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e lec t r icasy ste m s

e le c tro nic sy ste mdiagnosi

stud e nt guid

C O URSE C O DE: 34 S19O RDER N UM BER: FC S- 13 45 0- R

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IMPORTANT SAFETY NOTICE

Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles, aswell as the personal safety of the individual doing the work. This manual provides general directions for accomplishing serviceand repair work with tested, effective techniques. Following them will help assure reliability.

There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of theindividual doing the work. This manual cannot possibly anticipate all such variations and provide advice or cautions as to each.Accordingly, anyone who departs from instructions provided in this manual must first establish that he compromises neither hispersonal safety nor the vehicle integrity by his choice of methods, tools or parts.

As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each one is there for aspecific purpose. NOTES give you added information that will help you to complete a particular procedure. CAUTIONS are givento prevent you from making an error that could damage the vehicle. WARNINGS remind you to be especially careful in thoseareas where carelessness can cause personal injury. The following list contains some general WARNINGS that you should followwhen you work on a vehicle.

The recommendations and suggestions contained in this manual are made to assist the dealer in improving his dealership parts and/orservice department operations. These recommendations and suggestions do not supersede or override the provisions of the Warrantyand Policy Manual, and in any cases where there may be a conflict, the provisions of the Warranty and Policy Manual shall govern.

The descriptions, testing procedures, and specifications in this handbook were in effect at the time the handbook was approvedfor printing. Ford Motor Company reserves the right to discontinue models at any time, or change specifications, design, ortesting procedures without notice and without incurring obligation. Any reference to brand names in this manual is intendedmerely as an example of the types of tools, lubricants, materials, etc. recommended for use. Equivalents, if available, may beused. The right is reserved to make changes at any time without notice.

WARNING: MANY BRAKE LININGS CONTAIN ASBESTOS FIBERS. WHEN WORKING ON BRAKE COMPONENTS, AVOIDBREATHING THE DUST. BREATHING THE ASBESTOS DUST CAN CAUSE ASBESTOSIS AND CANCER.

Breathing asbestos dust is harmful to your health.

Dust and dirt present on car wheel brake and clutch assemblies may contain asbestos fibers that are hazardous to your health whenmade airborne by cleaning with compressed air or by dry brushing.

Wheel brake assemblies and clutch facings should be cleaned using a vacuum cleaner recommended for use with asbestos fibers.Dust and dirt should be disposed of in a manner that prevents dust exposure, such as sealed bags. The bag must be labeled per OSHAinstructions and the trash hauler notified as to the contents of the bag.

If a vacuum bag suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, techniciansshould wear government approved toxic dust purifying respirators.

OSHA requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only techniciansconcerned with performing brake or clutch service should be present in the area.

Copyright 2002 Ford Motor Company Produced and Coordinated byTechnical Support Operations

Ford Customer Service Division

October, 2002

Always wear safety glasses for eye protection. Use safety stands whenever a procedure requires you to

be under the vehicle.

Be sure that the ignition switch is always in the OFFposition, unless otherwise required by the procedure.

Set the parking brake when working on the vehicle. If youhave an automatic transmission, set it in PARK unlessinstructed otherwise for a specific service operation. If youhave a manual transmission it should be in REVERSE(engine OFF) or NEUTRAL (engine ON) unless instructedotherwise for a specific service operation.

Operate the engine only in a well-ventilated area to avoidthe danger of carbon monoxide.

Keep yourself and your clothing away from moving partswhen the engine is running, especially the fan and belts.

To prevent serious burns, avoid contact with hot metalparts such as the radiator, exhaust manifold, tail pipe,catalytic converter and muffler.

Do not smoke while working on the vehicle. To avoid injury, always remove rings, watches, loose

hanging jewelry, and loose clothing before beginning towork on a vehicle. Tie long hair securely behind your

head. Keep hands and other objects clear of the radiator fan

blades. Electric cooling fans can start to operate at anytime by an increase in underhood temperatures, eventhough the ignition is in the OFF position. Therefore,care should be taken to ensure that the electric coolingfan is completely disconnected when working under thehood.

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CUSTOMER EXPECTATIONS

Expectation 3

Fix It Right The First Time, on Time.

Both service advisors and technicians areimportant players when it comes to Expectation#3.

Why

Customers tell us Fixing It Right The First Time, on Time is one of the reasons theywould decide to return to a dealer to buy a vehicle and get their vehicles serviced.

Technician Training

It is our goal to help the technician acquire all of the skills and knowledge necessary toFix It Right The First Time, on Time. We refer to this as competency.

Technicians Role

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

STST New Model

Self Study Self Study

FordStar Broadcasts FordStar Broadcasts

Ford Multimedia Training (FMT) Instructor Led

Instructor Led

The Benefits

The successful implementation of expectations means:

Satisfied customers Repeat vehicle sales

Repeat service sales Recognition that Ford and Lincoln/Mercury technicians are the Best in the

Business

Customer Expectations: Service

1. Make it convenient to have my vehicleserviced at your dealership.

2. The Service Advisor shoulddemonstrate a genuine concern for myservice needs.

3. Fix it right the first time.

4. Complete servicing my vehicle in atimely and professional manner.

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

6. Call me within a reasonable amount oftime after my service visit to ensure thatI'm completely satisfied.

7. Be responsive to questions or concernsI bring to your attention.

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TABLE OF CONTENTS

Electronic System Diagnosis October, 2002 Table of Contents i

TABLE OF CONTENTS

COURSE INTRODUCTION..............................................COURSE INTRODUCTION1

DAY ONE.............................................................................................................DAY ONE1

Agenda...................................................................................................................Day One3

Students Objectives .............................................................................................. Day One4Prerequisite Review............................................................................................... Day One5

Workstation 1.......................................................................................................Day One15Workstation 2.......................................................................................................Day One27

Workstation 3.......................................................................................................Day One35

Workstation 4.......................................................................................................Day One51Homework ........................................................................................................... Day One69

DAY TWO ..........................................................................................................DAY TWO1

Agenda.................................................................................................................. Day Two3

Students Objectives ............................................................................................. Day Two4

Workstation 1........................................................................................................ Day Two5Workstation 2...................................................................................................... Day Two25

Workstation 3...................................................................................................... Day Two35

Workstation 4...................................................................................................... Day Two45Homework .......................................................................................................... Day Two65

DAY THREE ..................................................................................................DAY THREE1

Agenda................................................................................................................ Day Three3

Students Objectives ........................................................................................... Day Three4

Instructor-led Demonstration.............................................................................. Day Three5Workstation 1...................................................................................................... Day Three9

Workstation 2.................................................................................................... Day Three15Workstation 3.................................................................................................... Day Three21Workstation 4.................................................................................................... Day Three25

Homework ........................................................................................................ Day Three35

DAY FOUR....................................................................................................... DAY FOUR1

Agenda.................................................................................................................. Day Four3

Students Objectives ............................................................................................. Day Four4Workstation 1........................................................................................................ Day Four5

Workstation 2......................................................................................................Day Four11

Workstation 3......................................................................................................Day Four17Instructor-led Demonstration.............................................................................. Day Four23

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TABLE OF CONTENTS

ii Table of Contents October, 2002 Electronic System Diagnosis

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COURSE INTRODUCTION

Electronic Systems Diagnosis October, 2002 Course Introduction 1

COURSE

INTRODUCTION

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COURSE INTRODUCTION

2 Course Introduction October, 2002 Electronic Systems Diagnosis

ELECTRICAL SYSTEMS CURRICULUM PATH

Planned Training PathwayFord Motor Company has identified the skills and knowledge necessary to meet the curriculum

goals in the Electrical Systems specialty. The Planned Training Pathway is a series of courses

designed to provide you with these skills and knowledge. The chart above illustrates the coursesin this curriculum.

DescriptionThe Electrical Systems Curriculum consists of sixteen courses. The web-based courses and FMT

courses are self-paced training programs. The Classroom course is hands-on and is facilitated by

an instructor. The information in the Web, FMT, and Classroom courses are designed to prepareyou to successfully complete the instructor led course. You are currently in course seven of the

Electrical Systems Curriculum, Electronic Systems Diagnosis.

Basic Electrical Theory and

Operation

34S11W0

Battery Starting and Charging

System Theory and Operation

34S12W0Electrical Diagnostic Tools and

Testing

34S13M0

Basic Electrical Diagnosis

34S14T0 (5 Days)

Electronic Theory and Operation

34S15W0

Understanding Electronic Systems

34S16M0

Electronic Systems Diagnosis

34S19T0 (4 Days)

New Generation Star Tester

Operation

34S17W0Basic Worldwide Diagnostic Tool

Operation

34S18M0

Networks and

Multiplexing System

Operation and

Diagnosis

34S20W0

Antitheft Systems

Operation and Testing

34S21W0

Entertainment and

Navigation Systems


34S22W0

Speed Control System


34S23W0

SRS Operation and

Testing

34S24W0

Advanced WDS Tool

Operation

34S25W0

Advanced Electronic Systems

Diagnosis

34S26T0 (4Days)

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COURSE INTRODUCTION

Electronic Systems Diagnosis October, 2002 Course Introduction 3

Course Overview

This course has been designed to include both lecture and hands on activities. Students will have

several opportunities to practice what they learn in the form of workstations.

Audience Profile

This course is designed for any Ford, Lincoln and Mercury service technician who wants to starttheir certification process in any specialty as well as those who wish to be certified in Electrical

Systems.

Course Prerequisites

All students must have completed the first eight courses in the curriculum prior to enrolling in

this course. Students who do not show passing credit in their STARS planners for the previous

courses should not be admitted to this class. Their presence will slow down the course flow, aswell as monopolize valuable instructor time.

z Basic Electrical Theory and Operation (Web) 34S11W0

z

Battery Starting and Charging System Theory and Operation (Web) 34S12W0

z

Electrical Diagnostic Tools and Testing (FMT) 34S13M0

z

Basic Electrical Diagnosis (Classroom) 34S14T0

z

Electronic Theory and Operation (Web) 34S15W0

z

Understanding Electronic Systems (FMT) 34S16M0

z

New Generation Star Tester Operation (Web) 34S17W0

z Basic Worldwide Diagnostic System Tool Operation (FMT) 34S18M0

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COURSE INTRODUCTION

4 Course Introduction October, 2002 Electronic Systems Diagnosis

Course Objectives

The objectives of this course are to enable you to:

z

Use the SSCC (Symptom-to-System-to-Component-to-Cause) diagnostic process relating to

electronic concerns.

z Use special tools and service equipment associated with electronic diagnosis and repair.z

Use all service publications in their available formats and to obtain needed information for

diagnosis.

z

Perform diagnostic test procedures.

z

Perform repair procedures.

Number Of Days

This course has been designed to span a four-day period.

Number Of Students

This course has been designed to include up to twelve students.

Course RequirementsTo meet the requirements of this course, you must satisfactorily complete the hands-on posttest

and achieve a score of 80% or higher on the written post-test. Both tests will both be

administered on the last day of class.

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DAY ONE

Electronic Systems Diagnosis October, 2002 Day One 1

DAY ONE

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DAY ONE

2 Day One October, 2002 Electronic Systems Diagnosis

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DAY ONE AGENDA


DAY ONE AGENDA MORNING

ACTIVITY TIME

Introduction 8:30 am to 8:45 am

Prerequisite knowledge review 8:45 am to 10:15 am

Break 10:15 am to 10:30 am

Lecture 10:30 am to 11:30 am

Lunch 11:30 am to 12:30 pm

DAY ONE AGENDA AFTERNOON

Workstations 12:30 pm to 4:00 pm

Explain homework assignment 4:00 pm to 4:30 pm

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DAY ONE


STUDENTS OBJECTIVES CONTENT

Use the NGS to retrieve continuousand on demand codes and to monitor

and record PIDs

Use the WDS to retrieve continuousand on demand codes

Define power side switches, groundside switches, relays, and transistors.

Use the DMM and WDS with theoscilloscope function to check the

operation of a thermistor, apotentiometer, and a Variable

Reluctance Sensors (VRS)

NGS

WDS

Continuous and on demand codes

Power side switches

Ground side switches

Relays

Transistors

Thermistors

Potentiometers

Variable Reluctance Sensors (VRS)

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DAY ONE PREREQUISITE REVIEW


PREREQUISITE

REVIEW

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PREREQUISITE REVIEW DAY ONE

PREREQUISITE REVIEW


1. What is meant by the term "electronic systems"?

2. What is an input?

3. What is an output?

4. Name some electronic systems.

5. What are some of the advantages associated with electronic systems?

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PREREQUISITE REVIEW


7. What are the similarities and differences between a transistor and a relay?

8. What is the difference between direct module outputs and indirect module outputs?

9. Why should you determine how an electronic system operates before diagnosing it?

10. What is a Diagnostic Trouble Code (DTC)?

11. How are DTCs retrieved?

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PREREQUISITE REVIEW


16. What is an analog DC signal? (Write or draw your answer.)

17. What are some of the input devices that produce analog DC signals?

BEC603-A/VF

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DAY ONE PREREQUISITE REVIEW

PREREQUISITE REVIEW


18. What is an analog AC signal? (Write or draw your answer.)

19. What are some of the input devices that produce analog AC signals?

20. What is the unit of measure for frequency?

BEC603-A/VF

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DAY ONE WORKSTATION 1


WORKSTATION 1

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WORKSTATION 1 DAY ONE

WORKSTATION 1NGS


DIRECTIONS:

In this workstation you will use the NGS functions to retrieve Continuous Memory DTC's, OnDemand DTC's, view PID's and create a recording while diagnosing the front windshield wiper

system using the wiring diagram manual.

1. List below the components of the windshield wiper system using the wiring diagram manual.

Inputs Module Direct Outputs Indirect Outputs

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WORKSTATION 1NGS


TECHNICIAN A: Use the NGS during this workstation.

2. Perform the following steps.a. Verify that the fault switch is in position A.

b. Verify the symptom.

c. Connect the NGS to the DLC.

d. Select VEHICLE AND ENGINE SELECTION.

e. SELECT NEW VEHICLE and choose the model year for the vehicle you are working on.

f. Select vehicle model and engine size. Confirm selection and press TRIGGER.

g. Select DIAGNOSTIC DATA LINK.

h. Turn the ignition switch on.i. Select the module that controls the wiper system.

j. Select DIAG TEST MODES.

k. Select RETRIEVE/CLEAR CONT DTCs.

l. Select START by pressing button 3.

Use the table below to record any DTCs received during continuous code retrieval.

DTC DEFINITION

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WORKSTATION 1NGS


3. Continuous DTCs indicate: (Circle all that apply).A. A fault condition exists right now (Hard Fault).

B. A fault may be occurring now.C. Fault may be intermittent.

D. System being tested has no power.

4. Briefly explain how Continuous DTCs can help you diagnose a vehicle's concern.

5. Why do we clear Continuous DTCs?

6. When using the NGS, why should you always write down Continuous DTCs before clearing

them?

7. When clearing Continuous DTCs, why should you use the NGS as opposed to disconnecting

the battery?

Press button 7 CLEAR and follow on-screen directions to clear Continuous Codes.

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WORKSTATION 1NGS


11. On-Demand DTCs indicate: (circle all that apply)A. A fault condition exists right now (Hard Fault).

B. A faultmay be occurring now.C. A fault may be intermittent.D. System being tested has no power.

12. Briefly explain how OnDemand DTCs can help you diagnose a vehicle's concern.

13. Using the wiring diagram provided, list below the components and or circuits that could be

the cause of the On-Demand DTC(s).

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WORKSTATION 1NGS


TECHNICIAN C: Use the NGS during this workstation.

Press CANCEL twice to return to the diagnostic menu.

14. Use the NGS to perform PID (Parameter Identification) retrieval.a. Select PID/DATA MONITOR & RECORD and press TRIGGER.

b. Press 3 DEFN to view PID definitions.

c. For each of the PIDs listed below, highlight and press trigger to select (This symbol *

will appear when a PID is selected. To deselect a PID highlight the PID and press

TRIGGER).

d. As you select each PID, record its definition in the space provided.

NOTE: If a PID is not available write N/A.

PIDs DEFINITION

CCNT

IGN_R

WASH_SW

WPMODE

a. Press CANCEL once to view selection menu.

b. Press START.

.

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WORKSTATION 1NGS


15. According to the CCNT PID, how many codes are stored in memory?

16. Move the fault switch to position B. View each of the PIDs on the NGS while operating the

corresponding component and write your results below.


PIDs READINGS

IGN_R

WASH_SW

WPMODE

17. Move the fault switch back to position A. View each of the PIDs on the NGS while

operating the corresponding component and write your results below.


PIDs READINGS

IGN_R

WASH_SW

WPMODE

18. Based on the PID values above, your understanding of systems operation and the wiring

diagram provided, list below the circuits or components that are the potential cause of theconcern.

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WORKSTATION 1NGS


Use the NGS to view the recording.

a. When the next screen appears select VIEW RECORDING.b. Press TRIGGER to select WP_MODE.

c. Press button 6 GRAPH. This is a graphical representation of the PID.d. Press Button 8 to move forward in time.

e. Press Button 3 to move back in time.

20. Use the scroll knob to place the cursor at the trigger point (0.0) in the picture below. A T

will appear when you reach the trigger point. Label the NGS with the WP_MODE values on

the left of the screen. Label the NGS with the time values at the bottom of the screen. Drawthe graph as it appears on the NGS.

a. Press CANCEL to exit graphing function.

b. Press button 7 TABLE. This is a table displaying the PID information.

c. Turn the scroll knob to see the wiper mode change.

NOTE: You can use the PLAY, REWIND and FORWARD buttons.

21. Did the wiper mode PID change after the trigger point? YES NO

BEC113-A/VF

WPMODE

T 0.0 +

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WORKSTATION 1NGS


22. How can a recording be useful when diagnosing a vehicle?

23. Reset the workstation

a. Press CANCEL several times to return to the main menu.

b. Select VEHICLE AND ENGINE SELECTION.

c. Highlight DESELECT VEHICLE and press TRIGGER (this will erase the vehicle fromNGS memory).

d. Turn off the ignition switch and unplug the NGS.

e. Move the fault switch to position A to prepare the workstation for the next group.

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NOTES

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WORKSTATION 2

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WORKSTATION 2WDS


8. List DTCs retrieved:

DTC TYPE (check one)DTCODDTCs CMDTCs CLEARED CMDTCs

NOTE: Touch each DTC to view a definition of each code.

9. From the codes above list below the DTC(s) and definition(s) related to the concern.

10. What pinpoint test in the Workshop manual would help you diagnose this concern?

(DO NOT PERFORM THE PINPOINT TEST.)

Pinpoint Test:

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WORKSTATION 2WDS


a. Clear DTCs by selecting the CLEAR CODES icon.

13. List DTCs retrieved.

DTC TYPE (check one)

DTCODDTCs CMDTCs CLEARED CMDTCs

a. To exit the test, select the MENU icon in the upper RH corner of the screen.b. Select exit.

c. Select continue

d. Select the LOG VIEWER icon in the lower LH corner of the screen.

14. What type of information does the Log Viewer provide?

a. Select the CLOSE SESSION icon in the lower LH corner of the screen.

b. Select DELETE from the menu then select the CONTINUE icon to finish.c. Place fault switch in position A, turn off ignition, and disconnect all cables from the

WDS and vehicle.

d. Re-dock the WDS.e. To ensure the WDS is fully docked, the external power LED should be lit (green).

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WORKSTATION 3

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WORKSTATION 3INPUTS, PROCESSING AND OUTPUTS


DIRECTIONS:

In this workstation you will trace power flow and measure voltage in a basic electronic circuit.You will learn about inputs, processing and outputs.

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

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

A. Power side switchB. Ground side switch

3. Trace the power flow through the circuit below using colored markers. Use red to indicatepower, blue for power-side switched circuits, green for ground-side switch circuits, and blackfor ground.

BEC100-A/VF

V

A B

DC

12V

A: Switch (Input) B: Module

C: Resistor D: Lamps

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4. What will the voltage readings be with the module's internal voltmeter (V) connected asshown when the external input switch is opened and closed?

Switch Open

Switch Closed

BEC100-A/VF

V

A B

DC

12V


C: Resistor D: Lamps

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

9. What type of switch is used in the circuit below?

A. Power side switch

B. Ground side switch

10. Trace the power flow through the circuit below using colored markers. Use red to indicate

power, blue for power-side switched circuits, green for ground-side switch circuits, and black

for ground.

BEC102-A/VF

Signal Return

GRD

V

A B

C

12V


C: Resistor

11. What will the voltage readings be with the module's internal voltmeter (V) connected as

shown when the external input switch is opened and closed?

Switch Open

Switch Closed

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WORKSTATION 3

INPUTS, PROCESSING AND OUTPUTS

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


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An Electronic system consists of inputs, a control module, and outputs. In this workstation youhave taken voltage readings to see what the module sees when monitoring switched inputs. The

Central Processing Unit (CPU) receives the input as ON and OFF signals. The input circuitvoltage is converted into an eight-bit signal in the Analog to Digital (A-D) converter. This signal

is compared to a look-up table, which resides in the CPU memory. The CPU makes decisionsbased on the look-up table and sends a signal to the Digital to Analog (D-A) converter.

In this exercise you will predict what the module will do. Use the look-up table below to decidewhen the module turns the lights on or off.

Power to CPU

Input

BEC106-E/VF

Look-Up-Table

INPUT

>3V OFF

ON

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23. Explain the difference between direct and indirect outputs.

24. Why is it important to know the difference between direct and indirect outputs?

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WORKSTATION 4

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52 - Day One October, 2002 Electronic Systems Diagnosis

Thermistors are variable resistors that change resistance when temperature changes. Theyprovide temperature information to a module in the form of an analog DC signal.

Thermistors are made of a special resistive material that is very sensitive to changes in

temperature. In most thermistors, as temperature increases, the resistance of the thermistordecreases. As temperature decreases, thermistor resistance increases.

This change of resistance is used in a voltage divider circuit to produce an analog DC voltagethat indicates temperature. This analog voltage begins as five volts, which passes through a

current limiting resistor inside the module and then is wired to the external thermistor.

