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									                                                                                                                      1


                CHAPTER 1 - Service Information, Tools, and Safety


WORKSHEETS IN THE WORKTEXT:                                                                         Page

       Fire Extinguisher (NATEF Task: None Specified)                                                 1
       Vehicle Hoisting (NATEF Task: None Specified)                                                  2
       Safety Check (NATEF Task: None Specified)                                                      3
       Temporary Disabling of an Air Bag (NATEF Task: A6-H-6)                                         4
       VIN Code (NATEF Task: A6-A-3)                                                                  5
       Vehicle Safety Certification Label (NATEF Task: A6-A-3)                                        6
       Vehicle and Electrical Service Information (NATEF Task: A6-A-3)                                7
       Vehicle Service History (NATEF Task: A6-A-2)                                                   8
       Technical Service Bulletins (NATEF Task: A6-A-2)                                               9

TRANSPARENCY MASTERS:

       Figure 1-3
       Figure 1-5

CHAPTER OUTLINE:

       Objectives                                                       Brand Name versus Proper Term
       Vehicle Identification                                           Safety Tips for Using Hand Tools
       Vehicle Safety Certification Label                               Air and Electrically Operated Tools
       VECI Label                                                       Safety Tips for Technicians
       Calibration Codes                                                Safety in Lifting (Hoisting) a Vehicle
       Casting Numbers                                                  Jacks and Safety Stands
       Service Information                                              Drive-On Ramps
       Threaded Fasteners                                               Electrical Cord Safety
       Metric Bolts                                                     Jump Starting and Battery Safety
       Grades of Bolts                                                  Fire Extinguishers
       Tensile Strength                                                 Fire Blankets
       Nuts                                                             First Aid and Eye Wash Stations
       Washers                                                          Summary
       Electrical Tools                                                 Review Questions
       Basic Hand Tool List                                             ASE Certification-Type Questions
       Tool Sets and Accessories

ANSWERS TO REVIEW QUESTIONS:

       1.   Three precautions when hoisting a vehicle include: setting the pads correctly, raising the vehicle
            slightly, and checking the pads again and always watch the vehicle and surrounding area.
       2.   The grade of the fastener is identified by the number of lines on the head of fractional bolts and by
            numbers on the heads of metric bolts.
       3.   Wear: (a) protective gloves, (b) safety glasses, (c) hearing protection, (d) safety (steel-toed) shoes.
       4.   The types of fire extinguishers include: water, carbon dioxide (CO 2), and dry chemical (yellow).

Answers to ASE Certification-Type Questions:

       1-c, 2-d, 3-d, 4-b, 5-b, 6-b, 7-d, 8-a, 9-a, 10-d
2


             CHAPTER 2 - Environmental and Hazardous Materials


WORKSHEETS IN THE WORKTEXT:                                                                      Page

     Material Safety Data Sheet (MSDS) (NATEF Task: None Specified)                              10

TRANSPARENCY MASTERS:

     None

CHAPTER OUTLINE:

     Objectives
     Occupational Safety and Health Act
     Hazardous Waste
     Resource Conservation and Recovery Act (RCRA)
     Clean Air Act
     Material Safety Data Sheets (MSDS)
     The Dangers of Exposure to Asbestos
     Asbestos OSHA Standards Asbestos EPA Regulations
     Asbestos Handling Guidelines
     Used Brake Fluid
     Used Oil
     Disposal of Used Oil
     Used Oil Storage
     Solvents
     Solvent Hazardous and Regulatory Status
     Used Solvents
     Coolant Disposal
     Lead-Acid Battery Waste
     Battery Hazardous and Regulatory Status
     Battery Handling and Storage
     Fuel Safety and Storage
     Airbag Handling
     Used Tire Disposal
     Air-Conditioning Refrigerant Oil Disposal
     Summary
     Review Questions
     ASE Certification-Type Questions

ANSWERS TO REVIEW QUESTIONS:

     1.     Solvent, silicone spray, throttle body cleaner, trichloromethane, and brake cleaner.
     2.     The technician should wash his/her hands, wear protective gloves and safety glasses, dispose of all
            waste correctly and observe safe work habits including being familiar with the MSDS sheet for
            products being used.

ANSWERS TO ASE CERTIFICATION-TYPE QUESTIONS:

     1-c, 2-b, 3-d, 4-a, 5-d, 6-a, 7-d, 8-a, 9-b, 10-b
                                                                                                                  3


                         CHAPTER 3 - Electrical Fundamentals



WORKSHEETS IN THE WORKTEXT:                                                                      Page

     Electrical Fundamentals (NATEF Task: None Specified)                                        11

TRANSPARENCY MASTERS:

     Figure 3-6
     Figure 3-13
     Figure 3-15

CHAPTER OUTLINE:

     Objectives
     Electricity
     Sources of Electricity
     Summary
     Review Questions
     ASE Certification-Type Questions

ANSWERS TO REVIEW QUESTIONS:

     1.   Electricity is the movement of electrons from one atom to another.
     2.   An ampere is the unit of the amount of current flow; a volt is a unit of electrical pressure and an ohm is
          a unit of electrical resistance.
     3.   Conductors include steel, iron, copper, aluminum, mercury, brass, and all other metals.
     4.   Sources of electricity include friction, heat, light, pressure, and chemistry.

ANSWERS TO ASE CERTIFICATION-TYPE QUESTIONS:

     1-b, 2-b, 3-a, 4-b, 5-b, 6-b, 7-c, 8-b, 9-d, 10-a
4


                  CHAPTER 4 - Electrical Circuits and Ohm’s Law


WORKSHEETS IN THE WORKTEXT:                                                                    Page

     Electrical Circuits (NATEF Task: None Specified)                                          12

TRANSPARENCY MASTERS:

     Figure 4-4
     Figure 4-6

CHAPTER OUTLINE:

     Objectives
     Circuits
     Ohm’s Law
     Watt’s Law
     Summary
     Review Questions
     ASE Certification-Type Questions

ANSWERS TO REVIEW QUESTIONS:

     1.   The parts of a complete circuit include: the power source, the protection (fuse), the control (switch)
          power side conductor, electrical load, and return path.
     2.   A short-to-voltage involves a copper-to-copper connection whereas a short-to-ground involves a
          copper-to-steel connection.
     3.   An open results in the stoppage of the flow of current in the circuit, whereas a short is a path of
          reduced resistance, which usually causes an increase in the flow of current through the circuit and may
          or may not cause a fuse to blow.
     4.   Ohm’s Law states, “It requires one volt to push one ampere through one ohm of resistance.”
     5.   A corroded electrical connection results in increased unwanted resistance in the circuit. This
          increased resistance reduces the current (in amperes) as well as the voltage (amperes times volts) that
          are applied to the loads in the circuit.

ANSWERS TO ASE CERTIFICATION-TYPE QUESTIONS:

     1-b, 2-a, 3-c, 4-a, 5-c, 6-b, 7-d, 8-d, 9-b, 10-b
                                                                                                                 5


                                 CHAPTER 5 - Series Circuits


WORKSHEETS IN THE WORKTEXT:                                                                     Page

     Series Circuits #1 (NATEF Task: A6-A-4)                                                    13
     Series Circuits #2 (NATEF Task: A6-A-4)                                                    14
     Series Circuits #3 (NATEF Task: A6-A-4)                                                    15

TRANSPARENCY MASTERS:

     Figure 5-1
     Figure 5-5

CHAPTER OUTLINE:

     Objectives
     Series Circuits
     Ohm’s Law and Series Circuits
     Kirchhoff’s Voltage Law
     Series Circuit Laws
     Series Circuit Examples
     Summary
     Review Questions
     ASE Certification-Type Questions


ANSWERS TO REVIEW QUESTIONS:

     1.   Kirchhoff’s Voltage Law states, “The voltage around any closed circuit is equal to the sum (total) of
          the voltage drops across the resistances.”
     2.   If the voltage was doubled, the current flow in amperes would also double assuming that the resistance
          in the circuit remains the same.
     3.   If the resistance is doubled in a circuit, the current in amperes would decrease to one-half.
     4.   The formula for determining voltage drop is E = I x R where the letter E represents the voltage drop,
          the letter I represents the current in amperes through the resistance (load), and the letter R represents
          the resistance of the load.

ANSWERS TO ASE CERTIFICATION-TYPE QUESTIONS:

     1-a, 2-c, 3-d, 4-c, 5-a, 6-a, 7-c, 8-d, 9-b, 10-b
6


                               CHAPTER 6 - Parallel Circuits


WORKSHEETS IN THE WORKTEXT:                                                                         Page

     Parallel Circuits #1 (NATEF Task: A6-A-4)                                                      16
     Parallel Circuits #2 (NATEF Task: A6-A-4)                                                      17
     Parallel Circuits #3 (NATEF Task: A6-A-4)                                                      18

TRANSPARENCY MASTERS:

     Figure 6-1
     Figure 6-6

CHAPTER OUTLINE:

     Objectives
     Kirchhoff’s Current Law
     Parallel Circuit Laws
     Determining Total Resistance in a Parallel Circuit
     Parallel Circuit Examples
     Summary
     Review Questions
     ASE Certification-Type Questions

ANSWERS TO REVIEW QUESTIONS:

     1.   The total resistance of a parallel circuit is less than the resistance of the smallest resistance leg because
          the current splits, creating multiple paths for the current to flow back to the power source, thereby
          effectively reducing the overall resistance of the circuit.
     2.   Parallel circuits are used in most automotive circuits because if an open circuit occurs in one part,k the
          other components will continue to work.
     3.   Kirchhoff’s Current Law states, “The current flowing into any junction of an electrical circuit is equal
          to the current flowing out of that junction.”
     4.   The five methods that can be used to calculate the total resistance in a parallel circuit include:
               Treat each leg or branch as a separate circuit and total the current flow
               For two resistors in parallel use: RT = R1 x R2
                                                            R1 + R2
               For any number of resistors in parallel use: 1 = 1 + 1 + 1 + + +
                                                                   RT R1       R2     R3
               Use an electronic calculator to solve for total resistance
               If equal value resistors are included, divide the value of the resistor by the number of resistors
                   that are the same: RT = value
                                            number

ANSWERS TO ASE CERTIFICATION-TYPE QUESTIONS:

     1-b, 2-d, 3-a, 4-c, 5-b, 6-d, 7-c, 8-d, 9-b, 10-c
                                                                                                                    7


                          CHAPTER 7 - Series-Parallel Circuits


WORKSHEETS IN THE WORKTEXT:                                                                        Page

     Series-Parallel Circuits #1 (NATEF Task: A6-A-4)                                              19
     Series-Parallel Circuits #2 (NATEF Task: A6-A-4)                                              20
     Series-Parallel Circuits #3 (NATEF Task: A6-A-4)                                              21

TRANSPARENCY MASTERS:

     Figure 7-1

CHAPTER OUTLINE:

     Objectives
     Series-Parallel Circuits
     Solving Series-Parallel Circuit Problems
     Series-Parallel Circuit Examples
     Summary
     Review Questions
     ASE Certification-Type Questions

ANSWERS TO REVIEW QUESTIONS:

     1.   If the resistance increases in the series portion of a series-parallel circuit, the voltage id dropped and
          the current is reduced through the circuit.
     2.   An open in one branch of a parallel leg of a series-parallel circuit will affect only those components in
          the parallel leg that has the open.
     3.   If an open circuit were to occur in the series portion of a series-parallel circuit, it would stop the flow
          of current through the rest of the circuit or the parallel leg where the open occurred.

ANSWERS TO ASE CERTIFICATION-TYPE QUESTIONS:

     1-b, 2-b, 3-b, 4-a, 5-d, 6-c, 7-b, 8-c, 9-a, 10-d
8


                  CHAPTER 8 - Digital Meters and Oscilloscopes


WORKSHEETS IN THE WORKTEXT:                                                                    Page

     Digital Multimeter Use for Electrical Problems (NATEF Task: A6-A-6)                       22
     Test Light Usage (NATEF Task: A6-A-7)                                                     23
     Measure Voltage Using a Voltmeter (NATEF Task: A6-A-8)                                    24
     Measuring Current Using an Ammeter (NATEF Task: A6-A-9)                                   25
     Check Electrical Circuits Using an Ohmmeter (NATEF Task: A6-A-10)                         26
     Circuit Testing Using a Fused Jumper Wire (NATEF Task: A6-A-11)                           27

TRANSPARENCY MASTERS:

     Figure 8-1
     Figure 8-2
     Figure 8-6

CHAPTER OUTLINE:

     Objectives
     Test Lights
     Digital Multimeters
     AC/DC Clamp-On Digital Multimeter
     Electrical Unit Prefixes
     How to Read Digital Meters
     Analog versus Digital Storage Oscilloscope
     Oscilloscope Display Grid
     Graphing Multimeter
     Summary
     Review Questions
     ASE Certification-Type Questions

ANSWERS TO REVIEW QUESTIONS:

     1.   A high-impedance meter is a meter that has a high internal resistance so as not to affect the circuit
          when it is connected to measure voltage.
     2.   An ammeter must be connected in the circuit itself in series unless a clamp-on ammeter is used.
     3.   An ohmmeter applies a voltage so the circuit has to be off and the item being tested isolated from the
          rest of the circuit for best results.
     4.   An analog oscilloscope shows voltage changes as they occur and the waveform cannot be captured or
          saved. A digital storage oscilloscope (DSO) records the voltage measurements as a series of dots and
          then connects the dots to display a waveform, which can be stored and viewed later after the event.

ANSWERS TO ASE CERTIFICATION-TYPE QUESTIONS:

     1-c, 2-c, 3-b, 4-d, 5-d, 6-b, 7-c, 8-a, 9-b, 10-a
                                                                                                                     9


               CHAPTER 9 - Automotive Wiring and Wire Repair


WORKSHEETS IN THE WORKTEXT:                                                                      Page

     Fusible Links, Circuit Breakers, and Fuses (NATEF Task: A6-A-14)                            28
     Inspect and Test the Switches (NATEF Task: A6-A-15)                                         29
     Brake Switch Activity (NATEF Task: A6-A-15)                                                 30
     Inspect Wiring and Connectors (NATEF Task: A6-A-15)                                         31
     Wire Harness and Connector Repair (NATEF Task: A6-A-16)                                     32
     Solder Wire Repair (NATEF Task: A6-A-17)                                                    33

TRANSPARENCY MASTERS:

     Figure 9-4
     Figure 9-6

CHAPTER OUTLINE:

     Objectives
     Automotive Wiring
     Braided Ground Straps
     Battery Cables
     Jumper Cables
     Fuses and Circuit Protection Devices
     Terminals and Connectors
     Wire Repair
     Summary
     Review Questions
     ASE Certification-Type Questions


ANSWERS TO REVIEW QUESTIONS:

     1.   The AWG system uses numbers to represent the size of the connector and the higher the number, the
          smaller the wire. The metric system states the actual size of the conductor in square millimeters
          (mm2).
     2.   While there is no real standard, the usual practice is to designate any wire AWG 4 or larger (smaller
          number) as a cable and smaller wire as wire.
     3.   A terminal is the metal part attached to the end of a wire and makes the electrical connection to
          another terminal or a component. A connection is the plastic part that houses the terminal(s) and
          provides the mechanical (not the electrical) connection to another connector or component.
     4.   Fuses melt if current flow exceeds the rating of the fuse. A PTC circuit protector increases in
          resistance if the current exceeds the rating of the device. Fusible links will melt if excessive current
          flows through the link, destroying the device.
     5.   A wire repair should include the following steps:
              a. strip the ends of the wire
              b. make a mechanical connection using solder or a crimp-and-seal fastener.
              c. protect the repair using heat shrink tubing or heating the connector to melt the glue inside.

ANSWERS TO ASE CERTIFICATION-TYPE QUESTIONS:

     1-a, 2-c, 3-d, 4-b, 5-a, 6-a, 7-c, 8-b, 9-d, 10-d
10


                 CHAPTER 10 - Schematics and Troubleshooting


WORKSHEETS IN THE WORKTEXT:                                                                     Page

     Identify/Interpret Electrical Systems Concerns (NATEF Task: A6-A-1)                        34
     Diagnose Electrical/Electronic Circuits (NATEF Task: A6-A-4)                               35
     Use Wiring Diagrams to Diagnose a Circuit (NATEF Task: A6-A-5)                             36
     Short-to-Voltage Diagnosis (NATEF Task: A6-A-12)                                           37
     Short-to-Ground Diagnosis (NATEF Task: A6-A-12)                                            38
     Open Circuit Diagnosis (NATEF Task: A6-A-12)                                               39
     Resistance Problem Diagnosis (NATEF Task: A6-A-12)                                         40

TRANSPARENCY MASTERS:

     Figure 10-7
     Figure 10-10

CHAPTER OUTLINE:

     Objectives
     Wiring Schematics
     Switches
     Relay Terminal Identification
     Using Schematics for Troubleshooting
     Locating a Short Circuit
     Electrical Troubleshooting Guide
     Step-by-Step Troubleshooting Procedure
     Summary
     Review Questions
     ASE Certification-Type Questions

ANSWERS TO REVIEW QUESTIONS:

     1.   Many vehicle manufacturers number circuits starting at the front of the vehicle and moving toward the
          rear with the 100s meaning under the hood, the 200s under the dash, the 300s in the passenger
          compartment, and the 400s in the trunk area.
     2.   Terminals 85 and 86 represent the coil of the relay, terminal 30 represents the power in the relay,
          terminal 87a is the normally closed contact, and terminal 87 is the normally open contact.
     3.   A short circuit can be located by using the fuse replacement method (usually not recommended), the
          circuit breaker method, the test light method, the ohmmeter method, or by using a gauss gauge or
          electronic tone generator.
     4.   A tone generator is connected to the shorted circuit and a probe is used to locate where the tone stops,
          which indicates the location of the short circuit.

ANSWERS TO ASE CERTIFICATION-TYPE QUESTIONS:

     1-c, 2-b, 3-a, 4-b, 5-c, 6-d, 7-c, 8-d, 9-d, 10-a
                                                                                                             11


                     CHAPTER 11 - Capacitance and Magnetism


WORKSHEETS IN THE WORKTEXT:                                                                   Page

     Inspect and Test the Relays (NATEF Task: A6-A-15)                                        41

TRANSPARENCY MASTERS:

     Figure 11-2
     Figure 11-5

CHAPTER OUTLINE:

     Objectives
     Capacitance
     Capacitor Construction and Operation
     Factors of Capacitance
     Capacitor Uses
     Fundamentals of Magnetism
     Electromagnetism
     Electromagnetic Induction
     Electromagnetic Interference (EMI) Suppression
     Summary
     Review Questions
     ASE Certification-Type Questions

ANSWERS TO REVIEW QUESTIONS:

     1.   A capacitor stores an electrical charge by using a condenser, such as aluminum foil separated by an
          insulator, where electrons are stored at a voltage potential.
     2.   To increase the capacitance, two capacitors should be connected in parallel.
     3.   A cracked magnet becomes two weaker magnets.
     4.   Whenever electricity is flowing through a conductor, a magnetic field around the conductor is formed.
          Whenever a conductor is moved through a magnetic field or a magnetic field is moved past a
          conductor, electricity is created.
     5.   Self induction occurs when current starts to flow through a conductor, creating a self-induced voltage
          that opposes the current. Mutual induction occurs when the magnetic field in one conductor or coil
          induces a voltage in another conductor or coil.

ANSWERS TO ASE CERTIFICATION-TYPE QUESTIONS:

     1-d, 2-b, 3-c, 4-c, 5-b, 6-b, 7-c, 8-c, 9-d, 10-d
12


                        CHAPTER 12 - Electronic Fundamentals



WORKSHEETS IN THE WORKTEXT:                                                                      Page

     Electronic Fundamentals (NATEF Task: None Specified)                                        42

TRANSPARENCY MASTERS:

     Figure 12-3
     Figure 12-7

CHAPTER OUTLINE:

     Objectives                                                      How a Transistor Works
     Semiconductors                                                  How a Transistor Amplifies
     N-Type Material                                                 Field-Effect Transistor
     P-Type Material                                                 Darlington Pairs
     How Holes Move                                                  Transistor Gain
     Summary of Semiconductors                                       Solid-State, Integrated-Circuit, and Dual
     Diodes                                                          Inline Package Components
     Zener Diodes                                                    Heat Sink
     Clamping Diodes                                                 Phototransistors
     Zener Diode Despiking Protection                                Solar Cells
     Despiking Resistors                                             How to Test Diodes and Transistors
     Diode Ratings                                                   Transistor Gates
     Light-Emitting Diodes                                           Logic Highs and Lows
     Photodiodes                                                     Transistor-Transistor Logic
     Photoresistors                                                  Operational Amplifiers
     Varistors                                                       Polarity
     Silicon-Controlled Rectifiers                                   Electronic Component Failure Causes
     Thermistors                                                     Electrostatic Discharge
     Rectifier Bridges                                               Summary
     Passive and Active Circuits                                     Review Questions
     Transistors                                                     ASE Certification-Type Questions

ANSWERS TO REVIEW QUESTIONS:

     1.   P-type material is doped with an element that has only three electrons in the outer orbit, creating a hole
          in the silicon in which an electron could occupy. N-type material is pure silicon that has been doped
          with an element with five electrons in the outer orbit, resulting in an extra electron that could act as a
          current carrier.
     2.   A diode can be installed across a coil in the reverse bias direction to suppress the high-voltage spikes
          that can occur when the current stops following through the coil.
     3.   A transistor can be toggled on and off as well as throttled by controlling the current flow through the
          emitter-base circuit.
     4.   Never open a package until the part is ready to install; ground yourself often and never touch
          terminals.

ANSWERS TO ASE CERTIFICATION-TYPE QUESTIONS:

     1-c, 2-d, 3-a, 4-c, 5-d, 6-d, 7-b, 8-c, 9-a, 10-d
                                                                                                                13


                        CHAPTER 13 - Computer Fundamentals


WORKSHEETS IN THE WORKTEXT:                                                                      Page

     Body Electronic System Diagnosis (NATEF Task: A6-H-9)                                       43
     Module Communication (NATEF Task: A6-H-10)                                                  44

TRANSPARENCY MASTERS:

     Figure 13-1
     Figure 13-4

CHAPTER OUTLINE:

     Objectives
     Computer Control
     The Four Basic Computer Functions
     Digital Computers
     Computer Input Sensors
     Computer Outputs
     Fuel Control System Operating Modes
     Summary
     Review Questions
     ASE Certification-Type Questions

ANSWERS TO REVIEW QUESTIONS:

     1.   The CPU is the “brain” of the computer.
     2.   Volatile RAM means that it is erased whenever the power is removed from the computer, whereas
          non-volatile RAM means that the data is retained when power is removed.
     3.   Input sensors include: engine speed (RPM), MAP, MAF, ECT, O2S, TP, and vehicle speed.
     4.   Output devices include: fuel injection, ignition timing, transmission shifting, idle speed control, and
          evaporative emission control solenoids.

ANSWERS TO ASE CERTIFICATION-TYPE QUESTIONS:

     1-a, 2-b, 3-d, 4-c, 5-b, 6-d, 7-d, 8-a, 9-b, 10-c
14


                                     CHAPTER 14 - Batteries


WORKSHEETS IN THE WORKTEXT:                                                                 Page

     Key Off Battery Drain (NATEF Task: A6-A-13)                                            45
     Battery State-of-Charge Test (NATEF Task: A6-B-1)                                      46
     Battery Specifications (NATEF Task: None Specified)                                    47

TRANSPARENCY MASTERS:

     Figure 14-7
     Figure 14-8

CHAPTER OUTLINE:

     Objectives
     Purpose of a Battery
     Battery Construction
     Grids
     How a Battery Works
     Specific Gravity
     Specific Gravity versus State of Charge and Battery Voltage
     AGM Batteries
     Causes and Types of Battery Failure
     Battery Hold-Downs
     Battery Ratings
     Deep Cycling
     Hybrid Batteries
     Battery Council International Group Sizes
     Summary
     Review Questions
     ASE Certification-Type Questions

ANSWERS TO REVIEW QUESTIONS:

     1.   Discharged batteries can freeze because the electrolyte becomes almost water.
     2.   The three most commonly used battery ratings are CA, CCA, and reserve capacity.
     3.   Batteries can explode if exposed to a flame or spark because they release hydrogen and oxygen from
          the vents.

ANSWERS TO ASE CERTIFICATION-TYPE QUESTIONS:

     1-b, 2-d, 3-c, 4-a, 5-d, 6-a, 7-c, 8-b, 9-d, 10-b
                                                                                                                15


                     CHAPTER 15 - Battery Testing and Service


WORKSHEETS IN THE WORKTEXT:                                                                      Page

     Battery Capacity Test (NATEF Task: A6-B-2)                                                  48
     Electronic Memory Saver Usage (NATEF Task: A6-B-3)                                          49
     Service and Replace the Battery (NATEF Task: A6-B-4)                                        50
     Battery Charging (NATEF Task: A6-B-5)                                                       51
     Battery Cables and Connectors (NATEF Task: A6-B-6)                                          52
     Jump Starting (NATEF Task: A6-B-7)                                                          53

TRANSPARENCY MASTERS:

     Figure 15-8
     Figure 15-18

CHAPTER OUTLINE:

     Objectives                                                      Battery Electrical Drain Test
     Battery Service Safety Considerations                           Procedure for Battery Electrical Drain Test
     Battery Maintenance                                             Battery Drain and Reserve Capacity
     Battery Voltage Test                                            Finding the Source of the Drain
     Hydrometer Testing                                              What to Do If a Battery Drain Still Exists
     Battery Load Testing                                            Hidden Batteries
     Electronic Capacitance Testing                                  Battery Troubleshooting Guide
     Battery Charging                                                Summary
     Battery Charge Time                                             Review Questions
     Jump-Starting                                                   ASE Certification-Type Questions
     Battery Date Codes

ANSWERS TO REVIEW QUESTIONS:

     1.   After removing the surface charge, a battery voltage of 12.6 volts or higher indicates a fully charged
          battery. If 12.4 volts, it is 75% charged; 12.2 volts is 50% charged, and if 12.0 volts, the battery is
          only 25% charged.
     2.   A battery load test involves removing the surface charge, loading the battery to ½ of the CCA rating
          for 15 seconds, and observing the voltage at the end of the time with the load still applied.
     3.   A battery drain test is performed using either a clamp-on ammeter or by connecting an ammeter in
          series between the negative terminal of the battery and the disconnected negative battery cable end.

ANSWERS TO ASE CERTIFICATION-TYPE QUESTIONS:

     1-a, 2-a, 3-b, 4-a, 5-b, 6-c, 7-c, 8-d, 9-a, 10-b
16


                              CHAPTER 16 - Cranking System


WORKSHEETS IN THE WORKTEXT:                                                                       Page

     Starter Relays and Solenoids (NATEF Task: A6-C-3)                                            54
     Starter Control Circuit Components (NATEF Task: A6-C-5)                                      55
     Cranking System Identification (NATEF Task: None Specified                                   56

TRANSPARENCY MASTERS:

     Figure 16-5
     Figure 16-27

CHAPTER OUTLINE:

     Objectives
     Cranking Circuit
     How the Starter Motor Works
     How Magnetic Fields Turn an Armature
     Types of Starter Motors
     Armature and Commutator Assembly
     Permanent-Magnet Fields
     Gear-Reduction Starters
     Starter Drives
     Starter Drive Operation
     Positive-Engagement Starters
     Solenoid-Operated Starters
     Summary
     Review Questions
     ASE Certification-Type Questions

ANSWERS TO REVIEW QUESTIONS:

     1.   The control circuit includes those wires and components that carry a relatively small current such as
          the ignition switch, safety switch, and solenoid. The power circuit carries the heavy current needed to
          crank the engine and includes the battery itself, plus the battery cables, solenoid, and starter motor.
     2.   Parts of a typical starter include: main field housing, commutator-end housing and drive-end housing,
          plus the armature, field coils, brushes, and starter drive.
     3.   A gear reduction starter allows the armature to rotate faster than in a direct drive starter, which causes
          the starter to produce more CEMF, thereby reducing the current draw from the battery.
     4.   A defective starter drive will cause the starter to whine and not rotate the engine flywheel.

ANSWERS TO ASE CERTIFICATION-TYPE QUESTIONS:

     1-d, 2-b, 3-b, 4-c, 5-a, 6-c, 7-d, 8-a, 9-c, 10-b
                                                                                                                  17


            CHAPTER 17 - Cranking System Diagnosis and Service


WORKSHEETS IN THE WORKTEXT:                                                                       Page

     Starter Current Draw Test (NATEF Task: A6-C-1)                                               57
     Starter Circuit Voltage Drop (NATEF Task: A6-C-2)                                            58
     Remove and Install the Starter (NATEF Task: A6-C-4)                                          59
     Cranking Circuit Problem Diagnosis (NATEF Task: A6-C-6)                                      60
     Starter Disassembly and Testing (NATEF Task: None Specified)                                 61
     Starter Solenoid Testing (NATEF Task: None Specified)                                        62

TRANSPARENCY MASTERS:

     Figure 17-2
     Figure 17-3

CHAPTER OUTLINE:

     Objectives
     Starting System Troubleshooting
     Voltage-Drop Testing
     Control Circuit Testing
     Specifications for a Starter Amperage Test
     Starter Removal and Installation
     Starter Overhaul
     Testing Starter Armatures
     Growler Test for Shorted Armature Windings
     Testing the Armature for Grounds
     Testing the Armature for Opens
     Armature Service
     Testing Starter Motor Field Coils
     Starter Brush Inspection
     Bench Testing
     Starter Drive-to-Flywheel Clearance
     Starting System Troubleshooting Guide
     Summary
     Review Questions
     ASE Certification-Type Questions

ANSWERS TO REVIEW QUESTIONS:

     1.   The parts of the cranking circuit include the ignition switch, safety switch, solenoid, starter, plus the
          battery and cables/wires.
     2.   A voltage drop test is performed by connecting a voltmeter to two parts of the cranking circuit and
          cranking the engine. The voltmeter indicates the difference in voltage between the meter leads and
          should be less than 0.5 volt per cable and 0.1 volt or less per connection.
     3.   The negative battery cable should be removed from the battery and the vehicle hoisted safely in most
          cases. The attaching bolts should be removed and the starter removed from the engine. Often the
          wiring is easier to remove with the starter removed from the engine.

ANSWERS TO ASE CERTIFICATION-TYPE QUESTIONS:

     1-b, 2-c, 3-b, 4-a, 5-c, 6-d, 7-a, 8-a, 9-a, 10-b
18


                              CHAPTER 18 - Charging System


WORKSHEETS IN THE WORKTEXT:                                                                  Page

     Generator (Alternator) Identification (NATEF Task: None Specified)                      63

TRANSPARENCY MASTERS:

     Figure 18-4
     Figure 18-12

CHAPTER OUTLINE:

     Objectives
     Principles of Generator Operation
     Alternating-Current Generators (Alternators)
     Generator Construction
     Rotors
     Stators
     Diodes
     How a Generator Works
     Wye-Connected Stators
     Delta-Connected Stators
     Generator Output Factors
     Generator Voltage Regulation
     Battery Condition and Charging Voltage
     Temperature Compensation
     A and B Field Circuits
     Electronic Voltage Regulators
     How an Electronic Voltage Regulator Works
     Computer-Controlled Generators
     Summary
     Review Questions
     ASE Certification-Type Questions

ANSWERS TO REVIEW QUESTIONS:

     1.   The regulator controls the current flow through the field (rotor). Zero field current equals no
          generator output and maximum field current (about 5 amperes) results in maximum generator output.
     2.   The components of a typical generator (alternator) include the drive-end housing, the slip-ring
          housing, rotor, rectifier diodes, and a stator.
     3.   The computer controls the output of the generator by controlling the current flow through the field
          (rotor).
     4.   Voltage regulators are temperature compensated to provide a slightly higher charging voltage when
          the battery is cold and to prevent from overcharging a hot battery.

ANSWERS TO ASE CERTIFICATION-TYPE QUESTIONS:

     1-b, 2-c, 3-d, 4-c, 5-a, 6-c, 7-d, 8-a, 9-b, 10-b
                                                                                                               19


            CHAPTER 19 - Charging System Diagnosis and Service


WORKSHEETS IN THE WORKTEXT:                                                                     Page

     Starting and Charging Tests (NATEF Task: None Specified)                                   64
     Generator Fusible Link Check (NATEF Task: None Specified)                                  65
     Charging System Output Test (NATEF Task: A6-D-1)                                           66
     Charging System Diagnosis (NATEF Task: A6-D-2)                                             67
     Generator (Alternator) Drive Belt (NATEF Task: A6-D-3)                                     68
     Charging Circuit Voltage Drop (NATEF Task: A6-D-5)                                         69
     Remove and Install Generator (NATEF Task: Alternator) (A6-D-4)                             70
     Generator Disassembly (NATEF Task: None Specified)                                         71
     Generator Rotor Testing (NATEF Task: None Specified)                                       72
     Generator Stator Testing (NATEF Task: None Specified)                                      73
     Generator Diode Trio Testing (NATEF Task: None Specified)                                  74
     Generator Rectifier Bridge Testing (NATEF Task: None Specified)                            75

TRANSPARENCY MASTERS:

     Figure 19-16
     Figure 19-26
     Figure 19-27

CHAPTER OUTLINE:

     Objectives                                                     Generator Disassembly
     Charging System Testing and Service                            Testing the Rotor
     Accessory Drive Belt Inspection                                Testing the Stator
     AC Voltage Check                                               Testing the Diode Trio
     AC Current Check                                               Testing the Rectifier Bridge (Diodes)
     Charging System Voltage-Drop Testing                           Testing the GM Internal Voltage Regulator
     General Motors SI Test Light Test                              Brush Holder Replacement
     General Motors CS Series AC Generators                         Bearing Service and Replacement
     Diagnosing Problems with the General                           Generator Assembly
     Motors CS Series                                               Remanufactured Generators
     Generator Output Test                                          Summary
     How to Determine Minimum Required                              Review Questions
        Generator Output                                            ASE Certification-Type Questions
     Generator (Alternator) Removal/Installation

ANSWERS TO REVIEW QUESTIONS:

     1.   To test the voltage drop of the insulated charging circuit, attach one voltmeter test lead to the output
          terminal of the generator (alternator) and the other test lead to the positive terminal of the battery.
          Start the engine and turn on the headlights and observe the voltmeter. Repeat the test for the ground
          side.
     2.   To test the amperage output of the generator (alternator), use a carbon-pile tester, such as a Sun VAT-
          40 to provide the load with the engine running at 2000 RPM.
     3.   If a rectifier diode or stator is defective, an excessive amount of AC voltage (ripple voltage) will be
          measured at the output terminal of the generator (alternator).

ANSWERS TO ASE CERTIFICATION-TYPE QUESTIONS:

     1-a, 2-b, 3-d, 4-c, 5-a, 6-c, 7-a, 8-b, 9-d, 10-d
20


                  CHAPTER 20 - Lighting and Signaling Circuits


WORKSHEETS IN THE WORKTEXT:                                                                      Page

     Lighting System Diagnosis (NATEF Task: A6-E-1)                                              76
     Turn Signal and Hazard Lights (NATEF Task: A6-E-3)                                          77
     Headlight Replacement and Aiming (NATEF Task: A6-E-2)                                       78
     Bulb Trade Numbers (NATEF Task: None Specified)                                             79

TRANSPARENCY MASTERS:

     Figure 20-4
     Figure 20-26

CHAPTER OUTLINE:

     Objectives                                                      Dimmer Switches
     Lighting                                                        Stop Lamp and Turn Signals
     Bulb Numbers                                                    Flasher Units
     Brake Lights                                                    Courtesy Lights
     Headlight Switches                                              Illuminated Entry
     Sealed-Beam Headlights                                          Fiber Optics
     Headlight Aiming                                                Feedback
     Composite Headlights                                            Lighting System Troubleshooting Guide
     Halogen Sealed-Beam Headlights                                  Summary
     High-Intensity Discharge Headlights                             Review Questions
     Daytime Running Lights                                          ASE Certification-Type Questions

ANSWERS TO REVIEW QUESTIONS:

     1.   The same trade number bulb should be used as a replacement because this assures that the correct
          voltage and wattage bulb is used.
     2.   A halogen bulb contains a high-pressure gas and oils from the hands can affect the expansion of the
          glass, which can shorten the life of the bulb.
     3.   If only the turn signals work correctly on one side, the most likely cause is a defective bulb, whereas if
          both sides fail to operate, the problem is most likely a defective flasher or flasher relay.
     4.   An optical headlight aimer is required to correctly aim aerodynamic-style headlights.

ANSWERS TO ASE CERTIFICATION-TYPE QUESTIONS:

     1-c, 2-c, 3-d, 4-c, 5-d, 6-c, 7-b, 8-d, 9-d, 10-d
                                                                                                                    21


          CHAPTER 21 - Dash Instruments Operation and Diagnosis


WORKSHEETS IN THE WORKTEXT:                                                                      Page

     Fuel Gauge (NATEF Task: A6-F-1)                                                             80
     Oil Pressure Gauge or Warning Lamp (NATEF Task: A6-F-1)                                     81
     Coolant Temperature Gauge (NATEF Task: A6-F-1)                                              82
     Gauges and Sending Units (NATEF Task: A6-F-1)                                               83
     Gauge Printed Circuit Boards (NATEF Task: A6-F-2)                                           84
     Driver Information and Warning Devices (NATEF Task: A6-F-3)                                 85
     Electronic Instrument Circuits (NATEF Task: A6-F-4)                                         86
     Dash Display Activity (NATEF Task: None Specified)                                          87

TRANSPARENCY MASTERS:

     Figure 21-23
     Figure 21-24

CHAPTER OUTLINE:

     Objectives
     Analog Dash Instruments
     Computer-Controlled Instrument Panels
     Dash Instrument Diagnosis
     Telltale Lamps
     Oil Pressure Warning Devices
     Temperature Lamp Diagnosis
     Brake Warning Lamp
     Digital Electronic Dash Operation
     Electronic Speedometers
     Electronic Odometers
     Electronic Speedometer and Odometer Service
     Electronic Fuel-Level Gauges
     Electronic Dash Instrument Diagnosis and Troubleshooting
     Maintenance Reminder Lamps
     Summary
     Review Questions
     ASE Certification-Type Questions

ANSWERS TO REVIEW QUESTIONS:

     1.   Thermoelectric dash gauges used on older vehicles used current flow to deflect the needle.
          Electromagnetic dash gauges use the strength of the magnetic field to move the needle.
     2.   LED mans light emitting diode, LCD means liquid crystal display, VTF means vacuum tube
          fluorescent, and CRT means cathode ray tube.
     3.   To help diagnose the cause of a red brake warning lamp, disconnect the wire from the differential
          pressure switch and check that the parking brake is fully released.
     4.   If the tank unit is unplugged with the key on, the needle should either go to full or empty if the dash
          unit and wiring are okay.

ANSWERS TO ASE CERTIFICATION-TYPE QUESTIONS:

     1-b, 2-a, 3-c, 4-a, 5-b, 6-c, 7-c, 8-a, 9-c, 10-a
                                                                                                               22


          CHAPTER 22 - Horn, Wiper, and Blower Motor Circuits


WORKSHEETS IN THE WORKTEXT:                                                                     Page

     Horn (NATEF Task: A6-G-1)                                                                  88
     Horn Operation (NATEF Task: A6-G-1)                                                        89
     Windshield Wiper (NATEF Task: A6-G-2)                                                      90
     Windshield Washer (NATEF Task: A6-G-3)                                                     91
     Blower Motor Current Draw (NATEF Task: A6-H-1)                                             92
     Blower Motor Circuit (NATEF Task: A6-H-1)                                                  93

TRANSPARENCY MASTERS:

     Figure 22-2
     Figure 22-22

CHAPTER OUTLINE:

     Objectives
     Horns
     Windshield Wiper and Washer System
     Windshield Wiper Motors
     Blower Motor Operation
     Blower Motor Diagnosis
     Electrical Accessory Troubleshooting Guide
     Summary
     Review Questions
     ASE Certification-Type Questions

ANSWERS TO REVIEW QUESTIONS:

     1.   Three types of horn failure include: no horn operation, intermittent operation, or constant operation.
     2.   The switch usually completes the ground to the coil of the horn relay.
     3.   If the motor operates at all speeds and the wipers do not function correctly, then the problem is
          mechanical (linkage, etc.). If the motor does not work at all speeds, the problem is electrical.
     4.   A defective blower motor usually draws more current than a good motor due to wear of the bushings
          causing drag.

ANSWERS TO ASE CERTIFICATION-TYPE QUESTIONS:

     1-c, 2-a, 3-a, 4-b, 5-a, 6-c, 7-d, 8-c, 9-b, 10-d
                                                                                                              23


                             CHAPTER 23 - Accessory Circuits



WORKSHEETS IN THE WORKTEXT:                                                                    Page

     Power Windows (NATEF Task: A6-H-1)                                                        94
     Heated Glass Operation (NATEF Task: A6-H-2)                                               95
     Power Door Locks (NATEF Task: A6-H-3)                                                     96
     Cruise Control (NATEF Task: A6-H-4)                                                       97
     Door Panel (NATEF Task: A6-H-8)                                                           98
     Anti-Theft System Diagnosis (NATEF Task: A6-H-11)                                         99

TRANSPARENCY MASTERS:

     Figure 23-5
     Figure 23-13

CHAPTER OUTLINE:

     Objectives
     Cruise Control
     Heated Rear Window Defoggers
     Power Windows
     Power Seats
     Electric Power Door Locks
     Keyless Entry
     Anti-Theft Systems
     Electrical Accessory Troubleshooting Guide
     Summary
     Review Questions
     ASE Certification-Type Questions

ANSWERS TO REVIEW QUESTIONS:

     1.   Only one ground connection is required on power door locks because the current flows in one
          direction for unlock and the direction for lock through a relay. The one ground is at the relay.
     2.   The current flow through a rear window defogger will increase if the wires are cold and increase as the
          wires become warmer due to normal increased activity of the electrons in the atoms of the conductor.
     3.   The usual procedure to resynchronize a remote keyless entry is to press and hold both the lock and the
          unlock button for 10 seconds with the remote within 5 to 10 feet of the vehicle.
     4.   The anti-theft system that uses a resistor pellet in the key is called Passkey.

ANSWERS TO ASE CERTIFICATION-TYPE QUESTIONS:

     1-a, 2-c, 3-a, 4-a, 5-b, 6-d, 7-b, 8-b, 9-c, 10-c
                                                                                                              24


                 CHAPTER 24 - Airbag and Pretensioner Circuits


WORKSHEETS IN THE WORKTEXT:                                                                    Page

     Airbag Diagnosis (NATEF Task: A6-H-5)                                                     100
     Disarm and Enable Airbags (NATEF Task: A6-H-6)                                            101

TRANSPARENCY MASTERS:

     Figure 24-2
     Figure 24-6

CHAPTER OUTLINE:

     Objectives
     Airbags
     Airbag Testing and Service
     Driver Side Airbag Module Replacement
     Pretensioners
     Side Airbags
     Occupant Airbags
     Summary
     Review Questions
     ASE Certification-Type Questions

ANSWERS TO REVIEW QUESTIONS:

     1.   Disconnect airbag modules if service work is going to be performed in the area. Do not use self-
          powered test equipment around airbag circuits. Use care when handling an inflator module. Always
          wear safety glasses.
     2.   To deploy an airbag, the arming sensor and at least one discriminating sensor must be triggered at the
          same time.
     3.   A deployed airbag module must be handled as if it is a non-deployed airbag because many are two-
          stage units where only one of the stages may have deployed.
     4.   The purpose of pretensioners is to force the occupant into correct position in the seat and to remove
          any slack in the seatbelt prior to an airbag deployment.

ANSWERS TO ASE CERTIFICATION-TYPE QUESTIONS:

     1-c, 2-d, 3-b, 4-d, 5-b, 6-b, 7-c, 8-b, 9-b, 10-d
                                                                                                                  25


            CHAPTER 25 - Audio System Operation and Diagnosis


WORKSHEETS IN THE WORKTEXT:                                                                    Page

     Radio Diagnosis (NATEF Task: A6-H-7)                                                      102
     Blower Motor Radio Noise (NATEF Task: A6-H-7)                                             103
     Audio Speaker System (NATEF Task: None Specified)                                         104

TRANSPARENCY MASTERS:

     Figure 25-9
     Figure 25-10

CHAPTER OUTLINE:

     Objectives
     Radios
     Antennas
     Speakers
     Speaker Types
     Crossovers
     Powerline Capacitors
     Radio Interference
     Audio Noise Control Diagnostic Chart
     Summary
     Review Questions
     ASE Certification-Type Questions

ANSWERS TO REVIEW QUESTIONS:

     1.   AM signals travel longer distances than FM signals because they bounce off the upper atmosphere.
     2.   The ground plane represents one-half of the length of the antenna.
     3.   Speakers must be matched with the same impedance to allow all of the speakers to receive the same
          power, not only to produce the best sound possible, but also to help equalize the current through the
          speaker driver circuits.
     4.   A capacitor can be added to the power input to the radio and a braided ground strap can be added to
          the ground to help reduce radio noise.

ANSWERS TO ASE CERTIFICATION-TYPE QUESTIONS:

     1-d, 2-d, 3-a, 4-b, 5-c, 6-a, 7-a, 8-a, 9-c, 10-b
                                                                        26


Answers to Appendix 1 - Electrical/Electronic Systems Sample ASE Test


   1. a                      18. c                      35. b

   2. a                      19. d                      36. a

   3. b                      20. c                      37. d

   4. c                      21. a                      38. b

   5. c                      22. b                      39. c

   6. a                      23. c                      40. a

   7. c                      24. b                      41. b

   8. d                      25. a                      42. c

   9. d                      26. b                      43. a

   10. a                     27. b                      44. a

   11. c                     28. d                      45. a

   12. c                     29. b                      46. c

   13. d                     30. a                      47. a

   14. b                     31. c                      48. c

   15. c                     32. b                      49. c

   16. c                     33. d                      50. a

   17. a                     34. b
         27




LESSON
PLANS
27

                                            LESSON PLAN

                                       Service Information
Chapter # 1 Lesson # 1       Meets NATEF Task: A6-A-2, 3

           Classroom Content Outline                                       Lab Activities
Time Req’d     3-4 hours                               1.   Vehicle Service History worksheet
Text ref:                                              2.   Technical Service Bulletins worksheet
PowerPoint:                                            3.   VIN code worksheet
Handouts:                                              4.   Vehicle Safety Certification Label worksheet
Parts/Demo: Service manuals, electronic service        5.   Vehicle and Electrical Service Information
               information                                  worksheet
Student CD:
Discuss:                                               Tools/Resources Needed:
1. Vehicle identification                              1. Lab vehicles
2. VECI labels                                         2. Lab engines on stands
3. Casting numbers                                     3. Casting number charts
4. Service information                                 4. Service manuals and/or electronic service
                                                          information (CD/DVD or internet-based)
Notes:                                                 Notes:




                  Test Questions                                      Homework Assignment
1. Calibration codes are usually found on _______.     1. Research the amount of oil required to perform
   Answer: PCMs                                           an oil change (with filter) on your personal
2. The _______ VIN represents the vehicle's model         vehicle.
   year. Answer: 10th                                  2. Determine the manufacturer's specifications for
3. Listings of special service tools can be found in      the coolant in your personal vehicle.
   _________ __________. Answer: Service               3. Write a short paragraph discussing the
   manuals                                                advantages and disadvantages of internet-based
4. TSB stands for ________ ________ ________.             service information.
   Answer: Technical Service Bulletin                  4. Explain how to do a TSB search using electronic
                                                          service information.
                                                                                           28
                                             LESSON PLAN

                           Audio System Operation and Diagnosis
Chapter # 25 Lesson # 1       Meets NATEF Task: A6-H-7

           Classroom Content Outline                                    Lab Activities
Time Req’d     3-4 hours                               1. Radio Diagnosis worksheet
Text ref:                                              2. Blower Motor Radio Noise worksheet
PowerPoint:                                            3. Audio Speaker System worksheet
Handouts:
Parts/Demo: Radio receiver, antenna, speakers,
               crossover, powerline capacitor
Student CD:
Discuss:                                               Tools/Resources Needed:
1. Radios                                              1. Lab vehicles
2. AM and FM reception                                 2. Service information
3. Antennas                                            3. DMMs
4. Speakers                                            4. Hand tools
5. Speaker types
6. Crossovers
7. Powerline capacitors
8. Radio interference
9. Audio noise control diagnosis
Notes:                                                 Notes:




                   Test Questions                                   Homework Assignment
1. True or False: AM stands for Amplitude              1. Find one TSB related to a vehicle sound system.
   Modification. Answer: False                         2. Research to determine any self-diagnostics that
2. A(n) __________ can be used to test a                  are incorporated into the sound system of your
   automotive radio antenna. Answer: Ohmmeter             personal vehicle.
3. Internal coil resistance of a speaker is known as   3. Research automotive applications of wireless
   its _________. Answer: Impedance                       connectivity technology (ie; Bluetooth)
4. The two types of audio crossovers include           4. Print a diagnostic flowchart for customer
   _______ and ________. Answer: Passive,                 concerns related to a radio/audio circuit.
   Active
29

                                            LESSON PLAN

                                       Service Information
Chapter # 1 Lesson # 1       Meets NATEF Task: A6-A-2, 3

           Classroom Content Outline                                       Lab Activities
Time Req’d     3-4 hours                               1.   Vehicle Service History worksheet
Text ref:                                              2.   Technical Service Bulletins worksheet
PowerPoint:                                            3.   VIN code worksheet
Handouts:                                              4.   Vehicle Safety Certification Label worksheet
Parts/Demo: Service manuals, electronic service        5.   Vehicle and Electrical Service Information
               information                                  worksheet
Student CD:
Discuss:                                               Tools/Resources Needed:
1. Vehicle identification                              1. Lab vehicles
2. VECI labels                                         2. Lab engines on stands
3. Casting numbers                                     3. Casting number charts
4. Service information                                 4. Service manuals and/or electronic service
                                                          information (CD/DVD or internet-based)
Notes:                                                 Notes:




                  Test Questions                                      Homework Assignment
1. Calibration codes are usually found on _______.     1. Research the amount of oil required to perform
   Answer: PCMs                                           an oil change (with filter) on your personal
2. The _______ VIN represents the vehicle's model         vehicle.
   year. Answer: 10th                                  2. Determine the manufacturer's specifications for
3. Listings of special service tools can be found in      the coolant in your personal vehicle.
   _________ __________. Answer: Service               3. Write a short paragraph discussing the
   manuals                                                advantages and disadvantages of internet-based
4. TSB stands for ________ ________ ________.             service information.
   Answer: Technical Service Bulletin                  4. Explain how to do a TSB search using electronic
                                                          service information.
                                                                                        30
                                           LESSON PLAN

                                       Threaded Fasteners
Chapter # 1 Lesson # 2       Meets NATEF Task: Assumed knowledge

           Classroom Content Outline                                   Lab Activities
Time Req’d      2-3 hours                              1.
Text ref:
PowerPoint:
Handouts:
Parts/Demo: Assortment of fasteners, SAE and
                metric thread gauges and bolt gauges
Student CD:
Discuss:                                               Tools/Resources Needed:
1. Types of fasteners (cap screws, bolts, studs)       1.
2. Thread measurement (diameter, pitch)
3. Fractional (UNC, UNF) and metric bolts
4. Grades of bolts
5. Tensile strength
6. Nuts and washers
Notes:                                                 Notes:




                  Test Questions                                   Homework Assignment
1.                                                     1.
31
                                            LESSON PLAN

                                               Tools
Chapter # 1 Lesson # 3       Meets NATEF Task: Assumed knowledge

           Classroom Content Outline                                  Lab Activities
Time Req’d    3-4 hours                            1. Have students list ten electrical tools available in
Text ref:                                             your automotive lab.
PowerPoint:                                        2. Compare the hand tools available in your school's
Handouts:                                             automotive lab with the NATEF hand tool list.
Parts/Demo: Assortment of common automotive        3. Demonstrate safe methods for loosening tight
              hand and power tools                    fasteners using hand tools.
Student CD:                                        4. Perform simple inspection and maintenance on
                                                      your automotive lab's air compressor
Discuss:                                           Tools/Resources Needed:
1. Electrical tools                                1. Clip boards and paper
2. Basic hand tools                                2. NATEF hand tool list
3. Hand tool safety                                3. Assorted automotive hand tools
4. Power (air and electric-powered) tools          4. Check sheet of air compressor inspection items
Notes:                                             Notes:




                  Test Questions                                 Homework Assignment
1. Cordless soldering irons are powered with       1. Explain why two hammer heads should never be
   _______. Answer: Butane                            struck together
2. DMM stands for _______ ________ _______.        2. List maintenance that should be performed on air
   Answer: Digital Multimeter                         tools.
3. A T40 socket is a ________-type. Answer: Torx   3. Explain why water collects in an air compressor
4. The formal name for "dikes" is _______             reservoir.
   _______. Answer: Diagonal cutters               4. List advantages and disadvantages of air tools
                                                      when compared to electric tools.
                                                                                          32
                                           LESSON PLAN

                                                Safety
Chapter # 1 Lesson # 4      Meets NATEF Task: Assumed knowledge, A6-H-6

           Classroom Content Outline                                     Lab Activities
Time Req’d    4-5 hours                               1. Go over emergency evacuation routes for your
Text ref:                                                facility
PowerPoint:                                           2. Show location and operation of eye wash station
Handouts:                                                and location of first aid kit
Parts/Demo: Personal protective equipment, lift       3. Show locations of all personal protective
              safety videotape, shop safety policy       equipment and explain shop safety glasses policy
              handbook                                4. Fire extinguisher worksheet
Student CD:                                           5. Vehicle hoisting worksheet
                                                      6. Safety check worksheet
                                                      7. Temporary disabling of an airbag worksheet
Discuss:                                              Tools/Resources Needed:
1. General safety tips for technicians                1. Evacuation route chart
2. Personal protective equipment (PPE)                2. Battery charger and battery
3. Lift safety                                        3. Automotive jacks and safety stands
4. Jacks and safety stands                            4. Vehicle lift point charts
5. Electrical cord safety                             5. ABC-rated fire extinguisher(s)
6. Jump starting and battery safety                   6. Lab vehicles for safety check
7. Fire extinguishers
8. First aid and eye wash stations
9. Airbag safety (disabling procedure)
Notes:                                                Notes:




                  Test Questions                                   Homework Assignment
1. Safety glasses should be worn _______ in the       1. Determine the recommended lift points for your
   automotive lab. Answer: At all times                  personal vehicle
2. True or False: Wearing jewelry in the automotive   2. Research ANSI and determine what its name
   lab is a safe practice. Answer: False                 means and what it is responsible for
3. The process of ignition without an open flame is   3. Research another means of hearing protection
   known as _____ ______. Answer: Spontaneous            outside of what is used in your automotive lab
   combustion                                         4. Research carbon monoxide and why it is
4. True or False: Pound on steel with a brass drift      dangerous
   to avoid damage. Answer: True
33
                                           LESSON PLAN

                              Environmental and Health Issues
Chapter # 2 Lesson # 1       Meets NATEF Task: Assumed knowledge

             Classroom Content Outline                                   Lab Activities
Time Req’d       3-4 hours                            1. Show locations and proper use of used oil storage
Text ref:                                                in the automotive lab
PowerPoint:                                           2. Show locations and proper use of used coolant
Handouts:                                                storage in the automotive lab
Parts/Demo: Material Safety Data Sheets, Shop         3. Show location and proper use of fireproof storage
                 Safety Policy handbook                  cabinets for various automotive chemicals
Student CD:                                           4. Material Safety Data Sheet (MSDS) worksheet
Discuss:                                              Tools/Resources Needed:
1. Overview of enviromental legislation (OSHA,        1. Floor layout of automotive lab for locating
    RCRA, Clean Air Act)                                 safety-related areas
2. Discuss terminology (reactive, corrosive, toxic,   2. Selection of automotive chemicals for MSDS
    ignitable, radioactive)                              exercise
3. Asbestos regulations and handling
4. Automotive fluids: storage, handling, and
    disposal
5. Potential health hazards in automotive waste
6. Automotive components: storage, handling, and
    disposal
7. Material Safety Data Sheets
Notes:                                                Notes:




                  Test Questions                                   Homework Assignment
1. The release of only one gallon of used oil can     1. Look in the phone book to find the name and
   make __________ gallons of fresh water                phone number of a local recycler that handles
   undrinkable. Answer: One million                      used tires and batteries
2. Asbestos fibers are considered hazardous when      2. Look on the internet for a web site that can
   they are _________. Answer: Airborne                  explain the role of the Battery Council
3. True or False: Brake fluid is soluble in water.       International (BCI)
   Answer: True                                       3. Research the term HEPA and explain how it
4. PPM stands for _____ _____ _______. Answer:           relates to automotive service procedures
   Parts Per Million                                  4. Find the MSDS for one household chemical you
                                                         personally use
                                                                                             34
                                             LESSON PLAN

                                      Electrical Fundamentals
Chapter # 3 Lesson # 1        Meets NATEF Task: Assumed knowledge

           Classroom Content Outline                                      Lab Activities
Time Req’d     2-3 hours                                1. Demonstrate sources of electricity, including a
Text ref:                                                  photovoltaic panel (photoelectric), a knock
PowerPoint:                                                sensor or phonograph (piezoelectric), and a
Handouts:                                                  battery (chemical)
Parts/Demo: Assortment of conductors and                2. Electrical Fundamentals worksheet
               insulators, resistors, rheostats, and
               potentiometers
Student CD:
Discuss:                                                Tools/Resources Needed:
1. Basic atomic theory                                  1. Digital multimeter (DMM)
2. Electron flow theory/Conventional current flow       2. Knock sensor
    theory                                              3. Photovoltaic panel
3. Volts, Ohms, and Amperes                             4. Battery
4. Sources of electricity
5. Conductors and resistance
6. Resistors and Variable resistors
Notes:                                                  Notes:




                   Test Questions                                     Homework Assignment
1. An electrical load that has 12 volts applied to it   1. Research how electricity is generated for your
   with 2 amperes flowing through it is consuming          local utility. What energy source is being
   ________ watt(s) of power. Answer: 24                   harnessed?
2. True or False: Heat can be used to generate          2. Research the advantages and disadvantages of
   electricity. Answer: True                               using aluminum for an electrical conductor
3. True or False: Gold is a better conductor than       3. Look at a household electrical bill to determine
   silver. Answer: False                                   what units are used to measure electrical power
4. Conventional current flow theory states that            consumed
   electricity flows from _______ to ________.          4. Find an example of a thermocouple
   Answer: Positive, Negative
35
                                          LESSON PLAN

                            Electrical Circuits and Ohm's Law
Chapter # 4 Lesson # 1      Meets NATEF Task: Assumed knowledge

            Classroom Content Outline                                    Lab Activities
Time Req’d      2-3 hours                             1. Demonstrate basic circuit construction and
Text ref:                                                current flow using a battery, jumper wires, and a
PowerPoint:                                              light bulb and socket
Handouts:                                             2. Electrical Circuits worksheet
Parts/Demo: Ohm's Law pie chart
Student CD:
Discuss:                                              Tools/Resources Needed:
1. Circuits                                           1. Digital multimeter (DMM)
2. Parts of a complete circuit                        2. Battery
3. Open circuits                                      3. Jumper wires with aligator clips
4. Short circuits                                     4. Light bulb with socket
5. Ohm's Law
6. Watt's Law
Notes:                                                Notes:




                  Test Questions                                    Homework Assignment
1. A circuit that is continuous throughout has        1. Research some biographical information on
   ________. Answer: Continuity                          Georg Simon Ohm
2. True or False: Some current will flow in an open   2. Research the meaning of NO and NC and how
   circuit. Answer: False                                these terms relate to electrical circuits
3. A circuit failure where copper meets steel is      3. Find the rated electrical power consumption of an
   known as a short-to-________. Answer: Ground          appliance at home and calculate the current it will
4. If voltage stays the same and resistance              draw
   decreases, current will _______. Answer:           4. Calculate the kilowatt output of the engine in
   Decrease                                              your personal vehicle, based on its brake
                                                         horsepower rating
                                                                                          36
                                             LESSON PLAN

                                            Series Circuits
Chapter # 5 Lesson # 1        Meets NATEF Task: A6-A-4

            Classroom Content Outline                                    Lab Activities
Time Req’d      2-3 hours                             1. Series Circuits #1 worksheet
Text ref:                                             2. Series Circuits #2 worksheet
PowerPoint:                                           3. Series Circuits #3 worksheet
Handouts:
Parts/Demo: Light bulbs with sockets, battery,
                jumper wires with aligator clips,
                DMM
Student CD:
Discuss:                                              Tools/Resources Needed:
1. Series circuits                                    1. Calculators (if necessary)
2. Ohm's Law and series circuits
3. Kirchhoff's voltage law
4. Voltage drops as a testing method
5. Series circuit laws
Notes:                                                Notes:




                   Test Questions                                   Homework Assignment
1. Three 6-ohm resistors are connected in series.     1. Research some biographical information on
   Total resistance of this circuit is _____ ohms.       Gustav Robert Kirchhoff
   Answer: 18                                         2. Research the difference between a power-side
2. True or False: Individual voltage drops in a          switch and a ground-side switch
   series circuit will add up to equal the applied    3. Describe how Kirchhoff's voltage law can be
   voltage. Answer: True                                 used to diagnose a slow cranking condition in a
3. Current is _______ throughout a series circuit.       vehicle
   Answer: The same                                   4. Explain why fuses are used in automotive circuits
4. 12 volts is applied to a 0.5 ohm resistor. Total
   current is 24,000 _____. Answer: Milliamps
37
                                              LESSON PLAN

                                            Parallel Circuits
Chapter # 6 Lesson # 1         Meets NATEF Task: A6-A-4

            Classroom Content Outline                                        Lab Activities
Time Req’d      2-3 hours                                 1. Parallel Circuits #1 worksheet
Text ref:                                                 2. Parallel Circuits #2 worksheet
PowerPoint:                                               3. Parallel Circuits #3 worksheet
Handouts:
Parts/Demo: Light bulbs with sockets, battery,
                jumper wires with aligator clips,
                DMM
Student CD:
Discuss:                                                  Tools/Resources Needed:
1. Kirchhoff's current law                                1. Calculators
2. Parallel circuit laws
3. Determining total resistance in a parallel circuit
4. Parallel circuit examples
Notes:                                                    Notes:




                   Test Questions                                       Homework Assignment
1. Three 6-ohm resistors are connected in parallel.       1. Find an application of parallel circuits in your
   Total resistance of this circuit is _____ ohms.           home.
   Answer: 2                                              2. List three fuses in your vehicle that have multiple
2. True or False: Each load in a parallel circuit will       circuits connected to them.
   always have the same current flowing through it.       3. Explain why a 2-ohm bulb will be brighter than a
   Answer: False                                             6-ohm bulb.
3. The total resistance of a parallel circuit is always   4. Research how a shunt is utilized in the
   (more/less) than that of the smallest resistance          construction of an ammeter
   leg. Answer: Less
4. True or False: Adding more loads to a parallel
   circuit will decrease the current flow in the
   circuit. Answer: False
                                                                                                38
                                              LESSON PLAN

                                       Series-Parallel Circuits
Chapter # 7 Lesson # 1         Meets NATEF Task: A6-A-4

           Classroom Content Outline                                         Lab Activities
Time Req’d      2-3 hours                                 1. Series-Parallel Circuits #1 worksheet
Text ref:                                                 2. Series-Parallel Circuits #2 worksheet
PowerPoint:                                               3. Series-Parallel Circuits #3 worksheet
Handouts:
Parts/Demo: Light bulbs with sockets, battery,
                jumper wires with aligator clips,
                control switch, DMM
Student CD:
Discuss:                                                  Tools/Resources Needed:
1. Series-parallel circuits                               1. Calculators
2. Series-parallel circuit faults
3. Solving series-parallel circuit problems
4. Series-parallel circuit examples
Notes:                                                    Notes:




                   Test Questions                                       Homework Assignment
1. Increasing the resistance of the series section of a   1. Find an application of series-parallel circuits in
   series-parallel circuit will result in a(n)               your home.
   (increase/decrease) in current flow. Answer:           2. Explain why the dash lights in an automobile
   Decrease                                                  would be connected in series-parallel.
2. True or False: An open in the series section of a      3. Draw schematics illustrating the two different
   series-parallel circuit will only affect part of the      types of series-parallel circuits.
   parallel section of the circuit. Answer: False         4. Draw a series-parallel circuit of your own design
3. A 4-ohm resistor is in series with two 4-ohm              that could be used in an automotive application.
   resistors in parallel. The total resistance of this
   circuit is _____ ohms. Answer: 6
4. The voltage drop across the series section of a
   series-parallel circuit will (increase/decrease)
   when more loads are added to the parallel
   section. Answer: Increase
39
                                           LESSON PLAN

                                           Digital Meters
Chapter # 8 Lesson # 1       Meets NATEF Task: A6-A-6, 7, 8, 9, 10, 11

           Classroom Content Outline                                    Lab Activities
Time Req’d    4-5 hours                             1. Digital Multimeter Use for Electrical Problems
Text ref:                                              worksheet
PowerPoint:                                         2. Test Light Usage worksheet
Handouts:                                           3. Measure Voltage Using a Voltmeter worksheet
Parts/Demo: DMM with fused leads, 12 volt test      4. Measuring Current Using an Ammeter worksheet
              light, fused jumper wire              5. Check Electrical Circuits Using an Ohmmeter
Student CD:                                            worksheet
                                                    6. Circuit Testing Using a Fused Jumper Wire
                                                       worksheet
Discuss:                                            Tools/Resources Needed:
1. Test lights                                      1. Lab vehicles
2. Digital multimeters (DMMs)                       2. Service information
3. Measuring voltage, current and resistance        3. DMMs with fused leads
4. Electrical unit prefixes                         4. 12-volt test lights
5. How to read digital meters                       5. Fused jumper wires
Notes:                                              Notes:




                  Test Questions                                 Homework Assignment
1. True or False: Voltmeters should only be         1. Research the difference between True RMS and
   connected to circuits that have their power         Average-reading meters.
   disconnected. Answer: False                      2. Explain what a logic probe is and how it works.
2. 1 mA is the same as _______ amperes. Answer:     3. Explain what a frequency counter is and how it
   1/1000                                              can be used in automotive diagnosis
3. Fused jumper leads should only be used to        4. Research the MIN/MAX function used on many
   bypass (loads/controls). Answer: Controls           DMMs. How can this be used for automotive
4. True or False: 20 KV is the same as 0.2 MV.         diagnosis?
   Answer: False
                                                                                           40
                                           LESSON PLAN

                                           Oscilloscopes
Chapter # 8 Lesson # 2       Meets NATEF Task: None specified

           Classroom Content Outline                                     Lab Activities
Time Req’d    2-3 hours                                1. Demonstrate measurement of battery voltage
Text ref:                                                 with a scope and compare this to an AC
PowerPoint:                                               waveform.
Handouts:                                              2. Demonstrate the use of an automotive DSO for
Parts/Demo: Analog oscilloscope, digital storage          viewing various waveforms on a lab vehicle.
              oscilloscope, battery                    3. Have students measure one digital DC signal and
Student CD:                                               one AC signal on a lab vehicle using an
                                                          automotive DSO.
Discuss:                                               Tools/Resources Needed:
1. Analog vs. DSO                                      1. Lab vehicles
2. Oscilloscope display grid                           2. Service information
3. Oscilloscope adjustments (time base, volts per      3. Automotive DSOs
   division, coupling, trigger, trigger slope)         4. Backprobes
4. Waveform terminology (pulse trains, frequency,
   duty cycle, pulse width)
5. Scope leads
Notes:                                                 Notes:




                  Test Questions                                    Homework Assignment
1. True or False: AC coupling removes only the         1. Explain one advantage and one disadvantage that
   AC component of an electrical signal. Answer:          an oscilloscope has when compared to a DMM.
   False                                               2. Research the term "ground coupling" to
2. Adjusting the oscilloscope time base would affect      determine why it is used during oscilloscope
   the (vertical/horizontal) component of a               operation.
   waveform. Answer: Horizontal                        3. Research "BNC connector" to determine its
3. True or False: An oscilloscope can be used to          history and development.
   view a throttle position sensor (TPS) signal.       4. Research the purpose of having multiple channels
   Answer: True                                           on an oscilloscope.
4. DSO stands for Digital ______ Oscilloscope.
   Answer: Storage
41
                                            LESSON PLAN

                                        Automotive Wiring
Chapter # 9 Lesson # 1       Meets NATEF Task: A-6-14, 15

           Classroom Content Outline                                    Lab Activities
Time Req’d     3-4 hours                              1. Fusible Links, Circuit Breakers, and Fuses
Text ref:                                                worksheet
PowerPoint:                                           2. Inspect and Test the Switches worksheet
Handouts:                                             3. Brake Switch Activity worksheet
Parts/Demo: Examples of AWG and metric wire           4. Inspect Wiring and Connectors worksheet
               sizes, braided ground strap, battery
               and jumper cables, various circuit
               protection devices, terminals and
               connectors.
Student CD:
Discuss:                                              Tools/Resources Needed:
1. Automotive wiring                                  1. Lab vehicles
2. AWG vs. Metric wire gauges                         2. Service information
3. Braided ground straps                              3. DMMs
4. Battery cables                                     4. Scan tool for viewing PIDs
5. Fuses and circuit protection devices               5. Back probes
6. Terminals and connectors
Notes:                                                Notes:




                  Test Questions                                   Homework Assignment
1. True or False: A terminal is the housing for a     1. Research the difference between wire and cable.
   connector. Answer: False                           2. Measure the gauge of the largest conductor found
2. The majority of automotive wiring is made with        in your personal vehicle.
   (stranded/solid) wire. Answer: Stranded            3. Research "non-cycling" circuit breakers. How do
3. True or False: 18-gauge wire is smaller in            they work, and where are they used in
   diameter than 12-gauge wire. Answer: True             automotive applications?
4. AWG stands for __________ Wire Gauge.              4. Research where solid wire might be used in an
   Answer: American                                      automobile body wiring harness
                                                                                               42
                                             LESSON PLAN

                                              Wire Repair
Chapter # 9 Lesson # 2        Meets NATEF Task: A-6-16, 17

           Classroom Content Outline                                     Lab Activities
Time Req’d     3-4 hours                                1. Wire Harness and Connector Repair worksheet
Text ref:                                               2. Solder Wire Repair worksheet
PowerPoint:
Handouts:
Parts/Demo: Section of vehicle wiring harness,
               terminal picks, crimping tools,
               soldering iron, solder, shrink tubing,
               heat gun
Student CD:
Discuss:                                                Tools/Resources Needed:
1. Wire repair                                          1. Lab vehicles
2. Soldering tools, materials, and processes            2. Service information
3. Crimping terminals                                   3. Terminal picks
4. Heat shrink tubing                                   4. Crimping tools
5. Crimp-and-seal connectors                            5. Terminals
6. Aluminum wire repair                                 6. Soldering irons and solder
                                                        7. Shrink tubing and electrical tape
                                                        8. Heat gun
Notes:                                                  Notes:




                   Test Questions                                     Homework Assignment
1. True or False: Acid core solder should be used       1. Find one TSB concerning repair of vehicle
   on electrical connections. Answer: False                wiring harnesses.
2. Solder is primarily an alloy of tin and ______.      2. Research the tin/lead percentages in solder used
   Answer: Lead                                            for plumbing of drinking water pipes.
3. A higher tin content in the solder results in a      3. Find an MSDS for the type of solder used in your
   (higher/lower) melting point. Answer: Lower             automotive lab.
4. True or False: When soldering, it is important to    4. Explain why it is important to wash your hands
   concentrate the heat on the solder. Answer:             after completing soldering operations.
   False
43
                                            LESSON PLAN

                                              Schematics
Chapter # 10 Lesson # 1      Meets NATEF Task: A-6-1, 4, 5

            Classroom Content Outline                                    Lab Activities
Time Req’d      3-4 hours                             1. Identify/Interpret Electrical Systems Concerns
Text ref:                                                worksheet
PowerPoint:                                           2. Diagnose Electrical/Electronic Circuits
Handouts:                                                worksheet
Parts/Demo: Manufacturer's wiring diagrams,           3. Use Wiring Diagrams to Diagnose a Circuit
                copies of subsystem wiring diagrams      worksheet
                for lab vehicles.
Student CD:
Discuss:                                              Tools/Resources Needed:
1. Wiring schematics                                  1. Lab vehicles
2. Circuit information                                2. Service information
3. Switches                                           3. Scan tools
4. Relay terminal identification                      4. DMMs
5. Using schematics for troubleshooting
Notes:                                                Notes:




                  Test Questions                                   Homework Assignment
1. When interpreting wire color abbreviations in      1. Locate a schematic diagram for the horn circuit
   schematics, the second color is the color of the      on your personal vehicle.
   (stripe/wire insulation). Answer: Stripe           2. Use a schematic diagram to determine if the
2. True or False: S225 would refer to a splice in a      dome light in your personal vehicle is power-side
   wiring harness. Answer: True                          or ground-side switched.
3. An SPST switch has (two/three) positions.          3. Find a copy of the wiring diagram for a 60's
   Answer: Two                                           model vehicle and compare this to one for a late
4. A relay's wiring schematic can often be found         model vehicle.
   _____________. Answer: On the side of the          4. Explain the importance of schematics in the
   relay                                                 diagnostic process.
                                                                                            44
                                           LESSON PLAN

                                   Electrical Troubleshooting
Chapter # 10 Lesson # 2      Meets NATEF Task: A-6-12

            Classroom Content Outline                                      Lab Activities
Time Req’d       3-4 hours                             1.   Short-to-Voltage Diagnosis worksheet
Text ref:                                              2.   Short-to-Ground Diagnosis worksheet
PowerPoint:                                            3.   Open Circuit Diagnosis worksheet
Handouts:                                              4.   Resistance Problem Diagnosis worksheet
Parts/Demo: Manufacturer's wiring diagrams,
                 DMM, short finder(s)
Student CD:
Discuss:                                               Tools/Resources Needed:
1. Locating a short circuit (various methods)          1. Lab vehicles
2. Electrical troubleshooting guidelines               2. Service information
3. Step-by-step troubleshooting procedure              3. DMMs
                                                       4. Short finder
                                                       5. Fused jumper wires
Notes:                                                 Notes:




                  Test Questions                                     Homework Assignment
1. True or False: A short-to-voltage will always       1. Explain why a short-to-ground can be one of the
   blow the circuit's fuse. Answer: False                 most difficult circuit failures to diagnose.
2. For a device to work, it must have both power       2. Research the types of circuit protection used in
   and a __________. Answer: Ground                       your personal vehicle.
3. True or False: The preferred method for finding     3. Find a TSB related to short circuits.
   a short-to-ground is the fuse replacement method.   4. Explain why an open ground is indicated when
   Answer: False                                          power is measured on both sides of a load.
4. When using an ohmmeter to trace a short-to-
   ground, the ohmmeter lead should be connected
   to the (power/circuit) side of the fuse holder.
   Answer: Circuit
45
                                            LESSON PLAN

                                  Capacitance and Magnetism
Chapter # 11 Lesson # 1      Meets NATEF Task: A6-A-15

           Classroom Content Outline                                     Lab Activities
Time Req’d      2-3 hours                              1. Inspect and Test the Relays worksheet
Text ref:                                              2. Demonstrate the capacitance measurement
PowerPoint:                                               function as found on advanced DMMs.
Handouts:
Parts/Demo: Capacitors, relay, solenoid, ignition
                coil, DMM
Student CD:
Discuss:                                               Tools/Resources Needed:
1. Capacitance                                         1. Lab vehicles
2. Capacitor construction and operation                2. Service information
3. Factors of capacitance                              3. DMMs
4. Measurement of capacitance
5. Capacitor uses
6. Fundamentals of magnetism
7. Electromagnetism
8. Electromagnetic induction
9. Electromagnetic interference suppression
Notes:                                                 Notes:




                  Test Questions                                    Homework Assignment
1. True or False: Capacitors are also known as         1. Research Michael Faraday and his contribution to
   condensors. Answer: True                               our knowledge of electricity.
2. The material used between the plates of a           2. Explain why large capacitors are used in the
   capacitor is known as __________. Answer:              power feed to high output car stereos.
   Dielectric                                          3. Research the use of capacitors (condensors) in
3. True or False: Relays have a movable iron core.        point-type ignition systems. What was their
   Answer: False                                          primary function(s) in this system?
4. The type of induction exhibited in ignition coils   4. Explain the construction and operation of starter
   is _________ induction. Answer: Mutual                 motor solenoids.
                                                                                              46
                                             LESSON PLAN

                                     Electronic Fundamentals
Chapter # 12 Lesson # 1       Meets NATEF Task: None specified

            Classroom Content Outline                                      Lab Activities
Time Req’d      3-4 hours                                1. Electronic Fundamentals worksheet
Text ref:
PowerPoint:
Handouts:
Parts/Demo: Assortment of semiconductor
                devices (including diodes, transistors
                and IC chips), automotive electronic
                components
Student CD:
Discuss:                                                 Tools/Resources Needed:
1. Semiconductors                                        1. Computers with internet access
2. Diodes
3. Zener diodes
4. Light-emitting diodes (LEDs)
5. Silicon controlled rectifiers
6. Thermistors
7. Transistors
8. Transistor applications
9. Electrostatic discharge and how to prevent it
Notes:                                                   Notes:




                   Test Questions                                      Homework Assignment
1. Diodes allow current to flow through them when        1. Research the history of the transistor. What
   they are _______-biased. Answer: Forward                 component did the transistor replace?
2. True or False: Despiking can be done with             2. Find one TSB related to electrostatic discharge.
   resistors. Answer: True                               3. Explain how a transistor might be utilized in an
3. There are (one/two) junction(s) in a transistor.         automotive ignition system.
   Answer: Two                                           4. Compare/contrast a transistor with a relay.
4. An electronic component with no moving parts
   would be classified as ________ _______.
   Answer: Solid State
47
                                           LESSON PLAN

                                   Computer Fundamentals
Chapter # 13 Lesson # 1      Meets NATEF Task: A6-H-9, 10

            Classroom Content Outline                                 Lab Activities
Time Req’d     3-4 hours                             1. Body Electronic System Diagnosis worksheet
Text ref:                                            2. Module Communication worksheet
PowerPoint:
Handouts:
Parts/Demo: PCM and various modules,
               assortment of sensors and actuators
Student CD:
Discuss:                                             Tools/Resources Needed:
1. Computer control                                  1. Lab vehicles
2. Four basic computer functions                     2. Service information
3. Digital computers                                 3. Scan tools
4. Computer inputs (sensors)
5. Computer outputs (actuators)
6. Module communications
Notes:                                               Notes:




                  Test Questions                                  Homework Assignment
1. EEPROM stands for Electrically _______            1. Research how networks are utilized in
   Programmable Read Only Memory. Answer:               automobile design.
   Erasable                                          2. Find one TSB relating to reprogramming of an
2. True or False: Analog signals can be sent            automotive computer.
   directly to a computer processor. Answer: False   3. Research when computers were first utilized in
3. The programming for a PCM is stored in the           automobile design. What functions were they
   _________. Answer: PROM                              responsible for at that time?
4. True or False: Fuel injectors are outputs.        4. Determine what CAN stands for (relating to
   Answer: True                                         automotive electronics)
                                                                                            48
                                            LESSON PLAN

                                               Batteries
Chapter # 14 Lesson # 1      Meets NATEF Task: None specified

            Classroom Content Outline                                    Lab Activities
Time Req’d      2-3 hours                             1. Battery Specifications worksheet
Text ref:
PowerPoint:
Handouts:
Parts/Demo: Battery cutaway, DMM, hydrometer,
                refractometer
Student CD:
Discuss:                                              Tools/Resources Needed:
1. Purpose of a battery                               1. Lab vehicles
2. Battery construction                               2. Service information
3. How a battery works
4. Specific gravity
5. Valve regulated lead acid batteries
6. Causes and types of battery failures
7. Battery holddowns
8. Battery ratings
9. Deep cycling
10. Hybrid batteries
Notes:                                                Notes:




                  Test Questions                                   Homework Assignment
1. True or False: Battery electrolyte is made up of   1. List the advantages and disadvantages of using a
   hydrochloric acid and water. Answer: False            side-post battery.
2. Battery plates are made of an alloy of lead with   2. Research nickel-metal hydride (NiMH) battery
   either ________ or antimony added to it.              technology. How is this battery different from
   Answer: Calcium                                       the traditional lead-acid battery?
3. Battery internal resistance can be limited by      3. Find one TSB relating to batteries.
   using a _______ grid design. Answer: Radial        4. Research how batteries are recycled.
4. True or False: Electrolyte specific gravity
   increases as the battery is charged. Answer:
   True
49
                                              LESSON PLAN

                                             Battery Testing
Chapter # 15 Lesson # 1        Meets NATEF Task: A6-B-1, 2, 3

            Classroom Content Outline                                       Lab Activities
Time Req’d     3-4 hours                                 1. Battery State of Charge Test worksheet
Text ref:                                                2. Battery Capacity Test worksheet
PowerPoint:                                              3. Electronic Memory Saver Usage worksheet
Handouts:
Parts/Demo: Battery, hydrometer, refractometer,
               load tester, electronic battery tester,
               memory saver, battery jump box
Student CD:
Discuss:                                                 Tools/Resources Needed:
1. Battery service safety considerations                 1. Lab vehicles
2. Battery maintenance                                   2. Service information
3. Battery voltage test                                  3. DMMs
4. Hydrometer testing                                    4. Hydrometer
5. Battery load testing                                  5. Refractometer
6. Electronic capacitance testing                        6. Load tester
                                                         7. Electronic battery tester
                                                         8. