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BRIEF CONTENTS CHAPTER 1 Strategy-Based Diagnostics � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 1 CHAPTER 2 Safety � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 23 CHAPTER 3 Basic Tools and Precision Measuring � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 51 CHAPTER 4 Fasteners and Thread Repair � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 113 CHAPTER 5 Principles of Electrical Systems � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 137 CHAPTER 6 Sources and Effects of Electricity � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 155 CHAPTER 7 Ohm’s Law and Circuits � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 167 CHAPTER 8 Electrical Components � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 181 CHAPTER 9 Electronic Components � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 203 CHAPTER 10 Digital Multimeter Use and Circuit Testing Procedures � � � � � � � � � � � � � � � � 215 CHAPTER 11 Wires and Wiring Harnesses � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 263 CHAPTER 12 Electrical Testing Procedures � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 289 CHAPTER 13 Batteries � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 299 CHAPTER 14 Starting Systems � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 329 CHAPTER 15 Charging Systems � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 359 CHAPTER 16 Lighting System Fundamentals � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 383 Appendix A 2017 NATEF Automobile Accreditation Task List Correlation Guide � � � � � 405 Glossary � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 421 Index � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 429 CONTENTS CHAPTER 1 Strategy-Based Diagnostics � � � � � � �1 How to Avoid Broken Fasteners � � � � � � � � � � � � � � � � 128 Introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 2 Thread Repair � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 128 Vehicle Service History � � � � � � � � � � � � � � � � � � � � � � � � � 2 Ready for Review � � � � � � � � � � � � � � � � � � � � � � � � � � � 134 Strategy-Based Diagnostic Process � � � � � � � � � � � � � � � � 5 Key Terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 134 Documenting the Repair � � � � � � � � � � � � � � � � � � � � � � � 16 Review Questions � � � � � � � � � � � � � � � � � � � � � � � � � � � 134 Ready for Review � � � � � � � � � � � � � � � � � � � � � � � � � � � � 20 ASE Technician A/Technician B Style Questions � � � � 135 Key Terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 21 Review Questions � � � � � � � � � � � � � � � � � � � � � � � � � � � � 21 CHAPTER 5 Principles of Electrical ASE Technician A/Technician B Style Questions � � � � � 22 Systems � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �137 Introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 138 CHAPTER 2 Safety � � � � � � � � � � � � � � � � � � � � � � � �23 Electrical Fundamentals� � � � � � � � � � � � � � � � � � � � � � � 138 Introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 24 Volts, Amps, and Ohms � � � � � � � � � � � � � � � � � � � � � � 141 Personal Safety � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 24 Electrical 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� � � � � � � � � � � � � � � � � � � � � � � � � � � � 151 Review Questions � � � � � � � � � � � � � � � � � � � � � � � � � � � 151 CHAPTER 3 Basic Tools and Precision ASE Technician A/Technician B Style Questions � � � � 152 Measuring � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �51 Introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 52 CHAPTER 6 Sources and Effects General Safety Guidelines � � � � � � � � � � � � � � � � � � � � � � 52 of Electricity � � � � � � � � � � � � � � � � � � � � � � � � � � �155 Basic Hand Tools � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 58 Introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 156 Precision Measuring Tools � � � � � � � � � � � � � � � � � � � � � � 88 Sources of Electricity � � � � � � � � � � � � � � � � � � � � � � � � 156 Cleaning Tools and Equipment � � � � � � � � � � � � � � � � � 105 Effects of Electricity � � � � � � � � � � � � � � � � � � � � � � � � � � 160 Ready for Review � � � � � � � � � � � � � � � � � � � � � � � � � � � 108 Ready for Review � � � � � � � � � � � � � � � � � � � � � � � � � � � 162 Key Terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 109 Key Terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 163 Review Questions � � � � � � � � � � � � � � � � � � � � � � � � � � � 111 Review Questions � � � � � � � � � � � � � � � � � � � � � � � � � � � 163 ASE Technician A/Technician B Style Questions � � � � 111 ASE Technician A/Technician B Style Questions � � � � 164 CHAPTER 4 Fasteners and Thread Repair � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �113 CHAPTER 7 Ohm’s Law and Circuits � � � � � � � �167 Introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 114 Introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 168 Threaded Fasteners and Torque � � � � � � � � � � � � � � � � 114 Ohm’s Law� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 168 Fastener Standardization � � � � � � � � � � � � � � � � � � � � � � 115 Circuits � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 172 Bolts, Studs, and Nuts � � � � � � � � � � � � � � � � � � � � � � � � 116 Ready for Review � � � � � � � � � � � � � � � � � � � � � � � � � � � 176 Threadlocker and Antiseize � � � � � � � � � � � � � � � � � � � 123 Key Terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 177 Screws � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 124 Review Questions � � � � � � � � � � � � � � � � � � � � � � � � � � � 178 Torque-to-Yield and Torque Angle � � � � � � � � � � � � � � 125 ASE Technician A/Technician B Style Questions � � � � 178 CONTENTS v CHAPTER 8 Electrical Components � � � � � � � �181 CHAPTER 11 Wires and Wiring Harnesses � � �263 Introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 182 Introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 264 Switches � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 182 Wire Fundamentals � � � � � � � � � � � � � � � � � � � � � � � � � � 264 Fuses, Fusible Links, and Circuit Breakers � � � � � � � � � 184 Wiring Diagram Fundamentals � � � � � � � � � � � � � � � � � 270 Flash Can/Control � � � � � � � � � � � � � � � � � � � � � � � � � � � 186 Wire Maintenance and Repair � � � � � � � � � � � � � � � � � 275 Relays and Relay Control Circuits � � � � � � � � � � � � � � 186 Ready for Review � � � � � � � � � � � � � � � � � � � � � � � � � � � 285 Solenoids � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 189 Key Terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 286 Motors � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 190 Review Questions � � � � � � � � � � � � � � � � � � � � � � � � � � � 287 Ignition Coils and Transformers � � � � � � � � � � � � � � � � 193 ASE Technician A/Technician B Style Questions � � � � 287 Resistors � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 195 Capacitors � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 198 CHAPTER 12 Electrical Testing Procedures � � �289 Ready for Review � � � � � � � � � � � � � � � � � � � � � � � � � � � 199 Introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 290 Key Terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 201 Graphing Multimeters � � � � � � � � � � � � � � � � � � � � � � � � 290 Review Questions � � � � � � � � � � � � � � � � � � � � � � � � � � � 201 Oscilloscopes � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 294 ASE Technician A/Technician B Style Questions � � � � 202 Ready for Review � � � � � � � � � � � � � � � � � � � � � � � � � � � 296 Key Terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 297 CHAPTER 9 Electronic Components � � � � � � � �203 Review Questions � � � � � � � � � � � � � � � � � � � � � � � � � � � 297 Introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 204 ASE Technician A/Technician B Style Questions � � � � 298 Electronic Components � � � � � � � � � � � � � � � � � � � � � � 204 Transistors � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 207 CHAPTER 13 Batteries � � � � � � � � � � � � � � � � � � �299 Control Modules � � � � � � � � � � � � � � � � � � � � � � � � � � � � 208 Introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 300 Integrated Circuits � � � � � � � � � � � � � � � � � � � � � � � � � � 209 What Is a Battery? � � � � � � � � � � � � � � � � � � � � � � � � � � � 300 Microprocessors � � � � � � � � � � � � � � � � � � � � � � � � � � � � 209 Battery Charging and Discharging Cycles� � � � � � � � � 302 Microcontrollers � � � � � � � � � � � � � � � � � � � � � � � � � � � � 210 Lead Acid, Gel Cell, and AGM Batteries � � � � � � � � � � 306 Speed Control Circuits � � � � � � � � � � � � � � � � � � � � � � � 210 Battery Testing Procedure � � � � � � � � � � � � � � � � � � � � � 310 Ready for Review � � � � � � � � � � � � � � � � � � � � � � � � � � � 211 Ready for Review � � � � � � � � � � � � � � � � � � � � � � � � � � � 325 Key Terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 212 Key Terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 327 Review Questions � � � � � � � � � � � � � � � � � � � � � � � � � � � 213 Review Questions � � � � � � � � � � � � � � � � � � � � � � � � � � � 327 ASE Technician A/Technician B Style Questions � � � � 213 ASE Technician A/Technician B Style Questions � � � � 328 CHAPTER 10 Digital Multimeter Use CHAPTER 14 Starting Systems � � � � � � � � � � � �329 and Circuit Testing Procedures � � � � � � � � � � � �215 Introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 330 Introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 216 Engine Starting (Cranking) System � � � � � � � � � � � � � � 330 DMM Fundamentals � � � � � � � � � � � � � � � � � � � � � � � � � 216 Starter Motor Construction � � � � � � � � � � � � � � � � � � � 333 DMM Uses � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 220 Starter Motor Operation � � � � � � � � � � � � � � � � � � � � � 337 Measuring Volts, Ohms, and Amps � � � � � � � � � � � � � � � 223 Starter Drives and the Ring Gear � � � � � � � � � � � � � � � 340 DVOM/DMM Testing Procedures � � � � � � � � � � � � � � � 226 Starting System Procedures � � � � � � � � � � � � � � � � � � � 343 Current and Resistance Exercises � � � � � � � � � � � � � � 232 Ready for Review � � � � � � � � � � � � � � � � � � � � � � � � � � � 354 Series Circuit Exercises � � � � � � � � � � � � � � � � � � � � � � � 239 Key Terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 355 Parallel Circuit Exercises � � � � � � � � � � � � � � � � � � � � � � 246 Review