Table Of Contentker88839_fm.qxd 1/9/06 11:37 AM Page i
Automotive
Electrical
and
Electronic
Systems
Classroom
Manual
Fifth Edition Update
Chek-Chart
John F. Kershaw,Ed.D.
Revision Author
James D. Halderman
Series Advisor
Upper Saddle River, New Jersey
Columbus, Ohio
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Executive Editor:Tim Peyton
Editorial Assistant:Nancy Kesterson
Production Editor:Christine Buckendahl
Production Supervision:Angela Kearney, Carlisle Editorial Services
Design Coordinator:Diane Y. Ernsberger
Cover Designer:Jeff Vanik
Cover photo:Super Stock
Production Manager:Deidra Schwartz
Marketing Manager:Ben Leonard
This book was set in Times by Carlisle Publishing Services.It was printed and bound by Bind Rite Graphics.
The cover was printed by Lehigh.
Portion of materials contained herein have been reprinted with permission of General Motors Corporation,
Service and Parts Operations. License Agreement #0310805.
Copyright © 2007 by Pearson Education, Inc., Upper Saddle River, New Jersey 07458.
Pearson Prentice Hall. All rights reserved. Printed in the United States of America. This publication is
protected by Copyright and permission should be obtained from the publisher prior to any prohibited
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10 9 8 7 6 5 4 3 2 1
ISBN 0-13-238883-9
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Introduction
Automotive Electrical and Electronic Systemsis part of The entire series is job-oriented, designed for stu-
the Chek-Chart Series in Automotive Technology, dents who intend to work in the automotive service
which also includes: profession. Knowledge gained from these books and
the instructors enables students to get and keep jobs in
• Automatic Transmissions and Transaxles
the automotive repair industry. Learning the material
• Automotive Brake Systems
and techniques in these volumes is a giant leap toward
• Automotive Heating, Ventilation, and Air
a satisfying, rewarding career.
Conditioning
• Automotive Manual Drive Train and Rear Axle
• Automotive Steering, Suspension, and Wheel
NEW TO THE FIFTH
Alignment
• Automotive Engine Repair and Rebuilding EDITION UPDATE
• Engine Performance,Diagnosis,and Tune-Up
• Fuel Systems and Emission Controls.
The fifth edition of Automotive Electrical and
Since 1929, the Chek-Chart Series in Automotive Electronic Systems has been updated to include new
Technology has provided vehicle specification, coverage of ignition systems. Ignition coverage had
training, and repair information to the professional been a standard feature of the text through the fourth
automotive service field. edition, but was removed from the fifth edition. Based
Each book in the Chek-Chart series aims to help on feedback from numerous users who wanted the
instructors teach students to become competent and ignition material back in the book, this updated fifth
knowledgeable professional automotive technicians. edition was produced. It includes new ignition chap-
The texts are the core of a learning system that leads ters in both the Classroomand Shop Manuals.
a student from basic theories to actual hands-on
experience.
iii
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How to Use This Book
WHY ARE THERE • Each chapter is divided into self-contained sec-
tions for easier understanding and review. This
TWO MANUALS?
organization clearly shows which parts make up
which systems and how various parts or systems
Unless you are familiar with the other books in this that perform the same task differ or are the same.
series, Automotive Electrical and Electronic Systemsis • Most parts and processes are fully illustrated with
unlike any other textbook you have used before. It is drawings or photographs. Important topics appear
actually two books, the Classroom Manualand the Shop in several different ways, to make sure other
Manual. They have different purposes and should be aspects of them are seen.
used together. • Alist of Key Terms begins each chapter. These
The Classroom Manual teaches what a technician terms are printed in boldfacetype in the text and
needs to know about electrical and electronic theory, defined in the Glossary at the end of the manual.
systems, and components. The Classroom Manual is Use these words to build the vocabulary needed to
valuable in class and at home, both for study and for understand the text.
reference. The text and illustrations can be used for • Review Questions are included for each chapter.
years hence to refresh your memory about the basics of Use them to test your knowledge.
automotive electrical and electronic systems and also • Every chapter has a brief summary at the end to
about related topics in automotive history, physics, help you review for exams.
mathematics, and technology. This fifth edition update • Brief but informative sidebars augment the techni-
text is based upon detailed learning objectives, which cal information and present “real world” aspects of
are listed in the beginning of each chapter. the subject matter.
The Shop Manual teaches test procedures, trou-
The Shop Manualhas detailed instructions on test,
bleshooting techniques, and how to repair the systems
service, and overhaul procedures for modern electri-
and components introduced in the Classroom Manual.
cal and electronic systems and their components.
