Student Workbook - Module 2 - Electrical Electronic Systems

70-1802-W
10-1831-T
Automotive
Technology
Curriculum 2007
2005 Edition
Module 2: Electrical/
Student
Test
Workbook
Packet
Electronic Systems
Electrical/Electronic Systems

Automotive Technology
Module 2: Electrical/Electronic Systems
Student Workbook
Technical
Consultant:
Robin Ferguson
Editors:
Erica Kassel
Janis Levsen
Graphic
Artists:
Chris Benedict
Jacqueline Craig
Produced by the Instructional Materials Laboratory

1400 Rock Quarry Center
University of Missouri-Columbia
Columbia, MO 65211
(800) 669-2465
2007 Edition
Catalog no. 70-1802-W

© 2007. The Curators of the University of Missouri.
All Rights Reserved.

ii
Name:
MODULE 2: ELECTRICAL/ELECTRONIC SYSTEMS
STUDENT WORKBOOK TRACKING SHEET
Instructor Student
Assignment Instructor’s
Title of Assignment Sheet Guide Workbook Date
Sheet Initials
Page # Page #
AS1-L1-UI Basic Electrical Theory 21-24 W 1-2
AS1-L2-UI Electrical Measurement and Ohm’s Law 35-38 W 3-4
AS1-L1-UII Components of an Electrical Circuit 79-82 W 5-6
AS1-L1-UIII Basic Testing Information 115-118 W 7-8
AS1-L1-UIV The Basics of the Battery 221-224 W 53-54
AS1-L1-UV Starting System Components and Operation 293-296 W 75-76
AS1-L1-UVI Charging System Components and 359-362 W 93-94
Operation
AS1-L1-UVII Lighting Systems and Components 439-442 W 125-126
AS1-L1-UX Accessory Components and Operation 585-588 W 161-162
Instructor Student
Instructor’s
Job Sheet Title of Job Sheet Guide Workbook Date
Initials
Page # Page #
JS1-L2-UIII Complete a Work Order with Concern, 125-126 W 9-10
Cause, and Correction
JS2-L2-UIII Identify and Interpret Electrical/Electronic 127-128 W 11-12
System Concern
JS3-L2-UIII Identify Hybrid Vehicle High Voltage 129-130 W 13-14
Circuits and Service Plug Locations and
Safety Precautions
JS1-L3-UIII Diagnose the Electrical/Electronic Integrity 147-148 W 15-16
of Electrical Circuits Using Ohm’s Law
JS2-L3-UIII Measure Voltage in an Electrical Circuit 149-152 W 17-20
JS3-L3-UIII Measure Current in an Electrical Circuit 153-154 W 21-22
JS4-L3-UIII Check Continuity and Measure Resistance in 155-160 W 23-28
an Electrical Circuit
JS5-L3-UIII Check Electrical Circuits Using a Test Light 161-162 W 29-30
JS6-L3-UIII Check Electrical Circuits Using Fused 163-166 W 31-34
Jumper Wires
JS7-L3-UIII Locate Opens, Shorts, and Grounds in an 167-170 W 35-38
Electrical Circuit
JS8-L3-UIII Measure and Diagnose the Cause of Key-Off 171-172 W 39-40
Battery Drain (Parasitic Draw)
JS9-L3-UIII Test and Service Fuses, Fusible Links, and 173-176 W 41-44
Circuit Breakers
JS10-L3-UIII Test and Service Switches, Connectors, 177-178 W 45-46
Relays, Solid-State Devices, and Wires of
Electrical/Electronic Circuits
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STUDENT WORKBOOK TRACKING SHEET – PAGE 2
Instructor Student
Instructor’s
Initials
Page # Page #
JS1-L4-UIII Tin the Soldering Iron and Solder 189-190 W 47-48
Wire Splices
JS2-L4-UIII Repair Terminals, Wiring, and Wiring 191-194 W 49-52
Harnesses
JS1-L2-UIV Measure the Battery’s State-of-Charge 243-244 W 55-56
JS2-L2-UIV Perform a Load Test 245-248 W 57-60
JS3-L2-UIV Perform a Quick Charge Test 249-250 W 61-62
JS4-L2-UIV Inspect, Clean, Fill, and Replace a 251-254 W 63-66
Battery
JS5-L2-UIV Identify Electronic Memory Functions 255-256 W 67-68
Affected by Battery Disconnect and
Maintain or Restore the Functions
JS6-L2-UIV Charge a Battery 257-258 W 69-70
JS7-L2-UIV Jump-Start a Vehicle 259-260 W 71-72
JS8-L2-UIV Identify Hybrid Vehicle Auxiliary 261-262 W 73-74
(12v) Battery Service, Repair, and Test
Procedures
JS1-L2-UV Inspect the Starting System and 305-308 W 77-80
Perform a Current Draw Test
JS2-L2-UV Perform Starter Circuit Voltage Drop 309-310 W 81-82
Tests
JS3-L2-UV Test the Starter Control Circuit 311-314 W 83-86
Components
JS1-L3-UV Remove and Install a Starter 321-322 W 87-88
JS2-L3-UV Bench Test a Starter 323-324 W 89-90
JS3-L3-UV Disassemble, Test, and Reassemble a 325-326 W 91-92
Starter
JS1-L2-UVI Perform a Preliminary Inspection and 377-378 W 95-96
Test of the Charging System
JS2-L2-UVI Diagnose the Charging System 379-380 W 97-98
for Undercharge, No-Charge, or
Overcharge Conditions
JS3-L2-UVI Perform a Charging System Output 381-384 W 99-102
Test
JS4-L2-UVI Perform an Alternator Full-Field Test 385-388 W 103-106
JS5-L2-UVI Perform a Voltage Regulator Cutout 389-390 W 107-108
Test
JS6-L2-UVI Perform Circuit Resistance and 391-394 W 109-112
Voltage Drop Tests
JS7-L2-UVI Test the Charging System Using an 395-396 W 113-114
Oscilloscope
iv
Instructor Student
Instructor’s
Initials
Page # Page #
JS8-L2-UVI Determine the Current Requirements 397-398 W 115-116
for a Charging System
JS1-L3-UVI Remove and Install the Alternator 405-406 W 117-118
JS2-L3-UVI Disassemble, Inspect, and Reassemble 407-410 W 119-122
the Alternator
JS3-L3-UVI Remove, Inspect, and Install the 411-412 W 123-124
Voltage Regulator
JS1-L2-UVII Diagnose the Cause of Brighter Than 457-460 W 127-130
Normal, Intermittent, Dim, or No
Light Operation
JS2-L2-UVII Inspect and Diagnose Incorrect Turn 461-462 W 131-132
Signal or Hazard Light Operation
JS1-L3-UVII Inspect, Replace, and Aim Headlights 475-476 W 133-134
and Bulbs
JS2-L3-UVII Service the Lighting System 477-478 W 135-136
Components
JS1-L1-UVIII Inspect, Test, and Service Intermittent, 503-506 W 137-140
High, Low, or No Gauge Reading
JS2-L1-UVIII Test and Service the Incorrect 507-508 W 141-142
Operation of a Warning Light
JS3-L1-UVIII Test and Service the Incorrect 509-510 W 143-144
Operation of an Audible Warning
System Device
JS4-L1-UVIII Inspect, Test, and Repair Sensors, 511-514 W 145-148
Connectors, and Wires of Digital or
Electronic Instrument Circuits
JS1-L1-UIX Test and Service Incorrect Horn 539-542 W 149-152
Operation
JS2-L1-UIX Test and Service Incorrect Windshield 543-546 W 153-156
Wiper Operation
JS3-L1-UIX Test and Service Incorrect Windshield 547-550 W 157-160
Washer Operation
JS1-L2-UX Diagnose and Repair Motor-Driven 617-620 W 163-166
Accessory Circuits
JS2-L2-UX Diagnose and Repair Heated Glass and 621-624 W 167-170
Mirror Operation
JS3-L2-UX Diagnose and Repair Heated Seat 625-628 W 171-174
Operation
JS4-L2-UX Diagnose and Repair Electric Lock 629-632 W 175-178
Operation
JS5-L2-UX Diagnose and Repair Vacuum- 633-636 W 179-182
Operated Cruise Control Operation
JS6-L2-UX Diagnose and Repair Electric/ 637-640 W 183-186
Electronic Cruise Control Operation


Instructor Student
Instructor’s
Initials
Page # Page #
JS7-L2-UX Disarm and Enable the Air Bag System 641-642 W 187-188
for Vehicle Service
JS8-L2-UX Diagnose Supplemental Restraint 643-646 W 189-192
System (SRS) Concerns
JS9-L2-UX Diagnose and Repair Radio and Sound 647-650 W 193-196
System Operation
JS10-L2-UX Remove and Reinstall a Door Panel 651-652 W 197-198
JS11-L2-UX Diagnose and Repair Body Electronic 653-656 W 199-202
Circuits and Module Communications
Using a Scan Tool
JS12-L2-UX Diagnose and Repair Antitheft System 657-662 W 203-208
Operation
vi
AS1-L1-UI Name:
Basic electrical theory Date:
Directions — Answer the following questions by writing all responses on this

sheet.
1. A. What are electrons?
B. What are neutrons?
C. What are protons?
2. List four of the six forces that free electrons.
A.
B.
C.
D.
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3. A. What is attraction?
B. What is repulsion?
4. Determine if each of the following is a conductor, insulator, or

semiconductor by writing the corresponding number in the blank.
A. Rubber 1. Conductor
B. Germanium 2. Insulator
C. Glass 3. Semiconductor
D. Silver
E. Silicon
F. Copper
5. What must occur before current can flow through a circuit?
W
AS1-L2-UI Name:
electrical measurement and ohm’s law Date:

sheet.
1. Match the terms with the appropriate definition by writing the

corresponding number in the blank.
A. Volt 1. Unit of measurement for electron

resistance in a circuit
B. Current
2. Unit of measurement for electron force
C. Ampere
3. Flow of electrons through a wire
D. Ohm
4. Unit of measurement for electrical
current
2. What is Ohm’s law?
3. What are the two rules of electricity?
A.
B.
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4. A. How are electrical components connected in a series circuit?
B. How are all positive and negative component connections hooked in a

parallel circuit?
C. How are components arranged in a series-parallel circuit?
5. A. What type of circuit is the starter circuit?
B. What type of circuit is the headlight circuit?
W
AS1-L1-Uii Name:
Components of an electrical circuit Date:

sheet.
1. What are the five factors that influence resistance of conductors?
A.
B.
C.
D.
E.

2. What are the three types of circuit protection devices?
A.
B.
C.
3. What does a capacitor use to absorb or store an electrical charge?
W
4. What is the most common circuit control device?
5. What are the three parts of a bipolar transistor?
A.
B.
C.
W
AS1-L1-UIII Name:
Basic Testing Information Date:

sheet.
1. A. What should a technician wear when working on or around a vehicle

battery?
B. What safety precautions should be taken after service or repair of the

vehicle?
2. A. What is difficult to perform when using only pictorial wiring

diagrams?
B. When should the wiring schematic be used?
3. Describe the function of the following pieces of test equipment.
A. DMM—
W
B. Test light—
C. Jumper wire—
D. Oscilloscope—
4. A. What is the unit of measurement for the voltmeter?
B. What is the unit of measurement for the ammeter?
C. What is the unit of measurement for the ohmmeter?
5. When testing circuits, what circuit components should jumper wires be

used to bypass?
A.
B.
C.
D.
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JS1-L2-UIII Name(s):
complete a work order with concern, cause, and

correction
Date:
Directions:
1. The instructor will list a repair. Complete the work order on the following
page for the repair.
Evaluation
To receive credit, all sections of the work order must be complete.
Credit received for completing work order
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Smith’s Automotive Repair
Customer’s Name:_________________________________________ Date:______________ Invoice:____________
Address:_________________________________________________________________________ Phone:_____________
Year/Make:____________________ Model:_____________ VIN:______________ Mileage:___________
Service Writer:___________________________________________ Technician:______________________________
Customer Authorization Signature:_________________________________________________________________________
Customer Concern:________________________________________________________________________________________
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
Vehicle Service History Information:_________________________________________________________________________
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
Related Technical Service Bulletins:__________________________________________________________________________
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
Diagnostic Procedures Performed:___________________________________________________________________________
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
Cause:___________________________________________________________________________________________________
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
Correction:_______________________________________________________________________________________________
_________________________________________________________________________________________________________
_________________________________________________________________________________________________________
Labor Procedures and Costs Estimated Actual
Outside Labor Procedures and Costs
Total Labor Costs

Parts Costs
Quantity Part # Description
Labor Total
Parts Total
Sales Tax
GRAND TOTAL
W 10
Identify and interpret Electrical/Electronic System

concern
Date:
Equipment:
Personal protective equipment (PPE)

Service information
Evaluation
Procedure:

1. Wear PPE while performing the procedures on this job sheet.
2. Ask the customer to describe the electrical/electronic system concern.

