34S19T1 electronic diagnosis 2006

Use the colored jumper leads to connect the circuit as shown and measure voltage with the DMM.Take the reading with the external control switch in the opened and closed positions.. Use y

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.

• 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

RE-VERSE (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.

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

6. Call me within a reasonable amount of timeafter my service visit to ensure that I'mcompletly satisfied

7. Be responsive to questions or concerns Ibring to your attention

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

Expectation 3

“Fix It Right The First Time, On Time.”

Both service advisors and technicians are important players when it comes to Expectation

#3

Customers tell us “Fixing It Right The First Time, On Time” is one of the reasons they woulddecide to return to a dealer to buy a vehicle and get their vehicles serviced

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.”

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

The successful implementation of expectations means:

– Satisfied customers

– Recognition that Ford and Lincoln/Mercury technicians are “the Best in the Business”

Customer Expectations: Service

TABLE OF CONTENTS

COURSE INTRODUCTION INTRODUCTION–1 LESSON ONE 1–1

Prerequisite Review 1–1Lesson One Demonstration 1–19Workstation 1 1–21Workstation 2 1–34Workstation 3 1–47Workstation 4 1–64

LESSON TWO 2–1

Workstation 1 2–1Workstation 2 2–8Workstation 3 2–18Workstation 4 2–23

LESSON THREE 3–1

Lesson Three Demonstration 3–1Workstation 1 3–6Workstation 2 3–12Workstation 3 3–15Workstation 4 3–17

LESSON FOUR 4–1

Workstation 1 4–1Workstation 2 4–4Workstation 3 4–7Workstation 4 4–10

LESSON FIVE 5–1

Workstation 1 5–1Workstation 2 5–4Workstation 3 5–7Workstation 4 5–10

ROTUNDA ORDER FORM

COURSE INTRODUCTION

GENERAL COURSE INFORMATION

Course Description

This is the final instructor-led course in the Electrical/Electronics Curriculum This course is designed to provide hands-on opportunities for technicians to learn and improve their skills using tools and equipment, and to apply knowledge learned in previous curriculum courses in actual diagnostic situations Each day, students will have four opportunities to practice selected tasks Before the end of the course, they will have had 16 opportunities to practice diagnostic and service skills The results of the students’ work are

Upon successful completion of this course, the students will be able 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 to obtain needed information for diagnosis.

z Perform diagnostic test procedures.

Agenda

DAY ONE: Introductions, Prerequisite Review, Lesson 1 Workstations

DAY TWO: Lesson 1 Workstation Reviews, Lesson 2 Workstations

DAY THREE: Lesson 2 Workstation Reviews, Lesson 3 Workstations

DAY FOUR: Lesson 3 Workstation Reviews, Lesson 4 Workstations

PREREQUISITE

REVIEW

PREREQUISITE REVIEW

1 What best describes the above measurement with the switch turned on?

A Voltage drop measurement of the load

B Available voltage measurement to the load

C Voltage drop measurement of a positive wire

D Voltage drop measurement of the ground circuit

2 What would be an acceptable reading with the:

switch turned on?

switch turned off?

34

34

57

34

57

3 What best describes the above measurement with the switch turned on?

A Voltage drop measurement of the load

B Available voltage measurement to the load

C Voltage drop measurement of a positive wire

D Voltage drop measurement of the ground circuit

4 What would be an acceptable reading with the:

switch turned on?

switch turned off?

5 What would be an acceptable reading with the:

Switch turned on?

Switch turned off?

34

34

57

7 Is this an acceptable reading with the switch turned on? (circle one)

11 Which picture above shows a correct measurement of amperage in the circuit when the switch isturned on?

12 In the picture above, is the diode good? (circle one)

62.3 OL m

12V

13 The four tests above were performed on the same relay Relay coil resistance specification is

40-80Ω Which of the following best describes the relay’s condition?

