Nissan Electrical Components Diagnosis and Repair 1 PDF

ELTN9911B
REVISED MA
Y, 2003
MAY
This book is designed for instructional

use only for Nissan North America, Inc.
and authorized dealer personnel. For
additional information contact:
Nissan North America, Inc.
Corporate Training Office
Technical Training
18501 S. Figueroa St.
Gardena, CA 90248-4500
2003 Nissan North America, Inc.

All rights reserved. No part of this
publication may be reproduced in any form
without the prior written permission of the
publisher.
Printed in U.S.A.
First Printing: February, 1996
Revised:
May, 2003
This manual uses post

consumer recycled fibers
Corporate T
raining Office
Training
Technical Training
Nissan North America, Inc. reserves the right to alter specifications or methods at any time.
ii
ELECTRICAL COMPONENT DIAGNOSIS AND REP

AIR
REPAIR
TABLE OF CONTENTS
Section 1: T
ext
Text
Electrical Component Diagnosis and Repair Overview .......................................................................... 1
Introduction ............................................................................................................................................... 1
General Precautions ................................................................................................................................ 2
Circuit Requirements ...................................................................................................................................... 3
Source, Load and Ground ...................................................................................................................... 3
Circuit Protection Devices .................................................................................................................... 13
Circuit Controls ............................................................................................................................................. 17
Switch-Controlled Circuits .................................................................................................................. 17
Electrical Test Equipment ............................................................................................................................ 22
Analog Meters ......................................................................................................................................... 22
Digital Meters .......................................................................................................................................... 22
Ohmmeter Use ........................................................................................................................................ 23
Voltmeter Use .......................................................................................................................................... 25
Available Voltage .................................................................................................................................... 25
Voltage Drop ........................................................................................................................................... 26
Ammeter Use ........................................................................................................................................... 29
Relay Controlled Circuits ...................................................................................................................... 31
Meter and Gauge System ........................................................................................................................... 42
Spedometer Operation ......................................................................................................................... 43
Motors ............................................................................................................................................................. 44
Starting System ............................................................................................................................................ 45
Charging System Description .................................................................................................................... 49
iii
Electrical Diagrams ....................................................................................................................................... 51

Connector Symbols in Electrical Diagrams ...................................................................................... 55
Trouble Diagnosis Charts ..................................................................................................................... 61
Location of Electrical Units ................................................................................................................... 65
Foldout Circuit Diagrams ...................................................................................................................... 66
Using the Service Manual to Research Related Information ......................................................... 70
Electronically Controlled Circuits .............................................................................................................. 86
ECU Inputs .............................................................................................................................................. 87
Electronic Control Units (ECUs) ......................................................................................................... 88
Electrical Diagnosis ...................................................................................................................................... 93
Preliminary Diagnosis Tips .................................................................................................................... 94
On-Car Troubleshooting Tips .............................................................................................................. 94
Motors ....................................................................................................................................................104
Meter and Gauge Diagnosis ..............................................................................................................105
Meter and Gauge Check .....................................................................................................................107
Glossary of Terms .......................................................................................................................................109
iv
Section 2: Exercises
Module 1
Locate Service Manual Information
Module 2
Intepret Service Manual Information
Module 3
Measuring Available Voltage
Module 4
Measuring Voltage Drop
Module 5
Measuring Resistance
Module 6
Measuring Current
Module 7
Combination Switch Operation
Module 8
Diagnosing One Transfer (1T) Relay Malfunctions
Module 9
Diagnosing One Make (1M) Relay Malfunctions
Module 10
Diagnosing Two Make (2M) Relay Malfunctions
Module 11
Diagnosing One Make-One Break (1M-1B) Relay Malfunctions
Module 12
Circuit Diagnosis Exercise #1
Module 13
Module 14
Module 15
Module 16
Module 17
Module 18
How to Use a Digital Multimeter
Module 19
Fuel Gauge Tank Unit Testing
Module 20
Service Manual Electrical Symbols
Module 21
Testing Batteries, Starter and Charging Systems
ELECTRICAL COMPONENT DIAGNOSIS AND REP

AIR
REPAIR
OBJECTIVES
Upon completion of this training program, you will be able to:
Given an Electronic Service Manual (ESM), locate wiring diagram descriptions and interpret
the information as stated.
Given an ESM, interpret wiring information/diagram symbols and answer related questions.
Given a multimeter, a circuit simulator and a windshield wiper motor circuit, measure
available voltage at different points in a circuit and make comparisons for the purpose of
diagnosing faults.
Given a voltmeter and a test circuit, measure voltage drop as specified and evaluate the
results against established specifications.
Given a digital multimeter, a circuit simulator, a service manual, a fuel-injected vehicle and
other components, measure resistance and compare to specifications.
Given a digital multimeter, a circuit test kit with overlay #1, measure current flow through a
circuit and evaluate the results.
Given a combination switch and a combination switch circuit, read a combination switch
chart and diagnose various combination switch circuits using a digital multimeter.
Given a service manual (or ESM), a digital multimeter, a one transfer (1T) relay, circuit test
kit with overlay #2, diagnose the operation of a 1T relay.
Given overlay #3, a service manual and test equipment, test the operation of a vehicle with
1M relay circuit.
Given a service manual, a digital multimeter, a two make (2M) relay and a circuit test kit with
overlay #4, diagnose the operation of a 2M relay.
Given a test kit with overlay #5, a service manual, digital multimeter and a one make-one
break (1M-1B) relay, diagnose the operation of a 1M-1B relay.
Given a customer's repair order, a service manual and digital multimeter, verify, isolate, repair
and recheck the incident in question.
Given a digital multimeter, electrical components and a car, identify the different meter
features, connect the test leads, and perform voltage, resistance, amperage and continuity
tests.
vi
Given a digital multimeter, service manual and an on-vehicle tank gauge unit, test the
operation of the fuel tank gauge unit and evaluate the test results.
Given an ASIST/ESM workstation, identify and interpret the symbols used in electrical
wiring diagrams.
Given a vehicle, digital multimeter and model 620 tester, test the battery, starter and
charging system.
vii
NO
TES
NOTES
viii
T
E
X
T
ELECTRICAL COMPONENT DIAGNOSIS AND REPAIR OVERVIEW

Vehicles use electricity to control and operate many systems such as headlights, windshield
wipers and rear window defoggers. Todays vehicles also use sophisticated control units and
circuits to add to driving comfort and the driver's control of the vehicle.
Despite the number of electrical circuits in a vehicle, troubleshooting and repair techniques used
on all circuits are relatively basic and straightforward, given some basic skills. To repair an
electrical problem correctly the first time, you must know how to troubleshoot and repair circuits.
This course will provide you with the skills necessary to:
Verify symptoms by attempting to operate circuits. Verify what is working and what is not
working.
Isolate the source of the malfunction by:

- tracing current flow paths using wiring diagrams.
- locating harness connectors using harness layout diagrams.
- testing electrical circuits using a multimeter.
Repair electrical problems by:

- fixing broken wires and poor connections.
- replacing broken components.
- adjusting a switch or sensor.
Recheck to make sure the symptom is fixed. Duplicate conditions that caused the
problem, to be sure there are no new problems.
Introduction
The Electrical Component Diagnosis and Repair Course is a four day course covering diagnosis
and repair of electrical systems. The Course begins with a review of electrical fundamentals
followed by a series of shop exercises. The following skills are emphasized:
Reading wiring diagrams
Circuit testing techniques
Each of the exercises will challenge your troubleshooting skills. The objectives for this course
were carefully chosen to help you learn a more efficient way to diagnose electrical malfunctions.
INTRODUCTION
General Precautions
Do not use electrical test equipment on any circuit related to the Supplemental Restraint
System (SRS) unless instructed to do so by the service manual or your instructor. SRS
circuits are identified by yellow insulation covering the wiring harnesses or yellow harness
connectors.
Do not operate the engine without adequate exhaust ventilation.
Keep the work area well ventilated and free of any flammable materials. Take special care
when handling any flammable or poisonous materials, such as gasoline, refrigerant gas,
etc. When working in an enclosed area, be sure to properly ventilate the area before
working with hazardous materials.
Do not smoke while working on the vehicle.
Before elevating the vehicle, apply wheel chocks or other tire blocks to the wheels to
prevent the vehicle from moving. With the vehicle parked on level ground, support it with
safety stands at the points designated for proper lifting or use a hoist to support and
raise it if needed.
Before starting repairs or circuit diagnosis which do not require battery power:
- Switch the ignition OFF.
- Disconnect the negative battery cable
To prevent serious burns:

- Avoid contact with hot metal parts.
- Do not remove the radiator cap when the engine is hot.
Before working on the vehicle:

- Use fender covers, seat covers and floor mats.
- Be careful that keys, belt buckles or buttons do not scratch painted surfaces.
Do not touch the terminals of electrical components that are controlled electronically.
Static electricity may damage internal electronic components.
INTRODUCTION
CIRCUIT REQUIREMENTS
Source, Load and Ground
The basis for discussing electricity in vehicles is the circuit. A circuit is a complete path for
electricity to flow. Electrical circuits consist of wires, wire connectors, switches, circuit protection
devices, relays and electrical loads and grounds. The conventional current flow theory traces
current from the source to ground. Despite the complexity of the circuit or the number of parts in
the circuit, there are three essential elements all circuits must have to operate:
Source (voltage)The battery and the electrical path from the battery to the load. This is
the positive (+) side of the circuit.
LoadAny electrical component that uses electrical energy to perform work. Examples
are lights, motors and defroster grids.
GroundThe electrical path from the load back to the battery. This is the negative ()
side of the circuit.
If any of these essential elements is missing or not working, there is no current flow and the
circuit will not operate. Let's look at each of these elements.
Source side of circuit
Battery
Wire
Ground side of circuit

Load
Wire
Source (Voltage)
The source of voltage is the battery or alternator. The voltage source provides the energy to
push current through the circuit, which makes it operate. The source side of the circuit includes
all parts between the battery and the load. Refer to the battery rating charts (Page 46) at the end
of the text section for recommended battery applications.
Load
A load is the device that produces heat, light, sound or motion when the circuit is operating. Light
bulbs, motors and heating elements, such as cigarette lighters and rear window defoggers, are
typical electrical loads. A load always has resistance and consumes (uses up) voltage when the
circuit is ON.
Ground
A ground completes the circuit from the load back to the negative battery post. Notice that a
ground path is always on the other side of the load. As important as the ground is, it is the part
of the circuit that is most often overlooked.
Perhaps a reason for this is that technicians often think that circuit grounds consist of separate
wires. Using a separate ground wire to connect each vehicle circuit to the battery is not practical.
Most electrical circuits complete the ground path directly to the vehicle chassis or body.
Load
Negative
Battery
Ground
When source, load and ground are all operating correctly, a complete path for current flow exists.
This is a complete (or closed) circuit. An open circuit occurs when the electrical path is
interrupted. This might occur when a switch is open, a light bulb burns out, a wire breaks or a
wire connector becomes disconnected.
Voltage, Amperage and Resistance
Working circuits contain these three electrical elements:
Voltage - The electrical pressure that pushes current through the circuit.
Amperage - Flow of current moving in a circuit.
Resistance - Opposition to the flow of current.
Voltage (Symbol: V)
Voltage is the electrical pressure that pushes current through a circuit. Nissan and Infiniti vehicles
all use 12 volt batteries, but the system operates at up to 14.7 volts while the engine is running.
The charging system provides the additional voltage to keep the battery charged.
Electrical
current
Voltage = Electrical pressure
Amperage (Symbol: A)
Amperage is the measurement of current flow in a circuit. Current does not flow unless voltage is
present to push it through a circuit.
Research in chemistry and physics has established the electron theory to help explain what
electricity is and how it is used.
The electron theory states that all matter is made up of atoms. Atoms contain three types of
smaller particles called:
Protons
Neutrons
Electrons
Protons, which have a positive electrical charge, combine
with neutrons (which have no electrical charge), to form the
center or nucleus of the atom. Electrons have a negative
electrical charge and orbit around the nucleus, much like the
planets in our solar system orbit around the sun.
Certain materials such as copper and steel contain free electrons which can be pushed from one
atom to the next. This movement of electrons occurs in one direction, creating a chain reaction.
The chain reaction in which free electrons move from one atom to the next is called current flow
or electricity.
Resistance (Symbol:
Resistance opposes current flow in a circuit and is measured in Ohms.

Resistors are electrical devices that restrict current flow in a circuit. Because they restrict current
flow, voltage decreases as current is pushed through a resistor. Two types of resistors are used
in automotive circuits. A fixed resistor has a set resistance in a circuit. A variable resistor, such as
a dimmer control, changes the amount of current flow by mechanically changing its resistance.
Switch
Light bulb
Battery
Variable resistor
Earlier, we spoke of a circuit's requirements for source voltage, load and ground. The load is the
device that provides heat, light, or motion. When the resistance of the circuit load is in the normal
range, with power applied and a ground connected, the circuit operates as designed. However,
if either the source, load or ground is out of balance, the circuit will malfunction.
For example, suppose the battery voltage drops below the normal range. Circuits such as the
starting circuit cannot operate as designed. In such cases, the customer may complain of hard
starting.
Malfunctions occur when resistance in a circuit increases or decreases abnormally.
Increased circuit resistance can be caused by loose connections, corroded wire

connectors or dirty switch contacts. These conditions create unwanted resistance that
reduces the normal flow of current needed to operate the load. This causes bulbs to be dim
and motors to turn slowly because voltage is used up by the unwanted resistancethe
circuit has to work harder.
Decreased circuit resistance increases current flow in a circuit. This can be caused by a
partially shorted load. The result is a blown fuse. In some cases, higher than normal current
flow can overheat and burn wires and connectors.
The following chart summarizes the terms weve just described. We'll discuss circuit diagnosis in
a later section of this manual.
Term
Definition
Unit of Measure
Symbol
Voltage (E)
Electrical pressure
Volt
Amperage (I)
Current flow
Amp
Resistance (R) Opposition to current flow
Ohm
Conductors
Conductors are devices such as wires, that provide a path for current to flow. Some materials
conduct electricity much better than others. Copper and steel are good conductors. Gold and
silver are even better conductors because they have even more orbiting electrons. Since gold
and silver are quite expensive, they are used sparingly on circuits such as the Supplemental
Restraint System (SRS).
Insulators
Materials which do not conduct electricity are called insulators. Materials such as wood, glass,
rubber and plastic are some examples of insulators. These materials are made of atoms whose
electrons are very tightly bound to the nucleus and cannot easily move to other atoms. In vehicle
wiring harnesses, the insulation isolates each wire so current flows only through the intended
path.
Conductors
Best
m
er r
nu l
i
p
d
e
o l o p ilv um ee a d
G C S Al St Le
Insulators
ir
A
r
ic
ic
be a s t
m
b
a
l
P
er
Ru
C
Best
Ohms Law
In 1826, a German physicist named Georg Ohm developed a theory about electricity. Simply
stated, there is a relationship between voltage, resistance and amperage. To apply this in a
practical sense, consider the following two examples:
1.
If voltage (volts) stays constant and circuit resistance (Ohms) increases, current flow
(amps) decreases.
Resistance
(Ohms)
Current flow
(Amps)
Cause
Effect
Corrosion
Dim bulb
Loose ground
Fan runs
slow
12 Volts
(constant)
2.
If voltage stays constant and circuit resistance decreases, current flow increases.
Current flow
(Amps)
Resistance
(Ohms)
Cause
Effect
Short circuit
Fuse
blows,
circuit
stops
working
12 Volts
(constant)
Circuit Types
As previously stated, all circuits must have source, load and ground to operate properly. The way
in which these circuit elements are put together can be classified as either parallel, series, or
series-parallel.
Series Circuits
In a series circuit, the source, load and ground are arranged so current has only one path through
the circuit. Thus, the current flow (amps) will be the same no matter where it is measured in the
circuit. However, voltage in a series circuit decreases as current passes through each load.
Load #1
Source
Load #2
Switch
Current flows...
Battery
in one path
Ground
Ground
Note
Note: If the resistance of the loads are equal, the available voltage divides equally between the
loads.
A series circuit will operate if there are no opens in the circuit. In the circuit above, if the switch
fails (creating an open circuit), no current will flow and neither bulb will light.
Troubleshooting Tip #1:
An open at any point in a series circuit will prevent the entire circuit from operating.
Parallel Circuits
In a parallel circuit there are two or more paths for current to flow to ground. The tail light circuit
is an example of a parallel circuit. If one of the bulbs in a parallel circuit burns out, current will
continue to flow through the other path in the circuit and the other bulb(s) will still operate. In the
example below, if one of the bulbs does not work, current will continue to flow through the other
path in the circuit and the other bulb will still light.
Source
Switch
Load #1
Parallel branches
Load #2
Ground
Ground

An open circuit in a parallel branch prevents only the load in the open path from operating.
10
Series-Parallel Circuits
Besides series and parallel circuits, some vehicles also have series-parallel circuits. A seriesparallel circuit is a combination of the two circuit types. The parallel part of the circuit (load 1 and
2) can be diagnosed as a parallel circuit while the series part of the circuit (load 3) is diagnosed
the same way as a series circuit.
Load #1
Switch
Load #2
Battery
Load #3
Dimmer Control
(variable resistor)
Ground
Ground
Series-parallel circuits typically contain a dropping resistor either before the circuit branches or in
the ground side of the circuit after the loads. One common example of a series-parallel circuit is
the dash light circuit. The dimmer control (variable resistor) is installed in series between the
parallel loads (bulbs) and the circuit ground.
11
In a parallel circuit, if the resistance of each bulb is the same, current flow will be the same. If
resistance changes in any of the paths, current flow through that path will also change. A bad
connection at one of the bulbs will change the resistance for only that one bulb. In the example
below, high resistance causes load #2 to glow dimly, but load #1 operates normally.
Vehicles use parallel circuits so each load has the same available voltage to operate it. These
circuits typically branch out from the fuse box.
Load #1
Source
Switch
Load #2
Battery
Ground
Connection with
high resistance
Ground

An open in a parallel circuit only affects the operation of the load in the open branch.
However, if a problem occurs before the circuit branches, it will affect both loads. If one or
both loads operate poorly, look for high resistance in circuit connections.
12
Circuit Protection Devices

There are three types of circuit protection devices. They are fuses, fusible links and circuit
breakers.
Fuses, Fusible Links and Circuit Breakers
Most electrical circuits use protection devices such as fuses, fusible links and circuit breakers.
Circuit breakers open when excess current flow causes them to overheat. They reset after a
cool-down period. Fuses and fusible links are thin wires that melt very easily when overheated by
excessive current flow. Fuses and fusible links are built-in weak spots designed to protect circuit
components and wiring from damage. Fuses fail because of two conditions: short circuits and
grounded circuits.
A crossover circuit (short to voltage) occurs when two different circuit conductors
electrically touch each other. This occurs when a bare wire from one circuit touches a bare
wire from another circuit. Such conditions may cause wiring to overheat or fuses to melt if
the resulting current flow is greater than designed into either circuit. Normal circuit
switching is no longer effective when this condition occurs.
Conductor
Wire insulation
Short to voltage
Bare conductors touch and fuse melts to protect circuit
A short-to-ground occurs when current bypasses the circuit load and goes directly to
ground. When this occurs, the resistance in the circuit is so low that current increases
above the rating of the fuse protecting the circuit and the fuse melts. Never substitute a
higher amperage rating fuse when this condition occurs because wiring will surely melt
together as a result of higher than normal current flow.
Conductor
Wire insulation
Short to ground
Chassis Ground
Bare conductor touches and fuse melts to protect circuit
13
Fuses
Fuse ratings are based on the current flow needed to operate the circuit while protecting it from
excessive current flow. For example, a circuit that normally draws 6 amps might have a 10 amp
fuse to protect it.
If you replace one fuse with another that has a higher than recommended rating, a short circuit
(resulting in excessive current flow) could damage circuit components before the fuse melts.
Never substitute a fuse with a rating different than specified for that circuit. Refer to the label on
the fuse panel for the correct application.
Blade-type fuses have a high resistance to shock and vibration and greater durability once in
service. The fuse material of blade fuses is molded into the colored plastic. The current rating is
molded into the top of the fuse. The color also indicates the current rating.
Fuse Color
Current Rating
Brown
7.5 amps
Red
10 amps
Blue
15 amps
Yellow
20 amps
Green
30 amps
Fusible Links
Fusible links also protect against excessive current flow.
They protect circuits between the battery and the fuse
block. Like fuses, fusible links use different colors to
identify the amperage ratings of fusible links. The chart on
the opposite page shows the common sizes.
Fuses and fusible links blow because of increased
current flow (reduced resistance) in the circuit
between SOURCE and GROUND.
14
Color
Continuous Current Flow
Current to melt
fusible link within 5 sec.
Brown
15 amps
About 120 amps
Green
20 amps
About 200 amps
Red
25 amps
About 250 amps
Black
33amps
About 300 amps
Fusible links:
Protect high current, direct load circuits such as the radiator fan.
Provide current for multiple fused circuits (see illustration, next page).
Are only found on the source side of the circuit, never on the ground side.

If an unwanted ground occurs on the GROUND side of the a LOAD in a ground-switched
circuit, the LOAD will stay ON all the time.
Blown fuses often result after body or other major repairs to a vehicle. Always check for
pinched wires in areas where repairs have recently been performed.
Circuit Breakers
Circuit breakers are circuit protection devices that open when excessive current flow causes
them to overheat. The contacts close again after the circuit breaker cools down. Some circuits
are equipped with circuit breakers that protect multiple circuits. See the power supply routing
illustration that follows.
15
Fusible links
Fuses
Circuit breaker
protects multiple
circuits
Note
Note: Fuses and fusible links melt because of increased current flow (reduced resistance) in the
circuit.
Placing fusible links on the source side of a circuit will prevent wires from overheating.
16
CIRCUIT CONTROLS
So far, weve discussed circuit requirements (source, load and ground) and circuit arrangements
(series, parallel and series-parallel). Electrical circuits are controlled by three different devices.
They are:
1.
Switches
2.
Relays
3.
Electronic devices (such as the Engine Control Module). These will be covered later.
Switch-Controlled Circuits
Even though the only requirements for a circuit to operate are a power, load and ground, most
circuits are a little more complex. Switch-controlled circuits contain wires, connections, relays,
motors, bulbs and a switch.
Switches control either the source or ground side of the circuit. Some switches are manually
operated. Some switches are temperature controlled, and yet others are controlled by pressure.
No matter what type of switch is used, there are three important points to remember:
1.
Switches are not loads.
2.
Switches are wired in series with the circuit.
3.
Switches can be located on the source or the ground side of the load.