Record concern in the space provided.
3. Ask the customer the following series of questions. Record the answers in
the space provided.
a. What electrical/electronic system functions are involved?
b. When did the concern first occur?
c. Is the concern continuous or intermittent?
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d. Is the charge indicator functioning normally?
e. Is the malfunction indicator lamp on or flashing?
f. Has the concern affected vehicle performance?
g. What is the recent service history of the vehicle?
h. Is the vehicle making any unusual noises?
i. Are any unusual vibrations occurring?
4. Based on the answers to the questions, determine the next step in the
diagnostic process for the vehicle. Record in the space provided.
Average of the above evaluations
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js3-L2-UIII Name(s):
Identify hybrid vehicle high voltage circuits and

Service Plug locations and Safety precautions
Date:
Equipment:

Safety cones for the work area
Evaluation
Procedure:
2. Research applicable vehicle service information, such as vehicle service

history, VIN, certification labels, and calibration decals. Record the
necessary information in the space provided.
3. Using service information, determine the locations of the high-voltage

system components, including the high-voltage cables and service plug.
Record in the space provided.
4. Using service information, determine if special care is needed when

handling any components of the high-voltage system. Record in the space
provided.
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5. Using service information, locate a procedure for deactivating the high-
voltage system. Make sure the procedure is appropriate for the make and
model of the vehicle. Have the instructor check the box to approve the
procedure. (For general procedures for a Honda hybrid electric vehicle, see
section III.D.3.)
Using the procedure, deactivate the high-voltage system.
W 14
Diagnose the electrical/electronic integrity of

electrical circuits using Ohm's Law Date:
Equipment:
Digital multimeter (DMM)

Personal protective equipment (PPE) Evaluation
NOTE: Before performing the procedure, the instructor will set up a series
electrical circuit, a parallel electrical circuit, and a series-parallel electrical circuit.
The instructor will assign the type of test to be performed on each electrical
circuit. The electrical circuits may be good or have faults.
Procedure:
2. Test an electrical circuit wired in series using a DMM.
a. Measure one of the following: resistance and voltage, resistance and

current, or voltage and current. Record the readings in the space
provided.
b. Using Ohm’s law, determine the condition of the electrical circuit.

Use the space provided for the calculations. Include the findings on
the condition of the electrical circuit.
W 15
3. Test an electrical circuit wired in parallel using a DMM.

provided.

4. Test an electrical circuit wired in series-parallel using a DMM.

provided.

W 16
MEASURe VOLTAGE IN An electrical CIRCUIT

Date:
Equipment:
Automotive bulbs and sockets

Battery
Digital multimeter (DMM) Evaluation
Jumper leads

Procedure:

2. Measure voltage in electrical circuits using the voltmeter setting on a DMM.
a. Measure voltage on a battery. Record the polarity in the space

provided.
b. Wire two batteries in series. Measure the combined voltage. Record

the polarity in the space provided.
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c. Wire two batteries in parallel. Measure the combined voltage. Record
the polarity in the space provided.
d. Connect two automotive bulbs and sockets wired in series to two

batteries wired in series. Measure voltage at the two test points (TP 1
and TP 2). Record the polarity in the space provided.
e. Wire two automotive bulbs and sockets in parallel to two batteries

wired in series. Measure voltage at the two test points (TP 1 and
TP 2). Record the polarity in the space provided.
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history, VIN, certification labels, and calibration decals. Record necessary
information in the space provided.
4. Measure voltage in an automotive electrical circuit using the voltmeter

setting on a DMM.
a. Set the DMM to measure voltage.
b. Energize the electrical circuit.
c. Measure the voltage of the electrical circuit. Record in the space

provided.
d. De-energize the electrical circuit.
5. Based on the tests, determine the necessary action to correct any problems.
Include further diagnosis and/or repairs. Record in the space provided.
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W 20
MEASURe CURRENT IN An electrical CIRCUIT

Date:
Equipment:

Batteries
Procedure:

2. Measure current in electrical circuits using the ammeter setting of a DMM.

Wire the electrical circuits according to the illustrations.
a. Wire two automotive bulbs and sockets in series to a battery.

Measure current and observe the polarity. Record the readings in the
space provided.
b. Wire two automotive bulbs and sockets in parallel to a battery.

Measure current and observe the polarity. Record the readings in the
space provided.
W 21
4. Measure current in an automotive electrical circuit using a DMM.
a. Set the DMM to the ammeter function or for an inductive test.
b. Connect the DMM in series or connect the inductive pickup.
c. Energize the electrical circuit.
d. Measure current. Record the reading in the space provided.

e. De-energize the electrical circuit. Disconnect the DMM.
W 22
Check continuity and MEASURe RESISTANCE IN An

electrical CIRCUIT Date:
Equipment:

Test light
Procedure:

3. Check continuity in an electrical circuit.
a. Locate the appropriate wiring schematic for the selected electrical

circuit.
b. Perform a continuity test using a test light.
1. Connect the test light to ground.
2. Energize the electrical circuit.
3. Probe a wire along the circuit to check for current. Record

observations in the space provided.
4. De-energize the electrical circuit. Disconnect the test light.
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c. Perform a continuity (voltage) test using a DMM.
1. Set the DMM for parallel measure.
3. Probe the wire along the electrical circuit. Record the reading in
the space provided.
4. De-energize the electrical circuit.
d. Perform a continuity (resistance) test using a DMM.
1. Set the DMM for a resistance test.
3. Probe the wire along the electrical circuit to check for a low-
resistance current path. Record observations in the space
provided.
4. De-energize the electrical circuit.
W 24
4. Measure resistance in an electrical circuit using a DMM.
CAUTION: Do not measure resistance on a live electrical circuit. This

can damage test equipment.
a. Measure resistance on resistors or bulbs A and B. Record resistance in

the space provided.
1. Using Ohm's law, calculate resistance in the space provided.
b. Connect the resistors or bulbs A and B in series. Measure resistance.

Record resistance in the space provided.
1. Using Ohm's law, calculate resistance in the space provided.
W 25
c. Connect the resistors or bulbs A and B in parallel. Measure resistance.
Record resistance in the space provided.
d. Perform a resistance test across a diode.
1. Test resistance with the DMM leads in one direction. Record

2. Reverse the DMM leads and test resistance again. Record


e. Perform a resistance test across a throttle position sensor. Slowly

sweep the DMM leads. Record observations in the space provided.
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5. Measure resistance in an automotive electrical circuit using a DMM.
CAUTION: Do not measure resistance on a live electrical circuit. This

can damage test equipment.
a. Set the DMM for a resistance test.
b. Perform a resistance test across the electrical circuit. Record

Include further diagnosis and/or repairs.
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W 28
check electrical circuits using a test light

Date:
Equipment:

Battery
Test light
Procedure:

2. Wire two automotive bulbs and sockets in parallel to a battery. Using a

test light, measure voltage at the two test points (TP1 and TP2). Record the
readings in the space provided.
3. Wire two automotive bulbs and sockets in series. Using a test light,
check continuity of the electrical circuit. Record observations in the space
provided.
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W 30
check electrical circuits using fused jumper wires

Date:
Equipment:

Battery
Fuse (1 amp)
Fused jumper wires
Single-pole, single-throw switch
Procedure:

2. Set up an electrical circuit according to the following diagram. Have the

instructor place a fault in the electrical circuit.
a. Perform an operational test. Record observations in the space

provided.
b. Trace the current path. Include a listing of the relationship between

the components in the electrical circuit. Record in the space provided.
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c. Using fused jumper wires to bypass switches, connectors, sections
of wiring, and other nonresistive parts, isolate the fault. Record
d. Set up the DMM.
e. Perform the test procedure. Record observations in the space

provided.
3. Set up an electrical circuit according to the following diagram. Have the

instructor place a fault in the electrical circuit.
a. Perform an operational test. Record observations in the space

provided.
W 32
b. Trace the current path. Include a listing of the relationship between
the components in the electrical circuit. Record in the space provided.
c. Using fused jumper wires to bypass switches, connectors, sections

of wiring, and other nonresistive parts, isolate the fault. Record
d. Set up the DMM.
e. Perform the test procedure. Record observations in the space

provided.
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locate OPENS, SHORTS, AND GROUNDS IN AN ELECTRICAL

CIRCUIT Date:
Equipment:

Test light
Procedure:


3. Test a fusible link.
a. Set the DMM to measure resistance.
b. Probe the fusible link. Measure and record continuity in the space
provided.
4. Test the circuit breaker for opens.
b. Remove the circuit breaker from the panel.
W 35
c. Perform a resistance test across the circuit breaker. Record the
reading in the space provided.
5. Test the fuse for opens with a test light.
a. Connect the test light.
b. Probe both sides of the fuse for voltage. Record the reading in the
space provided.
c. Disconnect the test light.
6. Test a load device for shorts and grounds.
b. Measure resistance on a load device. Record in the space provided.
c. Use Ohm's law to calculate current. Compare current to

manufacturer's specifications. Record in the space provided.
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W 38
JS8-L3-Uiii Name(s):
Measure and Diagnose the cause of key-off battery

drain (parasitic draw) Date:
Equipment:
Digital multimeter (DMM) with low-amp induction pickup

Test light

Procedure:

2. Research applicable vehicle service information such as vehicle service

3. Using a test light, check for large current drain on the battery.
a. De-energize as many electrical circuits as possible.
b. Connect the test light clamp to the negative battery cable. Connect
the test light probe to the negative battery terminal.
c. Look for a bright light. Record observations in the space provided.
d. Disconnect the test light. Energize the electrical circuits.
4. Using a DMM, check for battery drain.
a. Set the DMM for amperage.
b. De-energize as many electrical circuits as possible.
c. Disconnect the negative battery cable.
W 39
d. Connect the negative DMM lead to the negative post of the battery.
Connect the positive DMM lead to the negative battery cable.
e. Measure current flow. Record the reading in the space provided.
f. Disconnect the DMM leads.
g. Connect the negative battery cable and energize the electrical circuits.
5. Using a DMM with a low-amp induction pickup, check for battery drain.
a. Place the low-amp induction pickup on the positive battery cable.
b. Measure current flow. Record the reading in the space provided.
W 40
test AND service fuses, FUSIBLE LINKS, and CIRCUIT

BREAKERS Date:
Equipment:

Test light

Procedure:


3. Test the fuses.
a. Connect one end of the test light to ground.
b. Energize the electrical circuits protected by the fuses.

c. Touch the other end of the test light to both ends of the fuses. Record
observations in the space provided. Compare to manufacturer's
specifications.
d. De-energize the electrical circuits protected by the fuses and

disconnect the test light.
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4. Inspect the fusible links.
a. Locate the fusible links. Use service information to identify the

electrical circuits protected by the fusible links. Record in the space
provided.
b. Conduct a visual inspection of the fusible links. Record observations

in the space provided.
c. Feel the fusible link for brittleness or a break in the wiring. Record
5. Test the circuit breakers.
a. Locate the circuit breakers. Use service information to identify the

electrical circuits protected by the circuit breakers. Record in the space
provided.
b. Use service information to verify that each circuit breaker is the

appropriate amperage. Record correct amperage in the space
provided.
W 42
c. Connect one end of the test light to ground.

d. Energize the electrical circuits protected by circuit breakers.
e. Check the circuit breakers by touching the other end of the test light
to both terminals of the circuit breaker. Record observations in the
space provided.
f. De-energize the electrical circuits protected by the circuit breakers

and disconnect the test light.
6. Based on the tests, perform the necessary action to correct any problems.
Retest as necessary. Record in the space provided.
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TEST and service SWITCHES, CONNECTORS, RELAYS, SOLID-

STATE DEVICES, AND WIRES OF ELECTRICAL/ELECTRONIC Date:
CIRCUITS
Equipment:

Fused jumper wire
Test light
Procedure:

3. Determine which switches need to be tested and select the appropriate

testing equipment. Using the correct procedures from section XI.A., test the
switches. Record observations in the space provided.
4. Determine which connectors and associated wiring need to be tested and

select the appropriate testing equipment. Using the correct procedures
from section XI.B., test the connectors and associated wiring. Record
W 45
5. Determine which relays need to be tested and select the appropriate testing
equipment. Using the correct procedures from section XI.C., test the relays.
Record observations in the space provided.
6. Determine which solid state devices need to be tested and select the
appropriate testing equipment. Using the correct procedures from section
XI.D., test the solid state devices. Record observations in the space
provided.
7. Based on the tests, perform the necessary action to correct any problems.
Retest as necessary. Record in the space provided.
W 46
Tin the soldering Iron and solder wire splices

Date:
Equipment:

File
Resin-core wire solder Evaluation
Resin-type soldering flux
Soldering iron stand or protective pad
Soldering iron with tip
Crimped wires with splices
Procedure:

2. Tin the soldering iron, as needed.
a. Using a file, dress the tip of the soldering iron down to the bare
copper.
b. File the surfaces of the tip until they are smooth and flat.
c. Plug in the soldering iron.
d. When the tip color begins to change to brown and light purple, dip
the tip in and out of a can of resin-type soldering flux.
e. Apply flux to soldering contacts before soldering.
f. Quickly apply resin-core wire solder to the surfaces.
g. Place the hot soldering iron on a soldering stand or protective pad.
NOTE: The soldering iron must be at normal operating temperature

to properly tin. Solder melts quickly and flows freely.
3. Solder a wire splice.
CAUTION: Never try to solder until the iron is properly tinned.
a. Clean the wires.
b. Crimp the wires together.
W 47
c. Apply the full surface of a tinned tip of a hot soldering iron against
the splice of the wire.

d. Apply flux to soldering contacts before soldering.
e. Apply the resin-core wire solder to the flat of the soldering iron where
it contacts the splice. As the wire heats, the solder flows through the
splice.
f. Apply enough solder to form a secure splice.
CAUTION: Do not move the splice until the solder sets.
g. Place the hot soldering iron on a soldering stand or protective pad.
h. Unplug the soldering iron.