Thermistors are two-wire sensors that are part of a voltage divider circuit. The voltage supply

and current limiting resistor are internal to the module. The wire from the current limitingresistor to the thermistor is called the signal wire. This is where the module monitors the analog

DC voltage signal created by the change in temperature. The wire from the thermistor to ground

is known as signal return.

BEC108-A/VF

5V

VoltReg

V

Signal Return

ThermistorSignal

T

A B

C

12V

A: Thermistor (Input) B: Module

C: Resistor

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3. Connect the power supply leads to the Voltage Divider Input board (FE-21) "B+" andGround terminals. Adjust the power supply to 12 volts. Using the DMM, measure and record

the available voltages at the following terminals.

Thermistor Signal

Signal Return

4. Connect the thermistor to "Thermistor Signal" and "Signal Return". Measure and record the

available voltage at the following terminals.

Thermistor Signal

Signal Return

5. While monitoring the voltage between the signal and signal return terminals, warm the

thermistor with your fingers. What happens to the voltage?

A. Voltage increases

B. Voltage decreasesC. Voltage stays the same

6. What type of signal does a thermistor produce?

A. Digital DC

B. Analog DC

C. Digital AC

D. Analog AC

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7. In the circuit below circle the thermistor(s).

BEC903-B/VF

2 1

C287

3

1 2

7 15

A231

Remote Climate

Control (RCC)module

20 RD/OG788 20 PK/BK470

23

20 WH/OG790

6

20 BN468

C228

22 WH/VT218

B241

15121

10 5

C201b

15 9

14

C219

A112

Generic Elec-

tronic Module

(GEM) (14B205)

592

22 BN46822 RD/OG788 22 WH/OG790

G200

S221

20 PK/BK47020 PK/BK470

1

B203

(19E702)

1511

20 BK/YE398

C2875

S206

B206

(19C734)

15120

C198

P78

Integrated con-

trol panel

10 26 C263

20 RD/OG788

C233

105

See page

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11. Connect the potentiometer to the Voltage Divider Input board as shown and measure voltagebetween the "Potentiometer Signal" and "Signal Return" terminals. Record the readings at:

A. Rest V

B. travel V

C. Full travel V

BEC110-D/VF

REF

B+

SIG RTN

THERMISTORSIGNAL

POTENTIOMETERSIGNAL

FE-21

FE-24

POTENTIOMETER THEMISTOR

SIGNAL VREFSIG RTN SIGNALSIG RTN

12V

12. What type of signal does a potentiometer produce?

A. Digital DC

B. Analog DCC. Digital AC

D. Analog AC

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A Variable Reluctance Sensor (VRS) produces an analog AC signal. It uses magnetism togenerate its voltage signal.

Variable reluctance sensors are used to provide position and speed information.

By monitoring the frequency of the signal, the module determines speed. Higher frequency

indicates higher speed.

A variable reluctance sensor consists of a toothed trigger wheel called a reluctor (indicator) and a

sensor, which is made of a permanent magnet with a coil of wire wrapped around it. This sensoris located at a specific distance from the reluctor (indicator). This distance is called an air gap.

BED304-A/VF

C DBA

A: Coil B: Permanent Magnet

C: Air Gap D: Reluctor

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TECHNICIAN C: Perform steps 14 16.

14. Use the DMM to measure the resistance of the variable reluctance sensor and write your

results

15. Turn off the power supply and connect power and ground to the DC motora. Turn on the power supply

b. Use the DMM to measure the AC voltage between "VRS +" and "VRS -" at each speed

setting.

Record the VRS AC voltage at each setting:

Low VRS AC V

Med VRS AC V

High VRS AC V.

12V

BEC111-B/VF

FE-23

VRS

SIGNAL

B+

VRS +OFF

LOW MED

HIGH

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16. Use the DMM to measure frequency.a. Adjust the dial to the AC voltage position.

b. Press and hold the yellow button in the center of the dial until it beeps (one beep then two

quick beeps).

c. The meter will now read AC frequency.

What is the unit of measure for frequency?

Record the VRS frequency at each speed setting.

Low Hz

Med Hz

High Hz

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TECHNICIAN A: Perform step 17.

17. Use the WDS to view the wave form of a VRS on an oscilloscope.

Connect the WDS to the VRS sensor as follows:

a. If the WDS screen is blank, touch it. If nothing happens, the unit is in suspend mode. In

this case, touch the green ON button at the upper RH corner.b. Connect the WDS probes to the VRS sensor, red to "VRS+" and black to "VRS"-.

c. Turn on the power supply and set the motor speed to low.

Watch the yellow trace on the WDS and draw a picture of the trace in the chart below.

BEC112-A/VF

T

T

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NOTES

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NOTES

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DAY ONE HOMEWORK


HOMEWORK

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DAY ONE HOMEWORK


CONTINUOUS DIAGNOSTIC TROUBLE CODES (DTC's)

Continuous DTC's are only logged during normal vehicle operation.

When the GEM energizes an external device, a faulty circuit condition may exist. If the device is

successfully energized before one second elapses, a Continuous DTC is not stored and no faultmanagement action is taken. If the fault continues after a predetermined fault time, a Continuous

DTC is stored and appropriate fault management action is taken.

Continuous DTC's should be retrieved from the GEM before an On-Demand Self-Test is run.

These Continuous DTC's are then compared by the technician against the DTC's retrieved afterrunning an On-Demand Self-Test. Results of Continuous and On-Demand Self-Test DTC's will

determine whether a fault is a hard fault or an intermittent one.

After retrieving Continuous DTC's the codes should be manually cleared.

Clearing DTC's ManuallyUsing a scan tool (NGS/WDS), DTC's can be cleared manually in one of two ways, clearing onlya single DTC, or clearing all DTC's at once.

Clearing DTC's AutomaticallyDTC's are cleared automatically when the fault is no longer detected by the GEM for 80 ignition

START cycles.

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HOMEWORK DAY ONE


ON-DEMAND SELF-TEST

An On-Demand Self-Test:

does not involve elaborate testing

covers most fault conditionsThe On-Demand Self-Test consists of an internal GEM test and a GEM subsystem input/output

circuitry test.

A general requirement of an On-Demand Self-Test is that no action by the technician, such as

activating a switch during the test, will be required.

The On-Demand Self-Test is designed to test the GEM's subsystem input output circuitry in a

quick and efficient manner. While the On-Demand Self-Test is designed to test input/output

circuitry, it cannot test complete circuits or components.

Running an On-Demand Self-Test

The technician cannot activate any controls while an On- Demand Self-Test is running or a false

DTC may be generated. Before initiating a test, the GEM and its subsystems must be set up in adefined state.

On-Demand Self-Test Results

Results of an On-Demand Self-Test are in the form of DTC'S, which the NGS/WDS will display

automatically.

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DAY ONE HOMEWORK


DIAGNOSTIC TROUBLE CODES (DTC's) AND CUSTOMER CONCERN DIAGNOSIS

Hard FaultsHard faults are reported as DTC's during an On-Demand Self- Test, and reflect faults that

currently exist in the GEM control system.

EXAMPLE: An On-Demand Self-Test is run on the windshield wiper/washer system, and theresults of the test indicate an open in the relay coil's circuit. A fault is reported, indicating a

failure currently exists.

The technician can now use diagnostic testing to trace the circuit backwards from the suspected

faulty component to the GEM.