If an entire circuit is dead, the problem is with a series component such as a switch or
SOURCE, wiring connections, faulty load or the GROUND.
CIRCUIT CONTROLS
17
Switch Positions
Switches are shown in wiring diagrams as if the vehicle is in the normal condition. A vehicle is
in the normal condition when:
Ignition switch is OFF
Doors, hood and trunk lid/back door are closed
Pedals are not depressed, and
Parking brake is released
Normally Closed Switch

(NC)
18
Normally Open Switch

(NO)
CIRCUIT CONTROLS
The following switches are normally open (NO): Brake pedals (usually not depressed), doors
(usually closed), hoods (usually down), parking brakes (usually released).
The front door switches in the diagram below are normally open (NO) switches. When the
doors are closed, both switches are open and the interior light is OFF. If the door switch
contacts were to close (interior light ON) when the door closes, it would be classified as a
normally closed (NC) switch.
Normally Open (NO)

switches
(manually switchable)
Door position
CIRCUIT CONTROLS
19
Multiple Position Switches

Multiple position switches are similar to single contact switches. However, multiple switches
connect more than one circuit so that separate devices (loads) can operate at the same time.
For example, the wiper switch is a multiple switch. It can make different contact point
connections to perform multiple functions.
TURN
Right turn
FOG LAMP
HEADLIGHT ON
OFF
N
OFF
High beam
INT
WASH
ON
Low beam
LO
OFF
Flash-to-pass
Left turn
HI
The wiper switch has several positionsOFF, INT, LO, HI and WASH. These positions are listed
across the top of the wiper switch chart that follows. The numbers along the left-hand side of
this chart identify each of the terminals housed in the switch connector. These numbers are
molded into the plastic housing of the wiper switch next to each of the switch terminals.
Wiper Switch Chart
Switch positions
Switch terminal
identification
numbers
OFF Switch Open

INT
Intermittent (delay)
LO
Constant Low Speed
HI
Constant hight speed
WASH Washers ON
Continuity points
The circles and interconnecting lines indicate the connections inside the switch.
Circles show the internal connections in each switch position.
Line between the circles show terminal connections for each switch position.
Note
Note: For example: In the LO switch position, only terminals #14 and #17 are connected or
have continuity.
20
CIRCUIT CONTROLS
Wiper Switch
Switch positions
Switch terminal
identification
numbers
Continuity points
To understand the wiper switch circuit above, simply read down the column which identifies a
particular switch position to see which terminals are connected by the circles and lines. Then
read the corresponding circuit terminal numbers in the far left column. The shaded example
shows terminals 14 and 17 connected when the switch is in the LO position.
Using the above chart for reference, identify the connected terminals for the other switch
positions:
Switch Position
CIRCUIT CONTROLS
Switch T
erminals
Terminals
OFF
and
INT
and
HI
and
WASH
and
21
ELECTRICAL TEST EQUIPMENT

There are two categories of test meters available for automotive electrical testing: analog and
digital. These categories refer to the type of meter display. The most common meter for
automotive testing is actually three meters in one. It is called a digital multimeter (DMM). The
three meters built into a multimeter are:
Ohmmeter
Measures resistance ( )
Voltmeter
Measures voltage (V)
Ammeter
Measures current flow in amps (A)
Analog Meters
Analog meters use a calibrated scale with a pointing needle to indicate the value of the
measurement being made. The needle points to the position on the scale. Analog meters have
serious limitations when used to test modern automotive computer-controlled circuits. Because
of their low internal impedance (resistance), electronic control units may be damaged from
increased current flow caused by connecting the meter in parallel. For this reason, they are not
recommended for testing automotive electrical systems.
Analog Meter
Digital Meters
Digital meters display a digital readout of the measurement being made. Use high impedance
digital multimeters to test automotive electrical circuits. The more reliable digital multimeters have
an input impedance of 10 megaohms or more.
22
Digital Multimeter (DMM) Safety Checklist:
Use a meter that meets accepted safety standards.
Use a meter with fused current inputs. Be sure to check fuses

before making current measurements.
Inspect test leads for physical damage before making a

measurement.
Use the meter to check continuity of the tests leads.
Only use test leads that have shrouded connectors and finger
guards.
Only use meters with recessed input jacks.
Select the proper function and range for the measurement you
intend to make.
Be certain the meter is in good operating condition.
Follow all equipment safety precautions.
Always disconnect the red (+) test lead first.
Use a meter which has overload protection on the Ohms function.
When measuring current without a current amp clamp, turn the power OFF before
connecting into the circuit.
Use extreme caution in high current and high voltage testing situations. Use the appropriate
equipment, such as high voltage probes and high current clamps, for your personal safety.
Ohmmeter Use
An ohmmeter has two important functions:
Measuring circuit or component resistance.
Checking continuity in a circuit or a component.
Most ohmmeters have different measuring ranges. If you dont know the resistance, start on the
highest test scale first, then switch to a lower scale to obtain the most accurate reading. Most
modern DMMs set the measurement range automatically (autorange).
23
CAUTION:
NEVER USE AN OHMMETER ON A CIRCUIT WHILE IT IS OPERATING. THIS
COULD DAMAGE THE METER.
To use an ohmmeter:
Step 1:
Set the meter to measure resistance

().
Step 2:
Check meter calibration by touching the

two test leads together. Typical test lead
resistance is between 0.2 and 0.5 .
Step 3:
Be sure the circuit being checked is

switched OFF. Never use an ohmmeter
on a circuit while it is operating. The
ohmmeter has an internal battery.
Additional voltage through the m eter may
damage it if the meter does not have
overload protection.
Rotary switch
Step 4:
Connect the meter leads to the ends of

the circuit or component to test and read
the resistance.
Note
Note: Take two (2) separate readings and compare
them to determine how good the ground is.
Non auto-ranging meters require you to multiply
your reading based on the scale selected.
Sending unit
1st
2nd
For example:
24
Voltmeter Use
A voltmeter is the most commonly used and most versatile of all automotive electrical testers. A
voltmeter has two functions:
Measuring circuit voltage
Measuring voltage drop
To measure voltage:
Step 1:
Set the meter to measure voltage:

DC (V ) or AC (V~). If circuit voltage is
unknown, use the scale closest to, but
higher than, 12 volts.
Step 2:
Connect the voltmeter probes in parallel

across the circuit to obtain a voltage
reading. Observe the polarity of the meter
when making these connections. In other
words, connect the red lead to the point
closest to the battery and the black lead
to the connection toward ground.
Step 3:
Operate the circuit being checked and

read the voltage in the display window.
DC volts
Available Voltage
Checking for available voltage measures the voltage available up to the location of the circuit to
which the meter is connected. In a normal circuit, there should be source (battery) voltage
available up to the load. Since the battery provides a constant 12 volts or more, any excessive
resistance in the circuit will reduce the available voltage to operate the load. Reduced available
voltage results in dim light bulbs, slower spinning motors and relay coil circuits that don't have
enough energy to close the contacts.
You can also use a test light to test high current, NON-ELECTRONIC circuits. A test light
can test bulb circuits, relay circuits and fuses for available voltage. However, a test light
CANNOT measure the amount of available voltage, a decided disadvantage.
25
Voltage Drop
Perhaps the biggest electrical problem faced by technicians is that of unwanted voltage drop in a
circuit. All loads in a circuit have resistance and use voltage. However, voltage drop can also
occur in other parts of a circuit, such as at connection points, and this can affect circuit
operation. A voltage drop test is a way of measuring the voltage used by an individual circuit load
or connections within the circuit. The voltage drop measurement tells you how much voltage is
used between the meter test leads.
Rule of Thumb for Voltage Drops at Connections
Note
Note: Maximum allowable voltage drops:
Wire Connections
less than 0.1 Volts
Ground Connections
0.1 Volts
Switch Contacts
0.3 Volts
Starter Solenoids
0.5 Volts
Each resistance in a circuit uses voltage, so a voltmeter can isolate circuit malfunctions by
measuring the voltage drop in a selected part of the circuit.
Earlier, we said that a switch is not a load. However, during diagnosis, use a voltmeter to
measure voltage at each of the switch contacts. This will indicate whether the switch is making
and breaking contact as it should. A voltage drop across the closed contacts indicates excessive
resistance and will cause the circuit to operate incorrectly.
The greater the resistance in any part of a circuit, the greater the voltage drop.
26
Look at the wiring in this drawing. If an ohmmeter were connected as shown, the single strand of
wire still making contact would give an ohmmeter reading of near 0 (zero) ohms (no resistance)
indicating a good circuit. However, during circuit operation this single strand of wire cannot carry
the amperes necessary for the circuit to operate properly. While the ohmmeter's low resistance
gives the indication that there is continuity, the single strand of wire impedes current flow.
Therefore, a voltage drop occurs at this point in the circuit.
Important Note:
Unwanted resistance can take many forms. For example, water can cause corrosion
inside a wire connector. This creates excessive resistance that reads on the voltmeter as
a voltage drop. Likewise, dirty or corroded switch contacts and loose wire connections
can produce unwanted resistance and cause a voltage drop.
When isolating circuit problems, perform tests that:
- You can do quickly
- You can do easily
- Tell you most about the problem
27
Inline Voltage Drop

To measure voltage drop:
V
V
Switch
V
Battery
(source)
Excessive Vdrop
V
Connection
with a high
resistance
a=b+c+d+e+f
Step 1:
Connect the voltmeter across the connection or portion of the circuit to be tested.
The positive lead of the voltmeter should be close to source and the negative lead
close to ground.
Step 2:
Operate the circuit.
Step 3:
The voltmeter will indicate how many volts are used by that part of the circuit.
Voltage drop can occur in any part of a circuit. Because a circuit must have source, load and
ground to operate, check the ground side of a load for voltage drop as well. Look for bad ground
connections at the vehicle frame, corrosion at the negative post of the battery and loose ground
straps or connections at components such as the starter motor and alternator.
28
Ammeter Use
An ammeter measures current flow in a circuit. If specifications are available, amperage (current)
readings can be helpful during diagnosis. Starter current draw (amperage) readings are listed in
the Service Data and Specifications of the service manual. However, amperage specifications are
not available for most other electrical circuits.
To measure current:
Step 1:
Connect the ammeter in series in the circuit. This means that all the current flowing
in the circuit will flow through the meter. Some hand-held meters can only measure
up to 2 amps. Some meters have the capability to measure up to 10 amps.
CAUTION:
THE AMMETER IS NOW PART OF THE CIRCUIT AND EXCESSIVE AMPERAGE,

SUCH AS MIGHT OCCUR IN A SHORT CIRCUIT, CAN DAMAGE THE AMMETER
FUSE. ALWAYS CHECK FUSES ACCORDING TO THE METER INSTRUCTIONS.
Step 2:
Be sure the positive lead of the ammeter is toward the battery plus (+) terminal
and the negative ammeter lead connects to the ground or negative () side of the
circuit.
Step 3:
Switch the circuit ON. An amperage reading above specifications indicates low
circuit resistance. A lower than normal current reading could be caused by a weak
battery, defective charging system or high circuit resistance.
Note
Note: Many ammeters have an inductive pickup instead of separate ammeter leads. Inductive
ammeters are both accurate and easy to use without becoming a part of the circuit.
Ammeter reads circuit current

Load
Battery
Connect ammeter to circuit at

fuse or switch to measure total
circuit current
29
Kent-Moore J-44373 Model 620 Tester

This tester is used to test batteries, starters and charging
systems. It uses the conductance method to determine the
battery's ability to produce voltage. Conductance is a
measure of the plate surface available in the battery to
determine how much voltage the battery can produce.
To determine the battery conductance, the tester produces a
small signal which is sent through the battery. The tester then
measures a portion of the AC current response. The tester
can test a battery exactly as received without having to
recharge it before testing. Because no loads are applied to
the battery, the test is completely safe. The results provide a
good indication of the battery condition based on the results
in the chart below. In some cases, the tester may recommend
a charge and retest.
WARNING:
NEVER RECHARGE A BATTERY IF THE TESTER INDICATES THERE ARE BAD CELLS.
DOING SO COULD CAUSE THE BATTERY TO EXPLODE AND INJURE YOU AND/OR
ANYONE NEARBY.
J-44373 T
est Results
Test
Battery T
ests
Tests
Starter T
ests
Tests
Charging System T
ests
Tests
Good battery
Cranking voltage normal
Good, but needs

recharge
Cranking voltage low

(starter suspected)
Charging system diode

ripple normal
Fully charge battery,

then retest
Charging system
incident caused by:
Replace battery and

retest
Bad cell detected
Charge battery
(insufficient charge for
test)
Replace battery
- No charging voltage
- Low charging voltage
- High charging voltage
- Excess ripple detected
Note
Note:
30
Record output codes for each test on the work order.

Record date and time before performing tests.
Relay Controlled Circuits

Relays are used to connect two parts of a circuit, much like a switch, by using low amperage
(thin) wires to control a higher amp circuit. However, a relay is not operated mechanically like the
other switches we discussed. Inside the relay housing there are two circuits: the control circuit
and the contact circuit. The control circuit contains a coil of fine wire which, when energized,
develops a magnetic field. The contact circuit contains a spring-loaded switch arm that connects
the relay contacts when the control circuit is energized. The magnetic field pulls the contacts
closed.
Relays have two separate circuits:
Coil control (low current) circuit
Contact (high current) circuit

Source
Source voltage to high

current circuit
Relay housing
Contact circuit (high
current), not yet connected
Control circuit (low

current)
Ground through ECM or

external switch
To circuit load
31
Like switches, relays can have normally open (NO) or normally closed (NC) contacts. In wiring
diagrams, hollow circles represent normally open relay contacts. Darkened circles represent
normally closed relay contacts. Refer to the following chart for more details.
NO and NC Relays
Not Energized
Does not flow
Energized
Flows
Normally Open
(NO) Relay
Switch 1
Battery
Switch 1
Battery
Does not flow
Flows
Normally Closed
(NC) Relay
Switch 1
Battery
Switch 1
Battery
Some relays have a single contact point circuit and others have two. Some relays have only
normally open contacts, while others have a combination of normally open and normally closed
contacts. The circuit design dictates the type of relay to use.
32
There are four types of relays used on vehicles:

1.
1M
(One-Make Relay)
2.
1T
(One-Transfer Relay)
3.
2M
(Two-Make Relay)
4.
1M-1B (One-Make, One-Break Relay)
To identify the connections used with each of the relays, a small diagram showing each of the
terminal numbers is molded into the top of the relay. On the bottom of each relay, terminal
numbers are shown next to each terminal.
33
1M (One-Make) Relay Operation

The 1M relay has four terminals in a single connector. Relays of this type are enclosed in either
a blue, green or yellow housing depending on the amperage rating of the contact point circuit.
The green relay is normally found on a ground circuit.
Wire terminals #1 and #2 of the 1M relay connect the coil to an external control. When current
flows through this circuit, a magnetic field develops causing the contacts between terminals #3
and #5 to close. This high current circuit connects the load to source or ground to complete the
circuit.
1-M Relay and Symbols Used
Bottom view
Color Code: Blue, Green or Y

ellow
Yellow
Circuit diagram
Wiring diagram

Although the configuration of the blue, green and yellow relays is the same, do not
interchange them. They have different operating specifications.
34
Relays plug into wire connectors or relay sockets. The service manual identifies each relay socket
with a connector number. In the following fog lamp relay circuit, the connector number is E49.
In the following wiring diagram:
The P/L (pink with blue stripe) wire (terminal #1) and the G/OR (green with orange stripe)
wire (terminal #2) are connected to the coil control circuit.
The OR (orange) wire (terminal #3) and the OR/B (orange with black stripe) wire (terminal
#5) are connected to the contact circuit.
Relay and relay socket

connector number
E49
1M Relay
35
1T (One Transfer) Relay Operation

The 1T relay has a black housing with five wire terminals. It operates like the 1M type relays with
one exception. There is normally contact between terminals #3 and #4 until the relay is
energized. When energized, current then flows from terminal #3 through terminal #5.
1T Relay and Symbols Used

1-T
Bottom view
36
Color Code: Black
Circuit diagram
Wiring diagram
1T Relay
1T Relay
37
2M (Two-Make Relay) Relay Operation

The 2M relay has a brown housing and is similar to the 1M type relay. However, the 2M relay
completes two separate circuits when the coil control circuit is energized.
Terminals #3 and #5 connect one circuit and terminals #6 and #7 connect the other. 2M relays
are used to divide current flow through two sets of contact points when high current flow may
burn the contacts in a 1M relay.
2-M Relay and Symbols Used
Bottom view
Color Code: Brown
Circuit diagram
Wiring diagram
A malfunction with a 2M relay can:
Prevent both loads from operating if the malfunction occurs in the coil control circuit.
Prevent one of the loads from operating if the malfunction occurs in either of the contact
point circuits.
38
In the following Rear Window Defogger circuit, two sets of contacts close at the same time
when the coil control circuit is energized. This provides two current paths to the rear window
defogger.
2M Relay
2M Relay
39
1M-1B (One-Make, One-Break) Relay Operation

The fourth type of relay, housed in a gray case, is the 1M-1B type relay. When the coil control
circuit of a 1M-1B relay is not energized, continuity exists through the normally closed contact
point circuit between terminals #3 and #4. When the coil control circuit between terminals #1
and #2 is energized, the circuit connecting terminals #3 and #4 opens. At the same time, the
normally open contact point circuit between terminals #6 and #7 closes, allowing current to flow.
1M-1B Relay and Symbols Used
Bottom view
Color Code: Gray
Circuit diagram
Wiring diagram
If the coil control circuit fails:
the normally closed circuit connecting terminal #3 to #4 will not open.
the normally open circuit between terminal #6 and #7 will not close.
40
In the following circuit, the inhibitor switch must be either in P or N to complete the
ground for the coil control circuit. This would then connect the contacts between terminal #6 and
#7 allowing the engine to start.
1M-1B Relay
This circuit
must be
energized to
start engine
1M-1B Relay
41
METER AND GAUGE SYSTEM

System Operation Overview
Automotive gauges display temperature, pressure or quantity. Most Nissan and Infiniti vehicles
use needle type gauges.
Instrument gauges activate when the ignition is switched ON. Needle-type gauges contain a
circuit that consists of a coil of wire connected in series to a sending unit, which is attached to
the object to measure. The sending unit is a resistor. Its resistance changes according to what
the gauge is designed to monitor (oil pressure, coolant temperature, fuel level, etc.). For example,
in a temperature gauge, when the engine temperature is high, the resistance in the sending unit
(and the circuit) is low. The voltage in a variable resistance circuit changes the magnetic field in
the gauge coil, which changes the position of the needle pointer. The scale in the gauge is
calibrated to the movement of the gauge needle.
Gauge sending units
2
2
1. Thermistor
2. V
ariable resistor
Variable
42
In the previous illustration, the tachometer, speedometer, fuel gauge and water temperature
gauge receive battery voltage with the ignition switch in the ON or START position. Voltage is
supplied through terminals #41, #10 and #22 to the speedometer, tachometer, water
temperature and fuel gauges.
The other combination meter terminals connect to ground and gauge sensors or transmitters.
For example, terminal #42 connects to the thermal transmitter to sense coolant temperature.
Terminal #14 connects to the fuel tank gauge unit to sense fuel level in the gas tank.
Speedometer Operation
The speedometer receives an alternating current (AC) signal from a vehicle speed sensor. The
vehicle speed sensor is attached to the drivetrain (transaxle/transmission). It mechanically
transmits the AC signal through terminals #24 and #30 at the combination meter (see the
previous illustration, ELTC1-46, page 36).
Speed Sensor
Speed Sensor Pinion
The AC signal is an analog signal (also called a sine wave). The voltage is measured continuously
in one second intervals. The number of complete sine waves produced in one second is called
the number of cycles-per-second or the number of Hertz (Hz). Hertz applies to the frequency of
any repetitive signal.
The vehicle speed sensor signals are also sent to the ECM, automatic transmission control unit
and ASCD control unit by way of the speedometer.
43
MOTORS
Motors are electromagnetic devices and have many applications. Youre probably most familiar
with the starter motor. Smaller motors operate windshield wipers, electric windows, power
seats, sunroofs, power antennas, and fuel pumps.
When current is applied to a motor, it creates two magnetic fields. The field coils are constant:
one is always north, the other always south. However, the magnetic field in the armature
switches so the attraction/repulsion effect of the armatures magnetic field will cause the
armature to spin. Repulsion of two north poles, for example, pushes the armature about a
quarter turn. Then the attraction of a north and south pole pulls the armature an additional
quarter turn to maintain the momentum of the motor.
To match the motor to the operating requirements of the system, many windings of wire are
wrapped around the field shoes and armature. The number of windings determines the speed
and torque of the motor.
Some motors, such as window and sunroof motors, need to rotate in two directions. Changing
the direction a motor rotates involves using a switch to change the polarity from positive (+)
(voltage), to negative () (ground) to the motor..
When diagnosing motor circuits, directional control of the motor is important. If one brush
is direct to SOURCE or GROUND, the motor runs in one direction.
44
MOTORS
STARTING SYSTEM
Typical Automatic T
ransmission-Equipped V
ehicle:
Transmission-Equipped
Vehicle:
The starting system cranks the engine when starting. The starting system consists of the:
starter motor
ignition switch
park/neutral position relay
park/neutral position switch
related fuse
fusible link
wiring and connections
For the starter to operate, a 40A fusible link to the ignition switch supplies source voltage from
the battery at all times. With the ignition switch in the ON or START position, a 15A fuse to the
park/neutral position relay supplies source voltage.
In addition, with the ignition switch in the START position, the ignition switch supplies source
voltage to the park/neutral position relay. The circuit is grounded when the selector lever is in
either the P or N position. The park/neutral position relay is energized by power supplied from the
ignition switch, through the park/neutral position relay to the starter motor windings. When this
circuit is complete, the starter motor plunger closes, providing a complete circuit between the
battery and the starter motor. The starter motor is grounded to the cylinder block. With source
voltage and ground supplied, the starter motor operates.
STARTING SYSTEM
45
Starting System: V
ehicles with A/T
Vehicles
46
STARTING SYSTEM
Typical Manual T
ransmission-Equipped V
ehicle:
Transmission-Equipped
Vehicle:
On manual transmission-equipped models, the starting system consists of the starter motor,
ignition switch, clutch interlock relay, clutch interlock switch, related fuse, fusible link, wiring and
connections. For the starter to operate, source voltage a 40A fusible link supplies at all times to
the ignition switch. With the ignition switch in the START position, source voltage is supplied
through the ignition switch to the clutch interlock relay.
In addition, with the ignition switch in the START position, a 10A fuse supplies source voltage to
the clutch interlock relay. While you hold the clutch pedal depressed, ground is supplied to the
clutch interlock relay through the clutch interlock switch and accompanying body grounds. The
clutch interlock relay is then energized and source is supplied from the clutch interlock relay to the
starter motor windings. The starter motor plunger closes and provides a closed circuit between
the battery and the starter motor.
The starter motor is grounded to the cylinder block. With source and ground supplied, the starter
motor operates.
Starting System Diagnosis & Repair Procedure
Note: If a starting system failure is indicated, you must complete visual inspections and voltage
drop tests before replacing the starter. Follow these steps to ensure that other possible
causes are ruled out first.
1.
Confirm starting system failure symptom by attempting to start the engine.
2.
Check condition of all fuses and fusible links connected to the starting system circuit.
3.
Check condition of all accessible harness connectors connected to the starting system
circuit.
4.
Ensure the vehicle has a fully charged battery that meets vehicle specifications installed.
5.
Ensure engine mechanical condition is good. A vehicle that exhibits extended cranking
symptoms may cause additional strain on the starting system. This could possibly result in
starter failure.
6.
Test starting system using Kent-Moore J44373 Battery, Starter, Charging System tester.
7.
If a starting system failure is indicated, perform voltage drop tests on the starting system
before replacing the starter. Perform voltage drop tests while cranking the engine.
8.
Compare your readings with the known good readings shown in the graphics on the
following pages. If your readings do not agree with these readings, check a known good
vehicle with the same engine as the one you are testing.
STARTING SYSTEM
47
Starting System: V
ehicles with M/T
Vehicles
48
STARTING SYSTEM
CHARGING SYSTEM DESCRIPTION

The charging system provides DC voltage to operate the vehicles electrical systems and to keep
the battery charged. It consists of the alternator, ignition switch, charge indicator lamp in the
combination meter and related fuse, fusible link, wiring and connections.
The IC regulator controls alternator output voltage at the S terminal. For the alternator to charge,
a 120A fusible link and a 10A fuse supplies power at all times to terminal S. Terminal B supplies
power to charge the battery and operate the vehicles electrical system. The alternator is
grounded to the engine block.
With the ignition switch in the ON or START position, a 10A fuse supplies source to the
combination meter for the charge warning lamp. Ground is supplied to the combination meter
through terminal L of the alternator. With source and ground supplied, the charge warning lamp
will illuminate. When the alternator is producing sufficient voltage with the engine running, the
ground is opened and the charge warning lamp will go off. If the charge warning lamp
illuminates with the engine running, a fault is indicated.
Charging System Diagnosis & Repair Procedure
Note: If a charging system failure is indicated, complete visual inspections and voltage drop
tests before replacing the alternator. Follow these steps to ensure that other possible
causes are ruled out first.
1.
Check the condition of all fuses and fusible links connected to the charging system circuit.
2.
Check condition of all accessible harness connectors connected to the charging system
circuit.
3.
Check condition and tension of the alternator drive belt.
4.
Ensure the vehicle has a fully charged battery that meets vehicle specifications installed.
5.
Ensure that engine mechanical condition is good. Any vehicle that exhibits extended
cranking symptoms may cause additional strain on the charging system. This could result in
alternator failure.
6.
With the ignition ON, engine OFF, confirm the Charge lamp is ON.
Note: If the Charge lamp is not on, diagnose this problem first. The charging system will not
work if the charge lamp is not working.
7.
Confirm charging system failure using Kent-Moore J44373 Battery, Starter, Charging
System tester.
8.
Perform voltage drop tests of the charging system circuits with the engine running at a
constant 1500-RPM. Load the alternator by turning headlamps and rear window defogger
ON.
CHARGING SYSTEM DESCRIPTION
49
Charging System
50
CHARGING SYSTEM
ELECTRICAL DIAGRAMS
Service literature uses two types of diagrams to help interpret and trace the wiring on vehicles:
Schematic Diagrams
Wiring Diagrams
Schematic Diagrams
The schematic diagram is a simplified electrical diagram of a circuit. This example of a turn signal
and hazard warning lamps circuit shows all the main components of the circuit. This makes it
easy to find source, load and ground on one page. However, the diagram does not show
important repair details such as connector numbers, wire color codes and fuse identification and
location. For that you need a wiring diagram.
Wiring Diagrams
ELECTRICAL DIAGRAMS
51
Wiring Diagrams provide a road map of electrical circuits and contain more detail than schematic
diagrams. They show:
Connector types and color
Wire colors
Wire position in the connector
Connector numbers (for location)
Location of wiring harness on the car
Fuse ratings
Accessory wiring harnesses
Number of pin receptacles in a connector
Splices in a circuit
Ground locations
Wiring diagrams provide a detailed view of a system. This can help isolate individual circuits for
testing. The ability to follow and interpret electrical diagrams is essential to diagnose and repair
electrical circuit malfunctions.
Wiring diagrams contain many important abbreviations, symbols, identifiers and codes. The
follow example describes these important features. Recognizing them and knowing what they
mean will help you use wiring diagrams more effectively when diagnosing and repairing electrical
malfunctions.
Though a wiring diagram may show only one wire in a connector, there may be more.
Other wires will not appear when they are part of different, unrelated circuits.
52
ELECTRICAL DIAGRAMS
The example wiring diagram below shows:
R/L is a Red wire with a blue stripe which connects terminal 12 of the combination switch
and terminal 12S of the fuse block.
Fuse block terminal 11S connects to both front side marker lamp assemblies.
Fuse block terminal 10Q connects to the taillamp circuit shown on the next page of the
repair manual.
Electrical wiring diagrams divide the entire electrical system into individual circuits. Thus, a typical
wiring diagram shows one circuit from battery to ground. Wiring and components that are not
part of the individual circuit are cross-referenced at connection points.
Tail lamp circuit continues on next page
ELECTRICAL DIAGRAMS
53
These wiring diagrams are easy to read and trace because the source (battery) is always at the
top of the page and the ground connections are always at the bottom of the page (as if current
flows down hill). Components, wires, switches, lamps and fuses are shown as simply as
possible. For example, a wire that is 6 feet in length on the vehicle may be shown no differently
than one that is 6 inches long.
The General Information (GI) section in the service manual describes how to read the new style
wiring diagrams. Review the sample diagram Graphical Wiring Diagram in this section as well as
the accompanying explanations of the lines and symbols.
The Electrical (EL) section of newer service manuals contains the following types of diagnostic
information:
Wiring diagrams
diagrams, which show the electrical current path when the circuit is operating
properly. It is essential to understand how a circuit should operate before attempting to
diagnose a malfunction.
System descriptions
descriptions, which describe how current flows through the system from the
source to the ground.
Component part locations

locations, which show a picture of where the component is actually
located on the vehicle.
Harness layout and connector locations

locations, which are found toward the back of the EL
section.
Diagnostic procedures
procedures, which provide a step by step diagnostic procedure based on the
malfunction symptom.
Example:
To review how the Meter and Gauge circuit operates, turn to the Meters and Gauges System
Description in the EL section of the service manual. Read the System Description and analyze
the wiring diagram(s) to get a basic understanding of how the circuits operate. After learning
how the circuit should operate, perform basic visual inspections and checks for available voltage
and ground. This is important because many diagnostic procedures assume you have checked
for voltage and ground before performing further diagnostic procedures.
54
ELECTRICAL DIAGRAMS
Connector Symbols in Electrical Diagrams

In order to diagnose and repair electrical malfunctions, you must understand how to read and
interpret wiring diagrams.
The wiring diagram includes all the details of how the circuit is actually wired on the vehicle. The
wiring diagram includes all connectors, wire colors, fuse locations and connector reference
locations.
In this vehicle wiring diagram the horn relay connects to the engine harness at E37. To further
isolate the location of this connector, refer to the Harness Layout Diagram in the EL section of
the service manual.
Horn Relay and

Connector E37
Typical switch details
Typical
ground
symbol
ELECTRICAL DIAGRAMS
55
Since electrical diagrams include a lot of information on a single page, accurate tracing of a single
circuit is not always easy. Remember these important points when you use the diagrams:
The two halves of a connector fold like a book.
Wires sometimes change colors from one side of a

wire connector to the other side.
All connector symbols in wiring diagrams are viewed

from the terminal side, unless otherwise noted.
Only the wires that are part of the circuit are shown
in the connector.
If the plastic connector is female, the terminals

inside are male, and vice versa.
As there are six cavities, the

connector has up to six terminals
Black print shows that it houses a
male terminal (metal part not plastic)
A chamfered corner shows that
it is a pin-type terminal
A right-angled corner means
that it is a flat or spade
terminal
Connector with pin terminals
Symbol
Since it is white here, it is a female
terminal (metal part)
There are eight cavities, so the
connector has up to eight spade
terminals
Connector with spade terminals
Note
Note: Though a wiring diagram may show only one wire in a connector, there may be more.
Other wires will not be shown when they are part of different, unrelated circuits.
56
ELECTRICAL DIAGRAMS
Connector guides for male terminals have a black mark on the connector symbol.
Connector guides for female terminals have a white or hollow area on the connector
symbol.
Male T
erminal
Terminal
Symbol
Guide
Actual connector
Number of cavities
Number of terminals available
Black print
Male terminal
White print
Female terminal
Chamfered corner
Pin-type connector (bullet)
Right-angled corner
Spade terminal
Connector symbol
Connector
Female T
erminal
Terminal
Guide
Connector symbol
Connector
Refer to a components wiring diagram to determine the number of wires, type of connector and
whether it is male or female.
Note
Note: An X in a wiring diagram wire connector means there is no terminal in that connector
cavity.
no terminal
X
Connector symbol
ELECTRICAL DIAGRAMS
57
Connector Direction Marks

A direction mark symbol is used to differentiate between the harness side of the connector and
the terminal side of the connector. These marks represent the side of the connector which should
be tested.
View from terminal side (TS)
View from harness side (HS)
All connector symbols shown from the terminal side are enclosed by a single line, and connector
symbols shown from the harness side are enclosed by double lines.
Connector symbols
Double line
Single line
View from terminal side
View from harness side
Each connector symbol also includes a guide for the connectors.