W 48
repair terminals, wiring, and wiring harnesses

Date:
Equipment:

Crimping tool
Wire cutters Evaluation
Heat shrink tubing
Heat gun
Miniature screwdriver or terminal pick
Measuring device such as a micrometer
Splice
Standard terminal
Resin-core solder
Soldering iron
Resin-type soldering flux
NOTE: These procedures may be used to repair most electrical wiring circuits
including CAN circuits. Some manufacturers do not recommend repairing fiber
optic, supplemental restraint system (SRS), and CAN wiring circuits. If damaged
or defective, the complete related harness must be replaced as a unit.
Procedure:

2. Repair terminals.
a. Identify the connector name, locking clips position, unlocking

direction, and terminal type. Record in the following space.

b. Disengage the locking device before releasing the terminal locking
clip and the terminal removed from the connector.
c. Unlock the secondary locking device with a miniature screwdriver or

terminal pick.
d. Locate the locks on the terminal and connector.
e. Release the locking clip to remove the terminal from the connector.
W 49
f. Gently push the terminal into the connector and hold in position.
g. Insert the miniature screwdriver or terminal pick into the connector in

the correct direction.
h. Move the locking clip to the unlock position, and hold it there.

i. Pull the lead toward the rear of the connector to withdraw the
terminal from the connector.
NOTE: Do not use too much force. If the terminal does not come out
easily, repeat steps f through i.
j. Using wire cutters, cut the lead at the base of the terminal.
k. Select the correct replacement terminal.
l. Using wire stripers, remove 1/2 inch of insulation from the lead.
m. Crimp the replacement terminal to the wire lead. Solder the lead to
the terminal, if required by service procedures.
n. Install the new terminal into the connector.
o. Reconnect the connector and install the locking devices.
p. Test the operation of the circuit.
3. Repair wiring and wiring harness leads.
a. Locate the defective or damaged portion of the harness.

b. Remove the harness plastic or tape protective cover to gain access to
the area to be repaired.
c. Using wire cutters, cut and remove the damaged sections of the leads.
d. Measure the nominal size of the wire lead, and select the correct size
and type of electrical wire to replace the damaged leads. Record the
reading in the following space.
W 50
e. Select the correct size of the splice.
f. Using wire strippers, remove 1/2 inch of insulation from each of the
leads to be spliced.
g. Cut a piece of heat shrink tube that is slightly larger in diameter than
the splice and slightly longer than the splice.
h. Slide the tube over the end of one wire to be spliced. This must be
done before joining the wires together.
i. Insert the stripped ends of both the harness lead and replacement
lead into the splice to overlap the wires inside the splice.
CAUTION: The crimping tool has positions marked for insulated

splices that are marked “INS.” These positions should not be used
because they do not crimp the splice tightly onto the wires. Only
use the position marked “NON INS.”
j. Center the splice between the crimping jaws and squeeze until the
contact points of the crimper come together.

k. Make sure that the splice is crimped tightly. Solder the splice if
required by service procedures.
l. Center the tube over the soldered splice.
m. With a heat gun, gently heat the tubing until it has shrunk tightly
around the splice.
n. After repairing the damaged leads, reinstall the harness protective

cover.
o. Test the operation of the circuit.
NOTE: After completing repairs of terminals, wiring, and wiring harnesses,

some service procedures require measuring circuit resistance and comparing
readings to specifications (too high of resistance would indicate a defective
repair). On CAN circuits, a scan tool may be used to test the circuit operation.
W 51
W 52
AS1-L1-UIv Name:
The Basics of the Battery Date:

sheet.
1. Describe the function of the battery in the following situations:
A. When starting the vehicle —
B. When the vehicle is running —
C. When the vehicle is off —
2. In a lead-acid storage battery, what are the active materials in the positive
and negative grid plates?
3. Name the fluid inside the battery’s cells and describe its composition.

W 53
4. What does the material in the positive and negative plates change to during
battery discharge?
5. What are the two most common battery ratings and what do they indicate?
A.
B.
W 54
JS1-L2-UIV Name(s):
MEASURe the battery's STATE-OF-CHARGE

Date:
Equipment:
Load tester
Hydrometer
Procedure:


necessary information in the following space.
3. Perform a hydrometer test on a serviceable battery.
a. Remove the battery cell vent caps. Make sure the cells contain a
sufficient amount of electrolyte.
b. Draw an electrolyte sample from cell 1. Draw enough electrolyte to

make the calibrated scale float but not enough to fill the hydrometer.
c. Hold the hydrometer vertically and read the number that is level with
the electrolyte surface.
W 55
d. Record the reading in the following chart.
NOTE: Consider the temperature when recording a reading. The

reading is not correct if water has just been added to the battery.

Cell Number
1 2 3 4 5 6
Specific Gravity Reading
Electrolyte Temperature
Corrected Gravity Reading
Gravity Range (Total + Variation)
e. Return the electrolyte sample to cell 1.
f. Repeat the procedure for the remaining cells.
g. Evaluate the battery's state-of-charge. Is the battery good, fair, or bad?

Record the evaluation in the following space.
4. Perform an open-circuit voltage test on a maintenance-free battery.
a. Allow the surface charge of the battery to diminish.
b. Using a load tester, place a 20-amp drain on the battery for 1 minute.
c. Immediately following the drain, measure the voltage. Record

observations in the following space.
d. Evaluate the battery's state-of-charge. Is the battery good, fair, or bad?

Record the evaluation in the following space.
5. Based on the tests, does the battery need to be replaced? Record the answer
in the following space.
W 56
JS2-L2-UIV Name(s):
perform a load test

Date:
Equipment:
Load tester
Evaluation
Procedure:

history, VIN, certification labels, and calibration decals. Include the
proper battery capacity for the vehicle application. Record the necessary
information in the following space.
3. Perform a preliminary battery load test.
a. Establish the battery's state-of-charge. Record observations in the

following space.
NOTE: Do not perform a load test unless the battery is at a 75%

charge or greater.

b. Determine either the amp hours or cold-cranking amps to establish
the battery's capacity requirement. Record observations in the
following space.
NOTE: The amp hours or cold-cranking amps should be noted on the

battery's identification tag.
W 57
c. Compare the battery's cold-cranking amps to the cubic-inch
displacement of the engine. Record observations in the following
space.
NOTE: Vehicles with four- and six-cylinder engines can require more
cranking current per cubic inch of displacement.
d. If the cold-cranking amp rating is too small when compared to the

cubic inch displacement of the engine, test the battery according to the
cold-cranking amps rating found on the battery. If the cold-cranking
amps are higher than the cubic inch displacement, test the battery
according to the cubic inch displacement. Record observations in the
following space.
e. Establish the proper load test specifications. Record observations in

the following space.
4. Perform a load test using the tester manufacturer's instructions.
a. Attach the load tester to the positive and negative terminals of the
battery, observing battery polarity.
NOTE: If the load tester has an inductive pickup lead, attach the lead
to measure current flow during the battery test.
b. Set the load tester to the correct settings.
c. Use the load tester to create a load on the battery.
d. After the specified amount of time, observe the voltage reading and
turn off the load.

W 58
e. Compare the reading to manufacturer’s specifications. Record
observations in the following space
5. Based on the tests, does the battery need to be replaced? Record the answer
W 59
W 60
JS3-L2-UIV Name(s):
PERFORM A Quick CHARGE TEST

Date:
Equipment:
Battery charger

Procedure:


3. Perform a quick charge test.
CAUTION: Do not perform a quick charge test on any type of sealed

battery.
a. Set the DMM to the voltmeter setting.
b. Connect the DMM and battery charger to the battery. Observe battery
polarity.
c. Set the battery charger to the correct voltage.
d. Charge the battery at a rate of 40 amps. Do not exceed 40 amps.
e. Observe the voltmeter readings. Record observations in the following

space.
W 61
f. Time the process for 3 minutes. Determine the battery's condition
with the battery charger still operating.
g. Evaluate the battery's state-of-charge. Is the battery good, fair, or

bad? Record the evaluation in the following space.
4. Based on the test, does the battery need to be replaced? Record the answer
W 62
JS4-L2-UIV Name(s):
Inspect, clean, fill, and replace a BATTERY

Date:
Equipment:

Baking soda
Distilled water Evaluation
Battery cleaning brush
Battery lifting tool
Battery pliers
Battery reamer/spreader
Common hand tools
Terminal expander

Procedure:

3. Inspect the battery. Complete the following chart.
OK Not OK
Case
Cable ends
Cables
Terminal eyes
Record observations in the following space.
W 63
4. Measure the amount of current leakage between the battery posts.
a. Set the DMM to the voltage setting.
b. Connect the negative DMM lead to the negative battery post.

c. Move the positive DMM lead to the following locations and note the
voltmeter reading at each location.
Next to negative post volts

Halfway between posts volts
Next to positive post volts
d. If the reading is above .5 volts, the battery should be cleaned. Record

5. Clean the battery case and terminals.
a. Remove the battery cables and use a battery lifting tool to remove
the battery. (See step 8a.) Move the battery to an area designated for
battery cleaning.

CAUTION: Always remove the negative battery cable first.
b. Mix a paste of baking soda and water. Brush the paste on the top of
the battery.
c. After the acid is neutralized, thoroughly wash the top with water.
CAUTION: Do not allow the cleaning solution to come into contact

with skin or clothing. Do not allow it to get inside a serviceable
battery.
6. Clean the cable ends and posts.
a. Using a battery cleaning brush, clean the cable and post surfaces until
shiny.
b. Turn any rounded cable or post surfaces with a battery

reamer/spreader.
W 64
c. To install the terminal, the taper on the terminal needs to match the
post. Tighten the bolts to 60 to 90 inches per pounds.
d. The cable end should have a small gap in the clamp. If it is touching,
remove the cable and file the gap wider.
e. If desired, apply anticorrosion paste.
7. Fill a serviceable battery.
NOTE: Maintenance-free batteries are designed to last for long periods

without losing electrolyte. This procedure is for serviceable batteries only.
a. Determine if the battery is serviceable. Record observations in the

following space.
b. Remove the vent caps.
c. Check the electrolyte level. Record observations in the following

space.
d. If the electrolyte is low, fill the cells to the proper level with distilled
water.
CAUTION: Never use tap water to fill a battery. There are

impurities in tap water that can reduce battery life.
8. After cleaning/filling, determine if a new battery is necessary. Replace the

battery, as needed.
a. Remove the battery.
• Disconnect the cables.
CAUTION: Remove the ground cable first.
• Loosen the battery hold-down.
• Using a battery strap or tool, lift the battery out of the vehicle.
W 65
NOTE: The Environmental Protection Agency considers
discarded batteries to be hazardous waste. Follow battery
disposal regulations.
b. Install a battery.
• Gently place the battery into the clean tray or box.
• Make sure the battery fits properly. The tray edge should not cut
or rupture the plastic battery case.
• Bolt on the battery hold-down.
• Install the cables.
CAUTION: Connect the ground cable last.
W 66
JS5-L2-UIV Name(s):
identify electronic memory functions affected by

battery disconnect and Maintain or restore the Date:
functions
Equipment:
Memory saver adapter (9-volt) or second 12-volt automotive battery Evaluation

Procedure:

3. Using service information, identify the electronic settings and adjustments

that will be lost when the battery is disconnected. Record the findings in the
following space.
4. Using the owner's manual and service information, locate the code and
method for reinitializing or restoring electronic memory functions. Make
sure the procedure is appropriate for the make and model of the vehicle.
Have the instructor check the following box to approve the procedure.
W 67
5. Using service information, locate a procedure for maintaining the electronic
memory functions before disconnecting the battery. Make sure the
procedure is appropriate for the make and model of the vehicle. Have the
instructor check the following box to approve the procedure. (Two methods
are listed in section V.C.)
Using the procedure, maintain the electronic memory functions.
6. If memory functions are lost due to disconnecting the battery, use the
procedure found in the owner's manual or service information (step 4) to
restore or reinitialize the memory functions.
W 68
JS6-L2-UIV Name(s):
Charge a battery
Date:
Equipment:
Battery charger
Procedure:


3. Determine the battery's state-of-charge. Record observations in the

following space.
4. Prepare for charging.
a. Clean the dirt, dust, or corrosion off the battery.
b. Clean the terminals.

c. If the battery is serviceable, make sure the electrolyte is at the proper
level in all cells.
d. Make sure the battery is not frozen.
CAUTION: Never charge a frozen battery. Charging a frozen

battery can cause the battery to explode.
e. Ensure that the work area is well-ventilated and that the battery is not
near flames or sparks.
W 69
5. Calculate the time and amp rate that is required to recharge the battery
completely. Record the results below.
Amps Time
6. Recharge the battery.
a. Make sure that the charger’s power cord is unplugged, the main
switch and timer switch are off, and the current adjust switch is at the
minimum position.
b. Connect the positive lead of the battery charger to the positive

terminal (+) and the negative lead of the charger to the negative
terminal (-).
c. Connect the power cable to the electrical outlet.
d. Set the voltage switch to the correct battery voltage.
e. Set the main switch at on.
f. Set the timer to the desired time and adjust the charging current to the
predetermined amperage.
CAUTION: Fast charging causes an increase in electrolyte

temperature; it is important to monitor the battery temperature. If
the electrolyte temperature rises above 125°F or if terminal voltage
exceeds 15.5 volts, reduce the charging rate. Also, do not exceed the
battery manufacturer's charging limits.
g. After the timer is off, check the charged condition using a DMM. The
correct voltage is 12.6 volts or higher.

h. When the voltage reaches the proper reading, finish the charging
process.
• Set the current adjust switch to minimum.
• Turn off the main switch of the battery charger.
• Disconnect the battery charger cables from the battery terminals.
• Wash the battery case to clean off the emitted acid.
W 70
JS7-L2-UIV Name(s):
JUMP-START A VEHICLE
Date:
Equipment:
Jumper cables or auxiliary power supply

Evaluation
Procedure:


3. Jump-start a vehicle.
a. Inspect the dead battery for cracks and excessive corrosion. Make sure
the battery is not frozen. Ensure that the cables and terminal ends are
clean. Record observations in the following space.
b. Connect the jumper cables or auxiliary power supply.
c. Start the engine in the donor vehicle or turn on the auxiliary power
supply. Allow it to run for 1 to 2 minutes at high idle.
d. Crank the engine in the dead vehicle for 15 seconds. Let it rest for 30
seconds and then crank again for 15 seconds.
e. Repeat the procedure until the dead vehicle starts.
f. Shut the engine in the donor vehicle off or turn off the auxiliary power
supply.
g. Disconnect the jumper cables, removing the negative cable first, or

disconnect the auxiliary power supply.
W 71
W 72
JS8-L2-UIV Name(s):
identify hybrid vehicle auxiliary (12v) battery service,

repair, and test procedures Date:
Equipment:

Manufacturer's specific hybrid safety equipment Evaluation
Load tester
Battery charger
CAUTION: Hybrid vehicles produce extremely high voltages. To avoid

potentially fatal shocks and burns, follow all safety guidelines for the vehicle
being serviced.
Procedure:


3. Locate and observe all safety information and procedures related to the
specific hybrid vehicle. Make sure the procedure is appropriate for the
make and model of the vehicle. Have the instructor check the following
box to approve the procedure.
4. Use service information to locate the auxiliary battery.
a. Determine if the hybrid battery must be disconnected before

servicing the auxiliary battery. If it must be disconnected, follow the
manufacturer’s procedure.
W 73
b. If required, remove components necessary to gain access to the
auxiliary battery. Record observations in the following space.

