Automotive Electricity & Electronics

Sixth Edition

CLASSROOM/SHOP MANUAL CHAPTER 3:

ELECTRICAL AND ELECTRONIC COMPONENTS/
TROUBLESHOOTING AND SERVICE

Barry Hollembeak

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Objectives
• Describe the common types of electrical system
components used and how they affect the electrical
system
• Explain the operation of the electrical controls,
including switches, relays, and variable resistors
• Explain the basic function of capacitors.
• Describe the basic operation principles of electronic
components

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Objectives (cont’d)
• Explain the use of electronic components in the circuit
• Explain the purpose of a circuit protection device and
describe the most common types in use
• Define circuit defects including opens, shorts, grounds,
and excessive resistance
• Explain the effects that each type of circuit defect has on
the operation of the electrical system

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 Automotive Electricity & Electronics, Sixth Edition
Chapter 3

Objectives (cont’d)
• Describe how different electrical problems cause
changes in an electrical circuit
• Diagnose and repair circuit protection devices
• Test switches with a variety of test instruments
• Test relays and relay circuits for proper operation

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 Automotive Electricity & Electronics, Sixth Edition
Chapter 3

Objectives (cont’d)
• Identify and test fixed and variable resistors with a
voltmeter, ohmmeter, or lab scope
• Test capacitors.
• Diagnose diodes for opens, shorts, and other defects
• Diagnose transistors for opens, shorts, and other defects
• Locate and repair opens in a circuit

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Objectives (cont’d)
• Locate and repair shorts in a circuits
• Locate and repair the cause of unwanted high resistance
in a circuit
• Set up a digital storage oscilloscope (DSO) and identify
wave form

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Electrical Components
• Switches
• Relays
• Solenoids
• Buzzers
• Fixed resistors
• Stepped resistors
• Variable resistors
• Capacitors

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Switches
• Can be normally open (NO)
or normally closed (NC)
• Simplest form is a single
pole, single throw (SPST)
• Some have one input and
two outputs (SPDT)
• Can have several inputs
and/or several outputs
(ganged switch)

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Relay Characteristics
• Uses a small current circuit
to control a larger current
circuit
• Uses an electromagnetic
switch to open or close
contacts that control the
larger current
• They can be normally open
or normally closed

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

To animate, click on graphic above

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

ISO Relay Terminal Identification

• 30 - Usually connected
to battery voltage
• 86 - Voltage supply for
the electromagnet (coil)
• 87A - Connected to
terminal 30 with the
relay de-energized
• 87 - Connected to
terminal 30 with the
relay energized
• 85 - Ground for the
electromagnet

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Solenoids
• An electromechanical device that operates similar to a
relay
• Are used to do mechanical work such as switching
– Electrical circuits
– Vacuum circuits
– Liquid circuits

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Buzzers
• Sometimes used to
warn driver of
possible safety
hazards
• Similar to a relay
except for internal
wiring
• Generates vibrating
signal

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Identifying Fixed Resistors

• The first two are the
digit bands
• The third is the
“multiplier”
– Number of zeros
• The fourth is the
tolerance band
– Gold = +/- 5%
– Silver = +/- 10%

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Resistors
• Stepped resistors
– Are usually used
to control motor
speeds
• Rheostats
– Have two wires
and are used to
regulate current
• Potentiometers
– Have three wires
and act as voltage
divider
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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Capacitors
• Capacitance is the ability
of two conducting surfaces
to store voltage.

• Capacitors
- are used to store and
release electrical energy.
- they do not consume any FIGURE 3-18 Capacitors that can be used in
power; however, they will automotive electrical circuits.
store and release electrical
energy.

