Transcript at the battery

Electrical Troubleshooting
&
Diagnosis
Chonan Technical Service Training Center
Body Electrical Troubleshooting
Contents
1. How to read ETM
2. Charging System
3. Starting System
4. Body Electrical
Chapter 1
How to read schematic diagram
Schematic Diagram
Ground Point : G07
Go4
Component location indexes
Ground Point : G07 Photo Location page
Component locations
CL Page : G07 Photo Location page
Connector configurations
CC Page : Connecter Configuration
Connector view and numbering order
Connector View
Female
Male
Remarks
It is not the shape of the
connector housing, but the
Actual
Illustration
connector pin that distinguishes
between male or female
connectors.
When numbering female and
male connectors, refer to the
numbering order in the following
Illustration
in
The Shop
manual
table.
Some connectors may not follow
this method of numbering order.
For individual detailed numbering,
refer to the CONNECTOR
CONFIGURATIONS
Numbering order
Female/Male Connector Numbering order
Numbering order Remarks
Female
Connector
Male
Connector
Numbering order Remarks
Numbered in order from upper
right to lower left
Numbered in order from upper
left to lower right
Harness layouts
Symbols in schematic
Symbols 1
Symbols in schematic
Symbols 2
Wire color abbreviations
Symbol
Color of wire
Symbol
Color of wire
B
Black
O
Orange
Br
Brown
P
Pink
G
Green
Pp
Purple
Gr
Gray
R
Red
L
Blue
T
Tan
Lg
Light green
W
White
LI
Light blue
Y
Yellow
Harness classification
Harness name
Location
Symbol
Engine harness
Engine compartment
E
Main, Floor, Roof, Seat harness
Passenger compartment
M
Control harness
Engine compartment
C
Rear and Trunk lid (Tail gate)
harness
Rear and Trunk lid
R
Instrument and Air bag harness
Under crash pad and Floor
I
Door harness
Door
D
Connector identification
Junction block identification
Chapter 2
Troubleshooting method
Troubleshooting procedures
☆ Verify the customer’s complaints
☆ Read and analyze the schematic diagram
☆ Inspect the circuit/ component with the problem isolated
☆ Repair the problem
☆ Make sure the circuit works
Troubleshooting equipment 1
★ Voltmeter and test lamp
★ Self-powered test lamp
and ohmmeter
Troubleshooting equipment 2
★ Jumper wire with fuse
★ Short finder
Troubleshooting test 1
◆ Testing for voltage
◆ Testing for continuity
Troubleshooting test 2
Testing for short to ground
Testing for a short with
a short finder
Chapter 3
Charging & Starting System
1. Charging System
2. Starting System
1. Charging System
Major Components of Charging System
- Alternator : Generates electricity.
- Rectifier : Changes the AC produced into the required DC.
- Regulator : Regulates the amount of electricity.
- Battery : Stores the electrical charge.
Alternator : Generates electricity.
HOT AT ALL TIMES
The amount of current
produced in the wire depends
on:
IGNITION KEY
ENG. ROOM
J / BOX
1) The strength of the magnetic field.
2) The difference in speed between the wire and field.
B
PASSENGER
ROOM
J / BOX
BATT.
G
CLUSTER
Charging
Lamp
G1
ETACS
B+
S
L
To Parking brake S/W
Brake F/Sensor
ALTERNATOR
G2
Rectifier : Changes the AC produced into the required DC.
HOT AT ALL TIMES
IGNITION KEY
ENG. ROOM
J / BOX
B
PASSENGER
ROOM
J / BOX
BATT.
G
CLUSTER
Charging
Lamp
G1
ETACS
B+
S
L
To Parking brake S/W
Brake F/Sensor
ALTERNATOR
G2
Regulator : Regulates the amount of electricity.
HOT AT ALL TIMES
IGNITION KEY
ENG. ROOM
J / BOX
B
PASSENGER
ROOM
J / BOX
BATT.
G
CLUSTER
Charging
Lamp
G1
IC regulator
ETACS
B+
S
L
To Parking brake S/W
Brake F/Sensor
Brush spring
ALTERNATORBrush
G2
IC regulator operation
Alternator operation – with Key ON position
Set the ignition switch in ON position.
