34S19T0 electronic diagnosis 2002

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.”

electrical systems

electronic systems

diagnosis

student guide

Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles, as well as the personal safety of the individual doing the work This manual provides general directions for accomplishing service and repair work with tested, effective techniques Following them will help assure reliability

There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual doing the work This manual cannot possibly anticipate all such variations and provide advice or cautions as to each Accordingly, anyone who departs from instructions provided in this manual must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods, tools or parts

As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS Each one is there for a specific purpose NOTES give you added information that will help you to complete a particular procedure CAUTIONS are given

to prevent you from making an error that could damage the vehicle WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury The following list contains some general WARNINGS that you should follow when you work on a vehicle

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

be under the vehicle

position, unless otherwise required by the procedure

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

the danger of carbon monoxide

when the engine is running, especially the fan and belts

parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler

hanging jewelry, and loose clothing before beginning to work on a vehicle Tie long hair securely behind your head

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

CUSTOMER EXPECTATIONS

Expectation 3

“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.”

Technician’s Role

Acquire the skills and knowledge for competency in your specialty via:

– 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”

Customer Expectations: Service

1. Make it convenient to have my vehicle

serviced at your dealership

2. The Service Advisor should

demonstrate a genuine concern for my

service needs

3. Fix it right the first time

4. Complete servicing my vehicle in a

timely and professional manner

5. Provide me with a clear and thorough explanation of the service performed

6. Call me within a reasonable amount of time after my service visit to ensure that I'm completely satisfied

7. Be responsive to questions or concerns

I bring to your attention

DAY TWO DAY TWO–1

Agenda Day Two–3 Student’s Objectives Day Two–4 Workstation 1 Day Two–5 Workstation 2 Day Two–25 Workstation 3 Day Two–35 Workstation 4 Day Two–45 Homework Day Two–65

DAY THREE DAY THREE–1

Agenda Day Three–3 Student’s Objectives Day Three–4 Instructor-led Demonstration Day Three–5 Workstation 1 Day Three–9 Workstation 2 Day Three–15 Workstation 3 Day Three–21 Workstation 4 Day Three–25 Homework Day Three–35

DAY FOUR DAY FOUR–1

Agenda Day Four–3 Student’s Objectives Day Four–4 Workstation 1 Day Four–5 Workstation 2 Day Four–11 Workstation 3 Day Four–17

COURSE INTRODUCTION

ELECTRICAL SYSTEMS CURRICULUM PATH

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

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

Operation 34S18M0

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

Advanced Electronic Systems Diagnosis 34S26T0 (4Days)

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

Course Objectives

The objectives of this course are to enable you to:

electronic concerns

diagnosis

DAY ONE

DAY ONE AGENDA — MORNING

STUDENT’S OBJECTIVES CONTENT

and on demand codes and to monitor

and record PIDs

and on demand codes

side switches, relays, and transistors

oscilloscope function to check the

PREREQUISITE

REVIEW

PREREQUISITE REVIEW

1 What is meant by the term "electronic systems"?

2 What is an input?

3 What is an output?

4 Name some electronic systems

5 What are some of the advantages associated with electronic systems?

PREREQUISITE REVIEW

6 The instructor will walk you through this question later Please move on to question 7

PREREQUISITE REVIEW

7 What are the similarities and differences between a transistor and a relay?

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?

10 What is a Diagnostic Trouble Code (DTC)?

11 How are DTCs retrieved?

PREREQUISITE REVIEW

12 What do PID's allow you to do?

13 What does Output State Control (Active Commands) allow you to do?

14 What is a digital DC signal? (Write or draw your answer.)

BEC603-A/VF

PREREQUISITE REVIEW

16 What is an analog DC signal? (Write or draw your answer.)

17 What are some of the input devices that produce analog DC signals?

BEC603-A/VF

PREREQUISITE REVIEW

18 What is an analog AC signal? (Write or draw your answer.)

19 What are some of the input devices that produce analog AC signals?

20 What is the unit of measure for frequency?

BEC603-A/VF

PREREQUISITE REVIEW

21 What is duty cycle?

22 What is pulse width?

PREREQUISITE REVIEW NOTE: Use the following schematic to follow the instructor’s presentation

GENERIC ELECTRONIC MODULE (GEM)

590 DB/W

C234

10 MODE SELECT INPUT 19

INTERVAL DELAY/WASH

993 BR/W

MULTI-FUNCTION SWITCH

FOR SWITCH TESTING

LOW

WASHER SWITCH OFF

Interval Wiper/Washer

G101

I/P FUSE PANEL

18

25A

SEE GROUNDS

65 DG

M

C101F C101M

S110

WINDSHIELD WIPER DYNAMIC BRAKE/RUN RELAY

589 O

WINDSHIELD WASHER PUMP MOTOR RELAY

WINDSHIELD WIPER SPEED

65 DG

65 DG

ENGINE COMPARTMENT FUSE BOX

65 DG 65 DG 65 DG 65 DG

PARK SENSE

GENERIC ELECTRONIC MODULE (GEM)