If the guide is not filled in, the wire terminals are female.
If the guide is black, the wire terminals are male.
In addition, the troubleshooting guide flow charts use symbols to indicate whether a test should
be performed with the connector connected or disconnected, as well as many other testing
conditions that must be met.
58
ELECTRICAL DIAGRAMS
Wire Color Code

A standard color code has a one or two letter code (e.g. R, W, B or BR). If a wire has a two
letter code separated by a slash (e.g. R/W or G/Y), the first letter represents the standard
color and the second letter represents the supplementary (stripe) color. The standard color for
grounding circuits is black. Wires connected to some components may also be black. Black
wires are not always ground wires.
If the wire insulation color is striped, the base color is given first, followed by the stripe color.
Example: L/W = Blue with White Stripe
Wire Color Code Chart

B
= Black
BR
= Brown
= White
OR or O
= Orange
= Red
= Pink
= Green
GY or GR
= Gray
= Blue
PU or V
= Purple
= Yellow
SB
= Sky Blue
LG
= Light Green
CH
= Dark Brown
DG
= Dark Green
Wire Gauge
Wire gauge describes the diameter of wire conductors. As the wire gauge number gets larger,
wire diameter gets smaller. Large gauge wire has greater current-carrying capacity. For example,
a 10 gauge wire conductor is thicker than a 14 gauge wire and can carry up to 24 amps while the
14 gauge wire can carry a maximum of 14 amps.
Insulation
Conductor
10 gauge wire compared with 18 gauge wire
ELECTRICAL DIAGRAMS
59
Wiring Repairs
Nissan and Infiniti provide wiring harnesses and most electrical
components as repair parts. An electrical terminal kit with an
assortment of electrical terminals and terminal remover tools is
available for minor wiring harness repairs. When working on wiring
harnesses, always use the appropriate terminal removal tool. Using
the proper tool reduces damage to the wire terminals and
connectors. Solder terminals and cover exposed wires with
shrink wrap.
Note
Note: When repairing electrical wiring, always use the correct wire
size and avoid using solderless terminals.
Connection Repair Kit
Wire Connectors
Harness connectors are designed to
stay tightly connected. To separate
these connectors, push or lift a
special locking section of the
connector. Never pull the wire
harness when separating
connectors.
Terminal retainer
Push
waterproof
seal
Terminal retainer
Lift
In spite of the locking design,

connectors sometimes become
loose or disconnected. Attempt to
pull the two connector halves apart
to verify they are making good
contact. When separating a
connector, be sure the waterproof
seal is in place when you reconnect
it. Look for signs of corrosion or
discoloration that can cause
increased resistance, which leads to
unwanted voltage drop.
Push
Push
Push
(for combination meter)
Push
Push
Push
(for relay)
Disconnecting, inspecting, and reconnecting wire connectors in a non-functioning circuit will

often return the circuit to operation. The act of separating and reconnecting the connector cleans
and reseats the connector terminals.
60
ELECTRICAL DIAGRAMS
Trouble Diagnosis Charts

Troubleshooting guides for many systems are also included in the EL section of the service
manual. They are a valuable source of information to solve circuit malfunctions. The chart is
divided into three columns to help pinpoint the cause of the circuit malfunction. The circuit wiring
diagram accompanies the Trouble Diagnosis Chart. Symbols are used to identify the tasks to be
performed.
Note
Note: Follow the chart completely. Do not skip around. Perform each test before going on to the
next.
Be sure you know what each test is telling you. You should have a good idea what part of
the circuit is being checked and the results a good component will give.
Harness Connector I.D.
Note terminal
location in
male/female
connectors
Circuit Wiring Diagram
ELECTRICAL DIAGRAMS
Circuit Diagnostic Flowchart
61
Trouble Diagnosis Charts contain symbols which are identified by a number. A description of
each symbol and number follows.
a
ohmmeter
An _______________
is used to check continuity.
ignition switch is OFF.

The _________________
wire connector
The __________________
is disconnected.
ground
One lead of the ohmmeter is connected to _____________.
connector number
E14 is the _____________________.
Male
_________
terminals inside connector.
terminal
Perform the test at _______________
#33.
harness side of connector E14.

Perform the test on the _______________
tested
The wire connector is viewed and ____________
from the harness side.
Disconnect
33
3
5
7
E14
1
Note
Note: All test conditions must be met if you want accurate results.
62
ELECTRICAL DIAGRAMS
Key to Electrical Symbols
ELECTRICAL DIAGRAMS
63
Harness Layout Diagrams

Harness Layout diagrams describe the locations of all connectors of a specific harness as they
appear on the vehicle. In addition, these diagrams show ground locations and some of the major
components that connect to the harness. This layout for the taillight harness shows the location
of each connector. Verify the correctness of the connector location by matching wire colors and
number of wires prior to performing tests.
Taillight Wiring Diagram

Locate harness connectors
using layout diagrams
Connector numbers
Harness Layout Diagram:

Tail Harness
64
ELECTRICAL DIAGRAMS
Location of Electrical Units

The EL section of the service manual shows the location of major electrical components in the
segment labeled Location of Electrical Units. Both under-hood and interior locations are
described. The location of components description is approximate and may change depending
on installed accessories and available options.
LOCA
TION OF ELECTRICAL UNITS
OCATION
Passenger Compartment

After tracing a circuit with the wiring diagram, use the Location of Electrical Units section
to locate test points that are easy to find and will help isolate the problem.
ELECTRICAL DIAGRAMS
65
Foldout Circuit Diagrams

The foldout pages at the back of some service manuals contain valuable information for
diagnosing circuit malfunctions. Information contained in these foldout pages varies depending
on the year of the service manual. Service manuals produced before the 1994-95 Model Year
contain different electrical information than manuals produced after those years. There are two
types of foldout pages used in service manuals:
1.
Foldout Circuit Diagrams used in 1994 and

older service manuals.
Service manuals produced before 1994 use

foldout pages that contain circuit diagrams of the
entire vehicle. These foldout circuit diagrams
separate the electrical system into three levels.
Each level has power at the top, the circuit load in
the middle and ground at the bottom. Analyzing a
circuit in this format helps to eliminate the clutter of
wires, components and connectors. Use the
foldout circuit diagram to determine what
components of other circuits interconnect with the
circuit youre tracing.
66
ELECTRICAL DIAGRAMS
2.
Foldout Circuit Diagrams used in 1995 and later service manuals.
1995 and newer service manuals have foldout pages that contain detailed connector
and terminal location information for these items:
Super Multiple Junction (SMJ)
Hybrid Electrical Connector (HEC)
Fuse and Fusible Link Box and the Junction Box.
Examine the following sample foldout page. Notice how the reference area on the starting system
wiring diagram page is linked to the SMJ terminal arrangement foldout page. This is helpful when
trying to locate a terminal for testing.
ELECTRICAL DIAGRAMS
67
Power Supply Routing Schematic

This is a schematic diagram that identifies all the system fuses and the different circuits that are
powered by each fuse. Use this chart to identify and locate the available voltage for a circuit.
Multi-Remote control relay

A/C relay
Clutch interlock relay (M/T models)
Inhibitor relay (A/T models)
Cooling fan relay-1

Horn relay
Front fog lamp relay

Theft warning relay
Theft warning lamp relay
Cooling fan relay-3
Horn relay-2
Cooling fan relay-2
68
ELECTRICAL DIAGRAMS
Ground Distribution Chart

These charts identify all the electrical system ground connections, connector numbers and wiring
diagrams for each circuit. When a system ground is suspected as being faulty, this chart can
identify the ground connector and the various circuits shared by common grounds.
Circuit description
Ground connection location
Circuit Identification
in service manual
Load connector number
200SX/Sentra service manual:

Answer the following questions in regard to the1997
__________________
1.
EL
-102
EL-102
What page in the service manual page contains the brake fluid level circuit? ________
2.
Where in the vehicle is the ground connection (E13/E25) for this circuit?
Behind
left front headlight
_______________________
3.
What page in the service manual page contains the Harness Layout chart for this circuit?
EL
-236
EL-236
___
______
4.
What are the coordinates on the Harness Layout that identify the location of the Brake Fluid
E-2
Level Switch connector (E1)? __________
ELECTRICAL DIAGRAMS
69
Using the Service Manual to Research Related Information

Now that you are familiar with the layout of the electrical (EL) section of the service manual and
learned how to interpret information, imagine youre in a situation where you need to thoroughly
research a circuit. You might look for related circuit information like component locations, power
feeds, SMJ connectors, electrical units, joint connectors or ground locations. The following
pages are similar to how you might research them in a diagnostic situation. By gathering these
pages, you should be able to better understand how various components are related.
The following pages are related to the horn circuit on a 2001 model Maxima. When conducting
research of your own, you might find it useful to have pages such as these to help you diagnose
a particular circuit fault.
Use this as a reference until you feel comfortable locating the different sections of the manual on
your own.
70
ELECTRICAL DIAGRAMS
HORN
Engine harness
See engine room harness

(ground distribution)
ELECTRICAL DIAGRAMS
71
VEHICLE SECURITY (THEFT WARNING) SYSTEM
72
ELECTRICAL DIAGRAMS
Horn circuit (power supply) fuses
POWER SUPPLY ROUTING
ELECTRICAL DIAGRAMS
73
74
ELECTRICAL DIAGRAMS
ELECTRICAL DIAGRAMS
75
HARNESS LAYOUT
Outline
76
ELECTRICAL DIAGRAMS
HARNESS LAYOUT
How to Read Harness Layout
ELECTRICAL DIAGRAMS
77
HARNESS LAYOUT
Engine Room Harness
78
ELECTRICAL DIAGRAMS
HARNESS LAYOUT
ELECTRICAL DIAGRAMS
79
GROUND
Engine Room Harness
80
ELECTRICAL DIAGRAMS
GROUND
ELECTRICAL DIAGRAMS
81
ELECTRICAL UNITS LOCATION

Engine Compartment
82
ELECTRICAL DIAGRAMS

Passenger Compartment
ELECTRICAL DIAGRAMS
83
84
ELECTRICAL DIAGRAMS
ELECTRICAL DIAGRAMS
85
ELECTRONICALLY CONTROLLED CIRCUITS

The last category of vehicle circuits found on vehicles is called electronically controlled circuits.
These circuits use an Electronic Control Unit (ECU) with various inputs and outputs. These
ECUs are sometimes called amplifier or timer circuits. For example, an A/C Auto Amp controls air
conditioning compressor operation; an automatic temperature control (ATC) head is called an
auto amplifier; a door lock timer controls power door lock operation.
Operation
Electronic circuits are unique because an ECU uses internal logic, circuitry and memory to
control circuit operation. Relay and switch circuits do not have these capabilities. Electronically
controlled circuits require:
Input - Sensors provide electrical signals to the ECU.
Logic - Processing of input signals to determine the output signal.
Output - Signal provided by the ECU that controls operation of the load.
Symptoms
ECU-controlled load circuits can have these malfunction symptoms:
The load does not operate or ...
The load operates all the time, or ...
The load operates at the wrong time
These symptoms can be caused by missing or incorrect sensor input signals, the logic inside the
ECU, or the output circuit.
Correct output signals from electronically-controlled circuits require correct input signals.
86
ECU Inputs
Input sensors for electronically controlled circuits report information to the ECU. The ECU uses
input information to determine how to control output loads. There are two types of ECU inputs:
Digital signals
Analog signals
Digital signals are ON-OFF voltage pulses, typically 2.5 or 5 volts. An example of a digital input
device is the camshaft position sensor which creates a camshaft position signal.
A typical digital signal looks like this:
Analog signals are produced by sensors that mechanically change resistance to deliver variable
voltage signals within a fixed operating range. These components are called variable resistors or
potentiometers. On vehicles, analog signals can come from:
Throttle position sensor
Fuel tank gauge units
Vehicle speed sensor
A typical analog signal looks like this:
While potentiometers change resistance mechanically, electronic components also provide

variable analog inputs to ECUs. These electronic, variable resistors are called thermistors or
thermal transmitters (see page 29). Thermistors change their internal resistance based on
temperature changes. Examples of thermistors include:
Engine coolant temperature sensors
Intake air temperature sensors
EGR temperature sensor
Fuel tank temperature sensor
Ambient temperature sensor

Thermistor
87
Electronic Control Units (ECUs)

The ECU in a circuit compares the input voltage it receives with data stored in its memory. This
type of analysis by the ECU results in an output from the ECU. As we said, ECU system outputs
rely on the inputs for the system to operate correctly.
Note
Note: Correct output from electronically controlled circuits requires correct input.
To process voltage inputs and to produce outputs, ECUs have two operating memories: Read
Only Memory (ROM) and Random Access Memory (RAM). ROM and RAM work together to
evaluate inputs and deliver the appropriate output signal.
ROM is permanently programmed with the operating
data necessary to control output. For example, ROM
in a timer control unit stores data to control the
length of time the interior lights stay on after the
doors have closed. The ROM program is burned
into the electronic chip in the ECU and is not
dependent on a power supply to maintain program
data. Since one input sensor can affect several
outputs, the ROM program is very complex. ROM
can take into account all the various combinations of
inputs to make the correct output decisions.
Unlike permanently programmed ROM, RAM can
create and store new data in addition to reading
previously stored information. An example of RAM is
the ECU built into a digital car radio for the station
selection memory switches. Because RAM is
dynamic, it requires an uninterrupted power supply to maintain its stored values. If battery power
is disconnected from the radio or if the battery goes dead, all RAM is lost and the station
selections must be reprogrammed.
Note
Note: When servicing a vehicle with an electronic radio, write down the radio station presets
before you disconnect the battery.
88
ECU Outputs
There are three types of outputs from electronically-controlled circuits:
Reference (typically 5 volts) constantly ON or OFF
Ground constantly ON or OFF
Pulsed reference or ground
Switched ECU voltage or ground can be

measured using a voltmeter or oscilloscope.
Voltmeter readings of pulse only indicate the
average voltage present. On the other hand, an
oscilloscope displays exact voltages as shown
in the illustration at right.
To diagnose the operation of ECU circuits, measurements must also include:
Frequency (Hz)
Duty cycle (% ON)
Pulse width (Duration ON)
Cycle
A complete cycle occurs when voltage is pulsed high, then low, then high again. It is said to be
measured from start-to-finish (digital) or peak-to-peak (analog). See the following illustrations.
Cycle
(Digital Signal)
(Analog Signal)
Frequency
Cycle
A pulse occurs when current is switched ON, then OFF. Each pulse or cycle starts when the
current switches ON and ends when it switches ON again. The frequency of the pulse is
determined by how often the current cycles ON and OFF per second. The unit of measurement
for frequency is Hertz, often abbreviated Hz. Frequency merely expresses the number of cycles
per second (cps) the pulsing occurs.
OFF
Voltage high (circuit OFF)
ON
Voltage pulled low (circuit ON)

(Ground switched ON)
89
The operation of a flywheel sensor is an example of how frequency is used to meet the operating
requirements of an engine. As engine speed changes, the frequency of the sensor input changes.
The ECM uses this sensor input to monitor engine misfire.
A vehicle speed sensor is a good example of how frequency is used as an input to the ECM.
Rotating
Magnet
Speed
Sensor
Dashboard
Control
Unit
ECM
Signal at 15 mph
Rotating
Magnet
Speed
Sensor
Dashboard
Control
Unit
ECM
Signal at 40 mph
Duty Cycle %
Frequency alone however, is not sufficient to describe pulsed signals. In some cases frequency
remains constant, but the length of ON time changes. Duty cycle is measured as percentage. For
example, a duty cycle of 50% means that the % of ON time and OFF time is the same. If the ON
time is 25% of the cycle, the duty cycle is 25%.
1Hz 50% Duty
5V
0V
Voltage high,
output device
OFF
1Hz 25% Duty
Voltage low
low,,
output device
ON
xamples:
Idle control solenoids
Shift solenoids A & B found on electronically-controlled automatic transmissions
Lock-up torque converter solenoids
Automatic transmission line pressure solenoids
90
5V
0V
Measuring Duty Cycle

Electronic test equipment reads and measures the duty cycle and displays an average that is the
result of readings over a long period of time. Duty cycles are used to control actuators such as
the auxiliary air control (AAC) valve of the ECCS system. The position of the AAC valve controls
engine idle speed and is determined by the average amount of ON time in relation to OFF time.
Pulse Duration (Time ON)
Pulse duration is similar to duty cycle. However, while duty cycle is a percentage of ON time in
relation to OFF time of the signal, pulse duration is more accurate. Rather than take an average
reading over a long period of time, pulse duration is a measurement of the length of time the
signal is ON, usually in milliseconds (thousandths of a second). Changes in pulse duration affect
the operation of some components. When the ECCS control unit determines the engine
requires more fuel, fuel injector pulse duration increases allowing the injector to stay open longer.
The ECM makes constant adjustment to fuel injector ON-time meeting the engine's everchanging fuel volume needs based on input from the camshaft position sensor (rpm). Or, simply
stated, the ECM changes pulse duration (injector ON-time) by increasing or decreasing the
amount of fuel delivered to the combustion chamber.
To review:
Frequency is the number of cycles per second.
Duty cycle is the percent (%) of time an output is ON in a cycle.
Pulse width is the length of time a signal is ON, usually measured in milliseconds (msec).
For electronically controlled circuits to operate, inputs from sensors are processed by the ECU
and outputs sent to actuator circuits.
The ECU is the processing center for these signals. However, if an ECU output load is
inoperative always check the ECU inputs. As with all computer controlled circuits, the acronym
GIGO is important to remember: Garbage In, Garbage out.
91
Depending on the type of signal, ECU inputs and outputs can be measured using:
A Duty Cycle Meter
A Pulse Duration Meter
An Oscilloscope
A Multimeter
A Logic Probe
CONSULT (Nissan/Infiniti Scan Tool)
When checking an output load in an ECU controlled circuit, supply the missing link to verify
output circuit operation. Remember the circuit requirements of source, load and ground. During
diagnosis, be careful because the loads in some ECU-controlled circuits use dropping resistors.
Never bypass one of these resistors to operate such circuits or wiring could overheat due to
higher current flow.
Fill in the blanks with the correct answer:
A __________is an event that includes voltages changes from start-to-start, or peak-topeak.
The number of times a cycle repeats in a second is measured in ___________.
The percentage of ON time during a cycle is expressed as ____________.
The length of time a pulsed signal is ON during a cycle is referred to as

__________________.
An example of a frequency input is _______________________.
An example of a duty cycle output circuit is ____________________.
An example of a pulse duration output circuit is __________________.

Electronically-Controlled Units: When servicing a vehicle with an electronic radio, write
down the radio stations before you disconnect the battery.
92
ELECTRICAL DIAGNOSIS
Diagnosing electrical malfunctions, like any other vehicle system, involves investigating the cause
of the problem and reaching a conclusion based on your investigation. Accurate diagnosis
requires understanding how the specific system functions, then evaluating whether it functions as
designed. Basic diagnosis involves the following steps:
1.
Verify the complaint .............
Apply knowledge and use reference materials to find

possible causes
2.
Isolate ..................................
Inspect and/or test for the possible cause in a logical order
3.
Repair ..................................
Diagnosis conclusion
4.
Recheck ..............................
Make sure the customer complaint is corrected
Inspect and diagnose, then notify customer.
Fuel tank gauge doesnt work
Neal Barnes
93
Preliminary Diagnosis Tips:

Step 1: For unfamiliar circuits, start with the schematic diagram. This provides an overview of
the circuit. The schematic diagram shows circuit components and how they are
connected. Always locate the circuit load first, then trace the wires back to the battery
and ground, if necessary. Check fuses and fusible links protecting the circuit in
question.
Step 2: Use the wiring diagram for a complete picture of the circuit. The wiring diagram is the
best source to logically trace the circuit. It includes information such as wire colors,
connector numbers and relay box layout. Use your knowledge of source, load and
ground along with the wiring diagram to help isolate the circuit for testing.
Step 3: The Harness Layout section of the service manual describes specific harness and
connector locations on the vehicle. The harness layout diagram will help you find the
exact locations on the vehicle to perform your diagnosis.
Step 4: Finally, locate the actual components and the most accessible test points by using the
Location of Electrical Units section of the service manual.
On-Car Troubleshooting Tips:
Always check the source voltage (at the battery) before testing circuit voltage.
Visually inspect the battery connections for looseness or corrosion.
Clean and tighten battery cables as necessary.
Check available voltage at the load and compare it to the source voltage. If it is not the
same or nearly the same, there is an abnormal voltage drop between the battery and the
load. Look for poor connections, frayed wires, etc.
Check tightness and the condition of ground connections.
Simulate the conditions of the problem.
94
Diagnosing Malfunctions in Circuits with Fuses or Fusible Links

Isolate malfunctions in circuits protected by fuses or fusible links by following these steps:
Locate the wiring diagram for the circuit that has the failed (melted) fuse or fusible link.
Make a note of all loads that operate on that circuit. There may be multiple loads protected
by a single fuse or fusible link.
Disconnect the circuit loads one at a time to isolate

which circuit load is causing the fuse to fail. You may
have to install a new fuse to check each individual
circuit. For more efficient testing, temporarily replace
the fuse or fusible link with a circuit breaker that will
reset by itself.
If the fuse or fusible link still fails after all circuit loads
are disconnected, you may have to separate the
harness to locate the malfunction.
Note
Note: Always check for pinched wires in areas where work has recently been performed
resulting from body repairs.
When diagnosing faults in circuits that use fuses and fusible links:
Verify the contact between the fuse and fuse holder is clean and tight. Poor contact
increases circuit resistance. The excessive heat caused by the poor connection may
eventually cause the fuse to melt.
Always use a fuse with the proper rating. If a fuse with a higher rating is used, the fuse will
not fail (melt) as designed. This could result in burned wiring or insulation.
A bad fuse or fusible link cannot always be detected from the outside. Always use reliable
test equipment to check for open circuits.
Be careful when removing a bad fusible link. When a fusible link melts, it becomes very hot.
This heat can burn you or damage nearby wiring.
95
Connector T
erminal Malfunctions
Terminal
Vibration T
ests
Tests
Tap gently
Shake gently
Bend gently
Connecting a meter to a connector terminal can

damage it if the tester probe enlarges the opening.
Use a T-pin designed for meter connections. Probe it
from the wire harness side of the connector. Inspect
terminals for damage from previous probing.
Note
Note: T-pins are available in different sizes at local
hobby stores.
96
Connector
Alligator clip
T pin
DMM
Available Voltage and Voltage Drop Tests

The following illustrations describe two methods of diagnosing a circuit using a voltmeter. Use
the available voltage method to determine if source voltage is available to the load.
Measuring Available V
oltage
Voltage
1.
Connect the voltmeter across the

connector or part of the circuit you want
to check. The voltmeter + lead should
be closer to the battery and the lead
closer to ground.
2.
Operate the circuit.
3.
The voltmeter will indicate how many

volts are availalbe in that part of the
circuit.
In this circuit, the available

voltage to the load is only 7.9
volts due to excessive resistance.
Use voltage drop tests to find components or circuit branches which have excessive resistance.
Measure V
oltage Drop Step by Step
Voltage
0V (OK)
0.1V (OK)
7.9V (dim bulb)
0V (OK)
V
Switch
4V
V
Battery
12V
V
Excessive Vdrop
Connection
with high
resistance
1. Connect the
voltmeter as shown,
starting at the
battery, then work
along the circuit.
2. An unusually large
voltage drop
indicates a
component or wire
needs repair. The
poor connection in
the illustration shows
a 4 volt drop.
In this circuit, excessive
circuit resistance has
dropped the available
voltage by 4 volts.
Note
Note: Each connection can (potentially) be the source of an unwanted or excessive
voltage drop. Normal voltage drop at each connection should be 0.1 volt or less.
97
Testing for Opens in a Circuit

Before diagnosing a system, draw a rough sketch of the system. This helps simplify the system
and reinforces your working knowledge of the system.
Diagnose for Open Circuit:
Ignition OFF when testing resistance ().