Battery
Ignition switch
Alternator
(S terminal)
Ground
Charge lamp ON
Alternator
(L terminal)
Alternator operation – with idling
Start the engine.
Alternator
(B terminal)
Charging current to the battery
Power supplied current
to the body electrical
Ignition switch
Alternator
(S terminal)
Ground
Battery
Ground
Ground
Charging system diagnosis
Clean the Connections
▷Battery Test (Surface Discharge)
▷ Static Battery Test (No Load)
▷ Battery Test (Parasitic Load)
▷ Battery Test (Load).
Battery Test (Surface Discharge)
This test checks for a low current discharge across
the battery case.
1. Select voltage on your multi-meter.
2. Connect the negative (-) meter lead to the
negative (-) battery post.
3. Touch the positive (+) meter lead to the battery case
around the positive (+) battery post: Do not touch the post.
☆ A reading of more than 0.5 volts indicates excessive
surface discharge.
Static Battery Test (No Load)
Checks for the battery charge rate.
⊙ Turn the headlights ON for 15 seconds to dissipate
any battery surface charge.
⊙ Disconnect the battery negative (-) terminal.
⊙ Select Voltage on your multi-meter.
⊙ Connect the positive (+) meter lead to the battery
positive (+) post.
⊙ Connect the negative (-) meter lead to the negative (-)
battery post.
A reading of less than 12.4 Volts indicates an undercharged
battery
Battery Test (Parasitic Load)
This test is to check for excessive parasitic drain on the battery.
◐ Disconnect the battery negative (-) terminal.
◐ Be sure ignition switch is OFF.
◐ Set the multi-meter to Amps. Set to the highest setting
if your meter gives you the option. You can always step down if needed
◐ Connect the meter lead wires into the proper meter terminal.
◐ Connect the meter positive (+) lead to the battery negative (-)
terminal.
◐ Connect the meter negative (-) lead to the disconnected
negative (-) battery cable.
Parasitic draw should not be more than 100mA.
Battery Test (Load).
This tests the battery’s capacity to deliver sufficient cranking voltage.
- Select Voltage on your multi-meter.
- Connect the positive (+) meter lead to the positive (+) battery terminal.
- Connect the negative (-) meter lead to the negative (-) battery terminal.
- If your meter has the option to record the lowest value, select this option.
Otherwise, keep a close eye on the readout.
- Disable the ignition: crank the engine for 15 seconds.
A reading of less than 9.6 volts at 21oC (70oF) indicates a weak battery
Charging system diagnosis
Test the Charging System
▷ Negative (-) Engine Ground
▷ Negative (-) Chassis Ground
▷ Alternator Output ( at the battery)
Negative (-) Engine Ground
This test is best performed with the engine thoroughly warmed up.
§ Select Voltage on your multi-meter.
§ Touch the negative (-) meter lead to the negative (-) battery post
and the positive (+) meter lead to the positive (+) battery post.
Remember this reading! This will be the base voltage to compare
your test voltage against.
§ Connect the positive (+) meter lead to a clean spot on the
engine block.
§ Connect the negative (-) mater lead to the negative (-) battery post.
§ Disable the ignition; crank the engine for 2 ~ 3 seconds.
Compare this reading with your base reading. A voltage drop
of more than 0.5 Volts indicates a poor ground circuit.
Clean and inspect the battery cable connections and ground, and retest.
Negative (-) Chassis Ground
This test is best performed with the engine thoroughly
warmed up.
◆ Select Voltage on your multi-meter.
◆ Establish the base voltage to compare against
◆ Connect the positive (+) meter lead to a clean point
on the fender or chassis.
◆ Connect the negative (-) meter lead to the negative (-)
battery post.
◆ Turn ON all accessories (high beams, A/C fan - high,
rear window defogger, etc.)
◆ Disable the ignition; crank the engine for 2 ~ 3 seconds.
Compare this reading with your base reading. A voltage
drop of more than 0.5 Volts indicates a poor ground circuit.
Alternator Output (at the battery)
Checks the alternator output at the battery.
a. Select Voltage on your multi-meter.
b. Connect the positive (+) meter lead to the
positive (+) battery terminal.
d. Connect the negative (-) meter lead to the
negative (-) battery terminal.
e. Make sure all accessories are OFF.
f. Start the engine and hold at 1500 RPM.
