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TOYOTA Collision Repair and Refinish TrainingBody Electrical Diagnosis And Repair Course T502 © 2008 Toyota Motor Sales, U.S.A., Inc.. Body Electrical Diagnosis and Repair Course T502 iT

TOYOTA Collision Repair and Refinish Training

Body Electrical Diagnosis And Repair Course T502

© 2008 Toyota Motor Sales, U.S.A., Inc.

All rights reserved This book may not be reproduced or copied, in whole or in part by any means, without the written permission

of Toyota Motor Sales, U.S.A., Inc.

Printed in U.S.A.

Toyota Motor Sales, U.S.A., Inc.

Body Electrical Diagnosis and Repair Course T502 i

Table of Contents

Course T502: Body Electrical Diagnosis & Repair

Contents

Introduction 1-1 Voltage 1-2 Current 1-3 Resistance 1-3 Ohm’s.Law 1-4 Basic.Principles.of.Series/Parallel.Circuits 1-5

Series.Resistance 1-5 Parallel.Resistance 1-6 Series/Parallel.Resistance 1-6 Why.Does.It.Matter? 1-7 On-Vehicle.Applications 1-7 of.Ohm’s.Law 1-7

Introduction 2-1 Meters 2-2 Analog.Multimeters 2-3 Digital.Multimeters 2-4 DMM.Components 2-5 DMM.Mode.Selector .2-6 DMM.Display .2-7 DMM.Auto-Ranging .2-9 DMM.Test.Leads.and.Input.Jacks 2-10 Voltage 2-11 Available.Voltage 2-15 Voltage.Drop 2-16 Measuring.Voltage.Drop 2-16 Current 2-19 Resistance 2-23 Introduction 3-1 Types.of.Circuits .3-2 Series.Circuits .3-4 Key.Features .3-4 Applying.Ohm’s.Law 3-5 Tips.For.Trouble.Shooting .3-6 Key.Features 3-15 Tips.For.Trouble.Shooting 3-18 Series-Parallel.Circuits 3-22 Key.Features 3-23 Load.Control.Source.or.Ground 3-25 Electrical.Symbols 3-27 Wiring.Diagrams 3-28 Introduction 4-1 Vehicle.Wiring.Terminal.and.Connector.Repair .4-2 Conductors .4-2 Power.or.Insulated.Conductors 4-2 Ground.Paths .4-3 System.Polarity .4-3 Harnesses .4-4 Wire.Insulation .4-5 Connectors .4-6

SRS.Harness.Components 4-7

High.Voltage.(HV).Harness.Components 4-8

Section 1:

Electrical Circuit Theory

Section 2:

Essential Electrical

Concepts

Section 3:

Electrical Circuits

Section 4:

Vehicle Wiring and

Terminal & Connector

Repair

TOYOTA Collision Repair and Refinish

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Table of Contents

Electric.Power.Steering.(EPS) .4-8

Connector.Repair 4-9

Conductor.Repairs 4-10 Wire.Size 4-11 American.Wire.Gauge.Sizes 4-11 Wire.Gauge.Number 4-12 Wire.Length 4-12 Wire.Repairs 4-13 Soldering 4-14 Solder 4-14 Soldering.Irons 4-14 Splices 4-15 Soldering.Wire.Splices 4-16 Rules.for.Good.Soldering 4-16 Terminal.Replacement 4-17 Introduction 5-1 The.Battery .5-2 Battery.Functions .5-3 Battery.Type 5-4 Battery.Construction .5-5 Battery.Case .5-5 Separators .5-6 Cells 5-7 How.Batteries.Work .5-8 Fully.Charged 5-8 Discharging .5-8 Fully.Discharges .5-8 Charging 5-8 Capacity.Ratings 5-10 Cold-Cranking.Amperes 5-10 Reserve.Capacity.(RC) 5-10 Ampere-Hours.(AH) 5-11 Safety.First 5-12 Precautions 5-12 Visual.Inspection 5-13 Battery.Drain.Tests 5-15 Battery.Analyzer.Tests 5-17 Preparing.the.Battery.for.Analyzer.Tests 5-18 Battery.Test Results 5-19 Fast.Charging 5-20 Slow.Charging 5-21 Jump.Starting 5-22

.6-1

.7-1 8-1

Section 5:

Resources

Appendix C:

Glossary of Terms

Appendix B:

How to Use an Electrical Wiring Manual

Appendix A:

Wiring Diagram Symbols

Body Electrical Diagnosis and Repair Course T502 O-1

Figure 1-1

T502f101

Body Electrical Safety

Safety considerations for body electrical operations go beyond the

obvious personal safety Technicians performing electrical repairs must now have the knowledge and ability to recognize and avoid High-Voltage and general electrical hazards Safe handling of electrical circuits may require disabling and testing for zero circuit current, as well as following proper procedures for live circuit testing.

Introduction

Figure 0-1

T502f001p

TOYOTA Collision Repair and Refinish

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Introduction

Electrical safety must also be a prime consideration for onboard systems that are responsible for operator and occupant safety Supplemental Restraint Systems (SRS) and Vehicle Dynamics Integrated Management (VDIM) rely heavily on high-speed electrical communications, so it

is critical to know the correct repair procedures and limitations when working around these circuits and components.

Figure 0-2

T502f002c

Body Electrical Diagnosis and Repair Course T502 O-3

Body Electrical Saftey

Each section of this training will provide detailed information on safe and proper diagnostic and repair procedures applicable to each topic, as well

as identify High Voltage and SRS circuit wiring and circuits that should not be repaired.

Figure 0-3

T502f003p