The Shop Manualprovides the practical, hands-on infor-
These are easy to understand and often include step-
mation required for working on automotive electrical
by-step explanations of the procedure. The Shop
and electronic systems. Use the two manuals together to
Manualcontains:
understand fully how the systems work and how to make
repairs when something is not working. This fifthedition • ASE/NATEF tasks, which are listed in the begin-
update text is based upon the 2002 NATEF (National ning of each chapter and form the framework for
Automotive Technicians Education Foundation) Tasks, the chapter’s content
which are listed in the beginning of each chapter. The • A list of Key Terms at the beginning of each
fifth edition update Shop Manual contains Job Sheet chapter (These terms are printed in boldface type
assessments that cover the 56 tasks in the NATEF 2002 where first used in the text.)
A6 Electrical/Electronics repair area. • Helpful information on the use and maintenance
of shop tools and test equipment
• Safety precautions
WHAT IS IN THESE
• Clear illustrations and diagrams to help you
locate trouble spots while learning to read ser-
MANUALS?
vice literature
• Test procedures and troubleshooting hints that
The following key features of the Classroom Manual
help you work better and faster
make it easier to learn and remember the material:
• Repair tips used by professionals, presented
• Each chapter is based on detailed learning objec- clearly and accurately
tives, which are listed in the beginning of each • Asample test at the back of the manual that is sim-
chapter. ilar to those given for Automotive Service
iv
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How to Use This Book v
Excellence (ASE) certification (Use this test to When reading the Classroom Manual,be sure to refer
help you study and prepare when you are ready to to the Shop Manualto relate the descriptive text to the
be certified as an electrical and electronics expert.) service procedures. When working on actual vehicle
systems and components, look to the Classroom
Manual to keep the basic information fresh in your
mind. Working on such a complicated piece of equip-
WHERE SHOULD ment as a modern automobile is not easy. Use the
information in the Classroom Manual,the procedures
I BEGIN? in the Shop Manual, and the knowledge of your
instructor to guide you.
If you already know something about automotive elec- The Shop Manual is a good book for work, not
trical and electronic systems and how to repair them, just a good workbook. Keep it on hand whileactually
this book is a helpful review. If you are juststarting in working on a vehicle. It will lie flat on the work-
automotive repair, then this book provides a solid foun- bench and under the chassis, and it is designed to
dation on which to develop professional-level skills. withstand quite a bit of rough handling.
Your instructor has designed a course that builds on When you perform actual test and repair
what you already know and effectively uses the avail- procedures, you need a complete and accurate source
able facilities and equipment. You may be asked to of manufacturer specifications and procedures for
read certain chapters of these manuals out of order. the specific vehicle. As the source for these specifi-
That’s fine. The important thing is to really understand cations, most automotive repair shops have the
each subject before moving on to the next. annual service information (on paper, CD, or
Study the Key Terms in boldface type and use the Internet formats) from the vehicle manufacturer or
review questions to help understand the material. an independent guide.
v
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Acknowledgments
The publisher sincerely thanks the following vehi- Mercedes-Benz USA, Inc.
cle manufacturers, industry suppliers, and organi- Mitsubishi Motor Sales of America, Inc.
zations for supplying information and illustrations Nissan North America, Inc.
used in the Chek-Chart Series in Automotive The Prestolite Company
Technology. Robert Bosch Corporation
Saab Cars USA, Inc.
Allen Testproducts
Snap-on Tools Corporation
American Isuzu Motors, Inc.
Toyota Motor Sales, U.S.A., Inc.
Automotive Electronic Services
Vetronix Corporation
Bear Manufacturing Company
Volkswagen of America
Borg-Warner Corporation
Volvo Cars of North America
DaimlerChrysler Corporation
Delphi Corporation The comments, suggestions, and assistance of
Fluke Corporation the following reviewers were invaluable: Rick
Fram Corporation Escalambre, Skyline College, San Bruno, CA,
General Motors Corporation and Eugene Wilson, Mesa Community College,
Honda Motor Company, Ltd. Mesa, AZ.
Jaguar Cars, Inc.
The publisher also thanks Series Advisor
Marquette Manufacturing Company
James D. Halderman.
Mazda Motor Corporation
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Contents
Chapter 1 — Tools,Fasteners,and Safety 1 Chapter 4 — Magnetism 53
Learning Objectives 1 Learning Objectives 53
Key Terms 1 Key Terms 53
Threaded Fasteners 1 Magnetism 54
Metric Bolts 2 Electromagnetism 55
Grades of Bolts 2 Electromagnetic Induction 60
Nuts 3 Transformers 65
Washers 4 Electromagnetic Interference (EMI)
Basic Tool List 4 Suppression 65
Tool Sets and Accessories 10 Summary 68
Brand Name Versus Proper Term 10 Review Questions 70
Safety Tips for Using Hand Tools 11
Chapter 5 — Series,Parallel,and Series-
Measuring Tools 11
Parallel Circuits 71
Safety Tips for Technicians 13
Learning Objectives 71
Safety in Lifting (Hoisting) a Vehicle 15
Key Terms 71
Electrical Cord Safety 17
Basic Circuits 71
Fire Extinguishers 19
Series Circuit 72
Summary 20
Parallel Circuit 72
Review Questions 20
Series Circuit Voltage Drops 73
Chapter 2 — Introduction to Electricity 21 Parallel Circuit Voltage Drops 75
Learning Objectives 21 Calculating Series Circuit Total
Key Terms 21 Resistance 76
What is Electricity? 22 Calculating Parallel Circuit Total
Atomic Structure 22 Resistance 78
Sources of Electricity 25 Series-Parallel Circuits 79
Historical Figures in Electricity 30 Series and Parallel Circuit Faults 82
Summary 31 Summary of Series Circuit Operation 84
Review Questions 32 Summary of Parallel Circuit Operation 84
Review Questions 85
Chapter 3 — Electrical Fundamentals 35
Learning Objectives 35 Chapter 6 — Electrical Diagrams and
Key Terms 35 Wiring 89
Conductors and Insulators 36 Learning Objectives 89
Characteristics of Electricity 36 Key Terms 89
Complete Electrical Circuit 40 Wiring and Harnesses 90
Ohm’s Law 42 Wire Types and Materials 92
Power 44 Wire Size 93
Capacitance 45 Connectors and Terminals 96
Summary 49 Ground Paths 99
Review Questions 50 Multiplex Circuits 100
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x Contents
Electrical System Polarity 103 Permanent-Magnet Fields 197
Common Electrical Parts 103 Starter Motor and Drive Types 198
Wire Color Coding 109 Overrunning Clutch 203
The Language of Electrical Diagrams 111 Summary 204
Diagrams 112 Review Questions 206
Summary 124
Chapter 10 — Automotive Electronics 209
Review Questions 126
Learning Objectives 209
Chapter 7 — Automotive Battery Key Terms 209
Operation 129 Semiconductors 210
Learning Objectives 129 Electrostatic Discharge (ESD) 213
Key Terms 129 Diodes 213
Electrochemical Action 130 Photonic Semiconductors 215
Battery Electrolyte 134 Rectifier Circuits 216
State-of-Charge Indicators 135 Transistors 217
Wet-Charged and Dry-Charged Silicon-Controlled Rectifiers (SCRs) 221
Batteries 136 Integrated Circuits 222
Battery Charging Voltage 136 Using Electronic Signals 222
Battery Selection and Rating Methods 136 Summary 223
Battery Installations 138 Review Questions 224
Battery Installation Components 140
Chapter 11 — The Ignition Primary and
Battery Life and Performance Factors 142
Secondary Circuits and Components 227
Summary 144
Learning Objectives 227
Review Questions 145
Key Terms 227
Chapter 8 — Charging System Operation 147 Need for High Voltage 228
Learning Objectives 147 High Voltage Through Induction 228
Key Terms 147 Basic Circuits and Current 229
Charging System Development 148 Primary Circuit Components 230
DC Generator 148 Switching and Triggering 230
Charging Voltage 148 Monitoring Ignition Primary Circuit
Diode Rectification 150 Voltages 234
AC Generator (Alternator) Components 152 Primary and Secondary Circuits 236
Current Production in an AC Generator 156 Ignition Coils 237
Voltage Regulation 161 Distributor Cap and Rotor 247
Electromagnetic Regulators 162 Ignition Cables 250
Solid-state Regulators 163 Spark Plugs 250
Charge/Voltage/Current Indicators 168 Spark Plug Construction 252
Charging System Protection 170 Summary 255
Complete AC Generator Operation 170 Review Questions 256
AC Generator (Alternator) Design
Chapter 12 — Automotive Lighting
Differences 171
Systems 257
Summary 179
Learning Objectives 257
Review Questions 181
Key Terms 257
Chapter 9 — Starting System Operation 183 Headlamp Circuits 258
Learning Objectives 183 Common Automotive Bulbs 268
Key Terms 183 Taillamp, License Plate Lamp, and Parking
Starting System Circuits 184 Lamp Circuits 269
Basic Starting System Parts 184 Stop Lamp and Turn Signal Circuits 270
Specific Starting Systems 188 Hazard Warning Lamp (Emergency Flasher)
Starter Motors 192 Circuits 274
Frame and Field Assembly 192 Backup Lamp Circuits 275
DC Starter Motor Operation 194 Side Marker and Clearance Lamp
Armature and Commutator Assembly 197 Circuits 276