A reading of 13.1 ~ 15.5 Volts is an acceptable charging
rate.
Charging system diagnosis
Test the Alternator
▷ Alternator Voltage Output (+), Loaded
▷ Overcharged Condition.
Alternator Voltage Output (+), Loaded)
Checks the alternator for output voltage.
a. Select Voltage on your multi-meter.
b. Connect the positive (+) meter lead to the battery
output (B+) on the back of the alternator.
c. Connect the negative (-) meter lead to the negative (-)
battery terminal.
d. Start the engine and hold at 1500 rpm.
A reading of 13.1 ~ 15.5 Volts is an acceptable charge rate.
Alternator Output Current (Amperage)
Turn ON high beams and blower fan to high, then
quickly increase engine speed to 2500 RPM.
Read the maximum output current on the meter.
Overcharged Condition.
If the battery is overcharged, remove the connector
at the alternator.
★ Turn the ignition switch to ON, but do not start the engine.
★ Connect a voltmeter between ground and the “S” terminal.
★ If no voltage is present, the circuit between the terminal
and the battery may be grounded or open circuit or
fuse open.
★ If voltage is above 16.0 volts with engine on,
the alternator is at fault.
Charging Circuit – Electric Charging current control by ECM type
Charging Circuit -- Electric Charging current control by ECM type
Electric Charging system internal circuit for current control by ECM type
R
IG S/W
R
BATT.
R
STATOR
COIL
R
R
C44-1. 1
A/T
ZD
R
R
R
ETCM
C44-2. 10
A/T
ROTOR COIL
※ introductory remarks
R : Resistor
TR : Transistor
ZD : Zener Diode
※ when No charging
“G” terminal “Low” signal : TR1 OFF - TR2 ON - TR3 OFF
§ when Charging
“G” terminal “High” signal : TR1 ON - TR2 OFF - TR3 ON
Electric Charging current control by ECM type Logic
FR & G Signal measure
CKP Signal
FR Signal
FR “ON” time
G Signal
2. Starting System
Starting System Diagnosis
Battery Power to Starter Solenoid (+)
Battery Power to Starter
Starter Current (Amperage)
Starting system major complaints
Starting system complaints are usually reported
as one of the following symptoms:
a. Starter will not operate.
b. Starter clicks, but will not crank the engine.
c. Starter cranks the engine slowly.
d. Starter spins, but will not crank the engine.
e. Starter spins, but is very noisy.
Battery Power to Starter Solenoid (+)
This test is best performed with the engine
thoroughly warmed up.
a. Select Voltage on your multi-meter.
b. Establish your base voltage.
c. Connect the positive (+) meter lead to the
positive (+) battery terminal.
d. Connect the negative (-) meter lead to the
positive (+) terminal on the start solenoid.
e. Disable the ignition; crank the engine for 2 ~ 3 seconds.
A voltage drop of more than 0.3 Volts indicates
a poor circuit.
Battery Power to Starter
This test checks battery power efficiency to the
starter motor through the solenoid.
a. Select Voltage on your multi-meter.
b. Establish your base voltage.
c. Connect the positive (+) meter lead to the positive (+)
battery terminal.
d. Connect the negative (-) meter lead to the positive (+)
terminal on the starter.
e.Disable the ignition; crank the engine for 2 ~ 3 seconds.
A voltage drop of more than 0.8 Volts indicates
a poor circuit through the solenoid.
Starter Current (Amperage)
a. Disconnect the battery cable at the starter.
b. Select Amps on your multi-meter.
c. Connect the positive (+) meter lead to the starter’s
battery terminal.
d. Connect the negative (-) meter lead to the disconnected
battery cable.
e. Ensure connections are tight, as high current will flow
through these.
f. Disable the ignition; crank the engine for 2 ~ 3 seconds.
Maximum amperage should be 80 ~ 100 Amps.