A Relay is OK

B Excessive resistance in the coil

C Defective “Normally Open” contacts (between points 3 and 5)

D Defective “Normally Closed” contacts (between points 3 and 4)

FUSE PANEL

LO

OFF HI LO

WIPER MOTOR AND SWITCH ASSEMBLY

14 An open at point C would cause:

A the wipers not to work on high speed

B the wipers to operate properly, but not to park

C the wipers not to work on low speed

D the wipers not to operate at all

15 An open at point A would cause:

A the wipers not to work on high speed

B the wipers to operate properly, but not to park

C the wipers not to work on low speed

D the wipers not to operate at all

Refer to the illustration below and answer questions 14 through 15

B

D

C

Refer to the illustration below and answer questions 16 through 19

16 An open at point A would cause:

A the relay to remain in the closed/latched position when the switch is closed

B the circuit breaker to open immediately

C the relay to remain in the open/unlatched position when the switch is closed

D the horn to always be ON

17 A short to ground at point B would cause:

A the circuit breaker to open only when closing the switch

B the circuit breaker to open immediately

C the horn to always be ON

D the relay to remain in the closed/latched position at all times

18 During diagnosis it is noticed that the relay does not “click” when depressing the horn switch Thecause could be:

A an open at point A

B a faulty horn relay

C a tripped circuit breaker

D all of the above

19 Component D in the schematic directly controls:

A power side current through the relay winding

B power side current through the horn

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

23 Name some electronic systems

22 What are outputs?

21 What are inputs?

20 What is meant by the term “electronics”?

26 How are DTCs retrieved?

27 What are PIDs?

28 What does Output State Control allow you to do?

25 What is a diagnostic trouble code?

30 Name some devices that produce a digital DC signal?

31 What is an analog DC signal? Write or draw your answer

32 Name some devices that produce an analog DC signal?

29 What is a digital DC signal? Write or draw your answer

34 Name some devices that produce an AC signal?

35 What is the unit of measurement for frequency?

36 What is duty cycle?

37 What is pulse width?

33 What is an AC signal? Write or draw your answer

V+

0

V-Time

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

39 What is the difference between a direct module output and an indirect module output?

Lesson One Demonstration

DIRECTIONS: As the demonstration is presented, identify the oscilloscope buttons in the picture

below Write the number that matches the button function in the table below

11

1 12

13 10

C Auto Configure

wodiWyalpsiDknirhSdadapx

E ZoomIn

noitamrofn

I Me u

elacSegatloVetega

C ResetCursor,Trace orTriggerSeti gs

elacSemiTetega

C C an el1Select

tsujdAreggir

T Play/Pause Buton

noitisopeilorezetegaC

WORKSTATION 1

DIRECTIONS: In this workstation you will trace power flow and measure voltage in a basic electronic

circuit You will learn about inputs, processing and outputs

1 Name the load(s) in the circuit below

2 What type of switch is used in the circuit below?

A Power side switch

B Ground side switch

WORKSTATION 1 INPUTS, PROCESSING AND OUTPUTS

3 Trace the power flow through the circuit below using colored markers Use yellow to indicate theload(s), red to indicate power, blue for power-side switched circuits, green for ground-side switchcircuits, and black for ground

GND SW SENSE

B+

D-A A-D

V

V

SIGNAL RETURN

FE-34

FE-30

BOARD WITH GLOVE BOX LAMP

GLOVE BOX LAMP

INTERIOR LAMPS B+

FE-32

SINGLE SWITCH BOARD

TECHNICIAN A: Perform Set up and step 5.

Turn on the power supply Adjust the Amps setting to maximum Setup the digital multimeter (DMM) tomeasure DC volts Connect the digital multimeter (DMM) leads to the positive and negative terminals atthe rear of the power supply Adjust the volts knob on the power supply until the digital multimeter(DMM) reads approximately 12 volts

5 Use the colored jumper leads to connect the circuit as shown and measure voltage with the DMM.Take the reading with the external control switch in the opened and closed positions Turn off thepower supply after you have taken the readings?

6 What type of signal does this input produce?

A Digital DC

B Analog DC

C Digital AC

7 Circle the power side switch input(s) in the schematic below.

BEC906-A/VF

C212 9

C205b

11

81–2 Wipers and Washers

22 LB/OG 680

16 LB 671

22 GY/LB 647

22 YE/WH 646

20 DB 682

22 PK/YE 684

22 TN/RD 686

VREF

SIG RTN –

A30 Instrument clus- ter 36) Safety belt indicator 57) Door ajar 60–2, 60–4

66–2 See page

S268

5 10 C220b

66–1 See page 7

N85 Door ajar switch, right front

151–38

2 1

10–10 See page

1 C602

2 C602

C248 13 8

N84 Door ajar switch, left front

151–37

2 1

10–9 See page

1 C526

2 C526

C201a

16 66–1 See page 23

N474 Safety belt switch

buckled

unbuckled 151–32

0 1

10–13 See page

1 C323

2 C323

G200

22 BK/YE 344

18 BK/YE

20 BN/LB 85

S304

20 BK 57

22 BK/PK 345 VPWR

C2224 with Central

Tim-er Module (CTM)

A38 Central Timer Module (CTM)

C2224 with Central

Tim-er Module (CTM)

8 Name the load(s) in the circuit below.

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 yellow to indicate load,red to indicate power, blue for power-side switched circuits, green for ground-side switch circuits,and black for ground

TECHNICIAN B: Perform step 12.

12 Use the colored jumper leads to connect the circuit as shown and measure voltage with the DMM.Take reading with the external input switch in the opened and closed positions

13 What type of signal does this input produce?

SENSE

GND SW SENSE

B+

D-A A-D

V

V

SIGNAL RETURN

14 Circle the ground-side switch input(s) in the schematic below.

BEC906-A/VF

C212 9

C205b

11

81–2 Wipers and Washers

22 LB/OG 680

16 LB 671

22 GY/LB 647

22 YE/WH 646

20 DB 682

22 PK/YE 684

22 TN/RD 686

VREF

SIG RTN –

A30 Instrument clus- ter 36) Safety belt indicator 57) Door ajar 60–2, 60–4

66–2 See page

S268

5 10 C220b

66–1 See page 7

N85 Door ajar switch, right front

151–38

2 1

10–10 See page

1 C602

2 C602

C248 13 8

N84 Door ajar switch, left front

151–37

2 1

10–9 See page

1 C526

2 C526

C201a

16 66–1 See page 23

N474 Safety belt switch

buckled

unbuckled 151–32

0 1

10–13 See page

1 C323

2 C323

G200

22 BK/YE 344

18 BK/YE

20 BN/LB 85

S304

20 BK 57

22 BK/PK 345 VPWR

C2224 with Central

Tim-er Module (CTM)

A38 Central Timer Module (CTM)

C2224 with Central Tim-er Module (CTM)

An Electronic system consists of inputs, a control module, and outputs In this workstation you havetaken voltage readings to see what the module sees when monitoring switched inputs The CentralProcessing Unit (CPU) receives the input as ON and OFF signals These signals are compared to a look-

up table, which resides in the CPU memory The CPU makes decisions based on the lookup table andcontrols the output transistors or drivers

In this exercise you will predict what the module will do Use the lookup table below to decide when themodule turns the lights on or off

15 Answer the question by identifying if the output will be ON or OFF in the table below

Will the module turn the lamp on or off when it sees the following input signals?

Power to CPU

Input

BEC106-E/VF

Look-Up-Table INPUT

P NV

GRD Signal Return

Grd Switch Sense

B+

Emitter CPU

t u p n

nepOdesolC

16 Name the load(s) in the circuit below.

17 Are the relay contacts 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 (driver) in this circuit acting as a power side switch or a ground side switch?

A Power side switch

B Ground side switch

Power to CPU

Input

BEC106-E/VF

Look-Up-Table INPUT

P NV

GRD Signal Return

Grd Switch Sense

B+

Emitter CPU

21 What will the available voltage be at the following locations with the input to the module in the openand closed positions?

Power to CPU

Input

BEC106-E/VF

Look-Up-Table INPUT

P NV

GRD Signal Return

Grd Switch Sense

B+

Emitter CPU

19 Trace the power flow through the circuit below using colored markers Use yellow to indicate load,red to indicate power, blue for power-side switched circuits, green for ground-side switch circuits,and black for ground

20 Label the components in the diagram as direct and indirect outputs

Relay (coil):

Lamps:

n o i t a c o

SINGLE RELAY SOCKET

22 Use the colored jumper leads to connect the circuit as shown Measure available voltage at thefollowing locations with the input switch in the open and closed positions?

TECHNICIAN C: Perform step 22.

n o i t a c o