 765 1 22 YE/BK
2 761 2 22 YE/RD
3 657 3 22 RD/BK
4 576 4
57
20 BK
57
20 BK 57 20 BK
57
20 BK
57
20 BK
G205 Hot at all times F2.26 10A C23 792 20 TN/YE 10 792 1 5 20 TN/YE C21 Battery saver relay C21 Auxiliary relay box 1 6 C20 Generic Electronic Module 22 LG Door ajar lamp C23
705
20 LG/OG 705 4 20 LG /OG C20B Instrument panel dimming module 6) Off 7) On Auxiliary relay box 1 Interior lamp relay 705
S220 20 LG/OG
6 705 1 20 LG/OG 5
C22
3 53
C22 20 BK/LB C24 Interior lamp assembly 1 0 C24 Glove box lamp n 0) Glove box closed 1) Glove box ope
57
20 BK
C24 G205
BEC712-A/VF
36 Day Two
October, 2002
FE-26
COMMON
LF DOOR BATT RF DOOR INTERIOR LAMP SLIDING DOOR DOOR AJAR LIFT GATE
INTERIOR LAMPS B+
MODE SELECT
INTERVAL WASH
SIGNAL RETURN
PARK SWITCH
BEC400-D/VF
2. Prepare the NGS to test the GEM module from a 1995 Windstar with a 3.8 liter engine. a. Select diagnostic data link. b. Select the GEM module (This vehicle has Rear Defrost, Keyless Entry, Illuminated Entry, and Power Door Locks) and select SAVE (Button 8) c. Select active command modes. How many active command tests are available?
SLIDING DOOR
COIL
FE-27
12V
COIL
N/O
N/C COMMON
LF DOOR
RF DOOR
N/C
DIRECT OUTPUTS
FE-25
VSS CKT 70 B+
FE-30
BRAKE RUN
WIPTER SPEED
INPUT
October, 2002
Day Two 37
OFF.
5. Explain what happened to the display on the left side of the NGS.
a. Press TRIGGER again. 6. Explain what happened to the Glove Box Lamp.
38 Day Two
October, 2002
8. Briefly describe what Active Command test mode is. What does it allow you to do?
Active Commands and PIDs a. Press button 7 PIDs. b. Select the BATSAV, INTLMP and P_DR_SW PIDs. c. Press button 7 START. 10. Record the PID values in the spaces below. Active Commands BATT SAVR: OFF BATSAV: INT LAMPS: : OFF INTLAMP: P_DR_SW: d. Press TRIGGER again to turn the battery saver relay back on. 11. Record the PID values in the spaces below. Active Commands BATT SAVR: ON BATSAV: INT LAMPS: OFF INTLAMP: P_DR_SW: e. Highlight INT LAMPS: f. Press TRIGGER. OFF. PIDs
PIDs
October, 2002
Day Two 39
13. Record the PID values in the spaces below. Active Commands BATT SAVR: ON BATSAV: INT LAMPS: ON INTLAMP: P_DR_SW: a. Press TRIGGER again to turn the Interior Lamps off. b. Remove the interior lamp relay. 14. Record the PID values in the spaces below . Active Commands BATT SAVR: ON BATSAV: INT LAMPS: OFF INTLAMP: P_DR_SW:
PIDs
PIDs
15. Turn on the interior lamp relay, record the PID values in the spaces below. Active Commands PIDs BATT SAVR: ON BATSAV: INT LAMPS: ON INTLAMP: P_DR_SW:
40 Day Two
October, 2002
a. Close the passenger front door. b. Press CANCEL to return to the Active Command menu. c. Send a door ajar signal to the GEM module by using the switch for the passenger front door. 19. Did the interior lamps come on when the door was ajar? YES NO
20. Why should you exit Active Commands when testing system operation?
October, 2002
Day Two 41
22. Use Active Commands to turn the Interior Lamps off. What voltage does MEAS: read?
23. Remove the lead at the Interior Lamps relay N/O terminal. Remove the interior lamp relay. Watch the NGS screen closely, press button 4 SIG. What happened to the screen on the NGS?
