Chapter 26

Electrical Repairs
 Objectives

Use various kinds of electrical test instruments

Find electrical problems
Explain the operation of automotive electrical-
electronic systems
Describe the operation of computer systems
Use scanners to find electrical-electronic
problems
 Introduction

Electrical systems, such as ignition, charging,

starting, lighting, and computer systems perform
needed functions for a vehicle
Electrical system repair is an essential aspect of
repairing a collision-damaged vehicle
Electrical repairs are becoming more common
due to use of computer-controlled systems
These repairs are complicated by many computer
circuits running throughout the vehicle
 Electrical Terminology

Current is the movement of electricity through a

wire or circuit
Voltage is the pressure that pushes the electricity
through the wire or circuit
Resistance is the obstacle to current flow and a
conductor carries current to the parts of a circuit
Hot wires connect the battery positive to the
components of each circuit
Insulation stops the current flow and keeps the
current in the metal wire conductor
 Electric Circuits

An electrical circuit contains a power source,

conductors, and a load
The load is part of a circuit that converts
electrical energy into another form of energy
A series circuit has only one conductor path or
leg for current through the circuit
If any part of the circuit is opened, all of the
series circuit stops working
 Electric Circuits (continued)

A parallel circuit has two or more legs or paths

for current
One path can be closed and the other opened,
and the closed path will still operate
A series-parallel circuit has both series and
parallel branches in it
Ohm's Law calculates an unknown electrical
value when two values are known
Figure 262. Ohms Law is a simple formula for calculating
electrical values in a circuit.
 Magnetism

Magnetism involves the study of how electric

fields act upon ferrous objects
A flux or magnetic field is present around
permanent magnets and current-carrying wires
An electromagnetic field is a set of windings or
wires wrapped around an iron core
Electric motors, solenoids, relays, and other parts
use this principle
 Diagnostic Equipment

Locating an electrical fault is not possible without

using diagnostic tools
A multimeter (VOM) is a voltmeter, ohmmeter,
and ammeter combined into one case
A digital multimeter (DVOM) has a number
readout for the test value
An analog multimeter (AVOM) has a pointer that
moves across the face of a scale
Use of an AVOM can damage sensitive
electronic components
 Test Light, Jumper Wires

Test light can determine if current is flowing

through a circuit
Jumper wires are used to temporarily bypass
circuits or components for testing
Figure 264. Jumper wires can be used to bypass resistive parts or to connect
power directly to parts to check their operation. For example, if a motor runs
when connected directly to voltage, you would know the circuit might not be
providing power or a ground to the motor.
 Using Multimeters

A multimeter must never be connected to a circuit

in which current is flowing
To measure resistance with a multimeter:
Set the range selector switch on the highest range
Connect the test leads to opposite ends of the
circuit
Reduce the range setting until the meter shows a
reading near the middle of the scale
 Checking Continuity
A circuit remains closed and operational when it
has continuity
The continuity check determines if the electrical
circuit has a complete path without any opens
Set the range selector switch on the highest
resistance range position
Connect the multimeter test leads to the opposite
ends of the wire or part being tested
Read the meter
An infinite reading shows an open circuit and a
zero reading shows continuity
 Measuring Voltage

The multimeter allows you to select either

alternating current voltage (ACV) or direct current
voltage (DCV)
AC current is the current found in your home
DC current is normally measured in an
automobile
Some signals from sensors can be AC
Current or amperage is sometimes measured to
check the consumption of power by a load
 Measuring Voltage (continued)

Modern ammeters have an inductive pickup that

slips over the wire or cable to measure current
A high current draw indicates a low resistance
A low current draw indicates a high resistance
 Checking for Shorts

When checking for a short between two adjoining

wires in a harness:
Set the range selector as for a continuity check
Connect the test leads to the opposite ends of the
adjoining wires
The multimeter should read almost infinity
 Wiring Diagrams

Wiring diagrams are used to determine and

isolate problems
Abbreviations are used on wiring diagrams so
that more information can be given
Electrical symbols are graphic representations of
electrical-electronic components
Wire color coding allows you to find a specific
wire in a harness or in a connector
 Wiring Diagrams (continued)

Circuit numbering specifies which part of the

circuit the service manual is referring to
Wiring harness has several wires enclosed in a
protective covering
Service manual gives illustrations with code
numbers for locating parts and connections
May also give a part location diagram for finding
electrical parts
 Electric Components

A switch turns a circuit on or off manually

A solenoid is an electromagnet with a movable
core or plunger
A relay is a remote control switch
A bad relay will often have burned points that
prevent current flow to the load
Motors use permanent and electromagnets to
convert electrical energy into a rotation motion
 Circuit Protection Devices

Prevent excess current from burning wires and

components
With an overload or short, too much current tries
to flow
Without a fuse or breaker, the wiring in the circuit
would heat up
 Fuses

Fuses burn in half with excess current to protect

a circuit from further damage
The cartridge fuse is found on most older
domestic vehicles and a few imports
Domestic vehicles use blade or spade fuses;
European imports may use ceramic fuses
A blown fuse has infinite resistance
Fuse ratings are current at which a fuse will blow
A fuse box holds various circuit fuses, breakers,
and flasher units for turn and emergency lights
 Fuse Links

Fuse links (fusible links) are smaller-diameter

wire spliced into the larger circuit wiring
Ensures over-current protection
Normally in engine compartment near battery
Often installed in the positive battery lead that
powers the ignition switch
Covered with a special insulation that bubbles
when it overheats
 Circuit Breakers

