BODY ELECTRICAL DIAGNOSIS COURSE AGENDA

BODY ELECTRICAL DIAGNOSIS COURSE AGENDA BODY ELECTRICAL DIAGNOSIS COURSE AGENDA BODY ELECTRICAL DIAGNOSIS COURSE AGENDA BODY ELECTRICAL DIAGNOSIS COURSE AGENDA BODY ELECTRICAL DIAGNOSIS COURSE AGENDA BODY ELECTRICAL DIAGNOSIS COURSE AGENDA BODY ELECTRICAL DIAGNOSIS COURSE AGENDA BODY ELECTRICAL DIAGNOSIS COURSE AGENDA BODY ELECTRICAL DIAGNOSIS COURSE AGENDA BODY ELECTRICAL DIAGNOSIS COURSE AGENDA BODY ELECTRICAL DIAGNOSIS COURSE AGENDA BODY ELECTRICAL DIAGNOSIS COURSE AGENDA BODY ELECTRICAL DIAGNOSIS COURSE AGENDA BODY ELECTRICAL DIAGNOSIS COURSE AGENDA BODY ELECTRICAL DIAGNOSIS COURSE AGENDA BODY ELECTRICAL DIAGNOSIS COURSE AGENDA BODY ELECTRICAL DIAGNOSIS COURSE AGENDA

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LEXUS Course L 652 - Body Electrical Diagnosis 1

Body Electrical Diagnosis Course L652

Day 2

Worksheet 2-4 Right Hand Mirror Does Not Go UP or DOWN

2.25 11:00 60 On-Car/Simulator Short & Parasitic Load Diagnosis

BODY ELECTRICAL DIAGNOSIS COURSE - AGENDA

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The ES 300 Body Electrical Simulator is a TMC produced training aid designed for use in body electrical courses.Nearly all body electrical systems from an ES 300 are fully operational, and can be used to teach both systemoperation theory and diagnosis

The relative position of all parts (including wire harness routing) are approximately the same as on an actual hicle

Wireless Door Lock

• These circuits illustrate the 4 major types of electrical problems encountered on the vehicle: Open, ground/parasitic load, high resistance, and feedback, with varying difficulty levels for each problem (seetable) The fault for each circuit is activated by moving the appropriate fault switch to the UP position

short-to-ES 300 Body Electrical Simulator Instructor Information

OVERVIEW

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LEXUS BODY ELECTRICAL SIMULATOR INFORMATION

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Lesson 1.00 Objectives

1 Instructor introduction to technicians

2 Complete attendance records

3 Introduce technicians to program goals, and objectives

4 Familiarize technicians with technician handbook

1 Technician will know what subjects the L 652 course will be covering

2 Through this review of L 622 course materials, the technician will be able to demonstrate an

understanding of the following concepts:

• Voltage

• Amperage

• Resistance

• An electrical circuit

• Series circuit theory

• Parallel circuit theory

3 Familiarize the technicians with EWD wiring diagram symbols

After completing this section, the technician will be able to:

1 Find and use each of the sections of the EWD

2 Given a system circuit diagram in the EWD:

• Identify each of the symbols used on the system diagram

• Understand the meaning of the labels that are used with those symbols

• Apply basic current flow theory to diagram the path of current flow through the circuit

3 Know how to apply the information in the EWD within the 6-step troubleshooting plan

After completing this worksheet:

1 The technician will have demonstrated the use of all the sections of the EWD during a "typical"

diagnostic process

2 Applied the concepts covered in lesson 1.1 on an actual system circuit diagram

3 Demonstrated an understanding of the symbols used on the system circuit diagram

1 Use the System Outline section of the EWD when available

2 Configure the switches/relays to the appropriate position for the operating condition

3 Follow the current flow path from the B+ source to ground in example EWD circuits

4 Apply "what-if" problem simulation scenarios to the circuit

Body Electrical Diagnosis Course L 652

Summary of Lesson Objectives

LESSON OBJECTIVES SUMMARY

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In this section the technician will demonstrate the ability to:

1 Use the system outline section of the EWD

2 Configure the switches/relays to the appropriate position for the operating condition

3 Follow the current flow path from the B+ source to ground

4 Determine the amount voltage that should be measured at given test points

5 Apply "what-if" problem simulation scenarios to the circuit

1 Use a voltmeter and measure voltage drops and open circuit voltage in a circuit

• Understand what an acceptable voltage drop is

• Understand the concept of what creates a voltage drop

• Understand the proper way to connect a voltmeter in a circuit

• Know how to use a voltmeter for continuity check only

• Understand the voltmeter's application in diagnostics

2 Use an ammeter to measure current flow

• Use a series type ammeter

• Use a inductive type ammeter

• Understand the concept of parasitic load

• Be able to apply parallel circuit current rules

• Understand the ammeter's application in diagnostics

3 Use an ohmmeter to measure the resistance of a component

• Understand the need for circuit isolation when using an ohmmeter

• Understand the ohmmeter's application in diagnostics

4 Use a jumper wire properly for circuit diagnosis

5 Apply basic circuit theory concepts with the use of an EWD on vehicle circuits

1 Implement the 6-step diagnostic process on a typical body electrical problem

2 Properly verify an electrical problem

3 Use defined techniques to analyze the related symptoms

4 Isolate and correct the trouble using the EWD and electrical diagnostic tools

5 Perform wire, connector, and harness repairs according to proper procedures

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1 Successfully diagnose an open circuit problem in an electrical circuit

2 Apply the 6 step diagnostic process

3 Learn the diagnostic strategy for diagnosing an open circuit problem in which the entire circuit is

1 Successfully diagnose a high resistance electrical circuit problem

2 Apply the 6 step diagnostic process for this type of problem

3 Locate a high resistance problem in the ground circuit

4 Locate a high resistance problem in the B+ circuit

After completing this section, the technician will have:

1 Successfully diagnosed 3 high circuit resistance problems

2 Practiced and applied the 6 step diagnostic process on these problems

3 Extensively used the EWD support sections to locate electrical/wiring components and determine

power flow from the fuses and junction blocks

4 Used the EWD System Circuit Diagrams to trace the path of current flow through circuits

1 Diagnose a short-to-ground in an electrical circuit

2 Diagnose an unwanted parasitic load problem

3 Apply the 6 step diagnostic process for each of these problems

4 Use the EWD to determine circuit power distribution through the various junction blocks and junctionconnectors

After completing this section, the technician will have:

1 Successfully diagnosed 3 short-to-ground/excessive parasitic load circuit problems

2 Practiced and applied the 6 step diagnostic process on these problems

3 Extensively used the EWD support sections to locate electrical/wiring components and determine

power flow from the fuses and junction blocks

4 Used the EWD System Circuit Diagrams to trace the path of current flow through circuits

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1 Successfully diagnose an electrical feedback circuit problem

2 Apply the 6 step diagnostic process for this type of problem

3 Diagnose a feedback problem in a lighting circuit

4 Diagnose a feedback problem in a general body electrical circuit

1 Accurately diagnose open circuit problems

2 Diagnose parasitic load problems

3 Diagnose short to ground problems

4 Diagnose high resistance problems

5 Diagnose feedback problems

This section will also:

1 Provide feedback on what the technician has learned from the course

2 Enhance the technicians' confidence in their electrical diagnostic ability

1 Define multiplexing and serial data

2 Explain the need for standard

3 Retrieve trouble codes (DTCs) from a multiplexing system

4 Diagnose a simple system fault in a multiplexing system

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Body Electrical Diagnosis

Course L652 Material Requirements and Approach to Instruction

• ES 300 Body Electrical Simulator (Should be located in the front of the classroom)

• Assorted jumper wires

• L 652 Technician Handbook

• 1998 ES 300 EWD (1 per technician)

• Spare body/engine wiring harness

• Assorted Lexus vehicles *

* The concept regarding vehicle usage is that any vehicle in the Lexus lineup can be used to teach these cal concepts However, some of the bugs cannot be placed on all vehicles because of limitations regarding ac-cess to bugged areas and/or the possible damage to related components The ES 300 simulator should always

be considered as an extra vehicle and included in rotations whenever practical In every case where the cal problem is not "system specific" an attempt has been made to make the bug generic Instructors are encour-aged to look at the concept of the bug (what the bug is designed to teach) and then try to install the bug on avail-able vehicles with the least amount of time and trouble

electri-Approach

The course is built around the simulator as a means of showing how the theory of electrical shooting can be applied to an automotive system The multimedia presentation has been designed to assist the instructor in the transition between theory and real world applications Just as the instructor is free to use additional relevant examples to relate a concept during his presentation, he is also encouraged to go beyond the confines of the outline to produce bugs and diagnostic scenarios which work for him and his group of technicians Another important consideration is the concept of "voltage drop" which has been used in a number of examples as a diagnostic approach that works and is very useful It is recommended that the instructor become familiar with this concept and make every effort to convey this knowledge to the technicians.