Ignition ON for voltage testing.
Available Voltage and Continuity Tests

Another method to pinpoint the cause of a circuit malfunction is to first use the voltmeter to
measure available voltage throughout the circuit. When no voltage is found where there should
be voltage, switch the source OFF and open switches to isolate the suspected circuit. Use the
multimeter in the ohmmeter mode to measure the continuity between test points. The above
illustration shows two opens at A and B. Note how the ohmmeter is connected to each part of
the suspected circuit to isolate the area causing the open circuit.
98
Testing for Shorts in a Circuit

Diagnose for Short Circuit
Resistance Check Method

1.
Disconnect the battery negative cable and remove the blown fuse.
2.
Disconnect all loads powered through the fuse (SW1 open, relay disconnected and solenoid disconnected).
3.
Connect one ohmmeter probe onto the load side of the fuse terminal. Connect the other probe to a known
good ground.
4.
With SW1 open, check for continuity (complete circuit).

Continuity:
The short is between the fuse terminal and SW1 (Point A)
No Continuity:
The short is further down the circuit (after SW1)
5.
Close SW1 and disconnect the relay. Connect the ohmmeter probes on the load side of the fuse terminal
and a known good ground, then check for continuity.
Continuity:
The short is between SW1 and the relay (Point B)
No Continuity:
The short is further down the circuit (after the relay)
6.
Close SW1, then connect a jumper wire onto the relay contacts. Connect probes at the load side of the
fuse terminal and a known good ground, then check for continuity.
Continuity:
The short is between the relay and the solenoid (Point C)
No Continuity:
Check the solenoid, then retrace your steps
Voltage Check Method

1.
Remove the blown fuse and disconnect all loads (Open SW1, disconnect relay and solenoid) powered
through the fuse.
2.
Turn the ignition switch to the ON or START position. Verify battery voltage at the B+ side of the fuse
terminal (DMM leads to B+ terminal of fuse block and known good ground).
3.
With SW1 open, check for voltage.

Voltage:
The short is between the fuse block and SW1 (Point A)
No Voltage:
The short is further down the circuit (after SW1)
4.
With SW1 closed, relay disconnected and the DMM leads across both fuse terminals, check for voltage.
Voltage:
The short is between SW1 and the relay (Point B)
No Voltage:
The short is further down the circuit (after the relay)
5.
With SW1 closed, jump the relay with a test lead, solenoid disconnected, then check for voltage.
Voltage:
The short is down the circuit of the relay or between the relay and the disconnected
solenoid (Point C).
No Voltage:
Retrace steps and check power to the fuse block.
99
Ground Inspection
Ground connections are very important for the proper operation of electrical and electronic
controls. Ground connections are often exposed to moisture, dirt and other corrosive elements.
This corrosion (rust) can become an unwanted circuit resistance and prevent the circuit from
operating properly or at all. Loose connections also create excessive circuit resistance.
Ground Inspection
Remove bolt (screw)
Inspect mating surfaces for

tarnish, dirt, rust, etc. Clean as
required to assure good
contact
Diagnostic Tips for Relays

When diagnosing faults on relay-controlled circuits:
Listen to or feel the relay click
If no click is heard or felt, remove the relay and

connect a fused jumper as shown in the
illustration at right:
- If the load now works,you have learned that the
load and ground are good.
- If the load does not work and system voltage is
available to the relay, look for circuit
malfunctions on the load side of the relay circuit.
Note
Note: Never jump the terminals for the coil control circuit (pins #1 and #2) because higher than
normal current can damage the wiring of the control circuit.
Jumping across these terminals will blow the fuse for this circuit or even damage the ECU
that controls the circuit.
100
Color
(Appl)
Relay T
ype
Type
Relay Symbols
One Make Relay (1M)

Control circuit terminal nos.
Blue or
Yellow
#______ and #______
(All Models)
Contact circuit terminal nos.

#______ and #______
One Make Relay (1M)
Blue or
Green
#______ and #______
(95 & older)

#______ and #______
One Make Relay (1M)
#______ and #______
Blue, Gray, or
Yellow
(All Models)

#______ and #______
Two Make Relay (2M)
#______ and #______
Brown
(All Models)

#______ and #______
#______ and #______
101
Relay T
ype
Type
Color
(Appl)
Relay Symbols
One Transfer Relay (1T)

#______ and #______
Not energized: #___ & #___
Energized:
Black
(95 & newer,
some circuits)
#___ & #___
One Transfer Relay (1T)

#______ and #______
Not energized:
#___ & #___
Energized:
#___ & #___
Black
(95 & older)
One Make-One Break

Relay (1M-1B)
#______ and #______
Gray
(All models)

Not energized:
#___ & #___
Energized:
#___ & #___
Note
Note: A relay removed from a circuit can be tested in the following manner:
1.
2.
3.
4.
102
Connect voltage to terminal #1.

Connect terminal #2 to a good ground. Listen for a click.
Use a multimeter to check continuity between the output terminals.
If there is continuity, the relay is working. If not, replace the relay.
Diagnosis (Electronic Control Units)

In the following illustration, the ECU is programmed to light the bulb when switch A and switch
B are ON and switch C is OFF. To diagnose a symptom of non-operation, separate the input
and output sides of the circuits. Begin by checking the output at the ECU wire connector.
Remember, ECU-controlled outputs have the same requirements for source, load, and ground as
any relay-controlled circuit. If an output signal is present, disconnect the ECU wire connector
and check the operation of the load with a jumper wire. Depending on how the load is wired,
apply either voltage or ground for the load to operate.
If the load operates when source or ground is applied, go to the input side of the ECU circuit.
With the wire connector removed from the ECU, check the inputs at the ECU wire connector to
be sure they are good. As in the example shown, some ECU output loads require more than one
input to operate. If the inputs are good and there is no output to the load, the ECU is defective.
Diagnosis (Thermistor circuits)
To diagnose circuits containing thermistors, check the resistance of the thermistor and compare
that to specifications. Then check circuit continuity between the ECM and the load (thermistor).
103
Motors
Symptoms
Motors are controlled by a switch, a relay or an ECU (Electronic Control Unit). If an

electrical failure occurs, it could be caused by an open circuit, preventing the motor from
operating. A short circuit inside the motor or within the circuit will cause the fuse or fusible
link to fail.
Motors can also fail mechanically. A mechanical failure will also cause the motor to be
inoperative. If the motor armature binds (stops rotating), electrical resistance decreases
and amperage increases which causes the fuse to fail.
Diagnosis
If a motor circuit does not operate, check the fuse or fusible link for the motor circuit. For
motor circuits that are relay controlled, use the same procedures to isolate the malfunction
as explained previously for other relay-controlled loads.
Motors that must rotate in both directions are switch-controlled. For example, if a window
motor is stuck in the down position there could be an open circuit in the up contacts of
the switch. To quickly check a window motor circuit, switch the ignition ON and watch the
vehicle interior lights. If the lights dim slightly when you press the window switch to the
down position, there is a complete circuit through the motor down circuit. If the lights do
not dim when pressing the switch to the up position, the switch could be bad. If the lights
dim when the switch is pressed to the up position, the motor could be mechanically stuck.
If the fuse or fusible link is bad, use the isolation procedures for fused circuits to determine
whether the malfunction is electrical. If you suspect a mechanical failure, remove the motor
from its operating position and bench test it by applying power and ground. Be sure to use
test wires with an in-line fuse. If the motor operates on the bench, check the linkage or
mechanical components that the motor drives to be sure they are not binding. Check wire
routing during the inspection. Wires can sometimes get tangled in the linkage and ground
the motor circuit.
104
Meter and Gauge Diagnosis

Symptom: The speedometer reads inaccurately (too fast or too slow)
Speed sensor malfunction. Check wiring harness continuity and check speed sensor signal
according to service manual procedures and specifications. Check condition of speed
sensor signal using CONSULT data monitor function.
Vehicle may have oversize tires.

- Oversize tires reduce axle speed which reduces speedometer reading.
- If oversized tires are installed on the vehicle, no corrections should be made other than to
recommend correct tire application.
A problem with a speed sensor may also appear at the engine ECM as well as the A/T and
ASCD control units.
- The revolution sensor is the primary input. The speed sensor will tell the A/T control
unit when to shift if the revolution sensor circuit fails. If the speed sensor or
revolution sensor circuit fails, the transmission O.D. light should blink for 7 seconds
after every vehicle start indicating a code is stored in the A/T control unit. Dont
forget to verify proper cruise cable adjustments.
- A/T control unit: Speed sensor input is used as a backup for the revolution sensor input.
Transmission may not indicate a symptom caused by a bad speed sensor.
- ASCD control unit: Speed may not set correctly if the control unit gets an inaccurate or
erratic speed input. Check wiring harness continuity and speed sensor signal according
to service manual specifications.
Symptom: Indicators do not operate
Check battery voltage input to the combination meter/microcomputer.

- If voltage is not present, trace and diagnose the circuit back to the power source.
- If the fuse is blown, look for a short between the fuse and the speedometer.
Symptom: Fuel gauge has inaccurate indication
Check fuel tank gauge unit adjustment according to service manual specifications.
- Check wiring harness continuity between the gauge unit and speedometer.
- If resistance is out of specification the gauge will register lower than normal fuel level.
Check Nissans ASIST system for additional possibilities.
Inspect hose and pipe connections in tank for mechanical interference.
105
Note
Note:
Quest only
If resistance is higher than the specification, the gauge reading will be higher than
the actual fuel level; if resistance is lower than the specification, the gauge
reading will be lower than the actual fuel level.
All other Nissan models:
If resistance is higher than the specification, the fuel gauge reading will be lower
than the actual fuel level; if resistance is lower than the specification, the gauge
reading wil be higher than the actual fuel level.
106
Meter and Gauge Checks

Thermal Transmitter Check
To verify the thermal transmitter is operating properly, check the resistance between the terminals
of the thermal transmitter and body ground.
The thermal transmitter is a variable resistor that affects the temperature gauge by controlling
current (amperage) in the circuit.
Water T
emperature
Temperature
Resistance
60C (140F)
Approx. 70-90
100C (212F)
Approx. 21-24
Fuel Tank Gauge Unit Check

To verify the unit operates properly, check the resistance between terminals 3 and 2 (see the
following diagram). (Note: To remove the fuel tank gauge unit refer to the FE section in the
service manual.)
The fuel tank gauge unit is a variable resistor that affects the fuel gauge reading by controlling
current (amperage) in the circuit.
Note
Note: The illustration that follows is an example of a test and specification chart for
a fuel tank gauge unit. Tank gauge units for each vehicle are not the same. The
resistance varies with each one, so be certain you refer to the service manual
when performing this procedure.
Ohmmeter
connection
Float Position, mm (in.)
Resistance
Value ()
*1
Full
95 (3.74)
Approx. 4-6
*2
1/2
184 (7.24)
31-34
*3
Empty
265 (10.43)
80-83
*1 and *3: When float rod is in contact with stopper
1999 Pathfinder
107
Nissan Original Equipment Battery Ratings

Note: For original equipment batteries, the label showing the rating is located on the top of the battery
Model
Xterra
Year
2000 & later
2000 & later
1997-98
1999 & later
1997
1998 & later
1997 & later
1997-99
1999.5
1997-98
1997-98
1997 & later
1997 & later
1997-98
2000 & later
1997-99
1997-99
Quest
Truck
Frontier
Pathfinder
200SX
Sentra
Altima
240SX
Maxima
Application
Standard
Optional
All
All
All
All
Standard
Optional
Optional
Standard
Optional
All
All
All
All
Standard
Optional
Rating
490 CCA
550 CCA
550 CCA
525 CCA
490 CCA
490 CCA
55D23R
75D31R
80D26R
490 CCA
550 CCA
490 CCA
550 CCA
55D23R
80D26L
55D23L
80D26L
Genuine Nissan Replacement Battery Ratings

Note: For original equipment batteries, the label showing the group rating (i.e., 24, 25, 27, etc.) is located on the top of the battery
Model
Altima
Axxess
Maxima
Pulsar
Stanza
Sentra
Pathfinder
Frontier
Truck
Quest
Van
200SX
240SX
300ZX
Xterra
Year
1993 & later
1990
1985 & later
1985 & later
1984
1984-90
1987-92
1984-86
1986-88
1987- & later
1985-86
1984
1987 & later
1987 & later
1999 & later
1999 & later
1984-97
1986
1982-85
1993 & later
1987-90
1995 & later
1982-88
1995-98
1989-94
1992-94
1990-96
1992-96
1984-89
2000 & later
2000 & later
Application
All
All
All
With cold package24F
All
All
All
All except Wagon
Wagon
All
All except diesel
All except diesel
All
All with heated seats
Four cylinder
Six cylinder
All except diesel
Diesel
Diesel
All
All
All
All
All
All exc. convertible 24
Convertible
All
Convertible
All
All (standard)
All (optional)
Group #
24F
35
35
25
35
35
25
35
35
24F
35
25
24
25
24
25
24 (2)
27
24F
25
25
24
25
25
24F
35
25
25
24
Nissan P/N
999M1-NB24F
999M1-NB35C
999M1-NB35C
999M1-NB24F
999M1-NB25C
999M1-NB35C
999M1-NB35C
999M1-NB25C
999M1-NB35C
999M1-NB35C
999M1-NB24F
999M1-NB35C
999M1-NB25C
999M1-NB24C
999M1-NB25C
999M1-NB24C
999M1-NB25C
999M1-NB24C
999M1-NB27C
999M1-NB24F
999M1-NB25C
999M1-NB35C
999M1-NB24C
999M1-NB25C
999M1-NB24C
999M1-NB25C
999M1-NB24F
999M1-NB35C
999M1-NB25C
999M1-NB25C
999M1-NB24C
CCA*
575
525
525
575
525
525
525
525
525
525
575
525
525
575
525
575
525
575
660
575
525
525
575
525
575
525
575
525
525
525
575
*CCA = Cold Cranking Amps
108
GLOSSARY OF TERMS
Alternating Current (AC) - Current that reverses its direction at regular intervals.
Amperes (amps) - Unit of measure for current flow in an electrical circuit.
Ammeter - An electrical test meter that measures the amount of current flow, in amperes, in a
circuit.
Analog multimeter - A device that measures voltage, resistance and current. The numerical
measurement is represented by a dial-type needle that points to the numerical value on one of
many scale ranges.
Battery - A device consisting of two or more cells for converting chemical energy into electrical
energy.
Coil - Thin wire wound into a circular shape, usually around an iron core. Current passing
through the coil creates a strong magnetic field to assist in electrical contacts and other circuit
functions.
Circuit - An assembly consisting of a voltage source, a load, a control device (such as a switch
and a ground path. A circuit carries electricity through a load to produce some type of work, such
as heat, light or motion.
Circuit breaker - A mechanism designed to break or open the circuit when certain conditions
exist; usually heat sensitive.
Circuit protection - A device which is used to protect wiring and electrical devices from
excessive current flow, so that they are not damaged.
Combination Circuit - A circuit which combines series and parallel circuits.
Conductor - The device which connects electrical components together so current can flow in a
circuit. Electrical conductors are more commonly referred to as wires. The most common
conductors are copper and aluminum, but gold is also a good conductor. The metal vehicle
chassis is also a conductor.
Connector - A mechanical device to connect single or multiple terminals. Usually surrounded by
an insulating material to electrically separate the conducting material.
Continuity - A complete path for current flow. In the service manual, continuity does NOT
necessarily mean 0 ohms resistance.
Conventional current flow theory - The theory that states that current flows from the positive
post of the battery through the external source side of the circuit, through the circuit loads and
back to the battery via the ground circuit.
GLOSSARY OF TERMS
109
Crossed Circuit - A malfunction. Current flow from a switch operates a LOAD from a different,
unrelated circuit.
Current Flow - The movement of electrons in a circuit. Also called amperage or electricity.
Digital Multimeter - A device that measures voltage, resistance and current. The numerical
measurement is shown in numbers using a LCD or LED display. Also called a digital voltohmmeter.
Diode - An electrical device that acts like one-way check valve. It permits current flow in one
direction, but stops it from flowing in the other direction.
Direct Current (DC) - Current that flows in one direction only.
ECU - Electronic Control Unit. An electronic logic device to operate electronically-controlled
circuits.
Electromagnet - A temporary magnet constructed by winding a number of turns of insulated
wire into a coil or around an iron core. It is energized by the flow of current through the coil. Used
in relays and solenoids.
Fuse - A type of circuit protection device that has a thin metal segment that melts when its rated
current-carrying capacity is exceeded. When this occurs, the circuit can not be completed until
the faulty fuse is replaced.
Fuse block/junction block - A grouping of fuses. A connection point for circuit wires to
separate to other circuits.
Fusible link - A type of circuit fuse that uses a length of heat sensitive conducting wire to
protect a circuit.
Grounded Circuit - A circuit in which there is an unwanted contact between a conductor and
ground. On the SOURCE side of a circuit, this will cause the fuse to blow. On the ground side of
the circuit, the LOAD may be ON all the time.
Group # (battery) - The storage battery size to mount into a specific vehicle.
Insulator - A material that will not allow current flow. Also, the material that separates
conductors, providing a barrier that shields them from interfering with each other. Insulators are
more commonly referred to as the wrapping, or sheaths around wires. The most common
insulating materials are plastic and rubber because they have excellent insulating properties yet
remain very flexible.
Light emitting diode (LED) - A type of diode that emit light when current flows from anode to
cathode. They normally emit red light, but other colors are available, including INFRA-RED LEDs.
They conduct current in one direction only, but can be damaged by reverse voltages.
110
GLOSSARY OF TERMS
Magnetic field - The property exhibited by certain substances and produced by electron (or
electric current) motion which results in the attraction of iron.
Motor - A device for converting electrical energy into mechanical energy.
Multimeter - A device that measures voltage, resistance and current (see analog and/or digital
multimeter).
Ohms - Unit of measure for resistance of electrical devices or circuits.
Ohms Law - A basic statement of the relationship between volts, amps and ohms.
Ohmmeter - A device for measuring ohms resistance of a circuit or electrical device.
Open Circuit - An incomplete circuit in which current cannot flow from SOURCE to LOAD to
GROUND because of a disconnection, broken wire, blown fuse or other interruption.
Parallel circuit - A circuit in which there is a separate path for current flow for each LOAD. If one
of the LOADs has an open circuit, the other loads will continue to operate.
Potentiometer - A variable resistor that is mechanically operated.
Parasitic load (draw) - Electrical current from the battery that exists when the vehicle is not
operating.
Polarity - A term relating to the direction of current flow in a circuit. For instance, a circuit is said
to have positive polarity when the current flows from positive to negative.
Primary ignition (primary circuit) - Equivalent to SOURCE voltage; the circuit used to signal or
switch the ignition system.
Rectifier (rectify) - An electrical device that changes alternating current to direct current.
Relay - An electrically-operated switch that uses low current flow in the coil control circuit to
activate higher current flow in the contact point circuit.
Reserve capacity - The ability of a battery to sustain current output when connected to a circuit
or a specified test load. Storage batteries are usually rated in Cold Cranking Amperes (CCA).
Resistance - The opposition or reluctance to current flow in a circuit. Resistance is expressed in
ohms, represented by the symbol (omega).
Secondary ignition (secondary circuit) - The circuit that creates a high voltage spark; operates
with and controlled by the primary circuit.
Semi-conductor - A device that is neither an insulator nor a conductor. With certain materials
added to their makeup, semi-conducting devices can be made into conductors. Semiconductors are more commonly known as transistors, diodes and electronic control devices.
GLOSSARY OF TERMS
111
Series circuit - A circuit in which there is only a single path for current flow. If one of the
components or LOADS in the circuit becomes open, the circuit no longer operates.
Series-parallel circuit - The electrical circuit formed when series-connected circuit elements are
combined with parallel-connected circuit elements.
Shorted Circuit - A circuit in which current flow takes a shorter path (less resistance) between
SOURCE and GROUND, bypassing part or all of the circuit LOAD. Short circuits increase
current flow and can cause blown fuses.
Solenoid - A device that allows electricity to pass through a coil of wire to create magnetism. A
mechanical lever moves as a result of the electromagnetism.
Source - A supply of voltage to operate a circuit.
Specific gravity - The ratio of the weight of a substance to the weight of an equal volume of
chemically pure water at 39.2F; used to measure the state of charge of a lead-acid storage
battery.
Static electricity - Accumulated electrical charges, usually considered to be those produced by
friction.
Storage Battery - A lead-acid electrochemical device that changes chemical energy into electric
energy. The action is reversible; electrical energy applied to the battery stores chemical energy.
Sulfation - A term used to describe a chemical condition that occurs within a battery when the
electrolyte has degraded to a condition that does not produce normal voltage. When a battery is
heavily sulfated, the electrolyte and plate material combine into a hardened substance (the
sulfate) which settles to the bottom of a cell, causing the cell to not accept a charge or deliver
current. When this occurs, the battery is not serviceable because this condition is irreversible.
Terminal - The metal connector attached to the end of a length of stranded wire which is used to
connect to another component or wire.
Thermistor - An electronic component that changes its resistance as its temperature changes.
Transistor - A semiconductor switching device. Can be used as a switch or a relay.
Variable Resistor - A component whose resistance value can be changed to change to
operation of a LOAD in a circuit.
Volt - A unit of measure of electrical pressure (voltage).
Voltage (electrical potential) - The electrical pressure required to push a current of electricity
through a circuit. Voltage is chemically produced in a lead-acid battery or from an
electromagnetic field, such as in an alternator.
112
GLOSSARY OF TERMS
Voltage drop(s) - The amount of voltage consumed by a LOAD during circuit operation. The total
of all voltage drops in a circuit is equal to the available voltage. A concept which describes what
occurs in a circuit when current passes through a load. A load in this case is loosely defined as
anything that causes resistance. This can include corrosion or looseness in wiring and
connections, fixed or variable resistance, or devices such as bulbs or motors.
Voltmeter - An electrical test meter that measures the amount of voltage or electrical pressure in
a circuit.
Wiring/ wire gauge - Diameter of a wire. Smaller gauge wire (larger number) can carry less
current.
Zener diode - A semiconductor. This type of diode conducts electricity in the reverse direction
from normal diodes. To pass electricity through a zener diode, it must be around eight to ten
times the value of the normal diode, typically 4.7volts. When four diodes are connected in a
certain way (i.e., "bridged") they will convert AC to DC, as in an alternator.
GLOSSARY OF TERMS
113
NOTES
114
NOTES
M
O
D
U
L
E
S
Date of Class
ELECTRICAL COMPONENT DIAGNOSIS AND REPAIR

SIGN-OFF SHEET
WORKSHEET
TITLE
Module 1
Locate Service Manual Information
Module 2
Interpret Service Manual Information
Module 3
Module 4
Module 5
Measuring Resistance
Module 6
Measuring Current
Module 7
Combination Switch Operation
Module 8
Diagnosing One Transfer (1T) Relay Malfunctions
Module 9
Diagnosing One Make (1M) Relay Malfunctions
Module 10
Diagnosing Two Make (2M) Relay Malfunctions
Module 11
Diagnosing One Make-One Break (1M-1B) Relay

Malfunctions
Module 12
Module 13
Module 14
Module 15
Module 16
Module 17
Module 18
How to Use a Digital Multimeter
Module 19
Fuel Guage Unit Testing
Module 20
Service Manual Electrical Symbols
Module 21
Testing Batteries, Starters & Charging Systems
INSTRUCTOR
ii
How to Use a
Digital Multimeter
Module 18
Measuring
Available Voltage
Module 3
Locate Service
Manual
Information
Module 1
Measuring
Current
Module 6
Service Manual
Electrical Symbols
Module 20
Measuring
Resistance
Module 5
Interpret Service
Manual
Information
Module 2
Measuring
Voltage Drop
Module 4
ELECTRICAL COMPONENT DIAGNOSIS AND REPAIR