Intermittent FaultsIntermittent faults are apparent when a Continuous DTC exists and an On-Demand Self-Test

does not detect the same fault.

NOTE: A DTC generated during a Continuous Test must also be a valid DTC for the On-

Demand Self-Test.

If the DTC is valid for both sets, and if the DTC was generated in the continuous mode but notafter an On-Demand Self-Test was run, then the fault is classified as intermittent.

EXAMPLE: An On-Demand Self-Test is run on the windshield wiper/washer system, and theresults of the test indicate no faults are presently detected in the relay coil; yet, there is a

Continuous DTC indicating an open in the relay driver circuit. The DTC has already been

determined to be valid for both continuous and on-demand modes. Therefore the fault isclassified as intermittent.

INTERMITTENT FAULTS HARD FAULTS

Continuous DTCs On-Demand DTCs

Continuous DTCs (*)

(*) Continuous DTCs may be caused by a hard fault if the continuous code has been cleared.

Then the vehicle is operated and the code reappears.

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DAY ONE HOMEWORK


Customer Concern Diagnosis

Customer concern diagnosis should follow a specific diagnostic procedure, Symptom to Systemto Component to Cause.

EXAMPLE: A customer comes into your dealership with a concern that the illuminated entry is

not operating. The Symptom would be that the illuminated entry is not operating. The Systemwould be illuminated entry. The Component and the Cause portion of the procedure would be

arrived at through diagnosis.

The following process correctly indicates the diagnostic procedure:

1. Customer symptoms should be the primary consideration when performing diagnosticprocedures.

2. Verify the Customer Concern.

3. Verify which system or systems are at fault then refer to the appropriate Workshop Manual

section.4. Check OASIS, TSBs and Vehicle History. Then, refer to the appropriate Workshop Manual

section.5. Use the Inspection & Verification chart to determine whether the concern is mechanical orelectrical.

6. The the Inspection & Verification chart will initially recommend a visual check of the

following items:

blown fuse

loose or corroded electrical connectors

loose or corroded ground

damaged switch

damaged components

Once a visual check of the system has been made, you will, then, be directed to

access the GEM for Continuous DTCs and On-Demand DTCs.7. Proceed to the Symptom or DTC Chart of the appropriate system identified.

8. The Symptom or DTC Chart will indicate an appropriate Pinpoint Test based on the verified

concern and you may be directed to monitor PIDs and perform Active Commands.9. The Pinpoint Test will initially recommend a visual check of the following items:

- blown fuse

- loose or corroded electrical connectors

- loose or corroded ground- damaged switch

- damaged component

Once a visual check of the system has been made, you will then be directed to access the GEMfor Continuous DTC's, On-Demand DTC'S, PID's and Active Commands.

After the concern has been diagnosed and corrected, manually erase the DTC(s), operate the

vehicle to try to reproduce the concern, then rerun Continuous DTC's and the On-Demand Self-

Test.

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DAY TWO INSTRUCTOR LED DEMO

Electronic Systems Diagnosis October, 2002 Day Two 3

DAY TWO AGENDA MORNING

ACTIVITY TIME

Review of Day One workstations and homework 8:30 am to 10:15 am

Break 10:15 am to 10:30 am

Lecture 10:30 am to 11:30 am

Lunch 11:30 am to 12:30 pm

DAY TWO AGENDA AFTERNOON

Workstations 12:30 pm to 4:00 pm

Explain homework assignment 4:00 pm to 4:30 pm

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DAY TWO WORKSTATION 1

WORKSTATION 1NGS PID DATA


a. Connect the NGS and prepare the NGS for the vehicle you are working on.b. Select diagnostic data link

c. Select PCMd. Select PID data monitor and record.

e. Choose SELECT ALLf. Select the IAT, IATV, TPV, and TP_MODE PIDs.

NOTE: Use the 1 and 0 on the NGS keypad to move forward and back one screen at a time. Use2 and 9 to move to the beginning and end of the screen.

g. Select START

2. With no faults in the IAT circuit complete the table below with voltage at component and PID

values.

VOLTAGE AT

COMPONENT

PID VALUE

Signal V IAT Deg.

Signal

Return V

PCM

BEC801-B/VF

SIGNAL

VREF

SIGNAL RETURN

T

IAT Volts

NOTE: Connect the negative DMM lead to the battery ground.

3. Warm the IAT with your finger while monitoring PIDs. Do any of the values change?

YES NO

If you answered yes, which ones?

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13. Repair signal wire and then place resistor wire A in the IAT SIGNAL RETURN wire.

Complete the table below with voltage at component and PID values.

VOLTAGE AT

COMPONENT

PID VALUE

Signal V IAT Deg.

Signal

Return V

BEC805-B/VF

PCM

SIGNAL

SIGNAL RETURN

T

VREF

IAT Volts

14. Refer to the DTC Chart. What code will be set by the PCM?

A. P0112

B. P0113C. No DTCs will be set

15. Warm the IAT with your finger while monitoring PIDs. Do any of the values change?

YES NO


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WORKSTATION 1 DAY TWO


12 Day Two October, 2002 Electronic Systems Diagnosis

16. Repair signal return wire and then create a short from the IAT SIGNAL wire to ground.


VOLTAGE AT

COMPONENT

PID VALUE

Signal V IAT Deg.

Signal

Return V

PCM

SIGNAL

SIGNAL RETURN

T

BEC806-B/VF

VREF

IAT Volts


A. P0112


18. Warm the IAT with your finger while monitoring PIDs.

Do any of the values change? YES NO


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TECHNICIAN B: Perform steps 19-33 of this workstation.

TP OVERVIEW

The Throttle Position Sensor (TP) is mounted on the throttle body and is attached to the throttleshaft. The sensor is used to send three operating conditions to the PCM. Those conditions are

closed throttle (CT), part throttle (PT) and wide open throttle (WOT). Please use the mockup

sensors rather than the vehicles sensors for this workstation.

19. Use the table below and the wiring diagram to identify the VREF, TP Signal and Signal

Return wires for the Throttle Position (TP) sensor on the vehicle you are working on. Writethe wire color for each wire in the table.

Circuit

Number

Wire

Color

Circuit

Number

Wire

Color

Circuit

Number

Wire

ColorSIG

RTNTP VREF

DTC CHART

P0122 - Throttle

Position (TP)

Circuit Low Input

If during key ON engine OFF

TP voltage is below a

minimum calibrated limit, thetest fails.

A TP PID (TP V PID) reading less than

3.42% (0.17 volt) in key ON engine OFF,

continuous memory or key ON enginerunning indicates a hard fault.

P0123 - Throttle

Position (TP)

Circuit High Input

If during key ON engine OFF

TP voltage is above

maximum calibrated limit,the test fails.

A TP PID (TP V PID) reading greater than

93% (4.65 volts) in key ON engine OFF,

continuous memory or key ON enginerunning indicates a hard fault.

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20. With no faults in the TP circuit, complete the table below with voltage at component and PIDvalues

VOLTAGE AT

COMPONENT

PID VALUE

VREF V

TP Mode

Signal V

SignalReturn V

BEC808-B/VF

VREF

PCM

SIGNAL

SIGNAL RETURN

VREF

TP Volts

21. Operate the TP sensor while monitoring PIDs.



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22. Create an open in the TP VREF circuit and complete the table below with voltage atcomponent and PID values.