trouble-MATERIAL REQUIREMENTS AND APPROACH TO INSTRUCTION

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ENROLLMENT AND INTRODUCTION 1.00

1 Instructor introduction to technicians

2 Complete attendance records

3 Introduce technicians to program goals, and objectives

4 Familiarize technicians with technician handbook

Lesson Key Points

• Use this time to take attendance and orient the technicians to the topics which will be covered each day ofthe course By using the time and topic, technicians will get a feel for what is to be covered throughoutthe day

• Discuss the technician incentive program depending on the make-up of the class

• This is also a time to “break the ice” so the class gets to know each other Have technicians introducethemselves and hobbies they enjoy

• Depending on your area policy you may wish to discuss technical problems and fixes at this time

Required Material

• Multimedia presentation

• LCD Projector and Screen

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Slide / Activities / Ref.

ENROLLMENT AND INTRODUCTION 1.00

I Enrollment

A Complete Attendance Record as indicated on back of form

B Have each technician enroll with appropriate information on dance Record

Atten-II Introduction

A Introduce yourself as instructor

B Introduce course: Lexus Body Electrical Diagnosis L652

C Prerequisites

1 Course L 622 - Electrical Fundamentals

D Have technicians introduce themselves

2 Dealership

3 Number of years as Lexus technician

4 Hobbies or interests

III Problems (Optional)

A Discuss Technician Incentive Program

B Discuss recent technical problems and fixes

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REVIEW OF ELECTRICAL CIRCUIT THEORY AND CONCEPTS 1.10

1 Familiarize the technician with the subjects to be covered during the course

2 Through a review of L 622 course materials, the technician will be able to demonstrate an understanding of thefollowing concepts:

• Voltage

• Amperage

• Resistance

• An electrical circuit

• Series circuit theory

• Parallel circuit theory

3 Familiarize the technicians with EWD wiring diagram symbols

Use this section to review the materials that were covered in L 622 Heavily emphasize the practical on-carapplications of electrical theory, with less emphasis on concepts that are “nice to know.”

During the review of the concepts, try to get a “feel” for the knowledge and skill level of the technicians, and tailoryour instruction to fit their needs as much as possible

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After the general introduction/attendance matters have been finished, proceed with the following.

NOTE: The instructor may feel the need to Assign Worksheet 1-1 and

go to the Worksheet 1-1 Presentation materials for review, or continue forward with Slide 2 If students need a review of L622 this option may be valuable.

Slide 1

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Slide 2

I Introduction to L 652 Course

A Course Objectives

1 Solidify the concepts taught in L 622

a L 622 concentrates on the theory aspects of electricityand electronics

2 How to diagnose electrical circuits on the vehicle

a Repairing body electrical problems can take too long, notvery profitable

b Have a lot of guesswork and parts changing

3 “Real World” electrical

a Some electrical problems are difficult to diagnose

b Using proper techniques will eliminate any unnecessarychecks

c The techniques in the course will make you faster andmore profitable

B Sections of the L 622 course

2 Tools of Electrical Diagnosis

a Explanation and practice with major tools for electrical agnosis:

di-1) Electrical Wiring Diagrams2) Digital Multimeters3) BE section of the Repair Manual

b Extensive lab/worksheet exercises for each of these

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3 Electrical Troubleshooting

a Explanation of the 6-step troubleshooting method

b Diagnostic techniques for:

1) Open circuit problems2) Short/parasitic load circuit problems3) High resistance problems

4) Feedback problems

c Extensive hands-on lab worksheets for each of theseproblems

4 Final exam

a 20 multiple choice questions, open book

b Hands-on diagnostic problem

C ES 300 Body Electrical Simulator

1 Nearly all of the body electrical systems of a 1998 ES 300

2 Systems are operational

3 The location of components, harnesses, and connectors/splices are in the approximate locations as they would be onthe car

4 A set of bug switches will be used to create electrical lems for class case studies and worksheets

prob-II Basic Electrical Terms

A Voltage

1 Definition

a Electrical pressure differential

b Pressure differential causes current flow if a completepath is present

2) Other terms

Demonstrate each of these voltage concepts on the Simulator using the Dome Light circuit.