COURSE MAP
Introduction
Terminology
Service Manual
Meter Familiarization
Combination
Switch Operation
Module 7
Fuel Gauge Tank

Unit Testing
Module 19
Diagnosing
One Transfer (1T)
Relay Malfunctions
Module 8
Circuit Diagnosis
Exercise: #1
Module 12
Diagnosing
One Make (1M)
Relay Malfunctions
Module 9
Circuit Diagnosis
Exercise: #2
Module 13
Diagnosing
Two Make (2M)
Relay Malfunctions
Module 10
Circuit Diagnosis
Exercise: #3
Module 14
Diagnosing One MakeOne Break (1M-1B)

Relay Malfunctions
Module 11
Circuit Diagnosis
Exercise: #4
Module 15
Circuit Diagnosis
Exercise: #5
Module 16
Testing Batteries,
Starters & Charging
Systems
Module 21
Circuit Diagnosis
Exercise: #6
Module 17
iii
NOTES
iv
LOCA
TE SERVICE MANUAL INFORMA
TION
LOCATE
INFORMATION
Module 1
Objective:
Given an Electronic Service Manual

(ESM), locate wiring diagram
descriptions and interpret the
information.
Relevance: An important part of vehicle repair is

the ability to locate diagnostic repair
information.
Both the General Information (GI
GI))
and Electrical (EL) sections of the
service manual contain useful
information relating to circuit operation
and testing.
Resources: ASIST/ESM
Skill Check: You will locate and identify electrical
components, symbols and information
in the ESM.
You will identify navigation controls in
the ESM.
Module 1
Use the ESM to answer the following questions:

ECTC
0016C
1.
On what page in the GI section is the

combination switch located? (See illustration on
left).
Page GI
GI-_________________
2.
What page describes the connector symbol

descriptions?
Page GI
GI- _________________
3.
In the illustration on the left, draw a circle around

each symbol that identifies a male connector.
4.
Locate the pages that describe standardized

relays in the service manual.
What color is a 2M relay case?
__________________________
5.
What pages in the EL section describe Power

Supply routing?
Pages EL
EL-______ to EL
EL-________
6.
Find the section that covers the location of

Electrical Units.
Other than relays, which other components are
located in boxes under the hood?
____________________________________
Module 1
M Main
I Instrument
E Engine
S Sunroof
YSTEM wiring
Locate the CHARGING S
SY
diagram in the service manual. What is the
connector number for the Charge Warning
Lamp?
F Eng. Control (EFI)
D Door
M__________________________________
A Alternator
B Body
T Tail
Z Air Bag
The chart on the left shows wiring harness code

prefixes (M for main harness).
Harness Symbols
R Room (Interior Lamp)
7.
8.
Module 1
Find main harness connector locator

information.
What is the grid coordinate for the location of
the charge warning lamp connector?
__________________________________
9.
Using the illustration of the A/T control unit

connector below as a reference, which side of
the connector is in view?
____________________________________
Module 1
10. Some service manuals also show joint

connector (J/C) locations. A joint connector
shows that two or more wires are electrically
joined together in a connector or a junction box.
ECTC
0016C
In the illustration below, which terminals are

joined together in connector M1?
____________________________________
Module 1
11. Using the GI section as a reference, match the

letter of each service procedure with the
corresponding symbol in the spaces provided.
a.
b.
c.
d.
e.
Disconnect
Switch ignition to ON
Harness side of connector
Measure with an ohmmeter
Do not start
12. Using the EL section as a reference, what type

of relay has a gray case?
______________ Page EL
EL-____
13. Where is the ECM located?
____________________________________
14. Locate the Power Supply Routing schematic in
the EL section of the service manual.
What amperage fuse protects the horn circuit?
_____ Amp Page EL
EL-____
What is the fuse number? _______________
a
15. What do the two symbols at left represent?

a. _________________________________
b. _________________________________
Module 1
Module 1
16. Using the engine compartment Harness Layout

page as a reference, which component
connects to connector E15?
ECTC
0016C
___________________________________
17. Find the engine control Harness Layout page.
What is the connector number for the Throttle
Position Switch?
_______________
Page EL
EL-_____
18. Identify the following navigation controls in the

ESM by placing the cursor over the icon.
C
___
___
___
___
___
___
Bookmark options
Last views
Search Commands
Open navigation menu
Print document or selected page(s)
View first, previous, next or last page
Module 1
When using the ESM or ASIST, you have the ability

to do keyword searches. Hold down the Ctrl key and
select the letter F to begin the search.
19. Located in the lower left corner of the keyboard
is the Ctrl key. Hold down the Ctrl key and then
press the letter F .
20. Place the cursor in the box and type the word
Power. Then select find
find. You should have
located the next place in this section with the
word Power.
You have just completed this worksheet. You should
now be able to locate necessary information to read
wiring diagrams. If you have any doubt about your
skills in completing this worksheet, please return to
step 1 and review your work. Once you are confident
of your skills, have your instructor verify your work.
Instructors Initials ______________________
Module 1
Return the workstation to the condition

that you found it.
Module 1
NOTES
Module
INTERPRETING SERVICE MANUAL INFORMA

TION
INFORMATION
Module 2
Objective:
Given an electronic service manual,

interpret wiring diagram symbols and
answer related questions.
Relevance: Your ability to diagnose electrical

malfunctions depends on how well you
can read and interpret vehicle wiring
diagrams.
Wiring diagrams illustrate how parts of
an electrical circuit fit together. Wiring
diagrams use electrical symbols to
describe switches, connectors,
motors, relays and fuses. There are
also symbols for wire colors and where
and how these wires connect to each
other.
Resources: ESM
Skill Check: You will locate and identify electrical
symbols and their descriptions in the
GI section of an ESM.
Module 2
Use the GI section in the ESM to answer questions

116.
ECTC
0016C
1.
This illustration shows two halves of a

connector.
Circle the male side of the connector.
2.
The numbers in this connector represent

terminal numbers.
What is the terminal number for the W wire?
___________________________________
What is the terminal number for the B/W wire?
___________________________________
B=
BR=
L=
GY=
P=
PU=
LG=
SB=
G/B=
OR/B=
G/R=
Y/L=
3.
Locate the service manual page that describes

the code for wire colors.
Record the correct wire color next to the color
code in the space provided in the chart.
4.
What do B1 and D0 represent in this

illustration? (Check one)
Connector location
Super multiple junction terminal location
Multiple switch terminal location
Module 2
5.
What do E5 and M4 indicate in the illustration?

(Check one)
Component location
Connector number
Module 2
Terminal number
6.
What is the normal position of each of these

switches?
Switch A: __________________________
Switch B: __________________________
7.
Match the symbol on the left with the letter of its

description below:
A.
Do not start engine, or check with

engine stopped.
B.
Circuit resistance should be measured

with an ohmmeter.
C.
Check after disconnecting the

connector to be measured.
D.
Turn ignition switch from ON to

OFF.
E.
Voltage should be measured with a

voltmeter.
F.
View from the harness side.
G.
Start engine, or check with engine

running.
H.
Check after connecting the connector

to be measured.
Module 2
8.
ECTC
0016C
Examine the sample wiring diagram shown in the

GI section. There are two types of wire splices:
What do these symbols mean?
a. _________________________________
b. _________________________________
9.
What type of meter is being used for the

diagnosis shown at left?
Ammeter / Ohmmeter / V
oltmeter
Voltmeter
(Circle one)
10. What connector terminals must be tested?

__________________________________
11. On which side of the harness should you
perform the inspection?
Terminal / Harness (Circle one)
12. For the inspection shown at left, the harness
connector should be:
Connected / Disconnected (Circle one)
13. The engine should be:
ON / OFF (Circle one)
14. What electrical test must be done?
(Check one)
Measure amperage
Measure resistance
Measure voltage
Module 2
15. Which connector terminal must be tested?

___________________________________
16. Which side of the connector is the meter being
probed?
Terminal side / Harness side (Circle one)
Refer to the charging system wiring diagram in the
ESM for answers to questions 1721.
17. What types of circuit protection devices are
used in the charging system?
___________________________________
___________________________________
18. Both the fusible link and fuse shown at left have
clear and dark circles. What do these circles
mean?
___________________________________
Fusible link
Fuse
___________________________________
19. How many pin openings are there in the charge
warning lamp connector?
___________________________________
20. What type of splice connects the battery to the
charging circuit?
___________________________________
21. Where is the alternator ground attached to the
vehicle? (Check one)
To a body ground under the dashboard
To a body ground behind the right kick panel
To a body ground in the engine compartment
or to a chassis ground under the hood
Module 2
Module 2
Refer to the illustration at left to answer questions

2227.
ECTC
0016C
22. To perform the test shown, should both

connectors be connected?
YES / NO
(Circle one)
23. These connectors are both:

Male / Female (Circle one)
24. What type of measurement is called for in this
step? (Check one)
Circuit voltage measurement
Circuit resistance measurement
Circuit amperage measurement
25. In what position must the ignition switch be set?
ON / OFF (Circle one)
26. What two terminals must be tested?
_____ and _____
27. Which side of the C/UNIT CONNECTOR must
be tested?
Terminal side / Harness side (Circle one)
Module 2
Refer to the illustration on the left to answer

questions 2833.
28. What type of measurement is being performed?
(Check one)
Check circuit voltage
Check circuit resistance
Check circuit amperage
29. What pedal is being applied?
Brake / Accelerator (Circle one)
30. What is the color of the wire connected to
terminal 1?
___________________________________
31. Is this inspection done with the connector
separated?
YES / NO (Circle one)
32. What does M107 refer to?
___________________________________
33. On which side of the connector should the
meter be connected?
Terminal side/Harness side (Circle one)
now be able to interpret wiring diagram symbols and
answer related questions. If you have any doubt
about your skills in completing this worksheet please
return to step 1 and review your work. Once you are
confident of your skills, have your instructor verify your
work.
Instructors Initials _____________________
Return the workstation to the condition in which
it was found.
Module 2
Module 2
NOTES
Module 2
MEASURING A
VAILABLE VOL
TAGE
AV
VOLT
Objective:
Given a multimeter, a circuit simulator

and a windshield wiper motor circuit,
measure available voltage at different
points in a circuit and make
comparisons for the purpose of
diagnosing faults.
Relevance: Voltage is electrical pressure. This

electrical pressure is necessary to
push current through a circuit. A
voltmeter is used to measure voltage
and can be very beneficial when used
as a diagnostic tool for testing
electrical malfunctions.
Resources: Digital multimeter
ESM
Circuit simulator
Skill Check: You will build a circuit and test
available voltage.
You will locate and identify the
windshield wiper motor circuit on a
test vehicle and measure the available
voltage.
Module 3
Module 3
1.
ECTC
0016C
Using the drawing in figure 1, build the circuit on

the simulator overlay. Use the parts provided to
build this circuit.
Switch the circuit ON to verify the load works,
then switch it OFF.
Overlay #1
Switch on negative side of circuit
Figure 1
2.
Rotate the selector knob on the meter to select

DC Volts (V
).
3.
Connect the red test lead to the V input jack and

the black test lead to the COM (common) input
jack.
Red
Black
Module 3
4.
Connect the red test lead to the battery positive

(+) terminal on the simulator and the black test
lead to the battery negative () terminal on the
simulator (Figure 2).
5.
Switch the circuit ON.

Module 3
D C
Figure 2
6.
RECORD
ANSWER
Measure available voltage at the battery, then

record the reading at left.
Note: This measurement indicates the voltage

available during circuit operation. Testing for
adequate available voltage should be the first
circuit measurement you make.
This also confirms that the meter and test
leads are in good working order. Battery
voltage less than 12 volts indicates a potential
problem.
Module 3
7.
ECTC
0016C
RECORD
ANSWER
Leave the black lead connected to the battery

negative and move the red lead to the positive
terminal of the load (Figure 2, position A ).
With the switch still ON (closed), measure the
voltage and record the reading in the space at
left.
Note: This measurement indicates the voltage

available at the load. This reading should be
slightly less than measured in step 6. Low
voltage readings indicate high resistance
between the power supply and the load. Low
voltage may result in false codes being stored
in ECM-controlled circuits.
A voltage reading close to the source voltage
confirms continuity between the battery and
the load, which means the wiring is good.
RECORD
ANSWER
8.
Leave the black lead connected to the battery

ground and move the red lead to the ground
side of the load (Figure 2, position B ).
9.
Turn the circuit switch OFF (open switch) and

measure the voltage on the ground side of the
load. Record your answer at left.
Based on this meter connection, is there voltage
immediately after the load?
____________________________________
Is the load operating at this time? ________
Why do you think this is the case?
____________________________________
____________________________________
____________________________________
Module 3
RECORD
ANSWER
10. Now close the switch (circuit ON) and record

the voltmeter reading in the space at left.
Instructors Initials _______________________
Module 3
11. Have your instructor assign a test vehicle for the

following voltage measurement exercises.
12. Set up the meter to measure DC volts.
RECORD
ANSWER
Connect both meter leads to the battery and

record the battery voltage at left.
13. With the ignition switch OFF, measure available
voltage to all fuses.
Note: On newer vehicles, all fuses are numbered in
the fuse box. If you cannot read the numbers,
use a flashlight or a drop light.
Connect the black lead to ground and the red
lead to each fuse in the fuse box.
Is battery voltage available to all the fuses?
Why?
___________________________________
___________________________________
Note: When testing circuit operation, refer to the
appropriate wiring diagram to determine which
switches (if any) must be ON before
measuring available voltage.
Module 3
14. To test the windshield wiper motor circuit, switch

the ignition ON (engine OFF) and measure
available voltage to the windshield wiper motor.
ECTC
0016C
Find the wiper motor wiring diagram in

the EL section of the service manual.
Using this diagram, trace the wiper motor
voltage feed wire from the wiper fuse to the
wiper motor.
15. What color is this wire on the test vehicle?
___________________________________
RECORD
ANSWER
16. Disconnect the connector, locate the wire

terminal feeding this circuit, then measure and
record the voltage in the space provided at left.
Note: This reading should be about the same as the
available battery voltage. By confirming that
the wiper motor has voltage available, you
know the fuse, wiring, connections and battery
are in good working order ... up to the load. In
other words, the source side of the circuit is
okay.
If a complaint of wipers dont work were
presented, the load and the ground path are
the only things left to check.
now be able to measure available voltage at different
points in a circuit and make comparisons for the
purpose of diagnosing faults. If you have any doubt
work.
Return the workstation to the condition in
which it was found.
Module 3
MEASURING VOL
TAGE DROP
VOLT
Objective:
Given a voltmeter, an Electrical

Lighting Simulator and an assigned
vehicle, measure voltage drop as
specified and evaluate the results
against established specifications.
Relevance: During circuit operation, it is normal for

electrical loads to use up the bulk of
the available voltage to make
them operate. Circuit connections,
wiring and grounds may also cause a
nominal amount of voltage drop
through each connection.
By using a voltmeter to measure
voltage drop at different points in a
circuit, you can quickly isolate the part
of the circuit that causes faulty circuit
operation (e.g. loose, dirty or damaged
connections).
Resources: Digital Multimeter
Test vehicle equipped with rear
window defogger
Electrical Lighting Simulator
Skill Check: You will measure the voltage drop in a
lighting circuit.
On a test vehicle, you will measure
voltage drop in a rear window
defogger circuit.
Module 4
Module 4
Use the Electrical Lighting Simulator to perform steps

18.
ECTC
0016C
1.
Switch the headlights ON.
2.
Measure available voltage at the source (battery

voltage), by connecting the multimeter to the
battery. Record the reading here.
____________ Volts
Headlamp bulb
Battery
Vehicle frame (body ground)
Test voltage drops as follows:
Battery
3.
Connect the red lead to the battery positive

cable and the black lead to the source side of
the headlamp (closest to battery).
4.
Switch the circuit ON and measure the voltage

drop between these points. The voltage reading
displayed on the meter is the voltage drop
between the battery and the load. Record the
reading here.
____________ Volts
Note: Voltage drop must be measured with the

circuit operating. When measuring voltage
drop across a portion of the wiring, the
voltage drop reading should be very small.
Module 4
5.
With the circuit still ON, move the black lead to

the ground side of the load. Move the red lead
to source side of the headlamp. Record the
reading here.
____________ Volts
Battery
Note: This reading is the voltage drop across the

load. This reading should be very close to
source voltage. If it is not close to source
voltage, there is high resistance at some other
point in the circuit.
6.
With the circuit still ON, measure voltage drop

across the ground circuit as follows:
Move the red lead to the ground side of the
same load and the black lead to the battery
negative terminal.
Record the reading here.
Battery
____________ Volts
Module 4
Module 4
7.
ECTC
0016C
RECORD
ANSWER
Add the readings obtained in steps 36 and

record the total here.
_____________ Volts
Does this value equal the reading obtained in
step 2?
Should they be the same?
Voltage Drop Chart
Note: The sum of the voltage drops in a circuit

should equal the available source voltage.
While a circuit is operating, the ground side
voltage drop should be .1 volt or less.
Maximum Allowable Voltage Drop*

Wire Connections
0.1 Volt or less

for each connection
Ground connections
0.1 Volts
Switch contacts
0.3 Volts
Starter Solenoids
0.5 Volts
*These guidelines are not applicable to

electronically-controlled circuits
A voltage drop greater than .1 volt may

indicate lose, dirty or corroded connections or
damage within the wiring harness between the
circuit load and the battery negative cable
connection.
8.
Have your instructor assign you a test vehicle

equipped with a rear window defogger system
to practice measuring voltage drop.
9.
Switch the ignition and rear window defogger

ON to activate the rear window defogger
circuit.
Module 4
10. Measure available voltage at the source side of

the load and record it here (see illustration
at left).
_______________ Volts
11. Is this reading acceptable?
Module 4
Rear
window
defogger
Battery
YES / NO
(Circle one)
12. Measure voltage drop between the battery

and the source side of the rear window
defogger and record it here.
_______________ Volts
+
Battery
Rear
window
defogger
13. Look again at the voltage drop chart on page 4.

Is this reading within specifications?
YES / NO
(Circle one)
Module 4
14. With the rear defogger circuit still operating,

measure voltage drop across the entire rear
window defogger grid and record the reading
here.
ECTC
0016C
_______________ Volts
Rear
window
defogger
Battery
Note: Simply looking at the brightness of a bulb, or

listening to the speed of a motor, or feeling the
warmth of a defogger gird will not tell you if
any of these devices are operating as they
normally should. Now that you know the
voltage drop on the source side of the load as
well as the voltage drop through the load, the
only missing link is the ground side of the
circuit.
15. With the circuit still ON, connect the red

multimeter lead to the ground side of the
defogger grid and the black lead to the negative
battery cable. This connection will allow you to
measure the voltage drop across the entire
ground circuit for the defogger grid.
The measured ground side voltage drop is:
_______________ Volts
Battery
Rear
window
defogger
Module 4
Note: A voltage drop measurement on the ground

side of a circuit tests all of the following:
Circuit connections within the wiring

harness
The connection at the body ground
location for the defogger grid
The frame of the vehicle
The battery ground cable
The connection at the battery post
Each of these listed points could be the root

cause of a voltage drop. The challenge is to
pinpoint the problem to the exact cause by
following a logical sequence of diagnosing
each part of the circuit and ruling out each part
one at a time.
16. Now that you know the total voltage drops
within the circuit, determine if anything could
have been overlooked. Fill in the boxes below to
verify the readings you just obtained.
Note
Note: A weak battery or insufficiently charged battery
will affect the results of a voltage drop test.
Module 4
Module 4
17. Now measure the available battery source

voltage and compare with the total voltage
drop measurements. Are they the same?
ECTC
0016C
YES / NO
(Circle one)
In summary, voltage drop testing is only partially

effective unless you have all of the facts. You must
know the available battery voltage to begin with, so
you can compare all of the other voltage drop
readings to this total. Keeping in mind the
specifications in the chart at step 8, you should be
able to determine if any of the readings are outside
the normal operating range. By putting all these facts
together with a solid customer concern, you should
be able to effectively diagnose problems in faulty
circuits.
now be able to measure voltage drop as specified
and evaluate the results against established
specifications. If you have any doubt about your skills
in completing this worksheet, please return to step 1
and review your work. Once you are confident of
your skills, have your instructor verify your work.
Return the workstation to the condition that you
found it.
Module 4
MEASURING RESIST
ANCE
RESISTANCE
Objective:
Given a digital multimeter, a circuit

simulator, a service manual, a fuelinjected vehicle and other components,
measure resistance and compare to
specifications.
Relevance: Electrical resistance opposes the flow

of current in a circuit. Electrical
accessories, also referred to as
loads, use up most of the voltage in a
circuit.
Excessive circuit resistance causes the
current flow to decrease. This
results in faulty circuit operation.
Circuit simulator
Service Manual
Various electrical components
Fuel injected vehicle
Combination Switch
Skill Check: Measure the resistance of various
electrical components with a digital
multimeter.
Check continuity of a combination
lighting switch.
Module 5
Module 5
1.
ECTC
0016C
Place the overlay for circuit #1 on the

simulator and build the circuit below. Do not
connect to the battery.
Source wire
Switch
Overlay #1
2.
Connect the test leads to the meter jacks and

switch the meter to . Touch the test leads
together and verify the readout is 00.3 Ohms
(Continuity).
3.
Measure the resistance of the source wire.

Readings of less than 1 Ohm are an exception.
Note: When using digital multimeters with autoranging capabilities, the meter automatically
selects the most accurate range when you
turn it ON. Most auto-ranging meters allow
you to change the range or displayed value
while the meter is in use.
Module 5
4.
Connect one of the ohmmeter leads to each of

the switch terminals, then close the switch.
Note: Never use the ohmmeter to make any tests

with power connected to the circuit being
tested.This could damage the meter and give
false readings.
RECORD
ANSWER
5.
Record the resistance (Ohms) you measured in

step 4 in the space at left.
Module 5
Note: Switch contacts should have very low

resistance.
6.
What would cause high resistance across

switch contacts?
___________________________________
RECORD
ANSWER
7.
Measure and record the resistance of the

following circuit components:
a.
Description: Load Resistance (Bulb)

Record your answer in the space at left.
RECORD
ANSWER
b.
Description: Resistance Across the Wires.

Record your answer in the space at left.
8.
Add the resistance values just taken (steps 57)

and record your answer below. This is the total
circuit resistance.
____________Ohms, Total circuit resistance.
Module 5
9.
ECTC
0016C
RECORD
ANSWER
Connect additional simulator wires to the load

and to the switch but do not connect to the
battery.
Measure the resistance, then record your
answer in the space provided at left.
10. Does this reading equal the value in step 8?

11. What could cause this reading to be different
than the other reading?
___________________________________
___________________________________
___________________________________
12. Ask your instructor to assign a test vehicle for
the following exercises.
RECORD
ANSWER
13. Measure the resistance of four injectors.

Record the resistance measurements below.
#1
_________
#2
_________
#3
_________
#4
_________
14. How would the engine run if the resistance of

each injector was significantly different?
___________________________________
___________________________________
Module 5
Stop
Have your instructor assign a vehicle for the following
steps.
TURN
Right turn
WIPER CONTROL
FOG LAMP
1st
ON
OFF
N
OFF
INT
Wash
2nd
B
LO
OFF
Left turn
HI
Lighting Switch*
OFF
A
1st
C
2nd
C
15. Using the vehicle service manual or ESM,

complete the switch charts at left and bottom
for the combination lighting, wiper and fog lamp
switch you're measuring.
Note: Depending on your vehicle, you may not use all
chart positions.
16. Using the ohmmeter, check continuity for each
switch position according to the charts. Record
your results here. (Circle one)
Wiper Switch*
OFF INT LO
HI
WASH
Lighting switch:
OK
Not OK
Wiper switch:
OK
Not OK
Fog lamp switch:
OK
Not OK
Turn signal switch:
OK
Not OK
Turn Signal Switch*

R
Fog Lamp Switch*

OFF ON
Module 5
Module 5

now be able to measure resistance and compare it to
specifications. If you have any doubt about your skills
in completing this worksheet please return to step 1
and review your work. Once you are confident of your
skills, have your instructor verify your work.
ECTC
0016C

found it.
Module 5
MEASURING CURRENT
Objective:
Given a digital multimeter, a circuit test

kit with overlay #1, measure current
flow through a circuit and evaluate the
results.
Relevance: Current is the flow of electrons in a

circuit. Amperage, the measurement of
current flow in a circuit, is affected by
the resistance of the circuit load and
the voltage applied to the circuit.
Malfunctions such as low voltage,
excessive circuit resistance or a faulty
component reduce current flow which
results in poor circuit operation.
Batteries, starter motors and
alternators operate under high current
demands. When you suspect one of
these is malfunctioning, measure the
current flow in the circuit and compare
it with specifications in the service
manual.
One of the more commonly overlooked
reasons for testing current flow is to
determine what causes a battery to go
dead overnight.
Circuit Test Kit
Circuit Overlay #1
Skill Check: Measure current flow in a circuit with a
multimeter.
Measure parasitic load in a test vehicle
battery.
Module 6
Module 6
1.
ECTC
0016C
Follow the drawing on simulator overlay #1 and

use the components provided to build the
circuit. Switch the simulator ON to be sure the
load works, then switch it OFF.
CAUTION:
Never attempt to measure current flow in excess

of 10 amps. Y
ou could damage the meter
You
(possibly beyond repair) or melt the 10A fuse.
To prevent damage to the meter or its fuse, be
sure to connect the meters red test lead to the
10A
10A meter jack and the black test lead to the
COM jack.
2.
Disconnect the source wire from the load.
3.
Connect the multimeter to the circuit as shown

in the following illustration.
Overlay #1
Switch in negative side of circuit
Module 6
RECORD
ANSWER
4.
Rotate the selector knob so the multimeter is in

the DC Amps position.
5.
Press the switch on the circuit tester to activate

the circuit and record the amperage reading at
left.
Module 6
Module 6
6.
Switch the simulator OFF, disconnect the meter

leads from the circuit, then reconnect the circuit
wiring and meter as illustrated below.
7.
Make sure the selector knob on the multimeter is

still in the DC Amps position.
ECTC
0016C
RECORD
ANSWER
8.
Switch the simulator and circuit ON and record

the amperage reading at left
Note: The amperage measured in a series circuit

should be the same at any point in the circuit.
9.
Were the two amperage readings taken in steps

5 and 8 about the same?
YES / NO
(Circle one)
Measure Parasitic Load

Have your instructor assign a vehicle for the following
steps.
10. Using an assigned vehicle, measure the parasitic
load on a battery.
11. Check to see that all circuits and the ignition
switch are OFF.
12. Disconnect the negative battery cable and
connect the multimeter in series between the
battery post and battery cable.
Module 6
13. With the meter still set up to read amperage,

what is the reading?
__________________ A
Note: In most cases, parasitic draw should be less
than 30 mA if the vehicle is operating normally.
Readings in excess of that typically indicate a
problem.
On cars equipped with BCM, a momentary
high current drain above 150 mA will occur,
but after 30 seconds, the reading should drop
below 30 mA.
14. Switch the meter OFF, then disconnect it from
the battery.
15. Reconnect the battery cable.
now be able to measure current flow through a circuit
and evaluate the results. If you have any doubt about
your skills in completing this worksheet, please return
to step 1 and review your work. Once you are
work.
found it.
Module 6
Module 6
NOTES
Module 6
COMBINA
TION SWIT
CH OPERA
TION
COMBINATION
SWITCH
OPERATION
Objective
Objective:
Given a combination switch and a

combination switch circuit, read a
combination switch chart and
diagnose various combination switch
circuits using a digital multimeter.
Sample Combination Switch
Relevance: A combination switch contains multiple

switches. Each multiple switch uses a
single control lever to control several
circuits.
In order to diagnose a malfunction in
one or more related circuits you must
understand how the switch works and
how it controls the various circuits.
Resources: Combination light switch
Skill Check: Identify the terminal contacts in a
combination light switch.
Identify circuit connections and current
paths in a lighting circuit.
Module 7
Module 7
TURN
Right turn
ECTC
0016C
FOG LAMP
OFF
N
ON
1st
A
INT
WASH
B
2nd
LO
OFF
C
Left turn
HI
Figure 1
Refer to Figure 1 and the switch chart for steps 13.