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Diodes
• Allow current to
flow in one
direction only
• Used for
– Rectification
– Clamping voltage
spikes
– Circuit isolation

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

To animate, click on each graphic above

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Other Types of Diodes

• Zener diode
– Allows current flow in the
reverse direction at a
specific voltage level
– Commonly used for
voltage regulation
• Light-emitting diode
– Gives off light when
current flows through it

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Other Types of Diodes (cont’d)

• Photo diode
– Allows current to flow
when exposed to light
• Clamping diode
– Used to suppress
voltage spikes

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Transistors
• Are made up of
three layers
– The emitter
– The collector
– The base
• Can be NPN type
or PNP type

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Transistor Operating Conditions

• Cutoff
– No current flows
in this condition
• Conduction
– When the
transistor turns on
• Saturation
– When the
collector to
emitter voltage is
reduced to near
zero
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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

The Characteristics of an Amplified Circuit

• The amplified
voltage at the
collector is greater
than that of the
base voltage
• The input current
increases
• The pattern has
been inverted

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Other Types of Transistors

• Phototransistors
– Current flow
increases when
light intensity
increases
• Thyristors
– Most common
type is the silicon-
controlled rectifier

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Integrated Circuits
• Are complex circuits
made up of
thousands of
transistors, diodes,
resistors, capacitors,
and other electronic
devices
• Are used to perform
multiple electrical
tasks by a single
computer

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Types of Circuit Protection

• Fuses
– Contain a metal
strip designed to
melt at a specific
current rating
• Three basic types
– Glass cartridge
– Ceramic
– Blade

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Types of Circuit Protection (cont’d)

• Fusible Links
– A special wire that is designed to melt when circuit current
exceeds a given level
• Maxi-fuses
– Take the place of fusible links
– Used to protect several circuits

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Types of Circuit Protection (cont’d)

• Circuit Breakers
– Designed to open when circuit current exceeds a given point
– Most will reset when current flow stops
• PTC circuit protectors
– Its resistance increases when current rises above a specific
level

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

To play video, click on screen above

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Circuit Defects
• Opens
– Breaks in the circuit
that stop current
flow

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Circuit Faults
• Shorts
– Unwanted paths
for current

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Circuit Faults
• High resistance
– Occurs when there
is unwanted
resistance in a
circuit

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Electrical Troubleshooting Steps

1. Verify the customers complaint
2. Operate the system to identify the problem
3. Study the wiring diagram for the affected circuit
4. Identify testing points and possible problem areas
5. Test and use logic to identify the cause of the problem

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Testing for Opens

• If possible, start testing at the
load component
• Check for voltage on the
power side of the component
– If voltage is present, check the
ground side
– If voltage is not present, test all
connections working toward the
battery
– If voltage is present at a
connection, then the open is
between it and the previously
tested point

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Testing for Opens (cont’d)

• If the power side of the
circuit tests good, test
the ground side
– Use a jumper wire to
bypass the ground side of
the circuit, and if the
component works, check
all ground side
connections
• If both the power and
ground circuits test
good, the load
component is open

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Testing for Shorts

• Use an ohmmeter to check resistance of the circuit
• If there is a short, the resistance will be less than
specified
• If the short is between two circuits, components may
operate when not intended

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Testing for a Short to Ground

• Use a cycling circuit
breaker and test light
in place of the fuse
– Disconnect
components and
connectors until the
light goes out
• Use a cycling circuit
breaker and a Gauss
gauge
– Move the gauge over
the wire
– The gauge will
fluctuate until the
short is passed

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Testing for Voltage Drop

• Voltage drop must always be tested with the circuit
energized
• The voltage drop indicated on the meter is the amount
of voltage used between the point where the red lead is
connected and the point where the black lead is
connected

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Testing for Voltage Drop (cont’d)

• 0.1 volts per connection
is acceptable in non-
computerized circuits
• 0.050 volts (50
millivolts) per
connection is
acceptable in
computerized circuits
• Excessive voltage drop
is an indication of high
resistance

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Testing Circuit Protection Devices

• Fuses
– Most fuses can be
checked visually
– The best way to check
them is with an
ohmmeter
• Fusible links
– Pull lightly on the wire; if
the insulation stretches
the link is melted
– They should be checked
with an ohmmeter

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Methods Used to Check Circuit

Protection Devices

• Visual inspection
• Continuity tester or
ohmmeter
• Voltage drop
• Test light

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Testing Normally Open Switches

• Use a jumper wire
to bypass the switch
– If the circuit
operates with the
jumper wire, the
switch is defective
• Voltage drop
– There should be no
voltage drop across
the switch when it is
closed

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Relay Testing Tips

• Never use a test light to
test a computer-
controlled relay
• Verify the presence of
voltage at both the
control and the
controlled side of the
relay
• Verify the continuity of
the relay coil
• Just because the relay
“clicks” doesn’t mean it
is good

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Resistor Testing Tips

• Remove the component from
the circuit before testing it
with an ohmmeter
• Never pierce a wire to test
for voltage
• When testing variable
resistors, the resistance or
voltage values must be
smooth and consistent

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Testing Capacitors

• Some DVOMs have a

capacitance test function.
• The reading on the DVOM
should match the rating of
the capacitor

FIGURE 3-33 A capacitor

with its rating marks.

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Testing Diodes
• With an Analog Ohmmeter
– Connect the leads across
the diode in one direction
and read the meter
– Reverse the meter leads
and read the meter again
– The resistance in one
direction should be high
or infinite
– The reading in the other
direction should be close
to zero

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Testing Diodes (cont’d)

• With a multimeter equipped with a diode tester
– When connected in the correct polarity, the meter will read
the voltage required to forward bias the diode
– When the leads are reversed, the meter will read “OL”

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Testing Transistors
• Identify type (NPN or PNP) and lead arrangement
• Identify transistor leg configuration using a multimeter
• If none or more than one lead combination indicates a
pair of low readings, the transistor is probably faulty

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Testing Transistors (cont’d)

• Once the type is identified, test using the diode function
of the DVOM
– With the red lead to the base of the transistor, and black to
the emitter, a good NPN will read a voltage between 450 and
900mv. A good PNP will read open
– With the leads reversed, a good PNP will read a voltage
between 450 and 900mv. A good NPN will read open

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Testing Transistors (cont’d)

• With one meter lead on the collector and other on the
emitter, the meter should read open. Reverse leads and
the meter should read open.
• Darlington transistors testing in the forward direction;
the base-to-emitter reading will be 0.2 to 1.4 volts

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Tips for Using a DSO

• Select the best voltage
and time base setting
– If the time base setting is
too long and the voltage
setting is too high, the
waveform is too small to
read
– If the time base setting is
too short and the voltage
setting is too low, the
waveform is too large for
the screen

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Tips for Using a DSO (cont’d)

• Select the nearest voltage setting higher than the
expected voltage
• Start at the highest time base and move down until the
proper pattern appears
• Select the proper trigger setting for the signal being
tested

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Knowledge Check ✓

• Switch can control on/off operation or direct the flow of

current through various circuits
• Relay is a device that uses low current to control a high
current circuit
• Buzzers are used to warn the driver by emitting an audio
signal

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Knowledge Check ✓
• Stepped resistor has two or more fixed resistor values
• Variable resistor provides for an infinite number of
resistance values within range
• Diode is an electrical one-way check valve
• Transistor is a three-layer semiconductor

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Knowledge Check ✓

• Open circuit has a break in continuity

• Shorted circuit allows current to bypass part of the
normal path
• Short to ground is a condition that allows current to
return to ground before it has reached the intended
load component

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Knowledge Check ✓

• Identify the current operation of the circuit before

testing for opens
• Start at the most accessible place in a circuit to start
testing for opens
• An ohmmeter can be used to check the resistance of the
component
• A cycling circuit breaker is used to test for a short to
ground

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Knowledge Check ✓
• The location of the excessive resistance can be identified
where the voltage drop decreases to within
specifications
• Fuses and fusible links should be checked with an
ohmmeter
• The easiest method of testing a NO switch is to use a
fused jumper wire to bypass the switch

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 Automotive Electricity & Electronics, Sixth Edition Chapter 3

Knowledge Check ✓

• Resistance or voltage values must be smooth and

consistent for variable resistors
• Capacitors are used to temporarily store and release
electrical energy.
• Diodes can be tested with an analog ohmmeter or a
multimeter equipped with a diode-testing feature
• A DSO samples electrical signals at great speeds

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