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c Open Circuit Voltage1) Measured at any point in the circuit when there is nocurrent flow present

2) Used when diagnosing an inoperative or open circuit

If you placed the negative probe of the DMM on the opposite side of the connector, it should also read about 12.6 V if the ground path of the circuit has continuity.

d Voltage Drop1) Measurement made with voltmeter connected in par-

allel to circuit or portion of a circuit that has current flow through it:

2) Can measure exactly how much voltage the load isgetting

a) Almost all body electrical components should

be receiving full battery voltage

3) Used to track down high resistance problems

Figure 1-8 illustrates a 0.1V drop across all the connections.

An additional explanation of voltage drop is to also call it an “I R” drop This application of Ohm's law can help the technician remember that for a voltage drop to occur, you need to have amperage and resistance If you are missing one of these components, you can’t have a voltage drop.

B Amperage or current flow

1 The rate of flow or “how much” electricity

2 Multiplied by voltage tells you the amount of power being used

3 Measured with meter in series or with accessory inductiveclamp

4 Watts = electrical horsepower

5 Knowing source voltage is key

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Fig 1-10 illustrates the amount of power the light bulb is using: 650

ma X 12.5V drop (not the battery voltage) = 8.125 watts.

C Resistance

1 Opposition to current flow

2 Regulates the amount of current flow in a circuit

3 Problems occur when resistance is excessive

1 Allows you to predict how an electrical circuit will behave

a States that current flow in a circuit will always be tional to the voltage and resistance in a circuit

propor-1) E, I, and R in a circuit are always proportional andmaintain a fixed ratio with each other

a) If you know the value any two of those nents, you can mathematically determinewhat the third one is

compo-2 Because we deal with predominately 12 V only circuits, the rule

to remember is that when there is more resistance in a cuit, there is always less current flow.

cir-3 On car applications of Ohm’s law

Demonstrate each of these conditions on the Simulator as you talk about them.

a If a circuit is inoperative: infinite resistance or opencircuit

b Partially operative: excessive series resistance

c Fuse is blown: excessive current flow from too littleresistance

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1) Short-to-ground before the load2) Too low circuit resistance from over-loading

Be sure to stress to the technician how these principles are time ers in the diagnostic process Ohm's law allows them to eliminate unnecessary checks and component changes Application of Ohm's Law allows you to quickly identify the type of problem (Open, short, high resistance), and using the EWD, you can eliminate any guesswork involved in identifying the potential problem areas.

sav-NOTES ARE ON EACH SLIDE

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III Series Circuits

A “True” definition has multiple loads with a single path of current flow

1 Example circuit is Lexus cooling fan circuit on most models

D Voltage

1 Divides proportionately between all the resistances

2 The sum of the voltage drops will equal the source voltage

You will always encounter a situation in class where the voltage drops DO NOT add up EXACTLY to the source voltage Small differ- ences (usually less than 0.10 volt) can be attributed to meter inaccura-

cy, meter lead resistance, fluctuations in source voltage, and ing error in the DMM.

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b High resistance problems can be identified by the voltagedrop There should only be a voltage drop of significance

IV Parallel Circuits

A Defined as a circuit with multiple loads, but also multiple paths toground

Never use the phrase “Current flow takes the path of least resistance!”

If you have a parallel circuit with a 2 and 4 W resistor, current flow does not just take the 2 W path, the path of least resistance If the phrase was changed to “Current flow will always take a path of no resistance and by-pass (short out) the rest of the circuit,” then it would

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D Resistance

1 Total resistance is less than the smallest resistor

2 On-car application

a We tend to look at parallel circuits in terms of amperage

b The more components in parallel, more amperage flows

c (With voltage constant) If amperage is increased, Ohm’slaw says that it can only happen if there is a decrease inresistance

Most technicians find this concept very confusing to understand As long as they can see that current flow is increased when a branch is added, that is all they need to know for this class.