VOLTAGE AT

COMPONENT

PID VALUE

VREF V

TP Mode

Signal V

SignalReturn V

BEC809-B/VF

VREF

PCM

SIGNAL

SIGNAL RETURN

VREF

TP Volts


A. P0122

B. P0123

C. No DTCs will be set




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25. Repair VREF wire and then create an open in the TP Signal circuit and complete the table

below with voltage at component and PID values.

VOLTAGE AT

COMPONENT

PID VALUE

VREF V

TP Mode

Signal V

Signal

Return V

BEC810-B/VF

VREF

PCM

SIGNAL

SIGNAL RETURN

VREF

TP Volts


A. P0122

B. P0123





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28. Repair signal wire and then create an open in the TP Signal Return circuit and complete thetable below with voltage at component and PID values.

VOLTAGE AT

COMPONENT

PID VALUE

VREF V

TP Mode

Signal V

SignalReturn V

BEC811-B/VF

VREF

PCM

SIGNAL

SIGNAL RETURN

VREF

TP Volts


A. P0122

B. P0123





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TECHNICIAN C: Perform steps 34-48 of this workstation.

34. Repair VREF wire and then place resistor wire B in the TP Signal circuit


VOLTAGE AT

COMPONENT

PID VALUE

VREF V

TP Mode

Signal V

Signal

Return V

BEC813-B/VF

VREF

PCM

SIGNAL

SIGNAL RETURN

VREF

TP Volts


A. P0122





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37. Repair the TP signal wire and then place resistor wire B in the TP Signal Return circuit.


VOLTAGE AT

COMPONENT

PID VALUE

VREF V

TP Mode

Signal V

Signal

Return V

BEC814-B/VF

VREF

PCM

SIGNAL

SIGNAL RETURN

VREF

TP Volts


A. P0122





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40. Repair Signal Return wire and then create a short from the TP Signal circuit to ground andcomplete the table below with voltage at component and PID values.

VOLTAGE AT

COMPONENT

PID VALUE

VREF V

TP Mode

Signal V

SignalReturn V

BEC815-B/VF

VREF

PCM

SIGNAL

SIGNAL RETURN

VREF

TP Volts


A. P0122

B. P0123





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43. Repair signal wire and then create a short from the TP Signal Return circuit to ground andcomplete the table below with voltage at component and PID values.

VOLTAGE AT

COMPONENT

PID VALUE

VREF V

TP Mode

Signal V

SignalReturn V

BEC816-B/VF

VREF

PCM

SIGNAL

SIGNAL RETURN

VREF

TP Volts


A. P0122

B. P0123





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NOTES

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WORKSTATION 2WDS DATALOGGER


DIRECTIONS:

In this workstation you will use the WDS to view and capture information using the dataloggerfunction.

TECHNICIAN B: Use the WDS during this workstation.

1. Refer to the Repair Order and verify the customer concern. What system(s) may beresponsible for this symptom?

2. List below the components that may be the cause of the concern of the suspected faultysystem using the EVTM /Wiring Diagram manual.

Inputs Module Direct Outputs Indirect Outputs

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a. ID the vehicle

b. Select TOOLBOX

c. Select Self-Testd. Select CONTINUE

e. Select BODY.f. Select SECURITY.

g. Select PERIMETER.

h. Select CONTINUE.i. Read instructions.

j. Select CONTINUE.

3. Perform a self-test on the Perimeter anti-theft security system that is at fault. List any DTCsrelated to the concern.

a. Select the TOOLBOX icon.

b. Select DATALOGGER.

c. Select CONTINUE (This will bring you to the System Identification

screen which is represented by this icon)

d. Select BODY.

e. Select SECURITY.

f. Select PERIMETER.g. Select CONTINUE.

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NOTE: In order to view the functions of an icon, press and hold the icon and read the

description in the status bar.

4. What does this icon allow you to do?



a. Press the PARAMETER SELECTION icon.

b. Press the CLEAR PIDs icon.

c. Select the KEY CODE, KEYPAD, and TNSMT_CMD PIDs

NOTE: The selected PIDs are dark gray with white lettering.

d. View the live data by pressing the CONTINUE icon.

7. What is the key code for this vehicle?

8. Use the vehicle key code to verify the customer concern.

Was the customer concern verified? YES NO

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9. List below the keypad PID values with the button pressed.

BUTTON PID VALUES

1-2

3-4

5-6

7-8

9-0

10. What component or circuit could be the cause of the concern?

Using the WDS to record PIDs.

Prepare the WDS to make a recording.

a. Select the MENU icon.

b. Select CAPTURE SET-UP to view the buffer settings.

c. Use the arrows to set the duration to 30 seconds.

d. Press the CONTINUE icon.

e. Press each button on the vehicle keypad.

f. Press the DATA CAPTURE icon.

NOTE: Watch the status bar in the lower right hand corner of the screen. Wait for the recording

to end, before proceeding to the next step.

Select the PLAYBACK DISPLAY icon.

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Press the TNSMT_CMD PID to highlight the box around it.

Select the Plot FORMAT, LIMITS AND RANGE icon

a. Press the GRAPH icon.

b. Press the CONTINUE icon.

15. Approximately 5 seconds before the trigger point, what was the TNSMT_CMD PID value?

16. Approximately 5 seconds after the trigger point, what was the TNSMT_CMD PID value?

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OSC Overview:

Like the NGS, the WDS allows you to control outputs. This function is called output statecontrol (OSC) on the WDS. Unlike the NGS, components are controlled from the same screen

that monitors PID values. A # sign is used to indicate a device can be controlled.

a. Reinstall key in ignition and turn on.

b. Ensure that the headlamp switch is turned off.c. Use the Parameter Selection screen to select the output PID provided by the instructor.

d. In the Live Data Display screen, select the same PID as in the previous step.

NOTE: Notice the # sign next to the PID. This indicates that this output can be controlled.

e. Press the OSC (Output State Control) Mode icon.

f. Press the CONTROL ITEM ACTIVATE icon.

17. What symbol is now displayed in place of the # sign?

18. Press the CONTROL ITEM INCREMENT icon.

What happened to the PID value?

19. What happened to the output component on the vehicle?

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20. Press the CONTROL ITEM DECREMENT icon.

What happened to the PID value?

21. What happened to the output component(s) on the vehicle?

a. Press the CLEAR CONTROL ITEMS icon to allow the module to controlthe headlamps.

b. Press the OSC Mode icon to exit OSC Mode.

c. Press the VEHICLE SELECTION tab.

d. Select the CLOSE SESSION icon.

22. What option would you use to save the recordings? (Do not perform this step)

23. What option would you select to delete recordings?

a. Select DELETE SESSION.b. Select CONTINUE.

Return the workstation back to its original condition.

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DAY TWO


NOTES

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WORKSTATION 3

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WORKSTATION 3NGS ACTIVE COMMANDS


TECHNICIAN C: Use the NGS during this workstation.

1. Wire the Interior Lighting system as shown below.

Turn on power supply and set to 12 volts. Verify the system operates by activating the door ajar

switches. If the system does not work, notify your instructor.