5. After accessing the battery, service, test, or replace the battery using the
same procedures that are used for nonhybrid vehicle batteries. (See the
various job sheets for this lesson.)
CAUTION: Some hybrid vehicles use Absorbent Glass Mat (AGM)

12-volt auxiliary batteries. These batteries require very low charging
rates and will be ruined if charged at an excessive rate. Be sure to review
vehicle service information before testing and servicing all hybrid
auxiliary batteries.
W 74
AS1-L1-UV Name:
Starting System Components and operation Date:

sheet.
1. What causes the armature in a starter motor to rotate and in turn crank the
engine?
2. Match the starting system component to its function or description. All the
components will not be used.
____A. Gear device used to engage the 1. Armature

starter to the flywheel.
2. Brush
____B. Connects brushes to armature to
allow current flow. 3. Commutator
____C. Device that produces magnetic 4. Field coil

fields.
5. Overrunning clutch
____D. Uses DC current and gears to drive
the flywheel. 6. Pole shoe
____E. Part of the field coil assembly 7. Solenoid

that increases the strength of
the magnetic field. 8. Starter drive

____F. Motor component that rotates 9. Starter motor
between the pole shoes.
____G. Magnetic coil that engages large

current-carrying contacts or
converts electrical energy to linear
mechanical energy.
____H. Contacts commutator; keeps

current flowing through armature.
W 75
3. What is the function of the neutral safety switch and how does it operate
with both automatic and manual transmissions?
4. What are the four types of starters?
A.
B.
C.
D.
5. What does a permanent magnet starter use instead of field windings to

create the magnetic field?
W 76
JS1-L2-UV Name(s):
inspect the starting system and perform a current

draw test Date:
Equipment:

Digital multimeter (DMM) with inductive pickup or load tester Evaluation
Procedure:

2. Research applicable service information such as vehicle service history,

VIN, certification labels, and calibration decals. Record necessary
3. Inspect the starting system.
OK Not OK
Battery
Hold-down
Terminals
Cables
Starter control circuit
Starter solenoid
If necessary, repair defective starting system components.
4. Using service information, locate a procedure for performing a mechanical

engine test to determine if the slow crank or no crank condition is due to an
electrical or engine problem. Make sure the procedure is appropriate for
the make and model of the vehicle. Have the instructor check the box to
approve the procedure.
W 77
Using the procedure, perform a mechanical engine test to determine if the
slow crank or no crank condition is due to an electrical or engine problem.
NOTE: Perform step 5 if conducting a current draw test with a DMM or step 6 if
conducting a current draw test with a load tester.
5. Perform a current draw test using a DMM.
a. Set the DMM to measure voltage.
b. Connect the DMM leads in parallel between the positive and negative
battery terminals.
c. Disable the ignition.
CAUTION: Disconnect the distributor battery lead to avoid high-

voltage arcing in the coil secondary lead.
d. Crank the engine for 15 seconds. Observe the voltage reading. Record
e. Set the DMM to measure amperage.
f. Connect the DMM inductive pickup lead to the negative battery cable.
g. Crank the engine for 15 seconds. Observe the amps reading. Record
CAUTION: Damage to the starter can occur if the engine is cranked

for more than the specified time. If repeating this portion of the
test is necessary, allow the starter to rest for a few minutes before
cranking again.

W 78
h. Determine if the starting system is using an acceptable amount of
current to crank the engine. Record observations in the following
space.
i. Recommend necessary repairs in the following space.
6. Perform a current draw test using a load tester.
NOTE: The following are general steps using a load tester. Operating
instructions vary depending on the manufacturer of the tester. Follow the
equipment manufacturer’s instructions.
a. Estimate the required cranking amps.

Number of cylinders
Cubic inch displacement
Estimated ampere draw
b. Connect the load tester leads in parallel between the positive and
negative battery terminals.

c. Set the load tester controls to the proper setting.
d. Connect the inductive pickup lead as specified in the load tester’s

instructions.

e. Disable the ignition so that the vehicle cannot start.
CAUTION: Disconnect the distributor battery lead to avoid high-

voltage arcing in the coil secondary lead.
f. Crank the engine continuously for the specified time, usually 10 to 15

seconds.
W 79
CAUTION: Damage to the starter can occur if the engine is cranked
for more than the specified time. If repeating this portion of the
test is necessary, allow the starter to rest for a few minutes before
cranking again.

g. Observe the readings. Compare the readings to the proper
specifications.
h. Determine if the starting system is using an acceptable amount of

current to crank the engine. Record observations in the following
space.
i. Recommend necessary repairs in the following space.
W 80
JS2-L2-UV Name(s):
PERFORM STARTER CIRCUIT VOLTAGE DROP TESTs

Date:
Equipment:

Evaluation
Procedure:

2. Research applicable service information such as vehicle service history, VIN,

certification labels, and calibration decals. Record necessary information in
3. Perform an insulated circuit resistance test using the voltmeter setting of a

DMM.
a. Adjust the DMM to the proper volts setting.
NOTE: The following connections are for a negatively grounded

starting system. The connections must be reversed for a positively
grounded starting system.
b. Connect the positive DMM lead to the positive battery post. Connect
the negative DMM lead to the starter motor input terminal.
c. Disable the ignition system.
d. Crank the engine. Observe the reading. Record observations in the

following space.
e. Enable the ignition system.
W 81
4. Perform a starter ground circuit test using the voltmeter setting of a DMM.
a. Adjust the DMM to the proper volts setting.
b. Connect the positive DMM lead to the starter end frame. Connect the
negative DMM lead to the negative battery post.
c. Disable the ignition system.
d. Crank the engine. Observe the reading. Record observations in the

following space.
e. Enable the ignition system.
5. If the voltage drop is unacceptable, recommend the necessary repairs or

service in the following space.
W 82
JS3-L2-UV Name(s):
test the STARTER control CIRCUIT COMPONENTS

Date:
Equipment:
Hand tools
Test light Evaluation
Test light (12-volt)
Procedure:


VIN, certification labels, and calibration decals. Record necessary
3. Perform a starter solenoid test using the voltmeter setting of a DMM.
a. Test the starter solenoid at the lug-to-cable connection.
1. Connect the positive DMM lead to the wire that connects to the
battery.
2. Connect the negative DMM lead to the lug on the starter

solenoid.
3. Disable the ignition system.
4. Crank the engine. Observe the reading. Record observations in

5. Enable the ignition system.
W 83
b. Test the starter solenoid disc contact and terminal connection.
1. Connect the positive DMM lead to the lug that has the wire that
connects to the battery.
2. Connect the negative DMM lead to the lug that has the wire that
connects to the starter.
3. Disable the ignition system.
4. Crank the engine. Observe the reading. Record observations in

5. Enable the ignition system.
4. Using service information, locate the procedure for performing a starter

relay test using a test light. Include the wiring diagram. Make sure the
instructor check the box to approve the procedure.

Using the procedure, perform a starter relay test using a test light. Record
5. Perform an ignition switch test using a test light.
a. Touch the test light to the starter solenoid start terminal.
b. Turn the key to the start position. Record observations in the

following space.
W 84
c. Release the key from the start position. Record observations in the
following space.
6. Perform a neutral safety switch test.
a. With the key turned on, move the transmission gear shift lever into
different positions. Note if the switch closes and lets the starter
operate in positions other than park and neutral. Record observations
b. Touch a 12-volt test light to the neutral safety switch input terminal.
Turn the ignition switch to the start position. Record observations in
c. With the transmission gear shift lever in park or neutral and the
ignition switch in the start position, touch the test light to the output
terminal. Record observations in the following space.
d. If the test light fails to glow in park or neutral, move the gear shift
to different positions while the test light is connected. Record
7. Determine if any of the starter control circuit components are defective.

W 85
8. Using service information, locate a procedure for repairing or servicing
the defective starter control circuit components. Make sure the procedure
is appropriate for the make and model of the vehicle. Have the instructor
check the box to approve the procedure.

Using the procedure, repair or service the defective starter control circuit
components.
W 86
JS1-L3-UV Name(s):
REMOVe AND install A STARTER

Date:
Equipment:
Hand tools
Vehicle lifting equipment Evaluation
Procedure:


3. Disconnect the negative battery cable.
4. Place the vehicle securely on safety stands or lift with a hoist.
5. Using service information, locate a procedure for removing the starter.

Make sure the procedure is appropriate for the make and model of the
vehicle. Have the instructor check the box to approve the procedure. (For
a general procedure, see section I.)

Using the procedure, remove the starter.
6. Complete a bench test and service the starter. Use JS2-L3-UV and
JS3-L3-UV to complete these procedures.
W 87
7. Using service information, locate a procedure for installing the starter.
Include the torque specifications for the mounting bolts. Make sure the

Using the procedure, install the starter.
8. Lower the vehicle and connect the negative battery cable.
9. Check the operation of the starter. Record observations in the following

space.
W 88
JS2-L3-UV Name(s):
BENCH TEST A STARTER

Date:
Equipment:
Jumper cables
Remote starter switch Evaluation
Vise
Load tester
Procedure:


3. Determine the correct free running amp draw for the starter and the
minimum voltage that the battery can reach. Record the specifications in
the following chart.

Free running amp draw
Minimum voltage
4. Bench test the starter.
a. Secure the starter so that it will not move.
b. Using service information, locate a procedure for connecting the

jumper cables and remote starter switch. Make sure the procedure
is appropriate for the make and model of the vehicle. Have the
W 89
Using the procedures, connect the jumper cables and remote starter
switch.
c. Using service information, locate a procedure for connecting the load

tester. Make sure the procedure is appropriate for the make and
procedure.

Using the procedure, connect the load tester.
d. Set the ammeter to the correct scale.
e. Crank the starter for 15-20 seconds. Observe the reading. Record
5. Determine if the starter is in good working condition. Record the

determination in the following space. If necessary, recommend repairs.
W 90
JS3-L3-UV Name(s):
disassemble, test, and reassemble A STARTER

Date:
Equipment:
Clean cloths
Electric motor cleaner
Growler Evaluation
Hand tools
Test light
Procedure:


3. Using service information, locate a procedure for disassembling the starter.

vehicle. Have the instructor check the box to approve the procedure. (For a
general procedure, see section III.A.)

Using the procedure, disassemble the starter.
4. Clean the components with clean cloths and electric motor cleaner. Check
the end frame for solder thrown from the armature connections.
W 91
5. Inspect the components. Complete the following chart.
OK Not OK
Bushing
Brushes
Drive
Armature Commutator
Replace any defective components.
6. Test the components. Record observations in the following chart.

Check the armature for shorts.
Check the armature for ground.
Check the field coil for opens. (not
applicable to permanent magnet starters)
Check the field coil for ground. (not
applicable to permanent magnet starters)
Check the permanent magnets for cracks.
(permanent magnet starters only)
Check that permanent magnets are
securely attached to case. (permanent
magnet starters only)
Repair any problems found during testing.
7. Using service information, locate a procedure for reassembling the starter.

general procedure, see section III.C.)

Using the procedure, reassemble the starter.
W 92
AS1-L1-UVI Name:
Charging System Components and operation Date:

sheet.
1. Describe the two main functions of a charging system.
A.
B.
2. Match the term to its function or description. All the terms will not be
used.
____A. Light or gauge that compares 1. Alternator
the alternator’s current output to the
requirements of the electrical system. 2. Carbon brushes
____B. Rotates within stator to induce 3. Charge indicator

current flow in the stator.
4. Diode bridge
____C. Process of converting AC to DC.
5. Electromagnetism
____D. Controls the charging rate of the
alternator. 6. Rectification

____E. Generator that changes mechanical 7. Rotor
energy to electrical energy.
8. Voltage regulator
____F. Composed of three sets of windings
wound through a stationary 9. Stator
iron ring.
____G. Ensures a single direction of current

from the alternator.
W 93
3. What are the two stator winding arrangements?
A.
B.
4. In what two charging system conditions does the charge indicator light
come on?
A.
B.
5. What are the three circuit arrangements that manufacturers use to wire the
voltage regulator to the alternator’s rotor circuit?
A.
B.
C.
W 94
JS1-L2-UVI Name(s):
Perform a PRELIMINARY inspection and TEST OF THE

CHARGING SYSTEM Date:
Equipment:

Evaluation
Procedure:


3. Conduct a visual inspection of the charging system. Record observations in

the following chart.