Several Problem Cases of start motor
Case 1 : Starter Will Not Operate
Case 2 : Starter clicks, but will not crank the engine
Case 3 : Starter cranks engine slowly
Case 4 : Starter spins but will not crank the engine
Case 5 : Starter Spins but Is very Noisy
Starting Circuit
Chapter 4
Body electrical
Lighting system
Head light circuit
Windshield wiper
Washer & Wiper Circuit
ST
IG1
IG2
IG2
Wiper Motor
A
Wiper Relay
M
M
Washer Motor
B
BATT 12V
Tr1
C
D
E
S
ETACSCM
H
LO
INT
OFF
HI
LO
W
M/Function wiper S/W
E
W INT INT
Power window
Power window Circuit 1
Power window
Power window Circuit 2
Power window
Power window Circuit 3
Power window
Power Window Circuit
Ignition Switch
To Drive Door Switch
To Assist Door Switch
To RR LH & RH Door Switch
AM Acc IG1 IG2 ST
Acc
ON
ST
Fusible
Link
ETACS
Control
Module
Power Window Relay
BATT.
Driver’s DR S/W
ETACS -- Defogger System
Defogger System Circuit
ST
IG1
IG2
IGN. S/W
Defogger Relay
5V
RR. Window
Glass
BATT 12V
Defogger S/W
ALT ˝L˝ terminal
ETACSCM
ETACS -- Door Key Hole Illumination Lamp
Door Key Hole Illumination Lamp Circuit
Driver side Door Handle Key Hole Illumination Lamp
CPU
5V
BATT 12V
ETACSCM
ETACS -- Room Lamp Delay Out & Keyless Unlock Timer
Room Lamp Delay Out & Keyless Unlock Timer Circuit(Dimming Lamp)
Room Lamp
ST
IG1
IG2
IGN. S/W
Receiver Antenna
BATT 12V
5V
Driver’s DR S/W
5V
Assist DR S/W
Remote Controller.
ETACSCM
ETACS -- Key Operated Warning
Key Operated Warning Circuit
to DR opening indicator
in cluster
Driver’s DR S/W
E
T
A
C
S
C
M
Key Operated Door Warning S/W
from BATT.
Chime Bell
ETACS – Battery saver
Tail Lamp Auto Cut(off) Circuit
ALTERNATOR
IGN SW
L
B1
B2 ACC IG2 IG1
DIMMER SW
ST
EB
ACC
R
HU
HS2
HS1
Lo
High
Pass'g
IG2
IG1
ST
100A
HL
LIGHT SW
TS
EL
OFF
TAIL
H/L
Fusible Link
Tail Lamp
Tail Lamp Relay
A5
A15
A8
H/Lamp RLY
BATT.
Driver’s
DR S/W
B14
B2
ETACSCM
Door Warning S/W
Head Lamp
ETACS – Auto Door Lock
Auto Door Lock Circuit
Ignition Switch
AM Acc IG1 IG2 ST
Acc
ON
ST
Battery
Dash
Fuse
Box
Fusible
Link
A
143Ω
143Ω
Battery
Unlock RLY
Battery
A
A
ETACS
Control
Module
Central Door Lock
Relay
A
Unlock
Each Door Lock
Actuator
Vehicle Speed Sensor
BATT.
Lock
Lock RLY.
Driver side
DR. Actuator
Lock/Unlock
S/W operated
by Key or
Knob
ETACS – Auto Door Unlock “1”
Auto Door Unlock Control “1” Circuit
Ignition Switch
Ignition Switch OFF → Auto DR Unlock
AM Acc IG1 IG2 ST
Acc
ON
ST
Battery
Dash
Fuse
Box
Fusible
Link
A
143Ω
143Ω
Battery
Unlock RLY
Battery
A
A
ETACS
Control
Module
Central Door Lock
Relay
A
Unlock
Each Door Lock
Actuator
Vehicle Speed Sensor
BATT.
Lock
Lock RLY.
Driver side
DR. Actuator
Lock/Unlock
S/W operated
by Key or
Knob
ETACS – Auto Door Unlock Control “2” by SRSCM
Auto Door Unlock Control “2” Circuit after A/BAGCM Crash Signal
A/BAG
Module
Ignition Switch
AM Acc IG1 IG2 ST
Acc
ON
A/BAGCM
CRASH
SIGNAL
A : Door Lock Actuator
ST
Fusible
Link
Dash
Fuse
Box
Battery
143Ω
ETACS
Control
Module
Vehicle Speed Sensor
BATT.
Lock
Lock RLY.
A
A
A
A
Unlock
Unlock RLY
143Ω
Central Door Lock
Relay in J/BOX.