1.
Switch
Positions
The combination switch (Figure 1) controls the

parking lights, high and low beam headlamps,
turn signals, windshield wipers and windshield
washer. Study the switch chart at left and
Figure 1.
How many light switch positions are there?
___________________________________
How many wiper positions are there?
Line
indicates
continuity
___________________________________
2.
Connector (terminal) numbers

Lighting Switch Chart, Sample
There are two types of illustrations in the service

manual that describe the operation of the
combination switch:
3.
Charts
Wiring Diagram
A Combination Switch Chart, like the one on the

left, illustrates the following:
Terminal numbers
Switch positions
Continuity indicators (the lines between
circles)
Which terminals are connected when the

switch is positioned in 2B?
___________________________________
Module 7
The wiring diagrams on the following page (Figures 2

and 3) illustrate the circuits attached to a hazard
switch. The light switch wiring diagrams shown
contain the following information:
Voltage source for the switch.
Switch terminal numbers
Wiring that connects the circuit

components.
Answer the following questions which refer to the

electrical diagrams on the following page (Figures 2
and 3).
4.
Which fuses connect the battery to the hazard

switch?
____________________________________
5.
What are the connector numbers for the front

turn signal lamps?
____________________________________
Component
Terminal
6.
Study Figures 2 and 3 on the following page.

Based on these wiring diagrams, locate the
hazard switch, then record the switch terminal
numbers for the circuits listed at left.
7.
What is the harness connector number at

the hazard switch?
Combination Flasher
Multi-Remote Control Relay-2
Turn Signal Lamp, RH
Combination Meter
(Turn Signal Lamp), LH
Ignition Switch
Battery power
___________________________________
Module 7
Module 7
Figure 2
Figure 3
ECTC
0016C
Module 7
8.
Identify the harness connector numbers at

the rear turn signal lamps.
___________________________________
9.
Identify and describe the fuses that protect the

Turn Signal and Hazard Warning Lamp circuits.
___________________________________
___________________________________
Note: An electrical schematic does not show the

detail found in a wiring diagram, but the
entire circuit is displayed on a single page.
This avoids having to follow the circuit through
several pages to trace a circuit or a wire.
Not all electrical circuits have a schematic
diagram. For those that are available, they will
help you understand how the circuit operates.
A System Description usually accompanies
the schematic to describe power distribution
within the circuit.
Module 7
Module 7
Answer the following questions about the Turn Signal

Circuit using the Turn Signal Operation information and
schematic diagram (Figure 4).
ECTC
0016C
10. From the system description, identify which fuse

powers the hazard switch:
#________
Fuse rating: _______A
11. From what terminal on the Combination Flasher

Unit does current enter from the Hazard
switch?
Terminal ________
12. Identify the circuit path (in sequence) from the
hazard switch to the rear combination lamp, LH
and ground when the turn signal switch is in the
LEFT TURN position.
Letter
Part Name
____
________________________
____
________________________
____
________________________
____
________________________
____
________________________
____
________________________
____
________________________
13. Starting from the LH front turn signal lamp,

trace the circuit back to the source.
14. Identify the letter that indicates where the LH
turn signal circuit becomes a parallel circuit.
_____________
Module 7
Module 7
C
F
O
K
N
E
D
I
G
J
Figure 4
Module 7
Use the wiring diagram on page 9 (Figure 5) to

answer the following questions:
ECTC
0016C
15. What is the fuse number and rating for the

combination switch circuit?
#________
Fuse rating: _______A
16. What does the black dot at 1 represent?

_________________________
17. Does 2 receive switched power or
constant battery power?
____________________
18. How much voltage should be at 3 in the
OFF position?
_________________________
19. How much voltage should be at 4 with
the ignition switch OFF?
_________________________
20. How much voltage should be 5 with the
Fog Lamp Switch ON?
_________________________
21. What happens to the front fog lamps if
there is an open circuit at 6 ?
LH lamp__________________
RH lamp__________________
Module 7
2
4
Module 7
Figure 5
Module 7

now be able to read a combination switch chart and
diagnose various combination switch circuits using a
digital multimeter. If you have any doubt about your
skills in completing this worksheet please return to
ECTC
0016C

Return the workstation to the condition in which
it was found.
10
Module 7
DIAGNOSING ONE TRANSFER (1T) RELA

Y MALFUNCTIONS
RELAY
From voltage source
Objective:
To hood
switch
To starter circuit
Sample 1T relay
1-T
Given a service manual or ESM, a

digital multimeter, a one transfer (1T)
relay and circuit test kit w/overlay #2,
diagnose the operation of a 1T relay.
Relevance: Unwanted circuit resistance can cause

abnormal voltage drops. Abnormal
voltage drops can lead to customer
complaints relating to faulty circuit
operation.
Poor connections or corrosion may be
the root cause of the high resistance. A
voltmeter can be used to analyze the
circuit while in operation to help locate
the fault.
Resources: Circuit Test Kit w/overlay #2
Digital Multimeter
1T Relay
Skill Check: Predict and measure available voltage
at the terminals of a 1T relay.
Module 8
Module 8
ECTC
0016C
Switch Open
Test P
oint
Point
Voltage, predicted
Terminal 1 A
Predicted V
oltage
Voltage
1.
Before you build the circuit shown on simulator

overlay #2, predict the voltage level at each of
the terminals.
Terminal 2 B
Examine the top of the relay and the simulator

overlay to identify the terminal numbers.
Terminal 3 C
Terminal 4 D
a.
Assume the black lead of the multimeter is

connected to ground and the red lead
touches the terminals listed in the charts.
b.
First, assume the coil control switch is

Open, then assume it is Closed
Closed.
Open
Terminal 5 E
Switch Closed
Test P
oint
Point
Terminal 1 A
Voltage, predicted
Record your predicted voltage readings in the

charts at left.
Terminal 2 B
Terminal 3 C
Terminal 4 D
Terminal 5 E
Overlay #2
Module 8
Measured V
oltage
Voltage
RECORD
ANSWER
a. Switch Open
Test P
oint
Point
Voltage, measured
2.
Use the 1-Transfer Relay and the attached

jumper wires to build the circuit shown on
overlay #2.
3.
Plug in the simulator and switch the circuit ON.

Using the multimeter, measure and record the
battery voltage in the space at left.
4.
Measure relay voltages on Circuit No. 2 as

follows:
Module 8
Connect the black lead of the multimeter to

ground, then touch the red test lead to the
harness side of each terminal and measure the
voltage.
Terminal 1 A
Terminal 2 B
Terminal 3 C
Terminal 4 D
Terminal 5 E
b. Switch Closed
Test P
oint
Point
Terminal 1 A
Terminal 2 B
Terminal 3 C
Terminal 4 D
Terminal 5 E
Module 8
a.
Measure with the coil control switch

open
open.
b.
Measure with the coil control switch

closed.
closed
Record the readings at left.
Voltage, measured
Note: If a relay buzzes, current flow through the coil

control circuit may be too low to keep the
contact circuit closed. This failure occurs if the
source voltage is below specifications or if the
circuit resistance is too great. The coil control
winding inside the relay should be the only
significant resistance in the circuit.
5.
Your voltage measurements should match the

predictions in step 1. If not, review your
predictions and determine why you were
incorrect.
6.
Examine the Antilock Brake System (ABS)

circuit diagram (Figure 1) on the next page and
answer the following questions:
ECTC
0016C
Two relays are illustrated in the circuit diagram.

Which one is a 1T relay?
___________________________________
7.
What type of relay is the other relay?

___________________________________
8.
Which terminal of the IT relay provides source

voltage to the coil control circuit?
___________________________________
9.
What terminal number of the ABS control unit is

connected to the source voltage of both relay
control coils?
___________________________________
Module 8
Antilock Brake System
Module 8
Figure 1
Module 8
10. What must happen at terminal 6 of the ABS

Control Unit so battery voltage is supplied to
the ABS solenoid valves? (Check one)
ECTC
0016C
_____ Provide battery voltage to terminal 6.

_____ Provide ground at terminal 6.
Ask your instructor to assign you a test vehicle and
circuit.
Use the Starting System Simulator for the remaining
steps.
11. Verify relay operation by operating the circuit.
RECORD
ANSWER
12. Remove the relay and use a voltmeter to test for

voltage at the coil control circuit, then record
the voltage reading at left.
Note: A One Transfer Relay has a coil control circuit
and two contact point circuits. Each circuit
must be diagnosed separately.
During diagnosis, remember to turn ON any
switches required to operate the circuit.
Refer to the wiring diagram for the circuit
you are testing.
13. If there is no voltage, diagnose the coil control
circuit between the relay socket and the voltage
source. Refer to the wiring diagram and choose
test points that are easy to locate that will help
you quickly isolate the problem.
Module 8
14. Connect the red lead to the positive post of the

battery and touch the black lead to the control
circuit ground terminal at the relay connector
socket. If there is no ground at the socket the
meter will read zero volts. If the meter reads
12 volts, the control coil ground is good. Select
test points that are easy to find and check, and
look for loose, dirty or damaged connections to
determine why the ground is faulty.
15. Use a fused jumper wire between terminal 3 and
5 in the relay socket to test operation of the
circuit controlled by the relay.
Caution:
Never bypass the coil winding with a jumper.
Doing so may damage the wiring harness
and/or control switches.
16. If the circuit does not work with the fused
jumper installed,
there may be no source voltage at terminal #3
there may be an open between terminal #5
and the load.
the ground for the load may be open.
17. Use the same procedure to test the normally
closed contact point circuit by jumping terminals
#3 and #4 at the relay socket.
Does the load in this circuit operate?
YES / NO
(Circle one)

now be able to diagnose the operation of a one
transfer (1T) relay. If you have any doubt about your
Module 8

found it.
7
Module 8
NOTES
Module 8
DIAGNOSING ONE MAKE (1M) RELA

Y MALFUNCTIONS
RELAY
Objective:
Given overlay #3, a service manual,

and test equipment, test a vehicle with
a 1M relay circuit.
Relevance: A one make (1M) relay contains a load

circuit and a control circuit. The load
circuit is completed when an external
switch in the control circuit closes.
In the example, terminals 1 and 3 are
connected to source voltage.
Terminal 5 connects to the load circuit
and terminal 2 connects the control
circuit to ground. When terminal 2 is
grounded, the contacts close,
completing the circuit through
terminal 5 to the load.
Circuit malfunctions can be caused by
a faulty relay, circuit wiring and
connectors or the actual load itself. To
be effective at diagnosing 1M relay
malfunctions, you must understand
relay operation.
Simulator w/overlay #3
Service manual
Skill Check: Use a multimeter to test the operation
of a circuit controlled by a 1M relay.
Module 9
Module 9
Predicted V
oltage
Voltage
Switch Open
ECTC
0016C
Test P
oint
Point
Voltage Predicted
Terminal 1
Terminal 2
Terminal 3
Terminal 5
1.

connected to ground and the red lead touches
each test point listed in the chart. First, assume
the coil control switch is OPEN, then assume it
is CLOSED.
Switch Closed
Test P
oint
Point
Voltage Predicted
Terminal 1
Terminal 2
Terminal 3
Terminal 5

overlay #3, predict the voltage levels at each
of the terminals.
Record the predicted voltage readings in the

spaces provided at left.
D
C
A
B
Overlay #3
Module 9
Measured V
oltage
Voltage
RECORD
ANSWER
2.
Plug in the simulator, then measure and

record the source voltage at left.
3.
Measure relay voltages as follows:
Switch Open
Test P
oint
Point
a.
Voltage Measured
Terminal 1
Terminal 2
Terminal 3
Terminal 5
Switch Closed
Test P
oint
Point
Voltage Measured
Terminal 1
Terminal 2
Terminal 3
Terminal 5
Use a 1 Make Relay to build the circuit

shown on overlay #3. Attach the black
multimeter lead to ground, then touch
the red lead to each of the numbered
terminals.
b.
Measure actual voltages at each of the

relay terminals.
c.
First, measure with the coil control

switch OPEN, then measure with the
coil control switch CLOSED.
Record the measured voltage in the

spaces provided.
4.
Are the voltage measurements in step 3 the

same as your predictions in step 1?
Module 9
Module 9
Theft W
arning Relay
Warning
ECTC
0016C
Test P
oint
Point
5.
Voltage Predicted
Terminal
Terminal
Terminal
Terminal
Terminal
Assume the ignition switch is in the START

position, the clutch interlock switch is in the
released position, and the Theft Warning Relay
control circuit is not grounded. Record the
voltages you expect to measure at each of the
theft warning relay terminals.
6.
Clutch Interlock Relay

Test P
oint
Point
Voltage Predicted
Terminal
Terminal
Terminal
Terminal
Now, assume the ignition switch is in the START

position, the clutch interlock switch is still
released. Record the voltages you expect to
measure at each of the clutch interlock relay
terminals.
Diagnostic Strategy
After verifying a customer complaint (symptom), the
most efficient way to diagnose relay circuit
malfunctions is to understand how the circuit should
operate.
7.
Refer to the Starting System Wiring Diagram

(Figure 1) to answer the following questions.
Check for voltage on both sides of each

fuse
Locate and test for voltage at the circuit

relays and switches.
Operate the circuit while touching and/or

listening to each relay in the circuit. You
should be able to feel or hear the contacts
close.
Substitute a known good battery and

retest circuit operation.
Look for loose ground connections.
As you have seen in this exercise, proper relay

operation is often affected by external
malfunctions in the circuit. Dont jump to
conclusions.
Module 9
Module 9
Figure 1
Module 9
ECTC
0016C
Blower Motor Relay:
Any V
ehicle
Vehicle
Fuel Pump Relay:
Any V
ehicle
Vehicle
Ignition Relay:
Any V
ehicle
Vehicle
Radiator Fan Relays:
Any V
ehicle
Vehicle
8.
Select one of the relay circuits at left to test on

the assigned vehicle:
Record the following information:
Vehicle model: ______________________
Vehicle year: _______________________
9.
What system are you working on?

___________________________________
10. Refer to the wiring diagram for the circuit you

are testing.
11. The coil control circuit and relay contact point
circuits are two separate circuits. Diagnose
them separately.
12. The circuit must be ON to test for voltage.
13. To check operation of the contact circuit,
connect a fused jumper wire to terminals #3 and
#5 in the relay socket. These contacts normally
close when the relay energizes. The load should
operate.
Does the load operate?
RECORD
ANSWER
14. If the load does not operate, test for available

voltage at terminal #3 in the relay socket, then
record the voltage reading at left.
15. If there is no voltage at terminal #3, test for
voltage at various places between the battery
and the relay. Use the wiring diagram to select
points that are easy to test to isolate the
malfunction quickly.
Module 9
RECORD
ANSWER
16. Test for available voltage to the coil control

circuit, then record the voltage reading at left.
17. If there is no voltage at the coil, test for voltage
at various places between the battery and the
relay. Use the wiring diagram to select points
that are easy to test to isolate the malfunction
quickly.
18. Connect the red meter lead to the positive
battery post and the black lead to the coil
control circuit ground terminal in the relay
socket.
19. What is the meter reading?
____________________________________
20. What does this indicate about the circuit?
___________________________________
Note: If the meter reading obtained is zero (0) volts,
the circuit is open between the relay socket
and ground. If the coil control ground is
computer-controlled, switch the circuit ON to
ensure the control unit is trying to supply
ground.
now be able to test a vehicle with a 1M relay circuit. If
you have any doubt about your skills in completing
this worksheet please return to step 1 and review
your work. Once you are confident of your skills, have
your instructor verify your work.
found it.
Module 9
Module 9
NOTES
Module xx
DIAGNOSING TWO MAKE (2M) RELA

Y MALFUNCTIONS
RELAY
to fuse
#1
to fuse
#10
to fuse
#4
Objective:
Given a service manual, a digital

multimeter, a Two Make (2M) relay and
a circuit test kit with overlay #4,
diagnose the operation of a 2M relay.
Relevance: A 2M relay contains two load circuits

and a control circuit. The load circuits
are completed when an external switch
in the control circuit closes.
Sample 2M relay

a faulty relay, circuit wiring and
connectors or the actual load itself. To
be effective at diagnosing 2M relay
circuit faults, you must understand
relay operation.
Assigned vehicle
Circuit Test Kit w/overlay #4
2M Relay
Module 10

of a circuit controlled by a 2M relay.
Module 10
ECTC
0016C
Predicted V
oltage
Voltage
Switch Open
Test P
oint
Point
Voltage Predicted
Terminal 1
Terminal 2
Terminal 3
Terminal 5
Terminal 6
Terminal 7
1.

each test point listed in the chart. First assume
the coil control switch is OPEN, then assume it
is CLOSED.
Switch Closed
Test P
oint
Point
Record the predicted voltage readings in the

spaces provided.
Voltage Predicted
Terminal 1
Terminal 2
Terminal3
Terminal 5
Terminal 6
Terminal 7

overlay #4, predict the terminal voltages in the
2M relay circuit.
C
E
F
A
B
Overlay #4 Schematic
2
Module 10
Measured V
oltage
Voltage
RECORD
ANSWER
Switch Open
Test P
oint
Point
2.
Plug in the simulator, then measure and record

the source voltage at left.
3.
Measure relay voltages as follows:
Voltage Measured
Terminal 1
Terminal 2
Terminal 3
Terminal 5
Terminal 6
Terminal 7
b.
Attach the black multimeter lead to

ground, then touch the red test lead to
each of the numbered terminals.
c.
Measure actual voltages at each of the

relay terminals.
d.
First, measure with the coil control

switch OPEN, then measure with the
coil control switch CLOSED.
Voltage Measured
Terminal 1
Terminal 2
Terminal 3
Terminal 5
Terminal 6
Terminal 7
Module 10
Use a 2M Relay to build the circuit

shown on the overlay.
Record the measured voltages in the spaces

provided.
Switch Closed
Test P
oint
Point
a.
4.
Are the voltage measurements in step 3 the

same as your predictions in step 1?
YES / NO
(Circle one)
Module 10
5.
ECTC
0016C
Answer the following questions about the

2M Multi-Remote Control Relay-1 in the Turn
Signal and Hazard Warning Lamp circuit
(Figure 1).
Situation:
When the hazard switch is ON (closed) the
hazard lamps remain OFF. How can you test the
relay to determine if the malfunction is in the
relay coil circuit or the contact circuit? Select
the best answer:
a.
With the relay removed, connect a

fused jumper wire between relay
sockets 3 and 5, then observe the turn
signal lamps. The left hand lamps
should illuminate.
b.
With the relay removed, jumper relay

socket 6 and 7 and observe the turn
signal lamps. The right hand lamps
should illuminate.
c.
With the relay removed, jumper relay

socket 1 and 2 and observe the lamp.
d.
Choices a and b are both correct.
Module 10
Module 10
Figure 1
Module 10
6.
ECTC
0016C
Answer the following questions using the

attached Rear Window Defogger wiring
diagram (Figure 2) and the service manual
description.
Identify the relay in the wiring diagram.
Relay name Type NO/NC Case color
__________________________________
7.
The Smart Entrance Control Unit controls the

ground for the Rear Window Defogger Relay.
Refer to the wiring diagram for this circuit and
check all of the following that apply.
Assuming fuse #1 is good, voltage is
available at terminal 11 at all times
when the ignition switch is ON.
On cars without power door locks,
voltage to terminal 1 at the rear
window defogger switch comes from
terminal 3 of the defogger timer.
If fuse #9 fails during operation of the
rear defogger, a 30 amp fuse should be
used to replace it.
8.
With the Rear Window Defogger Switch ON

(closed), what should the voltage reading be at
terminal 11 of the Smart Entrance Control Unit?
Battery voltage, 12 volts
Battery ground, 0 volts
9.
With the Rear Window Defogger Switch ON

(closed), what should the voltage reading be at
terminal 20 of the Smart Entrance Control Unit?
Battery voltage, 12 volts
Battery ground, 0 volts
Module 10
Figure 2
Module 10
Module 10
ECTC
0016C
Smart Entrance Control Unit

Test P
oint
Point
Voltage Predicted
Terminal 36
Terminal 10
Defogger Relay
Test P
oint
Point
10. Based on the circuit in Figure 2, assume the

ignition switch and Defogger Switch are both
ON. Record the voltages you expect to measure
at each of the Defogger circuit terminals in the
charts at left.
11. What is the primary reason for using a 2M relay
in the Defogger Circuit? (Circle one)
Voltage Predicted
a.
Due to the function of this circuit, there

is a need to control each circuit
independently. For example, power to
the indicator lamp can be controlled
independently by the defogger switch.
b.
Due to the high current demands

placed on this relay there is the danger
that a single set of relay contacts might
be damaged or burned.
Terminal 1
Terminal 2
Terminal 3
Terminal 5
Terminal 6
Terminal 7
Defogger Switch
Test P
oint
Point
Voltage Predicted
Terminal 1
Terminal 2

Terminal 3
Terminal 4
Terminal 5
Terminal 6
Shop Exercise
Ask your instructor to assign you a test vehicle.
12. Select one of these relay circuits to test on the
assigned vehicle.
Rear Defogger relay
Theft Warning relay
Module 10
13. Record the following information:

Vehicle model: ______________________
Vehicle year: ________________________
14. Which of the above circuits did you select?
___________________________________
15. Refer to the wiring diagram for the circuit you are
testing.
16. Switch the circuit ON when diagnosing circuits.
RECORD
ANSWER
17. Remove the relay from its connector and test for
available voltage at the coil control circuit
socket. Record the voltage at left.
18. If there is no voltage at this location, test for
voltage at selected points between the battery
and relay. Use the wiring diagram to select
points that are easy to test in order to isolate
the problem quickly.
19. Switch the defogger ON.
Module 10
20. Connect the red multimeter lead to the positive

battery post and the black lead to the coil
control circuit ground terminal to verify a good
ground, then record the voltage reading:
___________________________________
Based on this reading, do you think the ground
circuit is good?
YES / NO
Module 10
(Circle One)
21. The 2M Relay has two contact circuits.

ECTC
0016C
RECORD
ANSWER
To test them, remove the relay from the

socket and connect socket terminals
#3 and #5 with a fused jumper lead.
The load should operate.
Jump terminals #6 and #7 with the

fused jumper lead. The load should
operate.
22. If the load does not operate in either case, use

the wiring diagram to determine which terminal
numbers receive voltage for the contact circuits.
Use the voltmeter to test for voltage at the
terminals for the contact circuits in the relay
socket.
Record the readings in the space at left.
23. If voltage is not present, diagnose each contact
circuit between the relay socket and the voltage
source by testing for voltage at selected test
points. Use the wiring diagram to select points
that are easy to test in order to isolate the
problem quickly.
now be able to diagnose the operation of a 2M relay.
If you have any doubt about your skills in completing
this worksheet please return to step 1 and review
your work. Once you are confident of your skills, have
your instructor verify your work.
found it.
10
Module 10
DIAGNOSING ONE MAKE-ONE BREAK (1M-1B)

RELAY MALFUNCTIONS
Objective:
Sample 1M-1B Relay
Given a test kit with overlay #5, a

service manual, digital multimeter and a
One Make-One Break (1M-1B) Relay,
diagnose the operation of a 1M-1B
relay.
Relevance: A One Make-One Break (1M-1B) relay

contains two load circuits and a
control circuit. Each load circuit is
alternately powered depending on
whether the control circuit is energized
or not.
a faulty relay, circuit wiring,
connections or the load. To repair a
circuit containing a 1M-1B relay you
should understand how this type of
relay operates.
Circuit Test Kit w/overlay #5
Test vehicle
1M-1B relay
Starter simulator
Module 11

of a circuit controlled by a 1M-1B relay.
Module 11
Predicted V
oltage
Voltage
Switch Open
ECTC
0016C
Test P
oint
Point
Voltage Predicted
Terminal 1
Terminal 2
Terminal 3
Terminal 4
Terminal 6
Terminal 7
1.

overlay #5, predict the voltage levels at each of
the terminals.
To do this, assume the black multimeter lead is
each of the test points to the left. First, assume
the coil control switch is open, then assume it is
closed.
Switch Closed
Test P
oint
Point
Voltage Predicted
Terminal 1
Terminal 2
Terminal 3
Terminal 4
Terminal 6
Terminal 7
C
E
A
B
Overlay #5 Schematic
Module 11
Measured V
oltage
Voltage
RECORD
ANSWER
Switch Open
Test P
oint
Point
2.
Plug in the simulator, then measure and record

the source voltage in the space at left.
3.
Use the 1M-1B relay and build the circuit shown

on overlay #5. Then attach the black meter lead
to ground. Touch the red test lead to each of the
terminals in the charts at left.
4.
Measure relay voltages on Circuit No. 5 (1M-1B

Relay) with the coil control switch open and
record the readings at left.
Voltage Measured
Terminal 1
Terminal 2
Terminal 3
Terminal 4
Terminal 6
Terminal 7
Module 11
Switch Closed
Test P
oint
Point
Voltage Measured
Terminal 1
Terminal 2
Terminal 3
Terminal 4
Terminal 6
Terminal 7
Module 11
5.
Next, measure voltages with the coil control

switch closed, then record the readings at left.
6.
Are the measured readings the same as your

predictions (step 1)?
ECTC
0016C
Module 11
Schematic
Figure 1
7.
Examine the Automatic Speed Control Device

(ASCD) circuit diagram in figure 1 and answer
the following questions:
There are five relays in the circuit diagram. Using
the text section as reference, record the name
and relay type (1T, 1M, 2T, etc.), whether it is
NO or NC and the relay case color.
Relay name
T
ype
Type
NO/NC
Case color
A
B
C
D
E
8.
Which position must the inhibitor switch be in to

connect source voltage (through the inhibitor
relay) to terminal 5 of the ASCD control unit?
___________________________________
Module 11
___________________________________
9.
Which relay connects the voltage source to the

normally closed contacts of the Inhibitor Relay?
___________________________________
___________________________________
10. Which ASCD Main Switch position is used to

complete the circuit to the normally closed
contacts of the Inhibitor Relay?
OFF / ON
Module 11
(Circle one)
11. Select the inhibitor relay to diagnose on the test

vehicle.
ECTC
0016C

12. Ask your instructor to assign you a test vehicle
and circuit.
13. Check the operation of the load controlled by
this relay. Does the load operate?
YES / NO
RECORD
ANSWER
(Circle One)
14. If the load does not operate, remove the relay

and test for available voltage at terminal 1 in the
relay socket and record the reading at left.
15. If there is no voltage, test for voltage at different
points between the source and the control
circuit. Using the wiring diagram, locate the
most efficient test points.
Note: Diagnose malfunctions in the control coil
ground circuit:
Using an ohmmeter An ohmmeter checks the continuity of
the circuit.
Using a voltmeter A voltmeter tests for voltage at
different points in the circuit while it is
operating. While the circuit is
grounded, there should be almost zero
volts.
Module 11
16. If there is voltage at terminal #1, use a fused

jumper between socket terminal 6 and 7 and try
to operate the load again.
Does the load in this circuit operate?
17. If the load still does not operate, test for voltage
at the terminals for the contact point circuit in
the relay socket. Use the wiring diagram to
determine which terminals should be connected
to source voltage.
Record the meter readings in the space
provided at left.
RECORD
ANSWER
18. If there is no voltage available, test for voltage at

points that are easy to locate to help you quickly
isolate the problem.
now be able to diagnose the operation of a
1M-1B relay. If you have any doubt about your skills in
completing this worksheet please return to step 1
and review your work. Once you are confident of your
skills, have your instructor verify your work.
Module 11

found it.
Module 11
NOTES
Module xx
CIRCUIT DIAGNOSIS EXERCISE: #1
Objective:
Given a customers repair order, a

service manual and a digital multimeter,
verify, isolate, repair and recheck the
fault in question.
Relevance: Circuit diagnosis is a critical part of

making effective repairs. In this exercise
you will be given a customer concern.
The symptom applies to a vehicle
which you must repair. You must verify,
isolate, repair and recheck the cause of
the malfunction using the customer
repair order, vehicle service manual,
appropriate test equipment, and all
diagnosis skills.
Resources: Assigned vehicle
Electronic Service Manual
Digital Multimeter
Skill Check: Vehicle electrical fault repaired and
circuit operation verified by instructor
after repair. When performing
diagnostic procedures the following
items should always be followed:
1. Verify the complaint
2. Isolate the cause
3. Repair the fault
4. Recheck your repair
Module 12
Module 12
ECTC
0016C
Customer Concern:
Engine overheats. Customer uses A/C, engine overheats quickly when

outside temp. is hot
Cause:
Corrective Action:
Figure 1
Module 12
1.
Record the following information here and on

the repair order (figure 1).
Vehicle model: ______________________
Model year: ________________________
2.
Background information for Diagnosis #1:

Customer Concern: Engine overheats
Repair History:
On 7/5, thermostat was replaced, but repairs
were not verified.
On 7/8, the radiator cap was replaced and
coolant level topped off.
Car was towed in two days later for same
symptom.
3.
Module 12
With a teammate, think of all the possibilities for

this incident. On the following page, list all of the
possible causes for this overheating condition. If
you have difficulty recalling all of the possible
causes, you may use any diagnostic resources
within the classroom to help you build your list.
Once your list is complete to your satisfaction,
rank the causes in the order of most probable. In
other words, number them in the order you
would test them.
Module 12
Possible Causes (List all possible causes for

the given symptoms)
ECTC
0016C
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
Module 12
4.
After completing step 3, discuss your strategy

with the instructor.
5.
With the instructors approval, verify, isolate,

repair and recheck the fault in the order you
ranked them in step 3. Perform all tests
necessary to verify each possible cause.
6.
During your diagnosis, list below the results of

your findings for each of the items you check
from the list you created.
Item tested: Actual vehicle results:
1st _____________________________
2nd _____________________________
3rd _____________________________
Additional items tested:
________________________________
________________________________
________________________________
________________________________
________________________________
Module 12
________________________________
________________________________
7.
Module 12
When you have repaired the problem on the

vehicle and verified the repair, record the cause
and corrective action on the repair order
(page 2).
As a result of this exercise, you should see the need

for effective diagnostic skills and the benefit of taking
your time to follow repair procedures and get the
problem resolved before returning the vehicle to the
customer.
ECTC
0016C

now be able to verify, isolate, repair and recheck the
fault in question. If you have any doubt about your
found it.
Module 12
Objective:

fault in question.

diagnosis skills.
Digital Multimeter
Module 13

3. Repair the fault
Module 13
ECTC
0016C
Customer Concern:
Cause:
Corrective Action:
Figure 1
Module 13
1.

the repair order (Figure 1).
Vehicle model: ______________________
Model year: ________________________
2.

Customer Concern:
Customer claims that it takes a long time to
clear the rear window using the defogger circuit.
Repair History:
Checked voltage drop across rear window grid.
Voltage appeared to be in the normal range.
Replaced rear window defogger relay, but did
not validate the repair.
3.

possible causes for this defogging condition. If
you have difficulty recalling all of the possible
causes, you may use any diagnostic resources
within the classroom to help you build your list.
Once your list is complete to your satisfaction,
rank the causes in the order of most probable. In
other words, number them in the order you
would test them.
Module 13
Module 13

the given symptoms)
ECTC
0016C
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
Module 13
4.

5.

6.

1st _____________________________
2nd _____________________________
3rd _____________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
7.
Module 13
Module 13

(page 2).

customer.
ECTC
0016C

found it.
Module 13
Objective:

fault in question.

diagnosis skills.
Digital Multimeter
3. Repair the fault
Module 14
Module 14
ECTC
0016C
Customer Concern:
Cause:
Corrective Action:
Figure 1
Module 14
1.

Vehicle model: ______________________
Model year: ________________________
2.

Customer Concern:
___________________________________
___________________________________
___________________________________
Repair History:
___________________________________
___________________________________
___________________________________
3.

possible causes for this condition. If you have
difficulty recalling all of the possible causes, you
may use any diagnostic resources within the
classroom to help you build your list. Once your
list is complete to your satisfaction, rank the
causes in the order of most probable. In other
words, number them in the order you would test
them.
Module 14
Module 14

the given symptoms)
ECTC
0016C
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
Module 14
4.

5.

6.

1st _____________________________
2nd _____________________________
3rd _____________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
7.
Module 14

(page 2).
Module 14

customer.
ECTC
0016C

found it.
Module 14
Objective:

fault in question.

diagnosis skills.
Digital Multimeter
3. Repair the fault
Module 15
Module 15
ECTC
0016C
Customer Concern:
Cause:
Corrective Action:
Figure 1
Module 15
1.

Vehicle model: ______________________
Model year: ________________________
2.

Customer Concern:
___________________________________
___________________________________
___________________________________
Repair History:
___________________________________
___________________________________
___________________________________
3.

them.
Module 15
Module 15

the given symptoms)
ECTC
0016C
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
Module 15
4.

5.

6.

1st _____________________________
2nd _____________________________
3rd _____________________________
__ _____________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
7.
Module 15

(page 2).
Module 15

customer.
ECTC
0016C

found it.
Module 15
Objective:

fault in question.

diagnosis skills.
Digital Multimeter
3. Repair the fault
Module 16
Module 16
ECTC
0016C
Customer Concern:
Cause:
Corrective Action:
Figure 1
Module 16
1.

Vehicle model: ______________________
Model year: ________________________
2.

Customer Concern:
___________________________________
___________________________________
___________________________________
Repair History:
___________________________________
___________________________________
___________________________________
3.

them.
Module 16
Module 16

the given symptoms)
ECTC
0016C
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
Module 16
4.

5.

6.

1st _____________________________
2nd _____________________________
3rd _____________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
7.
Module 16

(page 2).
Module 16

customer.
ECTC
0016C

found it.
Module 16
Objective:

fault in question.

diagnosis skills.
Digital Multimeter
3. Repair the fault
Module 17
Module 17
ECTC
0016C
Customer Concern:
Cause:
Corrective Action:
Figure 1
Module 17
1.

Vehicle model: ______________________
Model year: ________________________
2.

Customer Concern:
___________________________________
___________________________________
___________________________________
Repair History:
___________________________________
___________________________________
___________________________________
3.

them.
Module 17
Module 17

the given symptoms)
ECTC
0016C
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
________________________________________
Module 17
4.

5.

6.

1st _____________________________
2nd _____________________________
3rd _____________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
7.

(page 2).
Module 17
Module 17

customer.
ECTC
0016C

found it.
Module 17
HOW T
O USE A DIGIT
AL MUL
TIMETER
TO
DIGITAL
MULTIMETER
Module 18
Objective:
Given a digital multimeter, electrical

components and a car, identify the
different meter features, connect the
test leads, and perform voltage,
resistance, amperage and continuity
tests.
Relevance: A digital multimeter is an important

tool to diagnose electrical
malfunctions. It can measure voltage,
voltage drop, current, resistance and
check continuity. A high impedance
digital multimeter should be used to
test automotive electrical circuits.
Spark plug wire
AA battery
Paper clip
Assigned vehicle
Coolant temperature sensor
Fuel tank sending unit
Fuel injector
Wrapped harness
Good fuse
Faulty fuse
1M relay with faulty coil circuit
Skill Check: Prepare and connect a digital
multimeter to measure voltage,
resistance, amperage and continuity.
Module 18
Safety Information:
ECTC
0016C
CAUTION:
Never use the meter if the meter or test
leads look damaged
Display
Bar Graph
Be sure the test leads and switch are in the

correct position for the desired
measurement.
Never measure resistance in a circuit when
power is applied.
Never touch the probes to a voltage source
when the test leads are plugged into the
10A or 300 mA input jack.
Test
Selections
Rotary Switch
Push Button
(location may
vary)
Never apply more than the rated voltage

between any input jack and earth ground.
Be careful when working with voltages
above 60 VDC or 30 V
AC. Such voltages
VAC.
pose a shock hazard.
Keep your fingers behind the finger guards
on the test probes when making
measurements.
Input Jacks
WARNING:
TO A
VOID F
ALSE READINGS, WHICH
AVOID
FALSE
COULD LEAD T
O POSSIBLE ELECTRICAL
TO
SHOCK OR PERSONAL INJUR
Y, REPLACE
INJURY
THE BA
TTER
Y AS SOON AS THE BA
TTER
Y
BATTER
TTERY
BATTER
TTERY
INDICA
TOR
INDICAT
(
) APPEARS.
Input Jacks
WARNING
10A RANGE UNFUSED. TO AVOID DAMAGE OR
INJURY USE ONLY IN PROTECTED
CIRCUITS WHICH CAN NOT EXCEED
EITHER 20 AMPS OR 4000 VOLT-AMPS
POWER-ON OPTION: AUTOMATIC TOUCH HOLD

PRESS WHILE TURNING METER ON
Press and
hold 2 sec.
while turning
meter ON
WARNING
TO AVOID ELECTRICAL SHOCK REMOVE TEST
LEADS BEFORE OPENING CASE.
TO PREVENT FIRE INSTALL FUSES
WITH AMP/VOLT RATINGS SHOWN.
630mA 250V FAST
3A 600V FAST
+ NEDA 1604 9V 6F22 9V
Module 18
Digital Multimeter Display Symbols

Symbol
Description
Module 18
Touch hold ON
Negative polarity
(switch meter leads when this is displayed)
Bar graph of meter reading
Over Limits
(The reading is out of the range of the meters
capability. Usually means OPEN circuit)
Mega (1 million)
kilo (1 thousand)
Digital Multimeter Symbols
Symbol
Description
Alternating Current (AC)
Volts AC (VAC)
Amps AC
Direct Current (DC)
Volts DC (VDC)
Amps, DC
300mV
Ohms (resistance)
DC Volts less than 300mV
Diode
)))
)
Audible Continuity
Important safety information
Ground
Meter fuse
Double Insulation
9V battery
Module 18
Rotary Switch
ECTC
0016C
1.
C
D
E
F
G
To switch the meter ON, rotate the meter switch

(left illustration) from OFF to another setting.
Each switch setting has only one function.
Identify the switch functions by filling in the
correct letter for each function:
____
Amps, AC
____
Ohms resistance
____
Volts, DC
____
Diode/Continuity
____
Volts, AC
____
Amps, DC
____
DC volts, 300 mV or less
Module 18
Input Jacks
2.
10A
C
1000V
750V
300
mA
FUSED
The meter has four (4) input jacks (left

illustration). Both amperage jacks (A & B) are
internally fused.
COM
WARNING:
NEVER ATTEMPT A VOLTAGE

MEASUREMENT IF A TEST LEAD IS IN THE
10A JACK (B). YOU MIGHT BE INJURED OR
DAMAGE THE METER.
Identify the input jack which corresponds to the
following switch positions:
____
Volts, Ohms, Diode Test and Continuity
____
Common (return) for Volts, Ohms,

Diode Test and Continuity
____
Amps (10 A continuous)
____
Amps (less than 300 mA current)
Note: Red is the electrical color code for positive

(+). Therefore, insert the red test lead into the
C ). To measure current, use
jack labeled V (C
A ).
the jack labeled 10A (A
A ) to
Only use the jack labeled 300mA (A
measure circuit current that is less than
300mA.
Black is the electrical color code for negative
(). Insert the black test lead into the jack
D ).
labeled COM (D
Module 18
Module 18
ECTC
0016C
Display
Symbol Meaning
AC
DC
V
k
M
m
Alternating current or voltage

Direct current or voltage
Volts
Manual range or Touch Hold ON
Ohms
kilo, Units x 1,000
Mega, Units x 1,000,000
Milli, Units x 1/1000
3.
Readings appear on a liquid crystal display

(LCD). See the figure below.
The symbols on the display indicate meter
status (see chart on left).
Digital segments
Low battery
Volts AC
Polarity incorrect
Volts DC
Touch Hold-ON or
manual mode
Bar graph
M (Mega)/k (kilo)
ohms
Floating decimal locations
4.
The bar graph shows readings relative to the full

scale range. The bar graph lengthens as the
measurement value increases.
5.
When switched from OFF to any position, this

bar graph display appears for 1 second as part
of a self-test. The meter is now ready to take a
measurement.
Note: If a measurement is too large to be displayed,

the letters OL (over limit) are displayed.
6.
While the meter is in use, this symbol ( + )

appears to show approximately 8 more hours of
battery life.
Module 18
Using the Multimeter

7.
Verify both meter leads are connected to the

input jacks (See the note on the bottom of page
5 if you are unsure).
8.
Rotate the meter switch to display resistance

( ).
On the illustration at left, record the meter
display.
What does this measurement indicate?
____________________________________
9.
Now touch the leads together. Record the

reading at left.
Note: If the meter reading displays very low

resistance (<.5 ), the meter leads are in good
condition.
10. Switch the meter OFF.
Module 18
Module 18
Manual Range symbol
Touch Hold Mode

ECTC
0016C
Press and hold

while selecting
measurement
11. Press and hold the pushbutton while rotating

the switch to measure DC voltage.
Note: The manual range mode symbol appears on
the display along with the measurement mode
(V, A, , etc.).
12. Measure the voltage of a flashlight battery using
the meter test leads. Record the battery voltage
at left.
13. What happens to the display when you remove
the leads from the battery?
____________________________________
____________________________________
14. To exit the Touch Hold function, press the
button.
Note: The meter beeps when Touch Hold is
updated. If you press the button again, the
meter goes back into Touch Hold mode.
To exit Touch Hold completely, switch the
meter OFF, then back ON.
Standby (Sleep) Mode
15. If the meter is ON but the rotary switch or the
pushbutton is not used for 60 minutes (20
minutes in diode test mode), the display goes
blank except for four bar graph segments. This
extends battery life.
Module 18
How to Measure Resistance

16. Verify the test leads are in the
jacks.
17. Rotate the meter switch to
and COM
Module 18
18. Obtain the parts below from the instructor to

measure resistance with the multimeter.
Red
COM
Black
Use the meter leads to measure the resistance

of each part. Make sure you have a good
contact between the probes and the device
being tested. Dirt, oil or other foreign matter
affects the resistance reading.
Note: Remember not to touch the test leads with
your fingers. This can affect the accuracy of
the resistance readings.
Spark plug wire
Radiator
____
Coolant temperature Sensor
____
Fuel tank sending unit, full tank
____
Fuel tank sending unit, empty tank
____
Throttle position sensor ______-_______
Temperature sensor
Measuring Resistance with a Multimeter
Module 18
Note: The resistance in the meter test leads is about

0.1 to 0.2 . When the resistance is less than
1 ohm, subtract this from the display reading.
How to Measure Voltage

ECTC
0016C
19. Insert the test leads into the and COM jacks
(see the illustration at left).
+
20. Rotate the meter switch to V .

300 m
WARNING:
NEVER ATTEMPT A VOLTAGE
MEASUREMENT WITH A TEST LEAD IN THE
10A INPUT JACK. YOU MIGHT BE INJURED
OR DAMAGE THE METER.
Go to an assigned vehicle in the shop.
Light Circuit
Black
Red
21. Switch the vehicle lights ON for 1 minute to

bleed off surface charge from the battery, then
switch them OFF.
22. Touch the probes to the battery terminals as
shown, in parallel with the circuit. Voltage must
be measured with the meter connected in
parallel with the circuit.
Relay
Measuring V
oltage with a Multimeter
Voltage
23. Read the voltage. If you reverse the probes, the

display indicates negative polarity with a minus
sign ().
Note: This no-load voltage measurement only
indicates the state of charge, not the condition
of the battery.
A fully charged battery typically shows

about 12.6V.
Voltage
12.60V
12.45V
12.30V
12.15
10
% Charge
100
75
50
25
Based on the meter display and the

specifications at left, what is the batterys state
of charge?
________ %
Module 18
How to Test Continuity

24. Switch all circuits OFF. Verify the ignition switch
is OFF.
25. Insert the test leads into the and COM jacks.
300 m
26. Rotate the meter switch to
27. Test the continuity of the following items on the

bench:
V
COM
Black
Stoplight switch
Red
Fuse 1
Continuity:
YES / NO
Fuse 2
Continuity:
YES / NO
1M Relay
(control circuit) Continuity:
YES / NO
Wrapped harness Continuity:

wire color _______
wire color _______
wire color _______
wire color _______
wire color _______
YES / NO
YES / NO
YES / NO
YES / NO
YES / NO
YES / NO
Female connector
(disconnected)
Brake pedal
Note: Continuity exists if resistance is less than

about 30 and the beeper sounds a
continuous tone.
Checking Switch Continuity with a

Multimeter
Module 18
11
Module 18
(A) 4-8
(B) 0.1-0.2
ECTC
0016C
Quick Check of Internal Fuses

28. Insert one test lead in the V
29. Rotate the switch to
jack.
30. Touch the probe to the 300 mA jack (A) and

read the display. Is the fuse good?
YES / NO
31. Touch the probe to the 10A jack (B) and read
the display. Is this fuse good?
(B)
(A)
YES / NO
06.0
OK
12
(Circle one)
(Circle one)
OL
OK
Module 18
How to Measure Current

Module 18
WARNING:
TURN POWER OFF BEFORE CUTTING,
UNSOLDERING OR DISCONNECTING THE
CIRCUIT.
Red
10A
COM
ALWAYS USE INDUCTIVE CURRENT CLAMPON PROBES IN CIRCUITS WHERE THE

AMPERAGE EXCEEDS 10 A.
32. Switch all circuits OFF, then identify and remove
the fuse for the dome light circuit.
Black
33. Insert the test leads into the 10A and COM
jacks.
34. Rotate the meter switch to A
35. Connect the red test lead to one fuse terminal

and the black lead to the other fuse terminal.
Fuse Box
Measuring Current with a Multimeter
Note: The meter can be connected to any convenient

test point in a circuit.
This places the meter in series with the circuit
to test and all current will flow through the
meter.
Always measure current with the meter in
series with the circuit being tested.
36. Switch the dome lamp ON, then read the meter
display and record the reading.
_________________ Amps
Module 18
13
Note: If the display shows a minus sign () to the left

of the reading, the polarity is reversed.
Reverse the leads if this occurs.
ECTC
0016C
RECORD
ANSWER
37. Switch the dome lamp OFF, then read the meter
display and record the reading at left.
Note: With the circuit switch OFF, the ammeter
should display less than 0.02 DC. If the
display shows current flow greater than about
0.20 amps, there is a parasitic load in the
circuit that will either melt a fuse or eventually
discharge the battery. If this is the case, further
diagnosis is necessary.
As previously noted, some computercontrolled circuits and certain accessories
(e.g. clock, radio, power seats, ECM keep
alive memory, Smart Entrance control, etc.)
may continuously draw a slight amount of
current. Even these circuits will eventually
discharge a battery if the vehicle is not run for
a few weeks.
14
Module 18
Autorange versus Manual Range Mode

When switched ON, the meter automatically defaults
to autorange display. In this mode, the meter
automatically sets to the most accurate scale.
For example, when measuring voltage, the display
automatically displays any voltage between
0-1000 volts.
Pushing the button on the rotary switch changes the
meter to manual mode.
Note movement of decimal point each
time you push the button
RECORD
ANSWER
__
Note: The manual range mode allows you to select a

scale to obtain the most accurate
measurement.
Manual ranging is available in V, and A modes.
38. Set the meter to read resistance, then connect
the red and black meter leads to a spark plug
cable. Record the resistance at left.
39. Press the button once to go into the manual
range mode. The meter displays the manual
range symbol shown at left.
Manual range symbol
RECORD
ANSWER
Note: The meter responds with a beep each time

the button is pressed.
__
40. Press the button again, then record the
resistance at left.
Module 18
15
Module 18
ECTC
0016C
RECORD
ANSWER
__
41. Push the button on the rotary switch again, then

record the resistance.
42. Push the button a third time, then record the
resistance.
RECORD
ANSWER
RECORD
ANSWER
__
__
43. Push the button a fourth time, then record the

resistance.
Note: Each of the above measurements are
equivalent (the same). The manual range mode
allows you to select a scale to obtain the most
accurate measurement. For example, these
resistance readings are the same:
10 = .01k = .00001M
44. To return to the default autorange display,
press the button for 1 second or rotate the
switch to another position.
45. Switch the meter OFF.
46. You have just completed this worksheet. You
should now be able to identify the different
meter features, connect the test leads, and
perform voltage, resistance, amperage and
continuity tests. If you have any doubt about
your skills in completing this worksheet please
return to step #1 and review your work. Once
you are confident of your skills, have your
instructor verify your work.
found it.
16
Module 18
FUEL GAUGE T
ANK UNIT TESTING
TANK
Module 19
Objective:
Given a digital multimeter, service

manual and an on-vehicle tank gauge
unit, test the operation of the fuel tank
gauge unit and evaluate the test
results.
Relevance: Testing the fuel gauge unit and tank

unit requires an understanding of
circuit operation and the ability to
locate circuit specifications. With that
knowledge in mind, circuit testing and
evaluation can help you isolate the root
cause of related problems.
Resources: Fuel Tank Gauge Unit (on-vehicle)
Fuel Tank Gauge Unit (on bench)
Digital Multimeter
Electronic Service Manual (ESM)
Skill Check: Use an ohmmeter to measure and
record the resistance of a tank gauge
unit.
With gauge unit removed from the
tank, but connected to the vehicle
circuit, test the operation of the gauge
and low fuel warning light.
Determine corrective action.
Module 19
1.
ECTC
0016C
Using the EL section of the service manual as a

reference, which fuse protects the combination
meter and what is the amperage rating?
___________________________________
2.
Which combination meter terminal(s) is (are)

connected through this fuse?
___________________________________
___________________________________
3.
The ignition switch supplies voltage to the

combination meter through the terminal
identified in step 2.
List the gauges connected to this fuse:
___________________________________
___________________________________
___________________________________
Note
Note: Identifying a common voltage source can help
isolate malfunctions.
4.
What color is the wire that connects the fuel

gauge to the fuel tank gauge unit?
___________________________________
5.
Do the fuel tank gauge unit and the tachometer

use a common ground connection?
Note
Note: Identifying a common ground can help isolate
malfunctions.
Module 19
6.
Referring to the level sensor and chart at left,

what should the resistance measure through the
fuel tank gauge unit when the float is at the 1/2
full position?
Module 19
____________________________________
Note
Note: The resistance between the fuel gauge and
ground changes in relation to the float
position. This specification is different for
some models. Always refer to the appropriate
service manual for specifications.
7.
Using a fuel gauge unit (on the bench) and an

ohmmeter, check the resistance of the gauge
unit.
a.
What is the resistance when the tank

float is held in the Full position?
________________________ Ohms
b.
Is this reading within specification?

8.
What is the resistance with the float in

Position #2?
______________________________Ohms
Module 19
9.
ECTC
0016C
Is this reading within service manual

specifications?
10. If the resistance in position #2 is 60 ohms, how

would this affect the fuel gauge reading?
__________________________________
Ask your instructor to assign you a test vehicle.
Using the service manual as a reference, gain access
to the fuel gauge tank unit, then perform the test
procedures and answer the following questions.
11. Unplug the fuel gauge unit harness connector,
then switch the ignition ON.
What does the fuel gauge read?
____________________________________
12. Connect the gauge unit harness connector to
the bench fuel gauge unit.
13. When you move the float, how long does it take
for the fuel gauge to move?
___________________________________
14. Does the fuel gauge respond as you would
expect when you move the float UP and
DOWN?
15. Switch the ignition OFF, then locate the
Warning Lamp Wiring Diagram in the service
manual. Perform the following tests on the low
fuel warning lamp circuit.
Module 19
16. Which terminal at the level sensor unit connector

connects to the low fuel warning lamp?
___________________________________
Module 19
___________________________________
Note
Note: The warning lamp wiring diagram identifies the
location and color of this wire.
17. Unplug the bench fuel gauge unit from the
harness connector. Connect a fused jumper
wire from the low fuel warning lamp terminal to a
chassis ground.
18. Switch the ignition ON. Does the low fuel
warning lamp glow?
Note
Note: The fuel warning lamp sensor or switch
provides a ground for the warning lamp when
the fuel level is low. The low fuel warning lamp
takes a short time for the bulb to light when
the ignition is first switched ON.
There are two types of low fuel warning
circuits depending on vehicle application. The
Fuel Warning Lamp test varies with the type of
system being tested.
Module 19
19. What type of low fuel warning circuit are you

testing?
ECTC
0016C
___________________________________
20. Reconnect the bench fuel tank gauge unit to the
vehicle harness connector, then perform the low
fuel lamp tests as described on page 107 in the
text section.
21. Switch the ignition OFF, then disconnect the
harness connector from the bench fuel tank
gauge unit.
22. Reconnect the harness onto the installed fuel
tank gauge unit.
23. A customer is concerned with a warning lamp
that does not light when the fuel level is low.
After verifying the complaint, what diagnostic
step should you perform to help identify the
cause of the malfunction?
___________________________________
___________________________________
___________________________________
now be able to test the operation of the fuel tank
gauge unit and evaluate the test results. If you have
any doubt about your skills in completing this
worksheet please return to step 1 and review your
work. Once you are confident of your skills, have your
found it.
Module 19
SERVICE MANUAL ELECTRICAL SYMBOLS
Objective:
Given an ASIST/ESM workstation,

identify and interpret the symbols used
in electrical wiring diagrams.
Relevance: In order to be efficient at diagnosing

electrical malfunctions, you must be
able to read and interpret electrical
diagrams.
The format used in recent service
manuals makes it easy to identify
components and trace the current path
from the battery, through the circuit
and to ground. This module provides
an opportunity for you to practice
locating, identifying and interpreting
electrical diagrams.
Resources: ASIST
ESM (Electronic Service Manual)
Skill Check: Identify and describe various electrical
symbols used in service manual wiring
diagrams.
Module 20
Module 20
ECTC
0016C
A
F
E
C
F
K
G
Figure 1
Module 20
A.
1.
B.
Using the electrical wiring diagram in Figure 1

as a reference, enter a description of the
components identified by the lettered callouts in
the chart at left.
C.
Module 20
D.
E.
F.
G.
H.
I.
J.
K.
2.
Module 20
In the diagram at left, why is the line between

terminals 14 and 1 wider than the line between
terminals 16 and 2? (Choose one)
a.
The wider line illustrates a greater

current carrying capacity of that circuit.
b.
The wider line represents a shield from

electromagnet interference (EMI) for
the other circuit.
c.
The wider line represents a fusible

material to protect both the vehicle
speed sensor and the ECM from
voltage spikes.
d.
The wider line represents a detectable

line for diagnostic trouble code (DTC)
On-board Diagnostics.
3
ECTC
0016C
Figure 2
Module 20
3.
Refer to the circuit in Figure 2 and the GI section

of the service manual to complete steps 48.
4.
What are the harness connector numbers in the

circuit between the electric speedometer and
the ECM?
_________________
Module 20
_________________
5.
Identify the electrical symbols that correspond

to the letters below:
A._______________________________
B._______________________________
C._______________________________
6.
What do the dashed lines between terminals 7

and 6, C4 and B2, and 5 and 1 represent?
_________________________________
_________________________________
7.
What amperage fuse protects the combination

meter?
_________________________________
8.
What is the wire color for the circuit that

supplies voltage to the combination meter?
__________________________________
Module 20
ECTC
0016C
Component Terminal T
est P
oints
Test
Points
Source
Ground Signal
Voltage
Speedometer
9.
Identify and record the terminal test points for

each of the combination meter components
listed in the chart at left.
10. How many combination meter/gauge terminals

are housed inside connector M69?
_________________________________
11. What does the dashed outline around the two
connectors (M65 and M66) at the bottom of
Figure 2 represent?
Tachometer
Fuel Gauge
_________________________________
Water Temp.
Gauge
_________________________________
12. Identify the Wiring Diagram Codes (Cell Codes)
and the section where they can be found in the
service manual in the chart at left.
Code Description
ATDIAG
DEF
KS
TPS
DTRL
SM
Section
Note
Note: For additional information on electrical
diagrams and Cell Codes, refer to the GI and
EL sections of the service manual. In addition,
review the video, Service Manual Usage Electrical.
now be able to identify and interpret the symbols used
in electrical wiring diagrams. If you have any doubt
work.
found it.
Module 20
TESTING BATTERIES, STARTERS &

CHARGING SYSTEMS
Objective
Objective:
Relevance
Relevance:
Given a vehicle, digital multimeter

and Model 620 Tester, test the
battery, starter and charging system.
The importance of visual inspections

must not be overlooked when
diagnosing malfunctions associated
with the battery, starter and charging
system. It is also important that you
determine that parasitic loads are not
draining the battery. If, after completing
these steps, the root cause has not
been pinpointed, use the J-44373,
Model 620 Tester to check each
system. It is a required tool. It displays
test result codes which must be
recorded on all warranty-related repair
orders.
Resources: A vehicle
CONSULT II
J-44373 Model 620 Tester
Digital multimeter
Skill Check: Confirm visual inspection, measure and
record parasitic load, then set date
and time on J-44373 and record all
test results.
Module 21
Module 21
1.
Go to the assigned vehicle.
2.
Visually inspect battery cables and battery

terminals to confirm connections are tight and in
good condition. If there is corrosion or
connections are loose, correct these conditions
before continuing.
ECTC
0016C
Record unsatisfactory conditions here:

_________________________________
_________________________________
Battery State of Charge
Voltage
% of Charge
12.60 V
100%
12.45 V
75%
12.30 V
50%
12.15 V
25%
3.
Measure and record the available battery

voltage.
________ Volts _______ % Charge
Note
Note: By measuring available battery voltage you
establish the batterys state of charge and
confirm a customer concern of hard starting or
no-start condition.
4.
If the available voltage is low, check for parasitic

load to determine if something is draining the
battery when all circuits should be OFF.
Conduct a Parasitic Load test as follows:
5.
Switch ignition OFF and remove the key.
6.
Close all doors and the rear hatch.
7.
With the hood open, disconnect the anti-theft

switch (if equipped).
8.
Switch the multimeter to measure DC Amps.
9.
Connect the red lead to the negative battery

cable connector.
Module 21
10. Loosen, but do not remove the negative battery

cable.
11. Connect the black lead to the negative battery

post below the cable connector.
12. Remove the negative battery cable while the
meter leads are still attached to the battery post
and the cable.
300 m
Red
10A
Module 21
Note: This ensures the customers preset radio and

auto air conditioning controls are not erased
due to a temporary loss of voltage.
COM
Black
Remove fuse
to identify
circuit
13. Wait 2 minutes, then record the meter reading in

the spaces below. Record both the amps and
milli-amps readings:
________ A ___________mA
Note: General Specification Guidelines
(after battery disconnected 2 minutes):
Measuring Parasitic Current Draw
WARNING
DO NO
TA
TTEMPT THIS TEST ON A
NOT
ATTEMPT
LEAD-ACID BA
TTER
Y THA
T HAS
BATTER
TTERY
THAT
RECENTL
Y BEEN RECHARGED.
RECENTLY
EXPL
OSIVE GASES MIGHT BE PRESENT
EXPLOSIVE
PRESENT..
.00 .02 amps (020 mA)
Good
.02 .05 amps (2050 mA)
Questionable
.05 amps (50 mA and above)
No Good
(Something is
draining the
battery)
14. Is your reading within the Good (normal)

operating range?
YES / NO
(Circle one)
CAUTION
Do not crank the engine or operate
accessories that draw more than 10A
ou
10A.. Y
You
could melt the fuse in the meter
Note:
Many computers draw 10 mA or more
continuously.
Module 21
15. If the amperage draw is excessive (above 50

mA), what steps should you take to isolate the
parasitic load and repair the malfunction?
ECTC
0016C
___________________________________
___________________________________
Note: By performing each of the above steps, you
now have a thorough understanding of the
batterys general condition. By confirming
connections and then testing for parasitic
loads you know whether additional testing is
necessary.
Remember that poor connections and
accessories left ON can affect operation of all
electrical systems because of excessive
battery drain.
16. Confirm that the engine is at normal operating
temperature.
Note
Note: When performing this procedure on a
customers vehicle, the engine temperature
must be recorded on the repair order. Use
CONSULT-II to find the actual engine
temperature.
17. Confirm the engine oil level is correct and make
sure that the recommended weight of engine oil
is being used.
Is the oil level full?
YES / NO
(Circle one)
Is the oil viscosity correct?

YES / NO
(Circle one)
Module 21
Note: Engine operating temperature and correct

engine oil and oil level are all checked as a
means of providing support data for the
starter test. When performing the battery test
on a customers car, record the engine coolant
temperature on the repair order.
18. Turn the ignition OFF.
19. Visually inspect the battery, terminals and cable
ends. Clean as necessary. If the battery case is
cracked or the terminals are damaged, the
battery must be replaced before performing the
tests. Note the battery condition below:
_____________________________________
20. Before performing any tests, be certain to set
the date and time on the tester. To do this, with
the tester disconnected from the battery, press
MENU
MENU.
21. Use the to scroll through the list until you find
the SET DATE & TIME selection, then press
ENTER to confirm the date and time. If the date
or the time are not correct, press the to
change the setting.
22. When the setting is correct, press ENTER to
advance to the next cell. When each of the
cells has been changed so that the date and
time are now correct, press ENTER to end this
mode.
Note: Failure to set the correct time and date will
result in improper claims coding and
reimbursement for the repair will be denied. Be
certain the date is correct before performing
the test.
Module 21
Module 21
23. Using the Model 620 tester, attach the two

alligator clip leads to the battery cables. Attach
the red lead to the positive battery post (+), and
the black lead to the negative battery post (),
also known as the ground cable ( ). Each of
the test leads must be securely connected or
the tester will not operate.
ECTC
0016C
CHOOSE TEST ??
OUT-OF-VEHICLE ?
24. With the tester leads attached to the battery

cables, the tester automatically comes on. The
display at left appears. If it did not start
automatically, check both cable connections
before proceeding.
25. Make sure all accessory loads are turned off and
that the ignition switch is OFF before performing
the battery test.
26. Locate the IN-VEHICLE test. It may be
necessary to scroll down the list to find this
particular test. To do so, press until that test
appears, then press ENTER to select it. This
should bring up the screen at left.
SELECT INPUT ??
TEST USING: CCA?
SET JIS# ? ?
80D26 ?
27. To perform battery tests, the tester must be

programmed to know the batterys rating
system. In order to test batteries on Nissan
vehicles, choose Cold Cranking Amps (CCA)
or Japanese Industrial Standard (JIS) for the
rating type. Most new cars will come with
batteries that have the JIS rating. This rating is
located on the top of the battery case. An
example JIS rating is 80D26L.
28. For this exercise, locate either the JIS or CCA
rating. To do this, press
on the keypad to
scroll down until the desired choice is showing,
then Press ENTER to select it. The screen at
left appears.
Module 21
*** TESTING***
80D26
29. Press to scroll down the list until you find the
correct battery rating for the battery you are
testing, then press ENTER to select that
choice. After choosing the battery rating, the
tester automatically performs the battery test.
While the test is being conducted, the screen at
left appears.
Note: The tester may give an indication that the
battery has a surface charge which must be
removed prior to testing the battery. If this
happens, follow the instructions on the tester,
then continue with the test.
12.71V
506CCA
GOOD BATTERY
BATTERY CODE
BATOR-DRL8N30
Module 21
30. When the test is complete, the test result is

displayed. The result will resemble the result
shown at left. Notice that the tester display
toggles between the TEST RESULTS and
PRESS ENTER FOR BATTERY CODE.
Note
Note: When performing this procedure on a vehicle,
it is essential to record all 12 characters of the
code on the repair order. Failure to do so will
result in the claim being denied or suspended.
Module 21
31.
ECTC
0016C
Press ENTER to find out the test code, then

record both the test results and the test code
below:
Record test results here.
__________________________________
Record the 12 character test code here.
__________________________________
Note: A screen similar to the one at left should

appear with the code. Notice once again that
the screen display toggles. This feature is
consistent with each of the remaining tests, so
further mention is not necessary.
CRANKING VOLTAGE
NORMAL
10.74V
32. Press ENTER to advance to the starting system

test. The prompt START ENGINE appears. At
this time, start the engine. While doing this, the
tester will perform a starting system test. A
screen similar to the one at left should appear at
the end of the test. Record the test result
below:
Starting System test result.
________________________________________
ALT VOLTS: 14.53V

ENTER TO CONT...
LOADS OFF
REV ENGINE FOR 5 SEC
33. Press ENTER to advance to the Charging

System test. A screen similar to the one at left
appears, showing the charging system output
voltage.
34. Press ENTER to continue. Confirm that all
electrical loads are switched OFF before
continuing with the next step. The screen at left
appears.
Module 21
ENTER TO CONTINUE...
AFTER REVVING
35. Rev the engine to about 1500-2000 RPM for 5

seconds. When the tester detects RPM, the
screen at left appears. Release the throttle and
let the engine idle.
RPM DETECTED
ENTER TO CONT...
Module 21
*** TESTING ***

ENGINE @ IDLE
*** TESTING ***

DIODE/RIPPLE
TURN LOADS ON
ENTER TO CONT...
36. After releasing the throttle, press ENTER

ENTER. At
idle, the tester conducts a Diode Ripple test,
then prompts you to apply loads.
37. Turn ON the high beam headlamps, the rear
window defogger, and the blower on high
(heat). Do not use cyclical loads such as the air
conditioner or windshield wipers as inaccurate
results will occur.
*** TESTING ***

AT IDLE LOADS ON
RPM DETECTED
ENTER TO CONT...
38. Again, rev the engine to about 1500-2000 RPM

for 5 seconds. When the tester detects rpm, the
screen at left appears.
39. Press ENTER to continue. The screen at left
appears while the test is being conducted.
ANALYZING DATA
PLEASE WAIT
Module 21
ECTC
0016C
CHARGING SYSTEM
NORMAL
40. At the conclusion of the charging system test,

the series of screens at left will toggle, indicating
the overall condition of the charging system.
DIODE RIPPLE
NORMAL
IDLE VOLTS: 14.00V

LOAD VOLTS: 14.08V
41. Press ENTER to find out the test code, then

record both the test results and the test code
below:
PRESS ENTER FOR
CHARGING CODE
Charging System voltage ____________

Diode Ripple ______________________
42. Record the 12 character test code below:
______________________________________
CHARGING CODE
ALTST-2ST483T
10
Note: The 12 character test code that appears at

the end of testing is the same code for
starters and charging systems. This code
must also be recorded on the repair order for
both the Starter test and the Battery test.
Module 21
43. Based on the results of these tests, what

conclusions can you make about the condition
of the battery, starter, and charging system?
Look at the following list of options and check
each one that matches your results:
Battery Condition:
GOOD BATTERYReturn to service.
GOOD-RECHARGEFully charge battery and

return to service.
CHARGE & RETESTFully charge the battery

and retest it. Failure to fully charge the battery
before retesting may cause false readings.
REPLACE BATTERYReplace the battery and

retest to perform a complete charging system
analysis. If this result appears, check battery
cable connections and perform an out-of-vehicle
test on the battery before replacing the battery.
If it fails the out-of-vehicle test, it should be
replaced.
BAD CELL-REPLACEReplace the battery and

retest to perform a complete system analysis.
Note: If charge and retest result appears for the

battery test, charge the battery, then perform
the test again. Make certain that you select
After Charge when you enter the type of test
or the battery may again fail the test.
Module 21
11
Module 21
Starter Condition:
ECTC
0016C
CRANKING VOLTAGE NORMALThe system

shows normal starter draw.
CRANKING VOLTAGE LOWThe cranking

voltage is below normal limits, troubleshoot the
starter. Refer to the service manual or bulletins
associated with this vehicle for additional
information relating to the starting system.
CHARGE BATTERYThe battery state-ofcharge was too low to perform a starting

system test. Charge the battery, then continue
with the starting system test.
REPLACE BATTERYThe battery must be

replaced before testing the starter. Replace it,
then continue with the starting system test.
Charging System Condition:
12
CHARGING SYSTEM NORMAL/DIODE

RIPPLE NORMALThe system is showing
normal output from the alternator. No incident
detected.
NO CHARGING VOLTAGEThe alternator is

not developing any charging voltage to keep the
battery charged.
LOW CHARGING VOLTAGEThe alternator is

not providing sufficient current for the systems
electrical loads and to keep the battery charged.
HIGH CHARGING VOLTAGEThe voltage

output from the alternator exceeds the normal
limits of a functioning regulator.
EXCESS RIPPLE DETECTEDOne or more

diodes are not functioning or there is stator
damage.
Module 21

now be able to perform a parasitic load test and test
the battery, starter and charging systems. If you have
any doubt about your skills in completing this
worksheet please return to step 1 and review your
work. Once you are confident of your skills, have your
found it.
Attach Printout Here
Module 21
13
Module 21
NOTES
14
Module 21
N
O
T
E
S
STARTING SYSTEM
NOTE: DISABLE IGNITION SYSTEM THEN CRANK VEHICLE.
MAXIMUM ALLOWABLE
VOLTAGE DROPS
Wire connections 0.0 Volts
Ground connections 0.1 Volts
Switch contacts 0.3 Volts
Starter Solenoids 0.5 Volts
TROUBLESHOOTING TIPS
TIP #1
An open at any point in a series circuit will prevent the entire circuit
from operating.
TIP #2
An open in a parallel circuit prevents only the LOAD in the open

path from operating.
TIP #3
If both LOADs in a parallel circuit are not operating, look for the
problem to be BEFORE the circuits split.
TIP #4
If an entire circuit is dead, the problem is with a series component,

such as a switch or POWER.
TIP #5
Fuses and fusible links blow because of increased current flow

(reduced resistance) in the circuit between POWER and
GROUND.
TIP #6
If an unwanted GROUND occurs on the GROUND side of a LOAD

in a ground switched circuit, the LOAD will stay on all the time.
Course Title
ELECTRICAL COMPONENT
DIAGNOSIS AND REPAIR
May 2003
Slide 1
Course Schedule
Start/End Time
Breaks
Lunch
Smoking Areas
Phones
Shop Safety
Emergency Procedures
First Aid
Fire Exits
Slide 2
Course Map
Slide 3
Course Map, Cont.
Slide 4
Connector Symbols in Circuits
Slide 5
Connector Guides
Slide 6
Connector Symbol
No Terminal
X
Connector Symbol
Slide 7
Connector Direction Mark
Slide 8
Connector Symbols
Slide 9
Harness Layout Diagram
Slide 10
Harness Layout
Slide 11
Foldout Diagrams
Slide 12
Power Supply Routing
Slide 13
Ground Distribution
Slide 14
ASIST/ESM Menu
Slide 15
Analog Meter
Slide 16
Digital Multimeter
Slide 17
DMM Scale: Ohms
Slide 18
J44373 Battery, Starter, Charging Tester
Slide 19
Circuit Requirements
Slide 20
Voltage
Slide 21
Current
Slide 22
Circuit Resistance
Slide 23
Circuit Conductors
Slide 24
Series Circuit
Slide 25
Parallel Circuit
Slide 26
SeriesSeries-Parallel Circuit
Slide 27
Excessive Resistance
Slide 28
Crossover vs. Short Circuit
Slide 29
Circuit Protection
Slide 30
10
NO, NC and Combination Switches
Slide 31
SwitchSwitch-Controlled Circuits
Slide 32
Relay Construction
Slide 33
11
1M Relay
Slide 34
1M Relay in Circuit
Slide 35
Simulator Overlay #3
Slide 36
12
1T Relay
Slide 37
1T Relay in Circuit
Slide 38
Slide 39
13
2M Relay
Slide 40
2M Relay in Circuit
Slide 41
Slide 42
14
1M1M-1B Relay
Slide 43
1M1M-1B Relay in Circuit
Slide 44
Slide 45
15
Parts of a Relay
Slide 46
Nissan Relay Types: Chart 1
Slide 47
Nissan Relay Types: Chart 2
Slide 48
16
Slide 49
Slide 50
Measuring Current
Slide 51
17
Starting System
Slide 52
Charging System
Slide 53
Digital & Analog Cycles
Slide 54
18
Cycle Frequency VSS
Slide 55
Duty Cycle %
Slide 56
Repair Order (blank)
Slide 57
19
NOTES
NOTES
NOTES
NOTES
NOTES
NOTES
NOTES
NOTES
NOTES
NOTES
10

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ELTN9911B

This book is designed for instructional

2003 Nissan North America, Inc.

This manual uses post

ELECTRICAL COMPONENT DIAGNOSIS AND REP

Electrical Diagrams ....................................................................................................................................... 51

Locate Service Manual Information

Intepret Service Manual Information

Measuring Available Voltage

Measuring Voltage Drop

Combination Switch Operation

Diagnosing One Transfer (1T) Relay Malfunctions

Diagnosing One Make (1M) Relay Malfunctions

Diagnosing Two Make (2M) Relay Malfunctions

Diagnosing One Make-One Break (1M-1B) Relay Malfunctions

Circuit Diagnosis Exercise #1

Circuit Diagnosis Exercise #2

Circuit Diagnosis Exercise #3

Circuit Diagnosis Exercise #4

Circuit Diagnosis Exercise #5

Circuit Diagnosis Exercise #6

How to Use a Digital Multimeter

Fuel Gauge Tank Unit Testing

Service Manual Electrical Symbols

Testing Batteries, Starter and Charging Systems

ELECTRICAL COMPONENT DIAGNOSIS AND REP

ELECTRICAL COMPONENT DIAGNOSIS AND REPAIR OVERVIEW

Isolate the source of the malfunction by:

Repair electrical problems by:

Reading wiring diagrams

Circuit testing techniques

Do not operate the engine without adequate exhaust ventilation.

Do not smoke while working on the vehicle.

To prevent serious burns:

Before working on the vehicle:

Ground side of circuit

Voltage = Electrical pressure

Resistance opposes current flow in a circuit and is measured in Ohms.

Malfunctions occur when resistance in a circuit increases or decreases abnormally.

Increased circuit resistance can be caused by loose connections, corroded wire

Resistance (R) Opposition to current flow

Troubleshooting Tip #2:

Troubleshooting Tip #3:

Circuit Protection Devices

Bare conductors touch and fuse melts to protect circuit

Continuous Current Flow

About 120 amps

About 200 amps

About 250 amps

About 300 amps

Troubleshooting Tip #5:

Switches are not loads.

Switches are wired in series with the circuit.

Troubleshooting Tip #7:

Ignition switch is OFF

Doors, hood and trunk lid/back door are closed

Pedals are not depressed, and

Parking brake is released

Normally Closed Switch

Normally Open Switch

Normally Open (NO)

Multiple Position Switches

OFF Switch Open