OK Not OK
Battery
Battery terminals
Alternator drive belt
Alternator pulleys
Alternator tensioners
Alternator pulley alignment
Alternator belt alignment
Alternator wiring harness
Alternator mounting
Voltage regulator wiring harness
Voltage regulator ground

Repair or replace any defective components. If necessary, adjust the belt
tension.
W 95
4. Perform battery tests.
a. Perform a state-of-charge test. See JS1-L2-UIV for the proper

procedure. Record observations in the following space.
b. Perform a load test. See JS2-L2-UIV for the proper procedure. Record
c. Replace a bad battery. See JS4-L2-UIV for the proper procedure.
W 96
JS2-L2-UVI Name(s):
diagnose the charging system for undercharge,

no-charge, or overcharge conditions Date:
Equipment:

Load tester Evaluation
Exhaust ventilation equipment
Procedure:

3. Using service information, locate the rated output for the alternator. Record
this in the following space.
NOTE: This information is sometimes stamped on the alternator housing.
4. Connect the load tester leads to the positive and negative battery terminals.
5. Connect the exhaust ventilation equipment.
CAUTION: Be sure to use approved exhaust ventilation equipment

when operating a vehicle in an enclosed area.
6. Start the engine.
W 97
7. Check the load tester reading. Record the reading in the following space.
8. Shut the engine off. Disconnect the test equipment and the exhaust
ventilation equipment.
9. Determine if the charging system is producing an undercharge,

no-charge, or overcharge condition. Record observations in the following
space. If necessary, include the recommended steps to correct any
problems found during testing.
W 98
JS3-L2-UVI Name(s):
Perform a charging system OUTPUT TEST

Date:
Equipment:

Load tester Evaluation
Procedure:

3. Test the charging system output using a DMM.
a. Set the DMM to measure volts.
b. Connect the DMM leads to the positive and negative battery posts.
c. Connect the exhaust ventilation equipment.

d. Start the engine and allow it to idle at the proper test specification
speed.
e. Turn on all vehicle electrical accessories including lights, blower

motor, AC, window heaters, and radio.
f. Record the DMM voltage reading in the following space. Compare it

to the proper specifications.
W 99
g. Shut off the engine and remove the exhaust ventilation equipment.
h. Determine if the alternator is functioning properly. Record

4. Perform a charging system output test using a load tester.
a. Connect the load tester leads in parallel to the battery. Observe

battery polarity.
b. Connect the inductive pickup lead over the battery cable.
NOTE: Follow load tester instructions when connecting the test

leads. The instructions may recommend placing the inductive pickup
on the negative battery cable, on the positive battery cable, or on the
alternator output cable.


d. Set the load tester controls to the proper setting.

e. Turn the key to the on position. Check the load tester voltage and
ammeter readings. Record the readings in the following space.
f. Start the engine and allow it to idle at the speed specified in the load
tester instructions.

g. Use the load tester to place a specified load on the battery. Record the
load tester battery voltage reading and charging system amperage
reading in the following space.
W 100
h. Shut the engine off. Disconnect the test equipment and the exhaust
i. Compare the load tester reading to specifications. Determine if the

charging system is functioning properly. Record observations in the
following space. If necessary, include the recommended steps to
correct any problems found during testing.
W 101
W 102
JS4-L2-UVI Name(s):
Perform an alternator full-field test

Date:
Equipment:
Hand tools
Jumper wire (12-gauge)
Load tester or digital multimeter (DMM)
Procedure:


3. Using service information, locate a wiring schematic to determine the type

of field circuit used in the alternator. Have the instructor check the box to
approve the wiring schematic.

Using the wiring schematic, determine the type of field circuit. Record
W 103
4. Determine the correct charging system voltage. Record observations in the
following chart.

Alternator
Voltage regulator setting
A circuit
B circuit
Charging system output
The rpm at which the test should be performed
5. Ensure the engine and all electrical accessories are off.
6. Connect a load tester or DMM to the battery posts. If using a DMM, set it to
the voltmeter function. Record the battery voltage in the following space.
7. Determine the best location for jumping the field circuit. Connect the
jumper wire or probe as necessary to perform the full-field test. Record
CAUTION: Be sure to use approved exhaust ventilation equipment when

operating a vehicle in an enclosed area.
9. Start the engine and allow it to run at the specified rpm.
10. Complete the field connection so that the system is bypassing the voltage
regulator.
CAUTION: To prevent damage to the electrical system, do not allow the

voltage to exceed 16.5 volts.
11. Check the voltmeter reading. Record the reading in the following space.
W 104
12. Shut the engine off. Disconnect the test equipment and exhaust ventilation
equipment.
13. Determine if the charging system is functioning properly. Record

observations in the following space. If necessary, include the recommended
steps to correct any problems found during testing.
W 105
W 106
JS5-L2-UVI Name(s):
Perform a VOLTAGE REGULATOR CUTOUT TEST

Date:
Equipment:

Load tester
Exhaust ventilation equipment Evaluation
Procedure:


3. Determine the correct charging system voltage and desired test rpm. Record

5. Connect the load tester in parallel to the battery. Observe battery polarity.
6. Start the engine and allow it to idle.
7. Use the load tester to place a load on the battery until the battery voltage
reads less than 10 volts.
8. Turn the load knob off.
9. Increase the engine speed to the desired test rpm.
W 107
10. Observe the voltmeter reading on the load tester. Record the reading in the
following space.
11. Shut the engine off. Disconnect the test equipment and exhaust ventilation
equipment.
12. Determine if the charging system is functioning properly. Record

observations in the following space. If necessary, include the
recommended steps to correct any problems found during testing.
W 108
JS6-L2-UVI Name(s):
Perform CIRCUIT RESISTANCE and voltage drop TESTs

Date:
Equipment:

Load tester
Procedure:


3. Perform a complete circuit resistance test.
a. Connect the load tester in parallel to the battery. Observe battery

polarity.
b. Set the DMM to measure voltage. Connect the positive DMM lead
to the alternator output terminal and the negative DMM lead to the
battery negative post.

d. Start the engine and increase to 2,000 rpm.
e. Increase the load until the charging system reaches the manufacturer's
specified output.
W 109
f. Observe the voltage reading on the load tester. Record the reading in
g. Observe the voltage reading on the DMM. Record the reading in the
following space.
h. Shut the engine off. Disconnect the test equipment and exhaust
i. Subtract the load tester voltage reading from the DMM voltage
reading. Record the voltage drop in the following space.
j. According to this test, is the voltage drop for the complete circuit
within specification? Record results in the following space. If
necessary, include the recommended steps to correct any problems
found during testing.
4. Perform an insulated circuit resistance test.
a. Connect the positive lead to the output connection on the back of the
alternator. Connect the negative DMM lead to the positive battery
terminal.
b. Connect the load tester positive and negative leads in parallel to the
battery.
c. Connect the load tester inductive pickup as recommended by the load

tester’s instructions.
W 110
d. Connect the exhaust ventilation equipment.
CAUTION: Always use exhaust ventilation equipment when

e. Start the engine and increase to 2,000 rpm.
f. Use the load tester to place a load on the battery until the charging
system reaches the manufacturer's specified output.
g. Observe the DMM's voltmeter reading. Record the reading in the

following space.
i. According to this test, is the voltage drop for the insulated circuit
within specification? Record results in the following space. If
necessary, include the recommended steps to correct any problems
found during testing.
5. Perform a ground circuit resistance test.
a. Connect the positive DMM lead to the negative battery terminal.

Connect the negative DMM lead to a good ground on the back of the
alternator housing.

b. Connect the load tester positive and negative leads in parallel to the
battery.
c. Connect the load tester inductive pickup as specified in the load

tester’s instructions.

d. Connect the exhaust ventilation equipment.
CAUTION: Always use exhaust ventilation equipment when

W 111
e. Start the engine and increase to 2,000 rpm.
f. Use the load tester to place a load on the battery until the charging
system reaches the manufacturer’s specified output.
g. Observe the voltage reading on the DMM. Record the reading in the
following space.
i. According to this test, is the voltage drop for the ground circuit within
specification? Record results in the following space. If necessary,
include the recommended steps to correct any problems found during
testing.
W 112
JS7-L2-UVI Name(s):
test the charging system using an oscilloscope

Date:
Equipment:

Oscilloscope
Exhaust ventilation equipment Evaluation
Procedure:


3. Connect the oscilloscope to the alternator according to the oscilloscope

manufacturer's instructions.
CAUTION: Always use exhaust ventilation equipment when operating a

vehicle in an enclosed area.
5. Start the engine and observe the alternator waveform. Compare the
pattern to the proper specification. Record observations below, providing
recommendations for repair if the pattern is abnormal.
6. Shut off the engine, remove the oscilloscope, and disconnect the exhaust
W 113
W 114
JS8-L2-UVI Name(s):
DETERMINe the current requirements for a CHARGING

SYSTEM Date:
Equipment:

Digital multimeter (DMM) with induction pickup Evaluation
Procedure:


3. Determine the maximum charging system output. Record observations in

4. Connect the DMM’s ammeter inductive pickup to the negative battery

cable.
5. Turn on all the accessory equipment including the ignition switch. Do not
crank the engine.
6. Observe the maximum ammeter reading. Record the reading in the

following space.
W 115
7. According to this test, is the charging system functioning properly?
Record observations in the following space. If necessary, include the
recommended steps to correct any problems found during testing.
W 116
JS1-L3-UVI Name(s):
REMOVe AND INSTALL the ALTERNATOR

Date:
Equipment:
Belt tension gauge

Hand tools
Torque wrench
Procedure:


3. Using service information, locate a procedure for removing the alternator.

general procedure, see section I.A.)

Using the procedure, remove the alternator.
4. Using service information, locate a procedure for installing the alternator.

general procedure, see section I.B.)

Using the procedure, install the alternator.
W 117

6. Start the engine.
7. Test the alternator operation. Record observations in the following space.
8. Shut the engine off and disconnect the exhaust ventilation equipment.
W 118
JS2-L3-UVi Name(s):
Disassemble, inspect, and reassemble the ALTERNATOR

Date:
Equipment:
Electric motor cleaner

Hand tools
Ohmmeter Evaluation
Pulley puller
Bearing puller
Procedure:


3. Using service information, locate a procedure for disassembling the

alternator. Make sure the procedure is appropriate for the make and model
of the vehicle. Have the instructor check the box to approve the procedure.
(For a general procedure, see section II.A.)

Using the procedure, disassemble the alternator.
4. Clean the alternator with electric motor cleaner. Wipe or blow the
components dry.
5. Check for smooth movement of the brushes. They should return all the
way to the stops when released. Replace the brush holder assembly if the
brushes do not move properly.
W 119
6. Inspect and test the rotor.
a. Inspect the field slip rings for excessive wear or roughness. Record
b. Test for continuity from one slip ring to the other using the ohmmeter.
c. Test for continuity from the field coil slip rings to the rotor shaft or
core using the ohmmeter. Record observations in the following space.
d. Determine if the rotor is defective. Record observations in the

following space.
e. If necessary, replace the rotor.
7. Inspect and test the stator.
a. Inspect the stator for signs of damage such as weak or broken leads,
distorted frame, or burned windings. Record observations in the
following space.
b. Use a scraper to clean a small area of the stator frame to ensure a good
electrical contact.
W 120
c. Test for continuity from the stator leads to the frame using an
ohmmeter. Record observations in the following space.
d. Test continuity from one stator lead to the other leads using an
ohmmeter. Record observations in the following space.
e. Determine if the stator is defective. Record observations in the

following space.
f. If necessary, replace the stator.
8. Test the rectifier.
a. Separate the positive diode leads from the negative diode leads.
b. Test for continuity from each of the positive diode leads to the
positive heat sink using an ohmmeter. Reverse the test probes and
repeat. Record observations in the following space.
c. Test for continuity from each of the negative diode leads to the
negative heat sink using an ohmmeter. Reverse the test probes and
repeat. Record observations in the following space.
d. Determine if the rectifier is defective. Record observations in the

following space.
e. If necessary, replace the rectifier.
W 121
9. Using service information, locate a procedure for reassembling the
alternator. Make sure the procedure is appropriate for the make and model

Using the procedure, reassemble the alternator.
W 122
js3-l3-uvi Name(s):
Remove, inspect, and install the voltage regulator

Date:
Equipment:
Hand tools
Terminal cleaning brushes Evaluation
Procedure:


3. Using service information, locate a procedure for removing the voltage

regulator. Make sure the procedure is appropriate for the make and model

Using the procedure, remove the voltage regulator.
4. Inspect the voltage regulator.
a. Check the terminal ends for dirt and corrosion. If necessary, use the
special terminal cleaning brushes to remove the dirt and corrosion
from the terminals. Record observations in the following space.
W 123
b. Check the voltage regulator for physical damage. If necessary, replace
a damaged voltage regulator. Record observations in the following
space.