Each Door Lock
Actuator
ETACS – Auto Door Unlock control by Auto fuel cut switch
◆ Auto
Door Unlock control Circuit
From Battery
Ignition Switch
M
AM Acc IG1 IG2 ST
Roll Over Switch
ECM
From IGN. SW
Fuel Pump
Fuel Pump Relay
Acc
ON
A : Door Lock Actuator
ST
Fusible
Link
Dash
Fuse
Box
Battery
143Ω
ETACS
Control
Module
Vehicle Speed Sensor
BATT.
Lock
Lock RLY.
A
A
A
A
Unlock
Unlock RLY
143Ω
Central Door Lock
Relay in J/BOX.
Each Door Lock
Actuator
ETACS – Ignition Key Reminder Control
Ignition Key Reminder Control Circuit
Ignition Switch
AM Acc IG1 IG2 ST
Acc
ON
ST
Door Lock Knob
Dash
Fuse
Box
143Ω
143Ω
Unlock RLY
Door Warning
Switch
A
A
A
ETACS
Control
Module
Central Door Lock
Relay
A
Battery
Unlock
Each Door Lock
Actuator
Fusible Link
BATT.
Lock
Lock RLY.
Driver side
DR. Actuator
Lock/Unlock
S/W operated
by Key or
Knob
ETACS – Central Door Lock Control
Central Door Lock Control Circuit by Remote Controller Circuit.
Ignition Switch
AM Acc IG1 IG2 ST
Acc
ON
ST
Battery
Dash
Fuse
Box
Lock
Lock RLY.
Fusible
Link
A
143Ω
143Ω
Battery
Unlock RLY
Battery
A
A
Unlock
Each Door Lock
Actuator
BATT.
ETACS
Control
Module
Central Door Lock
Relay
A
Driver side
DR. Actuator
Lock/Unlock
S/W operated
by Key or
Knob
ETACS – with Anti theft Function
Alarm & Hazard circuit
ST
IG1
IG2
Siren
IGN. SW
Hazard Warning Relay
From Flasher unit LH
Turn signal.
BATT. 12V
From Flasher unit LH
Turn signal.
Start out Relay
(Burglar Alarm Relay)
FRT LH, RH DR SW
Trunk-lid SW
Hood SW.
5V
From start
relay
Turn signal Lamp
LH
A/T : Inhibitor
M/T : IGN. Lock SW
ETACS
RH
ETACS – with Anti theft Function
Start Inhibitor circuit
To Start Motor
ST Terminal
ST
IG1
IG2
Q1.What we have to check is start motor
doesn’t work in Anti-theft system?(no power
Start Relay
supply to the “ST” terminal of start motor.
IGN. SW
Start Out Relay
(Burglar Alarm )
Q2.What is the voltage of the pin from Ignition
lock switch start out relay?(Pin No 8)
2-1.at Alarm mode : (
2-2.at Disarm mode : (
8
BATT 12V
M70-2
2-3.at Arm mode : (
) volt
) volt
) volt
Q3.What are the conditions for
Burglar Alarm Relay to be on?
A/TA : Inhibitor
Switch
ETACS
M/TA : IGN Lock
Switch
ETACS – with Anti theft Function
Start Inhibitor circuit 2
IGN SW
ALTERNATOR
L
R
B1
AC
C
B2
AC
C
IG2 IG1
ST
IG2
START RELAY
IG1
ST
100A
Start inhibitor relay
Inhibitor S/W(A/T)
2
L
3 D
N
R
P
C12
M
ST MOTOR
ETACSCM
IMS (Integrated Memory System)
System block diagram
IMS power seat control system construction
IMS mirror control system construction
IMS Circuit diagram
Rain sensing windshield wiper Diagnosis
FAULT DETECTION
The rain sensor has two levels of Fault detection as described below.
Fault A detected
Fault A is indicated when the sensor has detected that the sensor servo
operating point is above the expected limits.
This is an indication of damage to the windscreen in the area of the coupler
or the sensor has been removed from the coupler.
Fault B detected
Fault B is indicated when the sensor has detected that it no longer is responding
to rain signals. This is an indication of damage to the windscreen in the area of the
coupler or, more likely, that the sensor has detected an electrical failure within the
sensor.
Rain Sensor Diagnostic Flow
Use sensitivity adjustment(volume switch) to indicate fault
A method to indicate detected faults is available to a service garage technician by using
the sensitivity adjustment(volume switch) input and the wipers as an indicator.
The service method is described as follows:
Step 1
1. With ignition on, move the sensitivity adjustment to the high sensitivity setting with
“Auto” position of the wiper INT. volume switch.
2. Decrease the sensitivity(volume switch) by one setting.(5th to 4th speed of the INT.
volume switch)
3. If a wipe occurs, then Fault A has been detected and the service technician
should assure that the coupler area on the windscreen is not damaged
and the sensor is secured to the coupler.
Step 2
4. Decrease the sensitivity(volume switch) one more setting.(4th to 3th speed of the
volume switch)
5. If a wipe occurs, then Fault B has been detected and the sensor
should be removed and replaced with a known good sensor.
Circuit Diagram - Low speed control
Ignition Switch
AM Acc IG1 IG2 ST
Acc
ON
ST
Wiper Motor
Lo-SPD. Wiper Relay(ON)
M
4
Washer
Motor
M
1
6
BATT.
Rain
Sensor
Rain
Sensor
Module
7
2
5
8
Hi-SPD.Wiper Relay(Off)
S
3
AT
OFF
HI
LO
W
H
LO
E
W AT AT
Wiper Switch
(Multi Function S/W)
Circuit Diagram - High speed control
Ignition Switch
AM Acc IG1 IG2 ST
Acc
ON
ST
Lo-SPD. Wiper Relay(ON)
M
4
Washer
Motor
Wiper Motor
M
1
6
BATT.
Rain
Sensor
Rain
Sensor
Module
7
2
5
8
Hi-SPD. Wiper Relay(ON)
S
3
AT
OFF
HI
LO
W
H
LO
E
W AT AT
Wiper Switch
(Multi Function S/W)
HID Headlamp
Components : Bulb, Igniter, Ballast
Bulb
Igniter Socket
Ballast
HID Headlamp device waveform & ARC Image
IGN.
Key
ON
OFF
Heal Light ON
Switch
OFF
20
Kv
Voltage secure Area(AC current)
Heal Light
Bulb Voltage
400 Hz
85 volt(3A)
0 volt
25 ms 500 ms
HID Circuit
Fuse:15A
+
Battery
RH
Head Lamp Relay
H.I.D
Ballast
12V
RH
Bulb
Fuse:15A
LH
Head Lamp Relay
H.I.D
Ballast
12V
LH
Bulb
Caution items while inspect HID Lighting
◆ There is a high voltage around the HID Igniter while HID Bulb is ON.
so, that the inspection is allowed only while head Lamp Switch is Off.
◆ Do not Head Light Switch On when HID Lamp Igniter Connector
is disconnected.(When the switch is On, 20KV is applied to Igniter)
◆ The HID BULB manufacturer of RH & LH should be same.
Ex : Osram or Philips
◆ Do not fix HID Lighting System by customer when it fails.
Auto light sensor module
Specification
Item
Specification
Rated voltage
12 volts
Working voltage
9 ~ 16 volts
Load
Max 200mA relay load
Working Temperature
-30℃ ~ +80℃
Conservation
temperature
-40℃ ~ +120℃
Install location
On the crash pad
Auto Light Operation ON/OFF
Time Chart
500 ms Later “ON”
Tail Lamp
3 sec. Later “Off”
ON
Illumination
OFF
23.1 Lux (0.78 Volt)
48.1 Lux (1.3 Volt)
Head Lamp ON
Illumination
OFF
6.2 Lux (0.36 Volt)
12 Lux (0.52 Volt)
Auto Light Circuit Diagram
Ignition Switch
Multi Function switch
AM Acc IG1 IG2 ST
TS HS1 G
EB HL HU HS2
Acc
Lo
Off
ON
Hi
Tail
ST
P
H/L
AT
◐ Pin Voltage check
IG. & Auto switch ON
Pin
No.
Auto
Dash
Fuse
Box
1
Tail Lamp
Tail Lamp RLY
5
3
2
Fusible
Link
3
2
ETACS
4
1
BATT.
Head Lamp RLY
Head Lamp
Auto
Light
Sensor
6
5
6
at condition at condition
of lamp OFF of lamp ON
IGN.Off
IGN.ON
Auto mode
Auto mode