BEC400-D/VF

12V

Interior Lighting System

VSS CKT 70

LF DOOR

RF DOOR

SLIDING DOOR

LIFT GATE

MODE SELECT

INTERVAL WASH

SIGNAL RETURN

PARK SWITCH

B+

BATT

INTERIOR LAMP

DOOR AJAR

BRAKE RUN

WIPTER SPEED

FE-25

GEM BOARD

RELAY CONTROL INPUT

FE-26

DIRECT OUTPUTS

RELAY

N/O N/C

COIL

COIL

DOOR AJAR

COMMON

COMMON

N/O N/C

FE-27

DOORAJARSWITCHES

SLIDINGDOOR

REAR

DEFROST

TAIL

GATE

SLIDE

DOOR

RF

DOOR

LF

DOOR

LF

DOOR

RF

DOOR

AJAR

AJAR

AJAR A

JAR

AJAR

FE-30

BOARD WITH GLOVE BOX LAMP

GLOVE BOX LAMP

INTERIOR

LAMPS

B+

2. Prepare the NGS to test the GEM module from a 1995 Windstar with a 3.8 liter engine.

a. Select diagnostic data link.

b. Select the GEM module (This vehicle has Rear Defrost, Keyless Entry, Illuminated

Entry, and Power Door Locks) and select SAVE (Button 8)c. Select active command modes.

How many active command tests are available?

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3. List the active commands available for this module in the spaces below

a. Select BAT SAVER.b. Highlight BATT SAVR: OFF.

c. Press TRIGGER.

4. Explain what happened to the glove box lamp.

5. Explain what happened to the display on the left side of the NGS.

a. Press TRIGGER again.

6. Explain what happened to the Glove Box Lamp.

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7. Explain what happened to the display on the left side of the NGS?

8. Briefly describe what Active Command test mode is. What does it allow you to do?

9. How can Active Command tests help you in diagnosis?

Active Commands and PIDs

a. Press button 7 PIDs.b. Select the BATSAV, INTLMP and P_DR_SW PIDs.

c. Press button 7 START.

10. Record the PID values in the spaces below.

Active Commands PIDs

BATT SAVR: OFF BATSAV:INT LAMPS: : OFF INTLAMP:

P_DR_SW:

d. Press TRIGGER again to turn the battery saver relay back on.



BATT SAVR: ON BATSAV:

INT LAMPS: OFF INTLAMP:

P_DR_SW:

e. Highlight INT LAMPS: OFF.

f. Press TRIGGER.

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12. What happened to the Interior Lamps?




INT LAMPS: ON INTLAMP:

P_DR_SW:

a. Press TRIGGER again to turn the Interior Lamps off.b. Remove the interior lamp relay.

14. Record the PID values in the spaces below .




P_DR_SW:

15. Turn on the interior lamp relay, record the PID values in the spaces below.



INT LAMPS: ON INTLAMP:

P_DR_SW:

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a. Turn off interior lamp relay.

b. Install the interior lamp relay.

c. Send a door ajar signal to the GEM module by using the switch for the passenger frontdoor





P_DR_SW:

17. Did the GEM module "see" the door ajar signal? YES NO

18. Did the interior lamps come on when the door was ajar? YES NO

a. Close the passenger front door.

b. Press CANCEL to return to the Active Command menu.

c. Send a door ajar signal to the GEM module by using the switch for the passenger frontdoor.

19. Did the interior lamps come on when the door was ajar? YES NO

20. Why should you exit Active Commands when testing system operation?

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Signal Simulation and voltage measurement from the Active Command Screen

When viewing the Active Command screen, the NGS has the capability of measuring voltageand sending a signal from 0 to 6 volts. This feature can be used when diagnosing output faults.

NOTE: The NGS uses the cigarette lighter adapter for a ground.

21. Re-enter BAT SAVER Active Command menu but do not select any PIDs.a. Insert a probe lead into the red SIG jack at the base of the NGS.

b. Place the other end of the lead at the Interior Lamps relay N/O terminal.

c. Use active commands to turn on the battery saver and interior lamp relay.

What voltage does MEAS read?

22. Use Active Commands to turn the Interior Lamps off.

What voltage does MEAS: read?

23. Remove the lead at the Interior Lamps relay N/O terminal. Remove the interior lamp relay.Watch the NGS screen closely, press button 4 SIG.

What happened to the screen on the NGS?

24. Turn the NGS scroll knob until the SIGNAL OUT displays 6V

a. Press TRIGGER


NOTE: This voltage is coming out of the red SIG jack at the base of the NGS. It has no effect on

the module or the Active Command sent to it.

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25. Place the red lead at the interior lamp relay coil control side terminal.


26. Use active commands to turn the Interior Lamps ON.


27. Press button 4 SIG.

Turn the NGS scroll knob until the SIGNAL OUT displays OFF

Press TRIGGER


Return workstation to its original condition.

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NOTES

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DAY TWO-WORKSTATION 4


WORKSTATION 4

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WORKSTATION 4ELECTRONIC CIRCUITS


DIRECTIONS:

In this workstation you will use a Digital Multimeter and the WDS Oscilloscope to measure thesignals produced by a Hall Effect sensor circuit, a Phototransistor circuit and the Illumination

circuits of the headlamp switch. You will also learn how to identify these devices in a WiringDiagram.

Hall Effect sensors are devices that allow current to flow when a magnetic field is present. Theymay be used to measure RPM and/or the position of moving parts.

Hall Effect sensors feature a stationary permanent magnet positioned near the Hall device. When

the Hall element is exposed to the magnetic field, the circuit is completed. When the Hallelement is shielded from the magnetic field, the circuit opens.

Many Hall Effect sensors operate electronically like a simple ground switch. Magnetism, insteadof mechanical action, is used to open and close the circuit.

A: Hall Effect Element B: Amplifier

C: Schmitt Trigger D: Transistor

E: Module

BEC204-B/VF

12V

12V

H A S

V

D

A

E

B C

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TECHNICIAN A: Complete steps 1-6 of this workstation.

1. With the power supply for the DC motor turned off, create a Hall Effect speed sensor circuitas shown.

a. Adjust the voltage for the module to 8 volts.

b. Turn the trigger wheel so that the tooth of the wheel is away from the sensor.

Measure and record the voltage between Signal A and Signal Return terminals.

Hall Effect voltage V

12V

BEC201-E/VF

FE-20

B+

A

B

SIGNAL

SIGNAL RETURN

FE-23

VRS

SIGNAL

B+

VRS +OFF

LOW MED

HIGH

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2. Place a metal scraper against the surface of the Hall Effect sensor facing the trigger wheel.

a. Measure and record the voltage between Signal A and Signal Return terminals.

Hall Effect voltage V

b. Remove metal blade.

3. What type of signal is created by this Hall Effect speed sensor circuit?

A. Digital DC

B. Digital ACC. Analog AC

D. Analog DC

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5. Turn on the DC motor's power supply and adjust the speed to low, medium and high. Record

the voltage at the Signal A terminal at each setting.

Low V

Medium V

High V

6. Set the DMM to measure frequency. Adjust the DC motor's speed to low, medium and high.

Record the frequency at the Signal A terminal at each setting.

Low Hz

Medium HzHigh Hz

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7. Connect the WDS to monitor the Hall Effect signal with the oscilloscope function.

a. Connect the red probe to the Hall Effect Signal A terminal.

Turn on the DC motor's power supply and adjust the speed to low. Watch the yellow trace on theWDS and draw a picture of the trace in the chart below.

BEC112-A/VF

T

T

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TECHNICIAN B: Complete step 8 of this workstation.

8. Adjust the DC motor's speed to medium. Watch the yellow trace on the WDS and draw apicture of the trace in the chart below.

BEC112-A/VF

T

T

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TECHNICIAN C: Complete step 9 of this workstation.

9. Adjust the DC motor's speed to high. Watch the yellow trace on the WDS and draw a pictureof the trace in the chart below.

BEC112-A/VF

T

T

10. When the speed of the motor increases, the sensor's DC voltage:

A. Increases

B. Decreases

C. Stays the same

11. When the speed of the motor increases, the sensor's frequency:

A. IncreasesB. Decreases

C. Stays the same

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A phototransistor is an electronic device that acts like a simple ground side switch, except it is

activated by light.

Unlike standard transistors, phototransistors have only two leads. The two leads are the emitterand collector, which are wired into a circuit. When light strikes the base of the transistor, the

transistor is forward biased and completes the circuit. Without the light the circuit is open.

BEC205-A/VF

12V

0V

A

B

C

A: Base B: Collector

C: Emitter

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TECHNICIAN B: Complete steps 12, 15 and 16 of this workstation.

12. Replace the Hall Effect speed sensor with the phototransistor speed sensor as follows:a. Disconnect the Hall Effect speed sensor from the module and connect the photo transistor

speed sensor as shown.b. Connect the WDS red probe to the Signal A terminal.

c. Rotate the speed sensor and watch the yellow trace on the WDS.

What type of signal does the phototransistor produce?

A. Digital DC

B. Digital ACC. Analog AC

D. Analog DC

13. Do both the Hall Effect speed sensor and the phototransistor speed sensor produce the same

signal?

YES NO.

12V

BEC203-C/VF

FE-20

B+

A

B

SIGNAL

SIGNAL RETURN

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14. Circle the phototransistor(s) in the schematic below.

BEC903-B/VF

2 1

C287

3

1 2

7 15

A231

Remote Climate

Control (RCC)

module

20 RD/OG788 20 PK/BK470

23

20 WH/OG790

6

20 BN468

C228

22 WH/VT218

B241

15121

10 5

C201b

15 9

14

C219

A112

Generic Elec-

tronic Module

(GEM) (14B205)

592

22 BN46822 RD/OG788 22 WH/OG790

G200

S221

20 PK/BK47020 PK/BK470

1

B203

(19E702)

1511

20 BK/YE398

C2875

S206

B206

(19C734)

15120

C198

P78

Integrated con-

trol panel

10 26 C263

20 RD/OG788

C233

105

See page

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15. With the red probe still connected to the Signal A terminal, connect the black probe to the

Signal B terminal. Rotate the speed sensor clockwise. Watch the yellow and red traces on the

WDS and draw a picture of the traces in the chart below (to highlight the red trace touch thered "2" on the screen).

BEC112-A/VF

T

T

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16. Rotate the speed sensor counter-clockwise. Watch the yellow and red traces on the WDS and

draw a picture of the traces in the chart below.

BEC112-A/VF

T

T

17. Do you notice a difference between rotating clockwise and counter clockwise?

YES NO

If yes, what do you notice?

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TECHNICIAN C: Complete steps 18-20 of this workstation.

18. Connect the power supply to the Headlamp switch. Turn on the headlamps and adjust thepanel dimmer. Do the Illumination A and Illumination B operate properly?

YES NO

19. Measure the voltage at the Illumination A and Illumination B terminals while controlling thePanel Dim. Record the readings at the following positions.

Illumination A Illumination B

Dim V V

Medium V V

Bright V V

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20. Connect the WDS to the headlamp switch as follows:

a. Connect the red probe of the WDS to the Illumination A terminal and the black probe tothe Illumination B terminal.

Set the Panel Dim to its highest setting and note the two traces on the WDS. Draw the two tracesin the following picture.

BEC112-A/VF

T

T

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TECHNICIAN A: Complete step 21 of this workstation

21. Set the Panel Dim to a medium setting and note the two traces on the WDS. Draw the twotraces in the following picture.

BEC112-A/VF

T

T

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TECHNICIAN B: Complete step 22 of this workstation.

22. Set the Panel Dim to its lowest setting and note the two traces on the WDS. Draw the twotraces in the following picture.

BEC112-A/VF

T

T

23. The signal for the Illumination A (yellow trace) is:

A. Analog DC

B. Analog AC

C. Digital DCD. Digital AC

24. The signal for the Illumination B (red trace) is:

A. Analog DC

B. Analog AC

C. Digital DCD. Digital AC

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DAY TWO


NOTES

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NOTES

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DAY TWO HOMEWORK


HOMEWORK

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HOMEWORK DAY TWO


BEC700-D/VF

1

22 YE/BK765

1 2Door ajar

switch, left front

1) Door closed

2) Door open

Door ajar

switch, right front

1) Door closed

2) Door open

Generic Elec-

tronic Module

2

1 2

22 YE/RD761

20 BK57 20 BK57

1 2

20 BK57

Door ajar

switch, right rear

1) Door open

2) Door closed

3

3

22 RD/BK657

20 BK57

1 2

4

4

22 GY/RD576

1 2

C19

C18

20 BK57

Door ajar

switch, liftgate

1) Door closed

2) Door open

Door ajar

switch, liftgate

1) Door closed

2) Door open

1 2

G205

20 TN/YE792

F2.26

10A

Battery saver

relay

C21

C23

C20

C23

C21

5

3

1

2

20 TN/YE792Auxiliary relay

box 1

22 VT/OG1005

22 LG /OG1008

20 LG/OG705

6

8

22 LG10

Generic

ElectronicModule

Generic Elec-

tronic Module

C20

C20C24

S220

C24

G205

1 0

C24

Glove box lamp

0) Glove box closed

1) Glove box open

Hot at alltimes

Interior lamp

relay

C22

C22

5

3

1

2

20 LG/OG705

20 LG/OG705

20 BK/LB53

20 BK57

Auxiliary

Interior lamp

assembly

Door ajar

lamp

relay

box 1

Generic Elec-

tronic Module

7

6 7

20 LG /OG705C20B4 Instrument

panel dimmingmodule

6) Off

7) On

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DAY TWO - HOMEWORK


Use the schematic shown in the previous page to answer all questions in this homework activity.

1. Identify the Inputs and Outputs in the circuit.

INPUTS DIRECT OUTPUTS INDIRECT OUTPUTS

The customer is concerned that the interior lamps do not come on when any door is opened.

2. What is the SYMPTOM?

3. What SYSTEM is at fault?

4. Circle all COMPONENTS that may be at fault to cause this concern.

Fuse

Door ajar switches

GEM moduleBattery Saver Relay

Interior Lamp Relay

Interior Lamps

Glove Box Lamp

Instrument Panel Dimming Module

Wiring / Connectors

5. What should your next diagnostic step be?A. Perform Active Commands (OSC)B. Monitor PIDs

C. Perform Inspection and Verification

D. Retrieve DTCs

E. Perform basic electrical diagnosis

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HOMEWORK DAY TWO


6. The Door Ajar lamp (an output of the GEM module) comes on when any door is open.Circle the COMPONENTS that may still be at fault to cause this concern.

Fuse

Door ajar switches

GEM module

Battery Saver Relay

Interior Lamp Relay

Interior Lamps

Glove Box Lamp


Wiring / Connectors

7. The interior lamps turn on with the Panel Dimmer Switch (part of Instrument Panel

Dimming Module). Circle the COMPONENTS that may still be at fault to cause thisconcern.

Fuse

Door ajar switches

GEM module

Battery Saver Relay

Interior Lamp Relay

Interior Lamps

Glove Box Lamp


Wiring / Connectors

8. What should your next diagnostic step be?

A. Perform Active Commands (OSC)B. Monitor PIDs

C. Perform Inspection and Verification

D. Retrieve DTCsE. Perform basic electrical diagnosis

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DAY TWO - HOMEWORK


9. There is a diagnostic trouble code (DTC

001_34S19T0

Documents

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