5. Using service information, locate a procedure for installing the voltage
regulator. Make sure the procedure is appropriate for the make and model
Using the procedure, install the voltage regulator.
6. Test the voltage regulator operation. Record observations in the following

space.
W 124
AS1-L1-UVII Name:
Lighting Systems and Components Date:

sheet.
1. Match the term to its function or description. All the terms will not be
used.
____A. Component that determines which 1. Concealed
filament receives current to provide the headlights
high- or low-beam light.
2. Dimmer switch
____B. A gas used in HID headlights.
3. DRL
____C. Device that allows more power to be
drawn from the battery instead of 4. Filament
through the headlight switch.
5. Halogen
____D. System that operates the headlights at
a reduced voltage when the vehicle is 6. Headlight
running. switch

____E. Central core of an incandescent bulb 7. Relay
that glows when receiving current.
8. Rheostat
____F. Device in headlight switch that controls
the brightness of the dashboard lights. 9. Xenon
____G. System that has doors that open and

close over headlights.
2. List the four types of headlights and provide a brief description of each.
A.
B.
W 125
C.
D.
3. What happens to the DRL system when the headlight switch is on?
4. What are two functions of the turn signal switch?
A.
B.
5. What are three vehicle areas that are illuminated by courtesy lighting
systems?
A.
B.
C.
W 126
JS1-L2-Uvii Name(s):
diagnose the cause of brighter than normal,

intermittent, dim, or no light operation Date:
Equipment:
Hand tools
Jumper wires Evaluation
Test light
Procedure:


3. Verify the concern by testing the light operation and noting the
malfunctions. Record the malfunction in the following space.
4. Using service information, locate a wiring schematic for the lighting

system. Make sure the schematic is appropriate for the make and model
of the vehicle. Have the instructor check the box to approve the wiring
schematic.
Based on the malfunction identified, follow the wiring diagram to

determine which components should be tested.
W 127
5. Conduct tests based on the type of malfunction.
a. Brighter than normal
• Test the circuit by removing the bright light and measuring

the voltage at the light socket. Compare the voltage reading to
specifications.
• Inspect the bulb for damage or defects. Locate the bulb

identification number and compare the number to specifications
to determine if the bulb is the correct one for the location.
• Use a DMM to measure the resistance of various circuit

components. Compare the readings to specifications.
b. Intermittent
• Check for loose connections, damaged conductors, or defective

circuit components.
• Create the condition by wiggling each of the connectors and

conductors.
• When the malfunction is present, use a test light, jumper wires,

and DMM to identify the cause.
c. Dim
• Check for loose or corroded connections.
• Use a DMM to measure circuit resistance.
d. No light
• Check if the bulb is bad and for a loose connection in the circuit.
• Use a DMM to check for power to the circuit.
Include further diagnosis and/or repairs. Record observations in the
following space.
W 128
7. Perform the necessary action to repair the concern. Record observations in
8. Test the lights to be sure they operate properly.
W 129
W 130
inspect and diagnose incorrect turn signal or hazard

light operation Date:
Equipment:

Procedure:


3. Verify the concern by testing the turn signal or hazard light operation and
noting the malfunction. Record the malfunction in the following space.
4. Using service information, locate a wiring diagram for the turn signal and
hazard lights. Make sure the diagram is appropriate for the make and
wiring diagram.
Based on the malfunction identified, follow the wiring diagram to

determine which components should be tested.
a. If the turn signal or hazard lights fail to light, test the fuses, battery,
switch, and the wiring.
W 131
NOTE: If the fuse has blown, it will be necessary to locate and correct
the cause.
b. If the turn signal or hazard lights come on but do not flash, test the
flasher assembly.
NOTE: The turn signal and hazard light systems use separate flasher
units. Be sure to locate the correct one for the system being tested.
c. If only some of the lights function, use a DMM to test the bulbs,
sockets, and wiring.
d. If the turn signal or hazard lights flash too fast or slowly, ensure that
the proper flasher is installed. If the flasher is correct and operating
properly, use a DMM to measure circuit voltage and resistance.
e. If the concern is intermittent operation, use a DMM to check circuit

connectors, wiring, and the ground circuit.
f. If the turn signals light up on the front of the vehicle but not the rear
or light up only on one side, use a DMM to test the turn signal switch,
wiring, and ground circuits.
Include further diagnosis and/or repairs.

8. Test the turn signal and hazard lights to be sure they all operate properly.
Average of above evaluations
W 132
inspect, replace, and aim headlights and bulbs

Date:
Equipment:
Hand tools
Headlight aimer
CAUTION: High-intensity discharge (HID) headlights operate with extremely

high voltage that can pose a lethal hazard to anyone touching the conductive
parts. Do not touch the conductive parts of the HID headlights when the
system is on. Always turn the HID headlights off and disconnect the negative
battery cable before working on or around the HID system.
CAUTION: Do not handle the glass surface of halogen bulbs. Oil from hands
can cause the glass to swell and burst in extreme heat or cause the bulb to fail
prematurely.
Procedure:


3. Visually inspect headlight operation, checking both the low and high
beams. Check the headlight assembly for water and damaged, missing, or
cracked components. Record observations in the following space.
W 133
4. Using service information, locate a procedure for removing and installing
the headlights. Make sure the procedure is appropriate for the make and
procedure. (For general procedures, refer to the following sections: sealed-
beam–I.B., composite–I.C., and HID–I.D.)

Using the procedure, remove and install the headlights.
5. Using service information, locate a procedure for aiming the headlights.

general procedure using an aiming screen, see section I.E.)

Using the procedure, aim the headlights.
W 134
service the LIGHTING SYSTEM COMPONENTS

Date:
Equipment:
Hand tools
Special tools, as needed
Procedure:


3. Inspect the vehicle for malfunctioning lighting. Check the operation of

bulbs and fuses. Record observations in the following space.
4. Using service information, locate a procedure for servicing the

malfunctioning lights. Make sure the procedure is appropriate for the
make and model of the vehicle. Have the instructor check the box to
approve the procedure. (For general procedures, refer to the following
sections: headlight switch–I.F., taillight and brake light bulbs–II.A.; brake
switch–II.B.; turn signal switch–II.C.; small lamps–II.D.; and relays, flashers,
and reverse light switches–II.E.)
Using the procedure, service the malfunctioning lighting.
W 135
5. Test the operation of the newly serviced lighting. Record observations in
W 136
JS1-L1-Uviii Name(s):
inspect, TEST, AND service INTERMITTENT, HIGH, LOW, OR NO

GAuGE READING Date:
Equipment:

Procedure:


VIN, certification labels, and calibration decals. Record the necessary
3. Perform a visual inspection of the gauges, wiring, and sending units related
to the instrument concern. Record observations in the following space.
4. Test for voltage in the circuit(s) that supplies current to the gauges
using a test light. Use the proper service information to locate the fuses.
recommended steps to reinstate the current flow.
W 137
5. Using service information, locate a procedure for testing the sending units.
vehicle. Have the instructor check the box to approve the procedure.
NOTE: If the problem occurs in all gauges, skip this step.
Using the procedure, test the sending units. Record observations in the
following space. If necessary, include the recommended steps to service
the sending units.
6. Inspect and test the instrument voltage regulator.
a. Using service information, locate a procedure for exposing the voltage

regulator. Make sure the procedure is appropriate for the make and
model of the vehicle. Have the instructor check the box to approve
the procedure.
Using the procedure, expose the voltage regulator.
b. Using service information, locate a procedure for testing the voltage

regulator. Make sure the procedure is appropriate for the make and
model of the vehicle. Have the instructor check the box to approve
the procedure.
W 138
Using the procedure, test the voltage regulator. Record observations
in the following space. If necessary, include the recommended steps
to service the voltage regulator.
7. Inspect and test the printed circuit board on the back of the dashboard.
a. Using service information, locate a procedure for exposing the printed

circuit board on the back of the dashboard. Make sure the procedure
Using the procedure, expose the printed circuit board on the back of
the dashboard.
b. Using service information, locate a procedure for testing the printed

circuit board. Make sure the procedure is appropriate for the make
and model of the vehicle. Have the instructor check the box to
approve the procedure.
Using the procedure, test the printed circuit board. Record

observations in the following space. If necessary, include the
recommended steps to service the printed circuit board.
W 139
W 140
JS2-L1-UviiI Name(s):
Test AND service the incorrect operation of a warning

LIGHt Date:
Equipment:

Procedure:


3. Test for voltage in the circuit(s) that supplies current to the warning lights
using a test light. Use the proper service information to locate the fuses. If
necessary, include the recommended steps to reinstate the current flow.
W 141
the sending units.
5. Test the printed circuit board on a vehicle equipped with warning lights.
a. Using service information, locate a procedure for exposing the printed

circuit board on the back of the dashboard. Make sure the procedure
Using the procedure, expose the printed circuit board on the back of
the dashboard.
b. Using service information, locate a procedure for inspecting

and testing the printed circuit board. Make sure the procedure
Using the procedure, inspect and test the printed circuit board.
recommended steps to service the printed circuit board.
W 142
JS3-L1-UviII Name(s):
test AND service the incorrect operation of an AUDIBLE

WARNING SYSTEM DEVICE Date:
Equipment:

Procedure:


3. Test for voltage in the circuit(s) that supplies current to the audible warning
system device using a test light. Use the proper service information to
locate the fuses. Record observations in the following space. If necessary,
include the recommended steps to reinstate current flow.
W 143
the sending units.
W 144
JS4-L1-Uviii Name(s):
inspect, test, and repair sensors, connectors, and wires

of digital or electronic instrument circuits Date:
Equipment:

Test light
Scan tool
Fused jumper wire
Procedure:

2. Research applicable service information such as vehicle service history, VIN,

certification labels, and calibration decals. Record the necessary information
3. Verify the concern and record the problem in the following space.
4. Use service information to determine component locations, specific

procedures, and safety precautions. Make sure the information is
appropriate for the make and model of the vehicle. Have the instructor
W 145
5. Perform a visual inspection of the system components. Record observations
a. To test sending units and sensors, disconnect the wiring at the unit
and observe the reading on the display or on the scan tool. Record the
results in the following space.
b. Test for reference voltage with a DMM. Record the results in the
following space.
NOTE: Service information may recommend using a jumper wire to

bypass or ground the sending unit or sensor.
c. Test wiring, connectors, and ground circuits, as necessary. Record

the results in the following space. If the tests do not reveal a problem,
proceed to step 10.
Record in the following space.
8. Perform the necessary action to repair the concern.
9. Test the digital/electronic instrument cluster to ensure it operates properly.
W 146
10. If all related components are tested and found to function properly and the
computer is sending the correct signals, remove the instrument cluster.
NOTE: A considerable amount of disassembly is required to replace the

cluster on most vehicles. Most manufacturers service the instrument cluster
as a unit.
a. Disconnect the negative battery cable.
b. Power down the supplemental restraint system (air bags).
c. Remove the trim panels and dash components that interfere with
cluster removal, and remove the cluster.
d. If an electronic cluster uses an odometer memory chip, remove the

chip from the defective cluster and install it in the replacement cluster.
NOTE: Some odometer memory chips may be reprogrammed. State

laws vary regarding the replacement and programming of odometers.
Be sure that repairs follow legal requirements.
e. Install the replacement cluster and verify that it operates properly.
W 147
W 148
JS1-L1-Uix Name(s):
Test and service incorrect horn operation

Date:
Equipment:
Hand tools
Digital Multimeter (DMM)
Test light
Jumper wire
Procedure:


4. Using service information, locate the correct wiring diagrams and test and
safety procedures for the horn. Make sure the information is appropriate
for the make and model of the vehicle. Have the instructor check the box to
approve the information.
CAUTION: Identify and follow all safety procedures related to the

supplemental restraint system (SRS) while testing and servicing horn
components.
W 149
5. Diagnose a horn that does not sound.
a. Check the fuses and other connections. Test for voltage in the
circuit(s) that supplies current to the horn using a test light. Record
b. Test the horn relay by connecting a jumper wire from the switch
terminal to a good ground. Does the horn sound? Record observations
c. Test a horn that is power-side switched by connecting a jumper wire

to the positive battery terminal and to the positive horn terminal.
Does the horn sound? Record observations in the following space.

d. Test a horn that is ground-side switched.
• Confirm that the horn has a reliable voltage source.
• Connect a jumper wire from the negative horn terminal to a

good ground. Does the horn sound? Record observations in the
following space.

e. Test the horn button switch contacts.
• Disconnect and remove the horn relay.
• Use a DMM to measure the switch circuit resistance. Does the

switch circuit have low resistance when the horn button is
depressed? Record observations in the following space.
W 150
6. Diagnose a horn that sounds all the time.
a. Test the horn button switch contacts.
• Disconnect and remove the horn relay.
• Use a DMM to measure the switch circuit resistance. Does the

switch circuit test open when the horn button is not depressed?
b. Remove and measure the relay’s resistance. Compare the reading to

specifications and record observations in the following space.
c. With the relay removed, test for voltage at the horn. If voltage is
present at the horn with the relay removed, test for an electrical short
in the wiring between the relay and horn. Record observations in the
following space.
7. Diagnose incorrect horn volume or tone.
a. Use a DMM to back probe and measure voltage with the horn button
depressed. Record observations in the following space.
b. Use a DMM to measure horn ground-side voltage drop. Record

c. If the horn tone is adjustable, perform the adjustment procedure.
W 151
8. Based on test results, determine the cause of the concern and determine the
necessary action to correct the problem. Record in the following space.
9. Repair the horn system, as needed.
a. Replace a defective relay with the correct replacement relay.
b. Clean dirty horn switch contacts or replace defective contacts.
CAUTION: If the vehicle has an SRS, the air bags must be disabled
before disassembling the steering wheel to gain access to the horn
switch.

c. Replace a defective horn.

d. Use standard repair procedures to repair the horn system’s electrical
wiring or connectors.
e. When all repairs are complete, test the horn to be sure it operates
properly.
W 152
JS2-L1-UIX Name(s):
test and service incorrect WINDSHIELD WIPER operation

Date:
Equipment:
Hand tools
Procedure:

4. Using service information, locate the correct wiring diagrams and test
procedures for the windshield wipers. Make sure the information is
check the box to approve the information.
5. Check the fuses, circuit breakers, or fusible links. Test for voltage in the
circuit(s) that supplies current to the wipers using a test light. Record

W 153
6. Test the operation of the wiper motor. Complete the following chart and
answer the following questions.

Do the wipers operate in: OK Not OK
Slow mode
Medium mode
High mode
Intermittent mode
Mist mode
a. Do the wiper blades retract into the park position when the motor is
shut off?
b. Is the linkage tight yet able to move freely? If necessary, service the
linkage.
c. Inspect the wiper blades and arms for damage. Record observations
in the following space. If necessary, recommend steps to service the
wiper blades and arms.
7. Test the wiper motor using a DMM on the ohmmeter setting.
a. Disconnect the wiper motor connector.
b. Connect the DMM in parallel to the wiper motor.
c. Observe the reading and record it in the following space.
W 154
d. Calculate the resistance from the fuse size using Ohm's law. Record
8. Test the windshield wiper switch by using a DMM to measure voltage

flow through the switch or by removing the switch and using the DMM to
measure switch resistance. Record observations in the following space.
9. Based on the tests, determine the cause of the concern and determine the
11. Test wiper operation to verify the repair.
W 155
W 156
JS3-L1-UIx Name(s):
test and service incorrect WINDSHIELD WASHER

operation Date:
Equipment:
Hand tools
Test light
Jumper wire
Procedure:

4. Using service information, locate the correct wiring diagrams and test
procedures for the windshield washer. Make sure the information is
check the box to approve the information.
W 157
5. Check the fuses, circuit breakers, or fusible links. Test for voltage in the
circuit(s) that supplies current to the windshield washer circuits using a test
light. Record observations in the following space.
6. Check the solvent level of the windshield washer. Record observations in

the following space. If necessary, add solvent.
7. Inspect the windshield washer hose system. Complete the following chart
and record observations in the following space.