Circuit breakers heat up and open with excess

current to protect the circuit
Many circuits are protected by circuit breakers
Each circuit breaker conducts current through an
arm made of two types of metal bonded together
The arm heats up if it carries too much current
As one metal expands farther than the other, the
arm bends, opening the contacts and breaking
the current
 Electrical-Electronic Systems

Ignition system produces an electric arc in a

gasoline engine to cause the fuel to burn
Ignition coil is a step-up transformer that
produces high voltage needed to make the
current jump the spark plug gap
Spark plug wires are high-tension wires that
carry coil voltage to each spark plug
Spark plugs ignite the fuel mixture in the engine's
combustion chambers
 Starting and Charging Systems

Starting system has a large electric motor that

turns the engine flywheel
Ignition switch connects battery voltage to a
starter solenoid or relay
Starter solenoid, when energized, connects the
battery and the starting motor
Starting motor is a large DC motor for rotating the
engine flywheel
Flywheel ring gear meshes with the starter-
mounted gear while cranking
 Starting and Charging Systems
(continued)
Charging system recharges the battery and
supplies electrical energy to the running engine
Voltage regulator controls alternator output and
charging system voltage is 13 to 15 volts
To check for spark
Pull off one spark plug wire, install an old spark
plug; lay the spark plug on the engine ground
When you crank the engine a bright spark should
jump across the spark plug gap
To check for fuel, a pressure gauge on the
engine's fuel rail should read within specs
 Electrical Problems

Open circuit is an unwanted break in a circuit

Short circuit is an unwanted wire-to-wire
connection in a circuit
In a grounded circuit the current flows to ground
without flowing to the part
Abnormal resistance is due to a bad connection
or partial short
Diagnostic charts give possible causes for
electrical problems and symptoms
 Batteries
Battery stores electrical energy chemically
Voltage spikes are voltage surges that can
destroy may microcircuits in electronic systems
Good idea to remove the battery before doing
any kind of collision repair work
Once the battery has been placed on a bench, it
should be checked for damage
A voltmeter or a specialized battery tester checks
battery condition
 Batteries (continued)

Follow an eleven-step procedure for charging a

battery using a battery charger
Avoid jump starting whenever possible
Jumper cables connect two batteries when one is
dead
Special care is necessary when charging or jump
starting to avoid damaging computer circuits
Before reinstalling the battery after body work,
clean its terminals
Figure 2613. Jumper cables or a battery charger must be connected carefully to
prevent sparks or electronic component damage. Connect positive to positive and
negative to negative in the proper sequence: red to red, then black to any metal
ground away from the battery.
 Battery Safety

Keep batteries away from the welding

operations, open flames, sparks, or heat sources
Do not charge batteries with cracked case
Do not smoke near batteries
Ventilate the area around dead or damaged
batteries to avoid explosion
Do not charge a frozen battery
Electrolyte in the battery is a mixture of water and
sulfuric acid and must be kept in mind
 Lighting and Other Electric Circuits

Lighting system feeds electricity to the light bulbs

throughout the vehicle
When lights fail to function, check the bulb first
If the bulb is good, trace for an open feeding
current to the dead bulb
Other electrical circuits (horn, power windows,
etc) use the same principles just discussed
 Repairing Wiring and Connections

When servicing electrical wiring, never tug on the

connectors
Route wiring in the same location as the OEM
Protect the electrical connectors from moisture
and corrosion by using dielectric grease
Use the same size and type of wiring for repairs
 Solder Repair
Soldering uses moderate heat and solder to join
wires or other parts
All copper wire joints should be soldered
Use rosin-core solder, not acid-core, when
soldering electrical connections
Acid fluxes create corrosion and can damage
electronic components
Electrical tape can be used around wire splices
when they will not be exposed to moisture
 Electrical Connector Service

An automotive electrical connector includes two

plastic, snap together fittings
Allow several wires to connect together securely
Various connector designs are used on vehicles
Each requires a different method for disconnection
If needed, inspect electrical connectors when
trying to find opens
 Computer Systems

Basic computer system consists of sensors,

actuators, and a computer
Sensors are devices that convert a condition into
an electrical signal
Actuators are devices that move when
responding to signals from the computer
The computer is a complex electronic circuit that
produces a known electrical output after
analyzing electrical inputs
 Scanning Computer Problems

Scan tool is the fastest way to use on-board

diagnostics to find electrical-electronic problems
Scan tool talks to the vehicle's computers and
can tell you if it detects any problems
Scanner will convert computer or electronic
control module (EMC) data into plain English
Scan tools are removable cartridges that hold
information about the specific vehicle
Menu allows you to scan different test functions
Figure 2617. Numerous sensors provide inputs for the computer. The service
information for the specific make and model vehicle would be required.
 Using the Scanner

Connect the scan tool to a diagnostic connector

on the vehicle if an indicator light glows
Turn off all accessories that could trip false
trouble codes
Prepare tool for make and model being tested
Select the information you want from the scan tool
Correct the cause of the lower number code first
Erasing trouble codes removes the stored codes
from the computer memory
 Summary

Current is the movement of electricity through a

wire or circuit, measured in amps
Voltage is the pressure that pushes the electricity
through the wire or circuit, measured in volts
Resistance is a restriction or obstacle to current
flow, measured in ohms
Some diagnostic equipment used in finding
electrical faults includes the multimeter, test light,
and jumper wires
 Summary (continued)

Wires are often severed and electrical and

electronic components damaged during a
collision
Scan tool helps find the location of circuit faults
Scan tools display which circuits or components
are not operating within specifications