G102

61 Y/R 28 BK/PK

C101M C101F

WINDSHIELD WIPER MOTOR

C112M C112F

56 DB/O

58 W 58

21 WASHERPUMP CONTROL

C101M C101F

950 W/BK

950 W/BK

C112F C112M

57 BK

57 BK

S104

941 BK/W C119 WINDSHIELD WASHER PUMP MOTOR C119 57 SEE GROUNDS

S103 C113

HOT IN ACC OR RUN

15

WORKSTATION 1

WORKSTATION 1

NGS DIRECTIONS:

In this workstation you will use the NGS functions to retrieve Continuous Memory DTC's, On Demand DTC's, view PID's and create a recording while diagnosing the front windshield wiper system using the wiring diagram manual

1 List below the components of the windshield wiper system using the wiring diagram manual

WORKSTATION 1

NGS TECHNICIAN A: Use the NGS during this workstation

2 Perform the following steps

a Verify that the fault switch is in position A

b Verify the symptom

c Connect the NGS to the DLC

d Select VEHICLE AND ENGINE SELECTION

e SELECT NEW VEHICLE and choose the model year for the vehicle you are working on

f Select vehicle model and engine size Confirm selection and press TRIGGER

g Select DIAGNOSTIC DATA LINK

h Turn the ignition switch on

i Select the module that controls the wiper system

j Select DIAG TEST MODES

k Select RETRIEVE/CLEAR CONT DTCs

l Select START by pressing button 3

Use the table below to record any DTCs received during continuous code retrieval

WORKSTATION 1

NGS

3 Continuous DTCs indicate: (Circle all that apply)

A A fault condition exists right now (Hard Fault)

B A fault may be occurring now

C Fault may be intermittent

D System being tested has no power

4 Briefly explain how Continuous DTCs can help you diagnose a vehicle's concern

5 Why do we clear Continuous DTCs?

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

WORKSTATION 1

NGS

If you answered “yes” list below

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

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

WORKSTATION 1

NGS

11 On-Demand DTCs indicate: (circle all that apply)

A A fault condition exists right now (Hard Fault)

B A fault may be occurring now

C A fault may be intermittent

D System being tested has no power

12 Briefly explain how On–Demand DTCs can help you diagnose a vehicle's concern

13 Using the wiring diagram provided, list below the components and or circuits that could be the cause of the On-Demand DTC(s)

WORKSTATION 1

NGS TECHNICIAN C: Use the NGS during this workstation

Press CANCEL twice to return to the diagnostic menu

14 Use the NGS to perform PID (Parameter Identification) retrieval

a Select PID/DATA MONITOR & RECORD and press TRIGGER

b Press 3 DEFN to view PID definitions

c For each of the PID’s listed below, highlight and press trigger to select (This symbol *

will appear when a PID is selected To deselect a PID highlight the PID and press

TRIGGER)

d As you select each PID, record its definition in the space provided

NOTE: If a PID is not available write N/A

WORKSTATION 1

NGS

15 According to the CCNT PID, how many codes are stored in memory?

16 Move the fault switch to position B View each of the PID’s on the NGS while operating the corresponding component and write your results below

NOTE: If a PID is not available write N/A

IGN_R

WASH_SW

WPMODE

17 Move the fault switch back to position A View each of the PID’s on the NGS while

operating the corresponding component and write your results below

NOTE: If a PID is not available write N/A

WORKSTATION 1

NGS

Use the NGS to view and record the WP_MODE PID

19 Move the fault switch to position B and continue with the next step

a Press CANCEL to return to the PID selection screen

b Press button 5 CLEAR to deselect all PID’s

c Select the WP_MODE PID and press START to monitor

d Operate the wipers in the positions listed below and record the WP_MODE PID values

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

WORKSTATION 1

NGS

Use the NGS to view the recording

a When the next screen appears select VIEW RECORDING

b Press TRIGGER to select WP_MODE

c Press button 6 GRAPH This is a graphical representation of the PID

d Press Button 8 to move forward in time

e Press Button 3 to move back in time

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

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

BEC113-A/VF

WPMODE

WORKSTATION 1

NGS

22 How can a recording be useful when diagnosing a vehicle?

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

NOTES

WORKSTATION 2

WORKSTATION 2

WDS DIRECTIONS:

In this workstation you will learn the basic applications of the WDS You will Dock/Un-Dock the Portable Test Unit (PTU), retrieve Continuos Memory Diagnostic Trouble Codes (CMDTC), and retrieve On Demand Diagnostic Trouble Codes (ODDTC)

TECHNICIAN A: Use the WDS during this workstation

If the WDS screen is blank, touch it If nothing happens, the unit is in suspend mode In this case, touch the green "ON" button in the upper RH corner

1 Undock the PTU and list each step taken

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?

WORKSTATION 2

WDS

4 Use the repair order and your knowledge of system operation to answer the following

question:

a Verify that the fault switch is in position A

b Refer to the Repair Order and verify the customer concern

What system (s) may be responsible for this symptom?

5 List below the components of the system identified in question four using the EVTM /Wiring Diagram manual

WORKSTATION 2

WDS TECHNICIAN B: Use the WDS during this workstation

Touch 16 PIN from the menu Now select ALL-EXCEPT THOSE BELOW

Select the CONTINUE icon

6 Explain what the “CONTINUE” icon allows the user to do

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?