OK Not OK
Hoses
Spray Nozzles
8. Test the windshield washer switch by using a DMM to measure voltage

flow through the switch or by removing the switch and using the DMM to
measure switch resistance. Record observations in the following space.
9. Test the washer circuit.
NOTE: If the washer pump is an integrated component of the wiper motor,

verify correct wiper motor operation before diagnosing washer problems.
a. Disconnect the wiring connector.
b. Connect a jumper wire from the positive battery terminal to the

washer terminal.
W 158
c. Ground the other terminal. Record observations in the following
space.
12. Test the windshield washer to be sure it operates properly.
W 159
W 160
AS1-L1-UX Name:
accessory Components and operation Date:

sheet.
1. Match the accessory component to its function or description. All the

components will not be used.
____ A. Sends battery voltage to the power 1. AM/FM antenna

door lock motors.
2. Body electronic
____ B. In the event of unauthorized vehicle system
entry, locks down the vehicle and
may sound the alarm. 3. Cruise control
motor
____ C. Stores the power that activates the air
bag. 4. Diagnostic
module
____ D. Controls function of six seat
positions. 5. Electric heater
____ E. Minicomputers or sensors located 6. Impact sensors

throughout the vehicle.
7. Inflator module
____ F. Winds cable in and out to control
throttle position. 8. Power door lock
relay
____ G. Defrosts windows and mirrors.
9. Rack-and-pinion
____ H. Signal the air bag diagnostic module gear set
in the event of a collision.
10. Seat heating
____ I. Composed of an electromagnet elements
connected to a diaphragm.
11. Speaker
____ J. Type of power window motor.
12. Theft module
____K. Located in back and lower seat
cushions. 13. Trimotor
W 161
2. Explain how a window deicer operates.
3. Which power accessory system allows the user to lock or unlock the
vehicle’s doors remotely by a push of a button?
4. Explain what happens after a collision activates the impact sensors in the air
bag system.
5. What are the three external circuits used by the radio?
A.
B.
C.
W 162
JS1-L2-UX Name(s):
diagnose and repair motor-driven accessory circuits

Date:
Equipment:

Fused jumper wire
Procedure:
1. Wear PPE while performing the procedure on this job sheet.



W 163
6. Test the fuse/circuit breaker. Record the results in the following space.
NOTE: Testing methods vary based on the type of motor operation. The
following tests are common to most motor-driven accessories.
7. Use a DMM to test accessory motors. Record the results in the following
space.
a. Disconnect the electrical connector from the motor and use the
DMM to measure the motor resistance. Compare the reading to
specifications.
b. Test the voltage at the electrical connector.

c. Test the motor ground circuit.
8. Use the DMM to test the switch. Record the results in the following space.
a. Remove the switch and disconnect the electrical connector.
b. Use the DMM to measure the switch resistance. Place the switch in
various positions and record the resistance readings. Compare the
readings to specifications.
c. Test the electrical connector for voltage.
d. Reconnect the switch electrical connector. With power turned on to the

circuit, back probe the switch in various positions. Record the voltage
readings and compare to specifications.
W 164
9. Test motor relay operation. Record the results in the following space.
a. Locate the relay and disconnect it.
b. Use the DMM to test voltage to the relay.
c. Use a fused jumper wire to bypass the relay and record the results.
d. Use the DMM to measure relay resistance and compare the results to
specifications.
10. Test the motor circuit wiring and connectors. Record the results in the
following space.
a. Use the DMM to perform a power circuit voltage drop test.
b. Use the DMM to perform a ground circuit voltage drop test.
c. Test the circuits for shorts and opens. Disconnect the electrical
connector and measure circuit resistance. Record the reading and
compare the reading to specifications.
12. Repair the motor-driven accessory circuits, as needed.
NOTE: More detailed procedures for repair of motor-driven accessory

circuits are found in their respective job sheets in this lesson. The following
steps are the common steps used in the diagnosis and repair of electrical
motor-driven accessories.
W 165
a. Replace a defective motor, circuit switch, or relay. These components
are normally not repairable. Some switches are grouped together, and
it is necessary to replace two or more switches even though only one is
defective.
b. Use standard repair procedures to repair motor circuit wiring and

connectors.
c. When the repairs are complete, carefully test the vehicle to ensure that
the problem has been corrected.
W 166
JS2-L2-UX Name(s):
diagnose and repair heated glass and mirror operation

Date:
Equipment:

Fused jumper wire
Scan tool
Procedure:



W 167
7. Test voltage at the heating grid. Record the results in the following space.

8. Test the heating grid ground circuit. Record the results in the following
space.

9. Test the switch. Record the results in the following space.
10. Test the relay. Record the results in the following space.
11. Test the heater controller. Record the results in the following space.
NOTE: On most current vehicles, the control of the glass heating system
is part of the electronic body control module. This type of control system
may be tested using a scan tool. Test and service of individual components
remain similar.
W 168
12. Test the heating grid. Record the results in the following space.
13. Test the circuits’ wiring and connectors. Record the results in the following
space.

necessary action to correct the problem. Record in the following space
15. Repair the heated glass and mirror components, as needed.
a. Replace switches, relays, and timers/controllers found to be defective

because they are not typically repairable.
b. Use standard procedures to repair the circuits’ wiring and connectors.
c. A damaged heating grid in the glass can sometimes be repaired using

the following steps.
• Use masking tape to surround the damaged portion of the grid.
• Apply a special conductive material to the grid and allow it to

dry.
• After repairs are complete, use a DMM to check the grid

resistance.
d. Check service information for repairing a defective heating grid in

the mirror. Most manufacturers recommend replacing the mirror
assembly. Some designs are repairable using the following steps.
• Remove the mirror glass, disconnect the heating grid connector,

and remove the defective grid.
W 169
• Install the new grid by reconnecting the electrical circuit and
mounting the grid. Glue the mirror glass to the heater grid.
e. When the repairs are complete, carefully test the vehicle to ensure that
W 170
JS3-L2-UX Name(s):
diagnose and repair heated seat operation

Date:
Equipment:

CAN-capable scan tool
Procedure:


5. Conduct preliminary tests.
a. Perform a visual inspection of the system components. Record

W 171
b. Connect a CAN-capable scan tool and check for stored diagnostic
trouble codes (DTCs). Record any codes in the following space.

c. Check the vehicle battery’s open circuit voltage and charging system
performance. Record results in the following space.
d. Test the fuse/circuit breaker, using a DMM (provides more

information) or test light. Record results in the following space.
NOTE: If DTCs are present, the service information will identify

components that need to be tested. If no DTCs are present, but the
system fails to operate, it will be necessary to test the electrical circuits
and components based on the symptoms.
6. Test the seat heating element. Record results in the following space.
a. Measure heating element resistance and compare to specifications.
b. Check the heating element for short to ground.
c. Test the voltage at the heating grid.
d. Test the heating grid ground circuit.

7. Test the heated seat switch. Remove the heating switch and perform a
resistance test. Compare the reading to specifications. Record results in the
following space.

W 172
8. Test the heated seat control module. Record results in the following space.
a. Use a DMM to measure voltage by back probing the appropriate pin.
b. Use a DMM to test the module ground circuit.
c. Measure the resistance of the seat module internal circuits.
9. Test the cabin control module. Record results in the following space.
a. Use a DMM to measure voltage by back probing the appropriate pin.
b. Use a DMM to test the module ground circuit.
c. Measure the resistance of the cabin control module internal circuits.
11. Repair the seat heater system, as needed.
a. Replace any defective switches and controllers. These components are

normally not repairable.
b. Use standard procedures to repair circuit wiring and connectors.
c. To replace the seat heating elements, remove the seat cushion and
disconnect and remove the seat heating elements. Install new seat
heating elements and reinstall the seat cushions.
W 173
NOTE: The procedures for removing and installing seat cushions
differ among manufacturers and vehicle models. Review service
information for the vehicle.
d. After repair procedures, connect a scan tool and test the system.

W 174
JS4-L2-UX Name(s):
diagnose and repair electric lock operation

Date:
Equipment:

Procedure:



W 175
7. Test the lock switches. Record the results in the following space.

8. Remove the door panel. Refer to JS10-L2-UX.
9. Check the lock linkage. Record observations in the following space.

10. Test the lock solenoid/motor. Record the results in the following space.
11. Test the lock circuit wiring and connectors. Record the results in the
following space.
W 176
13. Repair the electric door locks, as needed.
a. Remove and replace the lock switches.
• Remove the defective switch and disconnect the wiring

connector.
• Connect the wiring connector to the new switch and install the
switch.
b. Remove and replace the lock solenoid/motor.
• Remove the door panel. Refer to JS10-L2-UX.
• Disconnect the solenoid/motor wiring connector and remove

the solenoid/motor mounting bolts or rivets.
• Disconnect the lock linkage from the solenoid/motor and

remove the lock solenoid/motor from the door.
NOTE: Some electric lock solenoids/motors are built into the

door latch assembly and must be replaced as a complete unit.
• Position the replacement solenoid/motor in place and connect

the lock linkage. Reinstall mounting bolts or rivets.
• Connect the solenoid/motor wiring connector.
• Test door lock operation. If lock operation is satisfactory, install

the door panel.
c. Repair or replace the door lock linkage.
• Remove the door panel. Refer to JS10-L2-UX.
• Remove the lock linkage and determine if it can be repaired or

must be replaced.
• Install the new or repaired linkage.
• Test door lock operation. If lock operation is satisfactory, install

the door panel.
W 177
d. Repair the electric door lock circuit wiring and connectors.
• Repair lock circuit wiring, connector, and terminals using

standard wire repair procedures.
• Test the lock operation.
W 178
JS5-L2-UX Name(s):
diagnose and repair vacuum-operated cruise control

operation Date:
Equipment:

Test light
Vacuum gauge
Vacuum pump
Procedure:



W 179
7. Check the operation of the speedometer. Record observations in the

following space.
8. Test the cruise control electrical circuits. Record the results in the following
space.

a. Test the operation of the cruise control switch, brake light switch, and
clutch pedal switch (vehicles with manual transmissions) using a test
light or DMM.
b. Test the cruise control wiring and connectors. Use a DMM to measure
voltage and resistance in the cruise control circuits. Compare the
9. Check the cruise control vacuum circuits. Record the results in the
following space.

a. If a low vacuum reading is recorded at the cruise control supply line,

connect a vacuum gauge to the vacuum supply hose (vacuum hose
from the engine).
• Start the engine and record the reading.
• Shut off the engine, remove the vacuum gauge, and reconnect
the vacuum hose.
b. To test the vacuum reservoir, disconnect the vacuum hose from

the vacuum reservoir to the cruise controller or vacuum servo and
connect the vacuum gauge.
• Start the engine and record the reading.
W 180
• Shut off the engine and monitor the vacuum reading for 60–90
seconds. The vacuum reading should not decline rapidly.
• Remove the gauge and reconnect the vacuum hose.
c. To test the vacuum servo, disconnect the vacuum line to the servo and
connect a vacuum pump to the servo. Use the vacuum pump to pull a
vacuum on the servo. The servo should move the throttle linkage.
10. Test the cruise controller (actuator) for electrical and vacuum operation.
Record the results in the following space.
a. Use a DMM to measure resistance in the controller electrical circuits.

Compare the reading to specifications.
b. With all of the electrical connectors in place, use the DMM to back
probe the electrical circuits connected to the controller. Compare the
reading to specifications.
c. Check for speedometer information to the controller.
d. Test the vacuum source to the controller. Use a vacuum gauge to

measure the vacuum source to the controller. Record the reading.
e. Test the controller by applying the correct vacuum to the servo.
• If the controller is receiving adequate vacuum, then connect a

vacuum gauge with a long hose with a tee in the line between
the controller and the servo. The vacuum gauge should be
placed in a position that can be observed from inside the vehicle
with the hood closed.
• Start the vehicle and test drive it. Engage the cruise control and
observe the vacuum reading. There should be an increase in
vacuum measured when the cruise is engaged and vehicle speed
decreases. Record the readings.
W 181
12. Repair the vacuum-operated cruise control components, as needed.
a. Replace any defective electrical switches or controllers. These

components are normally not repairable.
NOTE: Some controllers may have adjustment screws that can be used
to modify operation.
c. Use standard procedures to replace the vacuum hoses, connectors,

and fittings.
d. Correct vacuum problems that are the result of internal engine

problems by repairing the engine.
e. Correct speedometer problems by repairing or replacing the

speedometer components.
f. When the repairs are complete, carefully test the vehicle to ensure that
W 182
JS6-L2-UX Name(s):
diagnose and repair electric/electronic cruise control

operation Date:
Equipment:

Test light
Scan tool
Procedure:



W 183
7. Check the operation of the speedometer. Record observations in the

following space.
8. In systems controlled by an electronic control module (body control module

or powertrain control module (PCM)), connect a scan tool to check for
DTCs related to cruise control operation. If a DTC is present, use service
information to identify steps to diagnose and repair the problem. Record the
9. To test the electronic control module, disconnect the module’s electrical

connector and use a DMM to measure resistance between the unit’s pins.
Compare the reading to specifications. Record the results in the following
space.
10. Test the cruise control electrical circuits. Record the results in the following
space.

a. Test the operation of the cruise control switch, brake light switch, and
clutch pedal switch (vehicles with manual transmissions) using a test
light or DMM.
b. Test the cruise control wiring and connectors. Use a DMM to measure
voltage and resistance in the cruise control circuits. Compare the
W 184
12. Repair the electrical/electronic cruise control components, as needed.
a. Replace any defective electrical switches or control modules. These

components are normally not repairable.
c. Replace speed sensors or repair electrical circuits to correct

speedometer problems.
d. When the repairs are complete, carefully test the vehicle to ensure that
W 185
W 186
JS7-L2-UX Name(s):
DISArm and enable the air bag system for vehicle

service Date:
Equipment:
Hand tools
Specialty tools
Procedure:

3. Confirm that the vehicle is equipped with an air bag system by researching
the VIN and vehicle manufacturer's schematics and looking for markings
on the steering wheel cover. Record observations in the following space.
4. Using service information, locate a schematic and procedure for disarming

the air bag system. Make sure the schematic and procedure are appropriate
for the make and model of the vehicle. Have the instructor check the box
to approve the schematic and procedure. (For a general procedure, see
section VII.C.)
Using the procedure, disarm the air bag system.
W 187
CAUTION: After removing the negative battery cable, tape it to ensure
that it does not contact the battery.
CAUTION: The diagnostic module keeps the air bag activated for some
time after the negative battery cable has been disconnected. Wait for the
diagnostic module to deplete the reserve power before working on or
around the SRS. Depletion time can vary from a few seconds to over 30
minutes.
5. Using service information, locate a procedure for enabling the air bag
system. Make sure the procedure is appropriate for the make and model of
the vehicle. Have the instructor check the box to approve the procedure.
Using the procedure, enable the air bag system.