Questions � � � � � � � � � � � � � � � � � � � � � � � � � � � 356 Understand Circuit Types � � � � � � � � � � � � � � � � � � � � � 251 ASE Technician A/Technician B Style Questions � � � � 356 Locating Opens, Shorts, Bad Grounds, and High Resistance � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 256 CHAPTER 15 Charging Systems � � � � � � � � � � � �359 Ready for Review � � � � � � � � � � � � � � � � � � � � � � � � � � � 259 Introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 360 Key Terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 260 Charging System Theory � � � � � � � � � � � � � � � � � � � � � � 360 Review Questions � � � � � � � � � � � � � � � � � � � � � � � � � � � 260 Alternator Principles � � � � � � � � � � � � � � � � � � � � � � � � � 360 ASE Technician A/Technician B Style Questions � � � � 261 Hybrid Vehicle Charging Systems � � � � � � � � � � � � � � � 369 vi CONTENTS Charging System Procedures � � � � � � � � � � � � � � � � � � 370 Ready for Review � � � � � � � � � � � � � � � � � � � � � � � � � � � 400 Ready for Review � � � � � � � � � � � � � � � � � � � � � � � � � � � 379 Key Terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 402 Key Terms � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 381 Review Questions � � � � � � � � � � � � � � � � � � � � � � � � � � � 402 Review Questions � � � � � � � � � � � � � � � � � � � � � � � � � � � 381 ASE Technician A/Technician B Style ASE Technician A/Technician B Style Questions � � � � 381 Questions � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 403 CHAPTER 16 Lighting System Fundamentals � � �383 Appendix A 2017 NATEF Automobile Introduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 384 Accreditation Task List Correlation Guide � � � � � � 405 Types of Lamps � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 384 Glossary � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 421 Types and Styles of Lighting Systems � � � � � � � � � � � � 388 Index � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 429 Lighting Systems Procedures and Peripheral Systems � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 397 NOTE T O STUDENTS This book was created to help you on your path to a career in the transportation industry. Employability basics covered early in the text will help you get and keep a job in the field. Essential technical skills are built in cover to cover and are the core building blocks of an advanced technician’s skill set. This book also introduces “strategy-based diagnostics,” a method used to solve technical problems correctly on the first attempt. The text covers every task the industry standard recommends for technicians, and will help you on your path to a successful career. As you navigate this textbook, ask yourself, “What does a technician need to know and be able to do at work?” This book is set up to answer that question. Each chapter starts by listing the technicians’ tasks that are covered within the chapter. These are your objectives. Each chapter ends by reviewing those things a technician needs to know. The content of each chapter is written to explain each objective. As you study, continue to ask yourself that question. Gauge your progress by imagining yourself as the technician. Do you have the knowledge, and can you perform the tasks required at the beginning of each chapter? Combining your knowledge with hands-on experience is essential to becoming a Master Technician. During your training, remember that the best thing you can do as a technician is learn to learn. This will serve you well because vehicles keep advancing, and good technicians never stop learning. Stay curious. Ask questions. Practice your skills, and always remember that one of the best resources you have for learning is right there in your classroom… your instructor. Best wishes and enjoy! The CDX Automotive Team ACKNOWLEDGMENTS ▶ Editorial Board Daniel M� Kolasinski Milwaukee Area Technical College Keith Santini Steve Levin Addison Trail High School Columbus State Community College Addison, Illinois James Martin Merle Saunders Tarrant County College Nyssa, Oregon Jeffrey Rehkopf Tim Dunn Florida State College Sydney, New South Wales Australia Ronald Strzalkowski Baker College of Flint ▶ Contributors Joseph Wagner Joliet Junior College Jerry Clemons Elizabethtown Community and Tech College Dan Warning Joliet Junior College Robert Farro Moraine Valley Community College Mike Wichtendahl Kansas City Kansas Community College Dale Henry East Mississippi Community College Daniel L� Wooster Gateway Technical College Horizon Center Paul Kelley Cypress College CHAPTER 1 Strategy-Based Diagnostics NATEF Tasks ■ N01001 Review vehicle service history� ■ N01004 Research vehicle service information including fluid ■ N01002 Demonstrate use of the three C’s (concern, cause, and type, vehicle service history, service precautions, and technical correction)� service bulletins� ■ N01003 Identify information needed and the service requested on a repair order� Knowledge Objectives After reading this chapter, you will be able to: ■ K01001 Describe the purpose and use of vehicle service ■ K01005 Describe step two of the strategy-based diagnosis� history� ■ K01006 Describe step three of the strategy-based diagnosis� ■ K01002 Demonstrate an understanding of the active listening ■ K01007 Describe step four of the strategy-based diagnosis� process� ■ K01008 Describe step five of the strategy-based diagnosis� ■ K01003 Demonstrate an understanding of the strategy-based ■ K01009 Explain how the three Cs are applied in repairing and diagnosis process� servicing vehicles� ■ K01004 Describe step one of the strategy-based diagnosis� ■ K01010 Describe the information and its use within a repair order� Skills Objectives After reading this chapter, you will be able to: ■ S01001 Use service history in the repair and service of vehicles� ■ S01002 Complete a repair order� You Are the Automotive Technician A regular customer brings his 2014 Toyota Sienna into your shop, complaining of a “clicking” noise when he turns the steering wheel� You ask the customer further questions and learn that the clicking happens whenever he turns the wheel, especially when accelerating� He tells you he has just returned from vacation with his family and has probably put 300 miles (482 kms) on the car during their trip� 1� What additional questions should you ask the customer about his concern, the clicking noise he hears when turning? 2� How would you verify this customer’s concern? 3� What sources would you use to begin gathering information to address this customer’s concern? 4� Based on what you know this far about the customer’s concern, what systems might be possibly related to this customer’s concern? 1 2 CHAPTER 1 Strategy-Based Diagnostics ▶ Introduction The overall vehicle service involves three major components. Those pieces are gathering information from the customer, the strategy-based diagnostic process, and documenting the repair. The flow of the overall service can be seen below. 1� Initial information gathering is often completed by a service advisor (consultant) and should contain details about the customer concern and pertinent history. 2� Verifying the customer concern begins the strategy-based diagnostic process. Technicians will complete this step to ensure that a problem exists and that their repair eliminated it. 3� Researching the possible cause will provide a list of possible faults. The technician will expand this list as testing continues. 4� Testing will focus on the list of possibilities. Technicians will start with broad, simple tests that look at an entire system or group of components. Testing will progressively become more narrowly focused as it pinpoints an exact cause. 5� Repairs will be made using suggested tools and recommended procedures. This is done to ensure a reliable repair and that manufacturer requirements are met. 6� Repairs must always be verified. This confirms that the technician has completed the diagnosis accurately and completely. The repair must be documented. The technician has been doing this all along. When the customer concern is recorded, the tests are recorded, and the final repair procedure recorded, the repair has been documented. ▶ Vehicle Service History K01001 Describe the purpose and use Service history is a complete list of all the servicing and repairs that have been performed of vehicle service history� on a vehicle (FIGURE 1-1). The scheduled service history can be recorded in a service booklet or owner’s manual that is kept in the glove compartment. The service history can provide N01001 Review vehicle service valuable information to technicians conducting repairs. It also can provide potential new history� owners of used vehicles an indication of how well the vehicle was maintained. A vehicle with S01001 Use service history in the a regular service history is a good indication that all of the vehicle’s systems have been well repair and service of vehicles� maintained, and the vehicle will often be worth more during resale. Most manufacturers store all service history performed in their dealerships (based on the VIN) on a corporate server that is accessible from any of their dealerships. They also use this vehicle service his- tory when it comes to evaluating warranty claims. A vehicle that does not have a complete service history may not be eligible for warranty claims. Independent shops generally keep records of the repairs they perform. However, if a vehicle is repaired at multiple shops, repair history is much more difficult to track and, again, may result in a denial of warranty claims. Vehicle service history can be very valuable to the technician. This history is typically retrieved from service records kept by the shop, dealer network, original equipment manufacturer (OEM), or aftermarket service center. This information often contains a list of services performed on a vehicle and the date and mileage at which they were completed. Not all service history contains the same information. Some histories may only contain repair information, while others include every customer concern and maintenance task performed. This information can be very helpful when diagnosing a concern. Service history may help technicians diagnose a vehicle and can also be used to prevent costly duplicated repairs. Service history can also be used to guide repairs. Records of vehicle service history may indicate that the customer has recently been in for service and now has returned with a new concern. This all-too-common situation is usually found to be caused by error during the previous service. When working on a vehicle that has returned after a recent repair, the previous technician’s FIGURE 1-1 Print outs of completed repair order as saved in the online repair order system. work (whoever that may be) should be inspected meticulously.