E Current Flow

1 Total current flow is equal to the sum of the current flow ineach branch

2 On-car application

a Each branch works independently of each other

b The amperage that each accessory “draws” adds up tototal load on the charging system or fuse

c You can determine the amount of amperage a componentdraws by measuring the change in amperage at the bat-tery when the accessory is turned ON

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V Series Parallel Circuits

A Combination of elements of both series and parallel circuits together

b If problem occurred in series to a set of power/groundsthat are connected in parallel, it will affect all of the cir-cuits

3 Connectors

a Junction connectors in series with a fuse distributepower to multiple circuits

b Series power supply

c Parallel power connections at J12/J13

d Parallel grounds at J5/J6

e Series control through R5 rheostat

VI Electrical Circuit Concepts This section is meant to provide a review of the basic EWD schematic symbols as well as a theory review.

A Components in a basic circuit

Emphasize that for the circuit to function properly, you need all of these conditions present.

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2 Voltage source (power and ground)

a Provided by the battery and alternator

b Altenator provides AC

c Battery provides DC

d Other sources found on car:

1) Sensors (speed sensor)2) Capacitors

2) Circuit breakera) Some types have a hole at the top to resetthe breaker

2) Broken wires impact switch

b Resistors

c Transistors1) Acts as a non-mechanical switch with “logic” fea-tures

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b The amperage or electron flow occurs whenever there is

a complete pathway to ground

6 Connectors

According to Field Technical Product Report Summaries, connector and terminal problems are the #1 electrical problem, and account for

up to 75% of all electrical problems, depending on the model.

a Aids in assembly and service of the vehicle

b Typical problems1) Disconnected2) Terminal backed out3) Terminal corroded4) Terminal spread too wide5) Improperly made splice

These terminal/connector problems can be illustrated on a scrap ness Demonstration of a terminal with too wide a spread can be useful to illustrate how to inspect a terminal for this condition Also, show the Lexus Wire Repair SST to the class.

har-In L 652, we will not be discussing a lot of the theoretical aspects of electricity such as the 2 current flow theories This course will always assume the use of the conventional theory of current flow (+ to -).

B Requirements for current flow

1 A complete connection between the + and - sides of the age source

volt-a The pressure differential causes the current to flowthrough the conductor

b Using a voltmeter in parallel to the load, the voltage dropshould be about the same as the voltage drop at thesource

2 The resistance in the load and in the control device

a Regulates the amount of current flow

b When it will occur

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C In actual application, voltage drop at the load is approximately thesame as the source voltage

1 It will never be exactly the same because of the series tances that uses some of the pressure that is available topush current through the load

resis-VII Basic Diagnostic Tools

A Electrical Wiring Diagram

Show the EWD/point out the actual EWD to the class.

1 The EWD is your #1 source for information to make repairs tothe electrical system

2 You must know your basic circuit theory and all the conceptstalked about in L 622 in order to be able to use the EWD to fix

a problem

a Little information in it to guide you through problems

b You must be able to follow the paths of current flow in thecircuit:

1) If you cannot follow those current flow paths, youwill not know where to perform checks with a volt-meter, or know what to look for (possible open,short, or high resistance problem)

In short, using the EWD to diagnose and successfully repair the cuits brings all the L 622 concepts together!

2) The RM and NCF have information about the self agnosis systems that are used in circuits such asSRS, ABS, and the Cruise Control System

di-2 Use the RM when

a Diagnosing ECU controlled circuits

b You need guidance as to how to diagnose the circuit

c You need verification of something listed in the EWD thatdoes not match the actual vehicle

C Introduction to the RM Body Electrical Section

1 This is the last of the tools that will be covered in this course

2 Very useful, especially in conjunction with the EWD

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3 Advantages over the EWD

a Has information about the self-diagnostic systems1) Trouble code system is not mentioned in the EWDa) Code definition

b) How to access codesc) How to clear codes

b Diagnostic Assistance1) Clear set of procedures for dealing with troublecodes

2) Individual component inspection procedures3) Tables which explain where each switch should beunder a given condition

a) Power door lock system “sensors”

4) Troubleshooting matrices

a) Direct you to check, given a particularsymptom, specific components in a spe-cific order

The matrices in the RM may not take into account the accessibility of components, or even the past history of failures, like the technician would while diagnosing with the EWD alone However, for a situation where the technician is totally “lost”, it would be the resource to use (Although, after completing this course, that situation should not occur!)