W 188
JS8-L2-UX Name(s):
diagnose supplemental restraint system (srs)

concerns Date:
Equipment:
Bidirectional scan tool

Procedure:

3. Ensure the SRS is disarmed and the diagnostic module reserve power is
depleted before inspecting the system.
4. List the major components being inspected. Indicate if problems are

detected. Complete the following chart. Use the manufacturer-specific
terminology.

Component Name OK Not OK (List problems)
W 189
5. Record in the following space any other problems found during the
visual inspection.
6. Using service information or other information source, locate a procedure

for accessing and reading the fault codes. Make sure the procedure is
Using the procedure, access and read the fault codes. Complete the
following chart.

Code Meaning of Code
Determine what service procedures are necessary based on the fault codes
and record them in the following space.
W 190
7. Using service information, locate a procedure for accessing and reading
the memory codes. Make sure the procedure is appropriate for the make
and model of the vehicle. Have the instructor check the box to approve the
procedure.
Using the procedure, access and read the memory codes. Complete the
following chart.

Code Meaning of Code

8. Determine what service procedures are necessary based on the memory
codes and record them in the following space.
W 191
W 192
JS9-L2-UX Name(s):
diagnose and repair radio and sound system operation

Date:
Equipment:

9-volt battery
Nonmetallic screwdriver
Procedure:



W 193
6. Test for the failure to turn on (power up). Record results in the following
space.
a. Test the fuse/circuit breaker, using a DMM (provides more

information) or test light.
b. Test the sound system’s ground circuits at all locations.
NOTE: The radio and sound system may receive power through
more than one fuse. It is important to review service information and
identify all of the power and ground circuits.
7. To test for poor reception, test the antenna and antenna lead-in cable.
a. Unplug the antenna from the back of the radio.
b. Use the ohmmeter setting on a DMM to test the items in the following
chart. Complete one of the following charts.
NOTE: Test only one design.
Design: Fender Mount

Circuits Specification OK Not OK
Masting to center casing Low
Center terminal to casing High
Casing to mast High
Mast to ground High
Center terminal to ground High
Casing to ground Low
Design: Built into Windshield

Circuits Specification OK Not OK
Casing to center terminal High
Casing to ground High
Center terminal to ground High
W 194
c. Inspect the antenna cable connection contact points to ensure the
surfaces are making contact. Record observations in the following
space.
d. Check the antenna trim setting, if provided. Record results in the

following space.
a. Locate the adjustment screw, turn on the radio, and select a

station.
b. Use a nonmetallic screwdriver to turn the adjustment screw until

the best reception is achieved.
8. Test for noise or static in the sound system. Record results in the following
space.
a. Listen carefully to the radio with the engine running and with it off to
see if the noise or static changes.
b. Inspect the secondary components of the ignition system.
c. Inspect the charging system.
9. Test for poor sound quality. Record results in the following space.
a. Carefully inspect each of the speakers, looking for damage or foreign

material on the speakers.
b. Disconnect the lead to each speaker and connect a 9-volt battery to the
speaker’s terminals. The speaker should make a crackling sound.
c. Use a DMM to test the ground circuit of each speaker.
W 195
10. Based on the tests, determine the cause of the radio and sound system
concerns and determine the necessary action to correct the problem. Record
11. Repair the radio and sound system, as needed.
a. Repair defective electrical power circuits.
b. Repair defective ground circuits.
c. Replace the radio deck, if all of the power and ground circuits are
good.
d. Remove and replace damaged or defective speakers. Speakers are not

repairable.
W 196
JS10-L2-UX Name(s):
remove and reinstall a door panel

Date:
Equipment:

Clip remover
Hand tools Evaluation
Covers for interior components
Door handle pliers
Door handle remover
Putty knife
CAUTION: Before beginning to remove the door panel, check if the vehicle
is equipped with a side air bag that is located inside the door. Accidental
deployment of the air bag may cause severe personal injury and vehicle
damage. Follow service information for disarming the air bag system and
depleting the diagnostic module’s reserve power before removing the door
panel.
Procedure:


4. Remove any snap-on parts such as the power window switch and door
handle.
W 197
5. Remove other trim components necessary for trim panel removal.
6. After removing any screws around the perimeter of the panel, use the clip
remover to detach the trim panel.
7. Remove the water deflector sheet carefully with a putty knife.
8. After performing the required repairs, install the water deflector sheet
carefully using fresh adhesive or body caulking as required.
9. Replace any damaged clips and snap the trim.
10. Install the trim components removed in step 5 above.
11. Install the handles and covers, which were removed in step 4 above, in
reverse order of removal.

W 198
JS11-L2-UX Name(s):
diagnose and repair body electronic circuits and

module communications using a scan tool Date:
Equipment:

Test light
CAN-capable scan tool
Procedure:



W 199
7. Test the body electronic circuits using a scan tool. Record the results in the
following space.
a. Connect a scan tool and check for related DTCs.
b. Use the scan tool to test body electronic circuits.
c. Record the DTCs and the results of the body circuit tests. Determine
the necessary actions.
8. Check for module communication (CAN/BUS) errors using a scan tool.

Record the results in the following space.
a. Connect a CAN-capable scan tool and check for stored CAN-related

DTCs (U codes).
b. Use the scan tool to observe communication of the electronic control

modules and identify the modules that fail to communicate or respond
correctly.
c. Using service information, interpret the scan tool data. Determine the
necessary actions to correct module communication errors.
W 200
10. Repair the body electronic and communication circuits, as needed.
a. Use common repair procedures to repair the electronic and

communication circuits, terminals, and connectors. After repairing
the circuits, measure the circuit resistance and compare it to
specifications.
NOTE: Some electronic and communication circuits are not

repairable and must be replaced.
b. Replace a defective electronic control module. This component is not

repairable. After replacing the control module, use a scan tool to test
system operation.
c. After the repairs are complete, carefully test the vehicle to ensure the
problem has been corrected.
W 201
W 202
JS12-L2-UX Name(s):
diagnose and repair antitheft system operation

Date:
Equipment:

Fused jumper wire
Scan tool
Procedure:


5. If the antitheft system does not operate, perform the following steps.
a. Perform a visual inspection of the system components. Record

W 203
b. Test the fuse/circuit breaker. Record the results in the following space.
c. Before performing diagnostic checks, perform the following tests.
• Test the operation of the components below. Complete the chart.
OK Not OK
Parking and headlights
Dome and courtesy lights
Horn
Wipers
Clock
Electric door locks
• Check all circuits leading to the controller; make sure all switches
are in their normal or off positions. Record observations below.
d. Diagnose the antitheft system with a scan tool. Record the results in
• Connect a scan tool and check for system-related DTCs.
• Record all stored DTCs.
• Use service information to locate procedures to repair the DTCs

and identified component problems.
6. To diagnose false or intermittent operation, perform the following tests.
a. Test the resistor key system. (For transponder type systems, see step
b.) Record the results in the following space.
• Inspect the key for a damaged resistor.
W 204
• Inspect the lock cylinder sensing contacts.
• Check the wiring from the lock cylinder to the bottom of the
steering column.
b. Test the transponder key system. Record the results in the following
space.
• If the system fails to recognize the key, try a second key.
• Check all system electrical connections.
• Connect a scan tool and check for module communications.
• Check for transponder interference.
c. Test the theft module and PCM. Record the results in the following
space.
• If the theft module or PCM fails to communicate or fails to

respond correctly to communications, remove the electrical
connectors and use a DMM to measure resistance. Compare the
• Replace modules that fail the resistance test or fail to respond to

communication.
d. Test the theft module relay. Record the results in the following space.
• Use a DMM to test for voltage and ground at the relay. Using
service information, determine the power, ground, output, and
control circuits.
•. Use a DMM to perform a resistance test on the relay.
W 205
• Use a fused jumper wire to bypass the relay.
NOTE: Some antitheft systems use multiple relays to turn on and

off various circuits. Relays are used to flash lights and lock the
hood, trunk, and gas fill doors.
e. Test the antitheft electrical and communication circuits. Record the

• Use service information to locate a wiring diagram and identify

the circuits to be tested.
• Use a DMM to perform a voltage drop test or resistance test on

the circuits. Record the reading and compare it to specifications
to identify possible problems.
• Use a scan tool to test system communication circuits.
• Use a DMM to measure resistance in the communication circuits

that connect the modules. Record the readings and compare
them to specifications to identify possible problems.
8. Repair the antitheft components, as needed.
a. Replace a defective resistor key with a new key with the same code.
These keys are normally not repairable.
W 206
b. Replace defective resistor lock cylinders because they are normally not
repairable. If the lock cylinder is located in the steering column, it will
be necessary to disable the air bag system and remove the steering
wheel and steering locking components.
c. Reprogram transponder keys or replace them with new keys that have
been programmed for the vehicle.
d. Replace a defective transponder receiver. In some antitheft systems

this component is separate and in others it is combined with the theft
module. Use service information to determine where the receiver is
located and how to access it.
e. Replace a defective theft module and program it as a complete unit.

Use service information because of the wide variations between
manufacturers and models.
f. Use standard procedures for repairing antitheft system electrical and

communications circuits. After repair procedures, connect a scan tool
and test the system.
g. After repairs are complete, carefully test the vehicle to ensure that the
problem has been corrected.
W 207
W 208

Student Workbook - Module 2 - Electrical Electronic Systems

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Student Workbook - Module 2 - Electrical Electronic Systems

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70-1802-W

Module 2: Electrical/Electronic Systems

Produced by the Instructional Materials Laboratory

Catalog no. 70-1802-W

MODULE 2: ELECTRICAL/ELECTRONIC SYSTEMS

Basic electrical theory Date:

Directions ­— Answer the following questions by writing all responses on this

1. A. What are electrons?

B. What are neutrons?

C. What are protons?

2. List four of the six forces that free electrons.

4. Determine if each of the following is a conductor, insulator, or

5. What must occur before current can flow through a circuit?

electrical measurement and ohm’s law Date:

Directions ­— Answer the following questions by writing all responses on this

1. Match the terms with the appropriate definition by writing the

A. Volt 1. Unit of measurement for electron

2. What is Ohm’s law?

3. What are the two rules of electricity?

B. How are all positive and negative component connections hooked in a

C. How are components arranged in a series-parallel circuit?

5. A. What type of circuit is the starter circuit?

B. What type of circuit is the headlight circuit?

Components of an electrical circuit Date:

Directions ­— Answer the following questions by writing all responses on this

1. What are the five factors that influence resistance of conductors?

2. What are the three types of circuit protection devices?

3. What does a capacitor use to absorb or store an electrical charge?

5. What are the three parts of a bipolar transistor?

Basic Testing Information Date:

Directions ­— Answer the following questions by writing all responses on this

1. A. What should a technician wear when working on or around a vehicle

B. What safety precautions should be taken after service or repair of the

2. A. What is difficult to perform when using only pictorial wiring

B. When should the wiring schematic be used?

3. Describe the function of the following pieces of test equipment.

4. A. What is the unit of measurement for the voltmeter?

B. What is the unit of measurement for the ammeter?

C. What is the unit of measurement for the ohmmeter?

5. When testing circuits, what circuit components should jumper wires be

complete a work order with concern, cause, and

To receive credit, all sections of the work order must be complete.

Credit received for completing work order

Outside Labor Procedures and Costs

Total Labor Costs

Identify and interpret Electrical/Electronic System

Personal protective equipment (PPE)

2. Ask the customer to describe the electrical/electronic system concern.

a. What electrical/electronic system functions are involved?

b. When did the concern first occur?

c. Is the concern continuous or intermittent?

e. Is the malfunction indicator lamp on or flashing?

f. Has the concern affected vehicle performance?

g. What is the recent service history of the vehicle?

h. Is the vehicle making any unusual noises?

i. Are any unusual vibrations occurring?

Average of the above evaluations

Identify hybrid vehicle high voltage circuits and

Personal protective equipment (PPE)

1. Wear PPE while performing the procedures on this job sheet.

2. Research applicable vehicle service information, such as vehicle service

3. Using service information, determine the locations of the high-voltage

4. Using service information, determine if special care is needed when

Using the procedure, deactivate the high-voltage system.

Directions — Answer the following questions by writing all responses on this

Directions — Answer the following questions by writing all responses on this

Directions — Answer the following questions by writing all responses on this

Directions — Answer the following questions by writing all responses on this