24. Turn the NGS scroll knob until the SIGNAL OUT displays 6V a. Press TRIGGER What voltage does MEAS read?
NOTE: This voltage is coming out of the red SIG jack at the base of the NGS. It has no effect on the module or the Active Command sent to it.
42 Day Two
October, 2002
26. Use active commands to turn the Interior Lamps ON. What voltage does MEAS read?
27. Press button 4 SIG. Turn the NGS scroll knob until the SIGNAL OUT displays OFF Press TRIGGER What voltage does MEAS read?
October, 2002
Day Two 43
44 Day Two
October, 2002
DAY TWO-WORKSTATION 4
WORKSTATION 4
October, 2002
Day Two 45
12V
B A
12V
S
V
BEC204-B/VF
B: Amplifier D: Transistor
46 Day Two
October, 2002
12V
FE-23
B+
FE-20
A SIGNAL B
LOW
MED HIGH
SIGNAL B+
OFF
VRS +
SIGNAL RETURN
VRS
BEC201-E/VF
October, 2002
Day Two 47
3. What type of signal is created by this Hall Effect speed sensor circuit? A. B. C. D. Digital DC Digital AC Analog AC Analog DC
48 Day Two
October, 2002
62 1291 20 RD/YE
38 354 20 LG/RD
42 318
C175 20 GY/RD
14 2 C1236
17
21
23 1 S151
C1236
3 359
2 20 GY/RD 553
C1271
359
20 GY/RD
359
20 GY/RD
18 BK/WH
20 VT/LB
3 359
2 20 GY/RD 812
C1303
20 DB/LG
3 796 20 LB
C1180
87
65 SIG RTN
21
BEC905-A/VF
October, 2002
Day Two 49
6. Set the DMM to measure frequency. Adjust the DC motor's speed to low, medium and high. Record the frequency at the Signal A terminal at each setting. Low Medium High Hz Hz Hz
50 Day Two
October, 2002
T
BEC112-A/VF
October, 2002
Day Two 51
T
BEC112-A/VF
52 Day Two
October, 2002
T
BEC112-A/VF
10. When the speed of the motor increases, the sensor's DC voltage: A. Increases B. Decreases C. Stays the same 11. When the speed of the motor increases, the sensor's frequency: A. Increases B. Decreases C. Stays the same