c Additional Specifications1) Various resistance and voltage values

4 Disadvantages to using the RM Body Electrical Materials

a Black and White only

b Does not use the connector/component ID system used

in the EWD1) Slowly is being integrated into the RM

2) 1998 ES 300 BE section uses the EWD connector/component ID system

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D Digital Multimeter

1 This course concentrates on the DMM only Analog metershave their place, but in general, the DMM provides many ad-vantages:

a Highly accurate

b Additional features such as min-max, peak hold

c Low cost models available

d Good models are highly durable

e Many meters provide an analog bar graph to view ages that are changing rapidly (acts like a mini-oscillo-scope)

volt-f Can be used with confidence on solid state ECU trolled circuits

con-1) Some older or inexpensive analog meters havevoltmeters with a low internal impedance

a) The meter itself loads (uses power from) thecircuit you are testing

b) The additional current flow demand on anECU’s power supply can artificially “pull down”the circuit voltage

c) Leads to an inaccurate measurement

E Test Lights

1 Not emphasized in this class

2 have limited usefulness

3 can cause a number of problems

a ECUs

4 If hooked up in parallel becomes a load

5 Logic probe better for voltage testing

F Fused Jumper Wire

1 Should be used in place of straight jumper

2 Need to know the current before hookup

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USING THE ELECTRICAL WIRING DIAGRAM 1.20

1 Find and use each of the sections of the EWD

2 Given a system circuit diagram in the EWD:

• Identify each of the symbols used on the system diagram

• Understand the meaning of the labels that are used with those symbols

• Apply basic current flow theory to diagram the path of current flow through the circuit

Use the EWD to walk the technician through each of the sections thoroughly Answer any questions that theymay have about each of the sections, and add any additional information that you have about your experiences

in using the book

Although the sections of the EWD are illustrated in the Technician Handbook, it is recommended that you simplyuse the 1998 ES 300 EWD while talking about each of the Sections In this way, the technician will get practice

in using the actual tool that he has to work with in the shop

Component and parts location, and other information that is included with the system circuit diagrams will bediscussed later In this section, keep the technician focused on the schematic only

Use the ES 300 Body Electrical Simulator’s electrical circuits to illustrate what is being shown in the EWD

Required Materials

• L652 Technician Handbook

• Multimedia presentation

• 1998 ES 300 EWD (1 per technician)

• Spare body/engine wiring harness

• ES 300 Body Electrical Simulator

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Although each of these sections is illustrated in the Technician book, it is recommended that you have the technicians find and exam- ine each of these sections directly in the 1998 ES 300 EWD.

Hand-I Using the EWD

A Sections of the EWD

1 Section A: Introduction

a Defines what is in each section

2 Section B: How to use this manual

a Small explanation of diagnosis using the manual

b Definition of symbols and labels that are used on thesystem circuit diagram

c Explanation of each of the auxiliary sections of the tem circuit diagram

sys-3 Troubleshooting

a Techniques for measuring voltage

b Continuity and resistance checks

c Finding a short circuit

d Disconnecting male and female connectors

e Terminal removal techniques

4 Section D: Abbreviations

a A short list of some of the abbreviations that are used

on the system schematic

5 Section E: Glossary of terms and symbols

a Defines many of the schematic symbols that are used

on the system circuit diagrams

6 Section F: Relay Locations

a The first section that deals with the specific vehicle theEWD was written for

b Physical location of relay blocks and relays

c Junction Block diagrams and schematics

d Junction block connector and fuse information

e Relay block fuse and connector information1) Relay and junction blocks are grouped together andnumbered consecutively

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7 Section G: Electrical Wiring Routing

a Component location

b Wire harness routing

c Connector locations

d Wire harness to wire harness connector pin information

e Wire harness to wire harness connector locations

f Splice points

g Ground points

8 Section H: Power Source (Current Flow Chart)

a Power distribution to the each of the fuses and some

major components1) Not all components are covered Not entirely helpfulfor short-to-ground diagnosis

b Power distribution from each of the fuses1) Helpful in diagnosing short-to-ground or parasiticload problems

2) Gives page number of schematic, part name, andlocation code

9 Section I: System Circuit Diagrams

a Color schematics and additional information that is theheart of the EWD

10 Section J: Ground Point

a Gives ground point schematics and location tables

b Use to help find circuits that are connected to each otherthrough shared ground points

11 Section K: Overall Electrical Wiring Diagram

a Condensed version of “map” style wiring schematic

b Still useful to some technicians because “you can seeeverything at once”

c Because of increased circuit complexity, seeing thing at once is not necessarily an advantage anymore

every-d The new style circuit diagrams are easier to follow

The type of schematic a technician prefers many times depends on the type of schematic that he learned first For some technicians who have been in the business a long time, there may be some resistance

to the EWD schematics They are not used to turning pages to find the (power/fuse, ground, location) circuit information that is covered

in the different sections of the EWD.

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II System Circuit Diagram Features

A Breaks the vehicle electrical system into individual system circuits

B Provides identification code numbers for cross referencing to ServiceHints and location charts

C Lists all splices in harness wiring

1 Older versions of the EWD did not do this

D Provides references to circuits which share common nents

wiring/compo-E Provides all wires in color for easy identification

F Uses colors and grey shading to identify different components

G Fuses (power) are at the top, ground at the bottom

1 When a battery or fusible link is used in the circuit, it is located

on the lower left of the schematic

III Parts of the System Circuit Diagram Section I Recommend to the technicians to use the table of contents at the front

of the EWD to help locate the system circuit diagram that they are looking for It definitely helps speed up the process of finding the right circuit.

A System Title

1 Always at the top corner of the page

2 Power Source, Starting/Charging circuits are always first

3 The easiest way to find the circuit you need is to use the table

of contents either at the front of the book, or at the beginning

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* This is different from other manufacturers

2 If the wire has a stripe or “tracer” on the wire, the color is resented by a dash (-) and a second letter

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C Junction Block

Using the spare body/engine wiring harness, show an actual Junction Block and Junction Connector If possible, disassemble a Junction Block to show how it is constructed.

This slide is taken from the Moon Roof circuit on page 238 of the

1998 ES 300 EWD.

1 Always shaded grey

2 Different shading to differentiate the different junction blocks

3 ID number is always in an oval

a Number indicates the J/B number

b Letter indicates a specific connector

c Number next to the oval indicates the pin number in theconnector

Many times, you need to look at 2 or more different system circuit schematics to find a specific component, wire or connector An example of this would be all the schematics that have the Integration Relay

in it In order to know about all the terminals at the Integration Relay

on a 1998 ES 300, you need to look at the headlight, tailight, tion, Interior Light, and Tail Light wiring diagrams.

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D Relay Block

Using a Body or Engine harness, show the technicians an actual lay Block If that is unavailable, use the ES 300 Body Electrical Simu- lator.

Re-1 Relay blocks are not shaded

2 ID numbers in an oval symbol indicate which relay block thecomponent is located in

This slide is from the Headlight (Canada) schematic page 98 of the

1998 ES300 EWD

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E Components/Parts

1 Parts are always shaded Blue

2 ID numbers usuaully begin with the first letter of the name ofthe component

3 Use the parts location table found in the support section ally found behind the system circuit diagram to locate compo-nents

usu-4 Component ID number corresponds to the ID number on theschematic

a Pin numbering system is different for male or female minals:

ter-1) Female - left to right, with #1 in the upper left corner.2) Male - right to left, with #1 in the upper right corner

b View of the connector is from the terminal side of theconnector lock tab up

5 Explains cavities that are not used in the particular circuithave a “•” in them, and those cavities that are left empty andmarked by an X

It is usually helpful to match the wire color on the schematic to verify the correct pin on the connector when doing any pin/voltage inspection.

Slide 44

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F Multiple Connectors

1 Letter in a circle is used to designate which connector

2 ID Numbers

a E for Engine

b I for Instrument Panels B for Body

The Integration Relay on the headlight, tail light, interior light, and auto shut-off circuit schematics is shown in varying degrees of detail

on each system circuit diagram.

G Parts label

1 All parts are labeled and are colored sky blue

H Wire harness to wire harness connectors

1 On harness-to-harness connectors, the connector symbol cates which terminal is the male or female terminal

indi-2 Most connectors are white in color If the connector is a ent color, the color will be noted above the illustration

differ-3 Harness-to-harness connectors use an I, E, or B as the firstdigit in the ID number to indicate approximate location

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I Locating a Harness to Harness Connector

1 Use ID number on the location table

2 Column to the right of number gives page number

3 Find location of connector on designated page

J Switches and Relays

1 Switches shown in Normal position

2 Multi-pole switches (Combo Switch, Heater Fan, etc.)

a Circle and line show connections at various switch tions

posi-b Gang type switch has dotted line inside switch ing the arms

sur-b Used on low current flow ECU sensor circuits

2 Intermittent or erratic operation of ECU controlled systemscould be caused by the failure of the shielding

Slide 48

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