Body Electrical Diagnosis And Repair Course T502 TOYOTA Collision Repair and Refinish Training © 2008 Toyota Motor Sales, U.S.A., Inc All rights reserved This book may not be reproduced or copied, in whole or in part by any means, without the written permission of Toyota Motor Sales, U.S.A., Inc Printed in U.S.A Toyota Motor Sales, U.S.A., Inc Course T502: Body Electrical Diagnosis & Repair Table of Contents Section 1: Electrical Circuit Theory Contents Introduction 1-1 Voltage 1-2 Current 1-3 Resistance 1-3 Ohm’s Law 1-4 Basic Principles of Series/Parallel Circuits 1-5 Series Resistance Parallel Resistance Series/Parallel Resistance Why Does It Matter? On-Vehicle Applications of Ohm’s Law Section 2: Essential Electrical Concepts Section 3: Electrical Circuits Section 4: Vehicle Wiring and Terminal & Connector Repair 1-5 1-6 1-6 1-7 1-7 1-7 Introduction 2-1 Meters 2-2 Analog Multimeters 2-3 Digital Multimeters 2-4 DMM Components 2-5 DMM Mode Selector 2-6 DMM Display 2-7 DMM Auto-Ranging 2-9 DMM Test Leads and Input Jacks 2-10 Voltage 2-11 Available Voltage 2-15 Voltage Drop 2-16 Measuring Voltage Drop 2-16 Current 2-19 Resistance 2-23 Introduction 3-1 Types of Circuits 3-2 Series Circuits 3-4 Key Features 3-4 Applying Ohm’s Law 3-5 Tips For Trouble Shooting 3-6 Key Features 3-15 Tips For Trouble Shooting 3-18 Series-Parallel Circuits 3-22 Key Features 3-23 Load Control Source or Ground 3-25 Electrical Symbols 3-27 Wiring Diagrams 3-28 Introduction 4-1 Vehicle Wiring Terminal and Connector Repair 4-2 Conductors 4-2 Power or Insulated Conductors 4-2 Ground Paths 4-3 System Polarity 4-3 Harnesses 4-4 Wire Insulation 4-5 Connectors 4-6 SRS Harness Components 4-7 High Voltage (HV) Harness Components 4-8 Body Electrical Diagnosis and Repair Course T502 i Table of Contents Electric Power Steering (EPS) 4-8 Connector Repair 4-9 Section 5: Resources ii Conductor Repairs 4-10 Wire Size 4-11 American Wire Gauge Sizes 4-11 Wire Gauge Number 4-12 Wire Length 4-12 Wire Repairs 4-13 Soldering 4-14 Solder 4-14 Soldering Irons 4-14 Splices 4-15 Soldering Wire Splices 4-16 Rules for Good Soldering 4-16 Terminal Replacement 4-17 Introduction 5-1 The Battery 5-2 Battery Functions 5-3 Battery Type 5-4 Battery Construction 5-5 Battery Case 5-5 Separators 5-6 Cells 5-7 How Batteries Work 5-8 Fully Charged 5-8 Discharging 5-8 Fully Discharges 5-8 Charging .5-8 Capacity Ratings 5-10 Cold-Cranking Amperes 5-10 Reserve Capacity (RC) 5-10 Ampere-Hours (AH) 5-11 Safety First 5-12 Precautions 5-12 Visual Inspection 5-13 Battery Drain Tests 5-15 Battery Analyzer Tests 5-17 Preparing the Battery for Analyzer Tests 5-18 Battery Test Results 5-19 Fast Charging 5-20 Slow Charging 5-21 Jump Starting 5-22 Appendix A: Wiring Diagram Symbols 6-1 Appendix B: How to Use an Electrical Wiring Manual 7-1 Appendix C: Glossary of Terms 8-1 TOYOTA Collision Repair and Refinish Introduction Body Electrical Safety Figure 1-1 T502f101 Figure 0-1 T502f001p Safety considerations for body electrical operations go beyond the obvious personal safety Technicians performing electrical repairs must now have the knowledge and ability to recognize and avoid High-Voltage and general electrical hazards Safe handling of electrical circuits may require disabling and testing for zero circuit current, as well as following proper procedures for live circuit testing Body Electrical Diagnosis and Repair Course T502 O-1 Introduction Figure 0-2 T502f002c Electrical safety must also be a prime consideration for onboard systems that are responsible for operator and occupant safety Supplemental Restraint Systems (SRS) and Vehicle Dynamics Integrated Management (VDIM) rely heavily on high-speed electrical communications, so it is critical to know the correct repair procedures and limitations when working around these circuits and components O-2 TOYOTA Collision Repair and Refinish Body Electrical Saftey Figure 0-3 T502f003p Each section of this training will provide detailed information on safe and proper diagnostic and repair procedures applicable to each topic, as well as identify High Voltage and SRS circuit wiring and circuits that should not be repaired Body Electrical Diagnosis and Repair Course T502 O-3 .. .Toyota Motor Sales, U.S.A., Inc Course T502: Body Electrical Diagnosis & Repair Table of Contents Section 1: Electrical Circuit Theory Contents Introduction ... Appendix C: Glossary of Terms 8-1 TOYOTA Collision Repair and Refinish Introduction Body Electrical Safety Figure 1-1 T502f101 Figure 0-1 T502f001p... working around these circuits and components O-2 TOYOTA Collision Repair and Refinish Body Electrical Saftey Figure 0-3 T502f003p Each section of this training will provide detailed information on