October, 2002
Day Two 53
B A
0V
C
BEC205-A/VF
A: Base C: Emitter
B: Collector
54 Day Two
October, 2002
13. Do both the Hall Effect speed sensor and the phototransistor speed sensor produce the same signal? YES NO.
12V
FE-20
B+
A SIGNAL B
SIGNAL RETURN
BEC203-C/VF
October, 2002
Day Two 55
A231 Remote Climate Control (RCC) module 7 788 10 20 RD/OG 15 470 5 20 PK/BK 23 790 15 20 WH/OG 6 468 9 C228 20 BN C219 14 788 22 RD/OG S221 790 22 WH/OG 468 1 22 BN 218 2 A112 Generic Electronic Module (GEM) (14B205) C201b 592 22 WH/VT C287 B241 470 10 788 20 RD/OG P78 Integrated control panel S206 See page 105 G200 26 20 PK/BK C263 470 20 PK/BK 15121 5 398 C287 20 BK/YE
C198 B203
C233 B206
(19E702) 1511
(19C734) 15120
BEC903-B/VF
56 Day Two
October, 2002
T
BEC112-A/VF
October, 2002
Day Two 57
T
BEC112-A/VF
17. Do you notice a difference between rotating clockwise and counter clockwise? YES NO
58 Day Two
October, 2002
19. Measure the voltage at the Illumination A and Illumination B terminals while controlling the Panel Dim. Record the readings at the following positions. Illumination A Dim Medium Bright V V V Illumination B V V V
October, 2002
Day Two 59
T
BEC112-A/VF
60 Day Two
October, 2002
T
BEC112-A/VF
October, 2002
Day Two 61
T
BEC112-A/VF
23. The signal for the Illumination A (yellow trace) is: A. B. C. D. Analog DC Analog AC Digital DC Digital AC
24. The signal for the Illumination B (red trace) is: A. B. C. D. Analog DC Analog AC Digital DC Digital AC
62 Day Two
October, 2002
October, 2002
Day Two 63
64 Day Two
October, 2002
HOMEWORK
October, 2002
Day Two 65
1 765 1 22 YE/BK
2 761 2 22 YE/RD
3 657 3 22 RD/BK
4 576 4
57
20 BK
57
20 BK 57 20 BK
57
20 BK
57
20 BK
G205 Hot at all times F2.26 10A C23 792 20 TN/YE 10 792 1 5 20 TN/YE C21 Battery saver relay C21 20 LG/OG 705 4 20 LG /OG Instrument C20B panel dimming module 6) Off 7 7) On Auxiliary relay C22 box 1 Interior lamp relay 705 Auxiliary relay box 1 6 C20 Generic Electronic Module 22 LG Door ajar lamp C23
3 705
S220 20 LG/OG
6 5
3 53
C22 20 BK/LB C24 Interior lamp assembly 1 0 C24 Glove box lamp 0) Glove box closed 1) Glove box open
57
20 BK
C24 G205
BEC700-D/VF
66 Day Two
October, 2002
The customer is concerned that the interior lamps do not come on when any door is opened. 2. What is the SYMPTOM?
4. Circle all COMPONENTS that may be at fault to cause this concern. Fuse Door ajar switches GEM module Battery Saver Relay Interior Lamp Relay Interior Lamps Glove Box Lamp Instrument Panel Dimming Module Wiring / Connectors 5. What should your next diagnostic step be? A. Perform Active Commands (OSC) B. Monitor PIDs C. Perform Inspection and Verification D. Retrieve DTCs E. Perform basic electrical diagnosis
October, 2002
Day Two 67
6. The Door Ajar lamp (an output of the GEM module) comes on when any door is open. Circle the COMPONENTS that may still be at fault to cause this concern. Fuse Door ajar switches GEM module Battery Saver Relay Interior Lamp Relay Interior Lamps Glove Box Lamp Instrument Panel Dimming Module Wiring / Connectors 7. The interior lamps turn on with the Panel Dimmer Switch (part of Instrument Panel Dimming Module). Circle the COMPONENTS that may still be at fault to cause this concern. Fuse Door ajar switches GEM module Battery Saver Relay Interior Lamp Relay Interior Lamps Glove Box Lamp Instrument Panel Dimming Module Wiring / Connectors 8. What should your next diagnostic step be? A. Perform Active Commands (OSC) B. Monitor PIDs C. Perform Inspection and Verification D. Retrieve DTCs E. Perform basic electrical diagnosis
68 Day Two
October, 2002
9. There is a diagnostic trouble code (DTC) in the Module. DTC B1371. Interior Lamp Relay circuit failure. Circle the COMPONENTS that may still be at fault to cause this concern. Fuse Door ajar switches GEM module Battery Saver Relay Interior Lamp Relay Interior Lamps Glove Box Lamp Instrument Panel Dimming Module Wiring / Connectors 10. What should your next diagnostic step be? A. Perform Active Commands (OSC) B. Monitor PIDs C. Perform Inspection and Verification D. Retrieve DTCs E. Perform basic electrical diagnosis 11. When measuring available voltage, where should the negative (black) lead of the DMM be placed?
12. What voltage would you expect at C19, pin 1 of the GEM module, with the left front door open?
13. What voltage would you expect at C19, pin 1 of the GEM module, with the left front door closed?
14. What voltage would you expect at pin 1 of the Battery saver relay, with the relay off?
October, 2002
Day Two 69
15. What voltage would you expect at pin 1 of the Battery saver relay, with the relay on?
16. What voltage would you expect at pin 2 of the Battery saver relay, with the relay off?
17. What voltage would you expect at pin 2 of the Battery saver relay, with the relay on?
18. What voltage would you expect at pin 3 of the Battery saver relay, with the relay off?
19. What voltage would you expect at pin 3 of the Battery saver relay, with the relay on?
20. What voltage would you expect at C20, pin 7 of the GEM module, with the Battery saver relay off and the Interior lamp relay off?
21. What voltage would you expect at C20, pin 7 of the GEM module, with the Battery saver relay on and the Interior lamp relay off?
22. What voltage would you expect at C20, pin 7 of the GEM module, with the Battery saver relay on and the Interior lamp relay on?
70 Day Two
October, 2002
DAY THREE
DAY THREE
October, 2002
Day Three 1
DAY THREE
NOTES
2 Day Three
October, 2002
8:30 am to 10:15 am
Break
10:15 am to 10:30 am
Continue Review
10:30 am to 11:30 am
Lunch
11:30 am to 12:30 pm
12:30 pm to 1:30 pm
Workstations
1:30 pm to 3:30 pm
3:30 pm to 4:00 pm
4:00 pm to 4:30 pm
October, 2002
Day Three 3
CONTENT
Interior lighting system operation Wiper system operation WDS recording Windshield wiper system operation Variable Reluctance Sensors (VRS) Hall Effect Sensor
4 Day Three
October, 2002
October, 2002
Day Three 5
6 VBATT VBATT
C202a N442 Multifunction switch (13K359) 14) High beam 15) Flash to pass 19) Low beam 15110
14
1 9 5
1 5
14
19 15
4 218 19
C287 22 WH/VT
3 18 DB/OG 164
C202a 18 VT/LB
196
26 161 33
C2145c 20 DG/OG
1 697 60 33 697
G200
160
20 DB/WH
161
20 DG/OG
P93 Battery Junction Box (BJB) (14A003) 136 196 2 16 DB/OG C1050 K37 High beam relay P93 Battery Junction Box (BJB) (14A003) 136
18
C192
196 3
16 DB/OG
C1050
12
20 LG/B K S144
697 D
20 BN
3 161 3 20 DG/OG
4 1C
3 3
4 C 1
2 57
2 57
BEC900-C/VF
6 Day Three
October, 2002
YES
NO
2. Would you require the use of a scan tool to diagnose your concern?
October, 2002
Day Three 7
8 Day Three
October, 2002
WORKSTATION 1
October, 2002
Day Three 9
3. Is the verified symptom the same as what is stated on the repair order? (Circle one) YES NO
10 Day Three
October, 2002
5. Using the wiring diagram list the components or circuits that could be causing the concern?
6. Perform the needed diagnostic steps and record your actions and results in the spaces below. Use another sheet of paper if necessary. ACTIONS/TESTS RESULTS
October, 2002
Day Three 11
Notify your instructor when you have identified the cause of the concern. 8. What service actions would you take to resolve the concern?
Make the repair. 9. Does the circuit now work properly? Explain.
10. Diagnostic summary Fill in the blanks. Symptom: System: Component: Cause:
12 Day Three
October, 2002
October, 2002
Day Three 13
14 Day Three
October, 2002
WORKSTATION 2
October, 2002
Day Three 15
3. Is the verified symptom the same as what is stated on the repair order? (Circle one) YES NO
16 Day Three
October, 2002
7. Perform the needed diagnostic steps and record your actions and results in the spaces below. Use another sheet of paper if necessary. ACTIONS/TESTS RESULTS
October, 2002
Day Three 17
Notify your instructor when you have identified the cause of the concern. 9. What service actions would you take to resolve the concern?
System:
Component:
Cause:
18 Day Three
October, 2002
October, 2002
Day Three 19
20 Day Three
October, 2002
WORKSTATION 3
October, 2002
Day Three 21
22 Day Three
October, 2002
1. Wire the Wiper System as shown below. The inputs have already been wired for you. Operate the wiper system to verify the symptom What symptom is present?
Wiper System
FE-28
RELAY COIL
FE-26
COMMON
12V
COIL MODE INTERVAL WASH MULTIFUNCTION SWITCH DOOR AJAR SIGNAL RETURN
N/O
N/C COMMON
N/O
N/C
DIRECT OUTPUTS
FE-25
VSS CKT 70 B+ BATT
LF DOOR
RF DOOR
INTERIOR LAMP
SLIDING DOOR
DOOR AJAR
63
LIFT GATE
58
FE-10
MODE SELECT
BRAKE/RUN
56
INTERVAL WASH
WIPER SPEED
28
57
SIGNAL RETURN
RELAY CONTROL
PARK SWITCH
INPUT
GEM BOARD
BEC302-E/VF
October, 2002
Day Three 23
3. Perform the needed diagnostic steps and record your actions and results in the spaces below. Use another sheet of paper if necessary. ACTIONS/TESTS RESULTS
6. Diagnostic summary Fill in the blanks. Symptom: System: Component: Cause: Workstation complete. Return the workstation to its original condition.
24 Day Three
October, 2002
WORKSTATION 4
October, 2002
Day Three 25
12V
FE-23
LOW
MED HIGH
SIGNAL B+
OFF
VRS +
VRS
BEC111-B/VF
26 Day Three
October, 2002
T
BEC112-A/VF
3. With the DC motor still adjusted to medium, increase the air gap by gently moving the sensor away from the trigger wheel. With a blue marker draw the changes in the graphic above. 4. Using the DMM, measure and record the AC voltage between VRS+ and VRS-. Does the amplitude (peak voltage) change?
October, 2002
Day Three 27
12V
FE-23
LOW
MED HIGH
SIGNAL B+
OFF
VRS +
R es is to r
VRS
BEC303-B/VF
28 Day Three
October, 2002
7. Look at the DTC chart and circle the code(s) the module would set during this recording. DTC CHART C1155-Front Left Anti-Lock Brake Sensor (Electrical/Static) Possible Causes The ABS module continuously monitors circuit integrity for opens or shorts. The ABS module compares the ABS speed sensors to verify they are in agreement. The ABS module monitors the speed sensor signal to verify a signal is produced. The ABS module monitors the speed sensor carrier voltage on both wires. If voltages vary more than .5vDC the test fails. If a speed sensor signal is not within 10% of the other speed sensor signals the test fails.
Excessive Air Gap Excessive Circuit Resistance Damaged Indicator Mismatched Tires
If a speed signal is not detected above 10 MPH (as determined by the other speed sensors) the test fails.
8. List what you think are the most likely possible causes of the concern in the recording.
Close the recorded session by pressing the menu icon and then selecting exit.
October, 2002
Day Three 29
12V
FE-23
B+
FE-20
A SIGNAL B
LOW
MED HIGH
SIGNAL B+
OFF
VRS +
SIGNAL RETURN
VRS
BEC201-E/VF
30 Day Three
October, 2002
T
BEC112-A/VF
10. Increase the air gap by moving the sensor away from the trigger wheel. Note what changes on the oscilloscope. Does the amplitude (peak voltage) change?
October, 2002
Day Three 31
12V
FE-23
B+
FE-20
Resistor
A SIGNAL
LOW MED HIGH
SIGNAL B+
OFF
VRS +
SIGNAL RETURN
VRS
BEC505-E/VF
Return the workstation to its original condition before proceeding to question 12.
32 Day Three
October, 2002
13. Look at the DTC chart and circle the code(s) the module would set during this recording. DTC CHART P1836Transmission Transfer Case Front Shaft Speed Sensor Circuit Failure Possible Causes Open Circuit Shorted Circuit Module Excessive Air Gap Excessive Circuit Resistance Damaged Indicator Open Circuit Shorted Circuit Module Excessive Air Gap Excessive Circuit Resistance Damaged Indicator Resistance Damaged Indicator Mismatched Tires
The GEM module periodically monitors the speed sensor signal and compares it to VSS.
If the speed sensor signal is not within 10% of the VSS signal the test fails.
The GEM module periodically monitors the speed sensor signal and compares it to VSS.
If the speed sensor signal is not within 10% of the VSS signal the test fails.
14. List what you think are the most likely possible causes of the concern in the recording.
Close the recorded session by pressing the menu icon and then selecting exit.
October, 2002
Day Three 33
34 Day Three
October, 2002
HOMEWORK
October, 2002
Day Three 35
A 400 7 2 2 5 0 6 5 0 6 5 0 6 16 LB/BK C210 C504 1 5 0 6 N447 Master window adjust switch 0) Rest 1) Driver 2) Passenger 5) Up 6) Down
S212 400 5 16 LB/BK 400 1 16 LB/BK C2051 K50 Onetouch window relay C2051 22 YE/RD S210 Resistance wire .015 995 16 GY P111 Auxiliary relay box 1
5 57 16 BK S501
6 314
4 991
1 16 TN/LB 992 C D
C504
16 WH/BK 4 3 903 Used to sense current of driver window motor so that GEM will turn of f OTD relay when window is completely opened or when up window switch is pressed during OTD mode. 991 16 TN/LB 16 RD 2 1007
G200
903 S204
16 RD 996 12
S202 16 OG/WH C2100a 9 C2100b 11 C2100a A112 Generic Electronic Module (GEM) (14B205) 12 992 C2100b 16 WH/BK C210
1 0 2
1 0 2
991
16 TN/LB
1 333
5 14 YE/RD 334
C604
11
14 RD/YE C608 M79 Power window motor , passenger side front (23394)
C 2 1 C524 M80 Power window motor, driver side front (23395) 992
S500 16 WH/BK
BEC915-A/VF
NOTE: The GEM Module used on this vehicle has three separate connectors. Notice in this schematic two different connectors to the GEM module have pins labeled "11" and two pins labeled "12".
Pin 11 in connector C2 100b is used to sense the one-touch-down request (switch pressed for less than 1 second) Pin 11 in connector C2 100a in conjunction with Pin 12 in connector C2 100a are used to sense the increase in current flow through the motor when it reaches the end of its travel to turn the one-touch relay off. Voltage on Pin 12 in connector C2 100b indicated the operator is raising the window.
36 Day Three
October, 2002
Use the schematic shown in the previous page to answer all questions in this homework activity. 1. Identify the Inputs and Outputs in the circuit. INPUTS DIRECT OUTPUTS INDIRECT OUTPUTS
The customer is concerned that the driver's window does not operate properly, however, the passenger window operates normally. 2. What is the SYMPTOM?
4. Circle all COMPONENTS that may be at fault to cause this concern. Fuse Master Window Switch Passenger Window Switch Resistance Wire GEM Module One-Touch Window relay Left Power Window Motor Right Power Window Motor Wiring / Connectors
October, 2002
Day Three 37
5. What should your next diagnostic step be? A. Perform Active Commands (OSC) B. Monitor PIDs C. Perform Inspection & Verification D. Retrieve DTCs E. Perform "basic electrical diagnosis" 6. The driver side window will go up with the switch. Circle the COMPONENTS that may still be at fault to cause this concern. Fuse Master Window Switch Passenger Window Switch Resistance Wire GEM Module One-Touch Window relay Left Power Window Motor Right Power Window Motor Wiring / Connectors 7. The driver side window will go down with the switch held, but the one-touch down feature is not working. Circle the COMPONENTS that may still be at fault to cause this concern. Fuse Master Window Switch Passenger Window Switch Resistance Wire GEM Module One-Touch Window relay Left Power Window Motor Right Power Window Motor Wiring / Connectors
38 Day Three
October, 2002
8. What should your next diagnostic step be? A. Perform Active Commands (OSC) B. Monitor PIDs C. Perform Inspection & Verification D. Retrieve DTCs E. Perform "basic electrical diagnosis" 9. There is a diagnostic trouble code in the module. DTC B1400 Power Window Driver One-Touch Window Relay Coil Circuit Short to Battery. Circle the COMPONENTS that may still be at fault to cause this concern. Fuse Master Window Switch Passenger Window Switch Resistance Wire GEM Module One-Touch Window relay Left Power Window Motor Right Power Window Motor Wiring / Connectors
10. What should your next diagnostic step be? A. Perform Active Commands (OSC) B. Monitor PIDs C. Perform Inspection & Verification D. Retrieve DTCs E. Perform "basic electrical diagnosis"
October, 2002
Day Three 39
11. What voltage would you expect at C2100b, pin 12 of the GEM module, with the left front window switch in the up position?
12. What voltage would you expect at C2100b, pin 12 of the GEM module, with the left front window switch in the down position?
13. What voltage would you expect at pin 1 of the One-touch window relay, with the relay off?
14. What voltage would you expect at pin 1 of the One-touch window relay, with the relay on?
15. What voltage would you expect at pin 2 of the One-touch window relay, with the relay off?
16. What voltage would you expect at pin 2 of the One-touch window relay, with the relay on?
17. What voltage would you expect at C2100b, pin 9 of the GEM module, with the One-touch window relay off?
18. What voltage would you expect at C2100b, pin 9 of the GEM module, with the One-touch window relay on?
40 Day Three
October, 2002
DAY FOUR
DAY FOUR
October, 2002
Day Four 1
DAY FOUR
NOTES
2 Day Four
October, 2002
8:30 am to 9:00 am
Workstations
9:00 am to 10:15 am
Break
10:15 am to 10:30 am
Review workstations
10:30 am to 11:15 am
11:15 am to 12:00 pm
Lunch
11:00 am to 1:00 pm
Final Exam
1:00 pm to 4:30 pm
October, 2002
Day Four 3
CONTENT
Rear defrost system operation NGS recording Interior lighting system operation
4 Day Four
October, 2002
WORKSTATION 1
October, 2002
Day Four 5
3. Is the verified symptom the same as what is stated on the repair order? (Circle one) YES NO
6 Day Four
October, 2002
5. Use the wiring diagram to answer the following questions. a. What components or circuits could be causing the concern?
6. Perform the needed diagnostic steps and record your actions and results in the spaces below. Use another sheet of paper if necessary. ACTIONS/TESTS RESULTS
October, 2002
Day Four 7
8 Day Four
October, 2002
Notify the instructor when you have identified the cause of the concern. 8. What service actions would you take to resolve the concern?
System:
Component:
Cause:
October, 2002
Day Four 9
10 Day Four
October, 2002
WORKSTATION 2
October, 2002
Day Four 11
1 765 1 22 YE/BK
2 761 2 22 YE/RD
3 657 3 22 RD/BK
4 576 4
57
20 BK
57
20 BK 57 20 BK
57
20 BK
57
20 BK
G205 Hot at all times F2.26 10A C23 792 20 TN/YE 10 792 1 5 20 TN/YE C21 Battery saver relay C21 20 LG/OG 705 4 20 LG /OG Instrument C20B panel dimming module 6) Off 7 7) On Auxiliary relay C22 box 1 Interior lamp relay 705 Auxiliary relay box 1 6 C20 Generic Electronic Module 22 LG Door ajar lamp C23
3 705
S220 20 LG/OG
6 5
3 53
C22 20 BK/LB C24 Interior lamp assembly 1 0 C24 Glove box lamp 0) Glove box closed 1) Glove box open
57
20 BK
C24 G205
BEC700-D/VF
12 Day Four
October, 2002
2. What electronic module controls the door ajar light of this 95 Windstar?
4. The vehicle was road tested and PID data is stored in recorder area 1. A. Once the vehicle is moving, at what speed did the door ajar light first come ON?
B. When was the first time during the road test (in relation to when you pressed the TRIGGER) that the light came ON?
5. What occurs at the same time, which may provide you with a clue to the cause of the concern?
October, 2002
Day Four 13
7. Were there times when the door ajar light came ON without a right rear door signal?
NOTE: When repairing a fault, you should always try and determine the cause of the failure. 8. What would you do next to determine the root cause of the concern?
Exercise complete. Please return workstation to its original condition for the next team.
14 Day Four
October, 2002
October, 2002
Day Four 15
16 Day Four
October, 2002
WORKSTATION 3
October, 2002
Day Four 17
1 765 1 22 YE/BK
2 761 2 22 YE/RD
3 657 3 22 RD/BK
4 576 4
57
20 BK
57
20 BK 57 20 BK
57
20 BK
57
20 BK
G205 Hot at all times F2.26 10A C23 792 20 TN/YE 10 792 1 5 20 TN/YE C21 Battery saver relay C21 Auxiliary relay box 1 6 C20 Generic Electronic Module 22 LG Door ajar lamp C23
705
20 LG/OG 705 4 20 LG /OG C20B Instrument panel dimming module 6) Off 7) On Auxiliary relay box 1 Interior lamp relay 705
S220 20 LG/OG
6 705 1 20 LG/OG 5
C22
3 53
C22 20 BK/LB C24 Interior lamp assembly 1 0 C24 Glove box lamp n 0) Glove box closed 1) Glove box ope
57
20 BK
C24 G205
BEC712-A/VF
18 Day Four
October, 2002
FE-26
COMMON
LF DOOR BATT RF DOOR INTERIOR LAMP SLIDING DOOR DOOR AJAR LIFT GATE
INTERIOR LAMPS B+
MODE SELECT
INTERVAL WASH
SIGNAL RETURN
PARK SWITCH
BEC400-D/VF
SLIDING DOOR
COIL
FE-27
12V
COIL
N/O
N/C COMMON
LF DOOR
RF DOOR
N/C
DIRECT OUTPUTS
FE-25
VSS CKT 70 B+
FE-30
BRAKE RUN
WIPTER SPEED
INPUT
October, 2002
Day Four 19
3. Perform the needed diagnostic steps and record your actions and results in the spaces below. Use another sheet of paper if necessary. ACTIONS/TESTS RESULTS
20 Day Four
October, 2002
System:
Component:
October, 2002
Day Four 21
22 Day Four
October, 2002
October, 2002
Day Four 23
Controls current flow to rear heated window switch, heated grid and heated mirrors when energized. K1 Rear window defrost relay 15148
86
87
C2021
F2.12 10A
8 VBATT
16 VBATT
C201d A112 Generic Electronic Module (GEM) (14B205) 591, 592 C201b
11
C270b
18 185
186 1 186
C201a
938
20 BK/LG
1010 17
22 DB/OG
694 7
22 DG/VT C2009 1.2k P78 Integrated control panel 1 C402b 12 BK S402 1 C402a R19 Rear window defrost grid (18C618) 15129 15141 wagon
C410
BEC901-A/VF
24 Day Four
October, 2002
Diagnostic Summary: Symptom: System: Component: Cause: 1. Will your concern set a DTC? YES NO
2. Would you require the use of a scan tool to diagnose your concern?
October, 2002
Day Four 25
26 Day Four
October, 2002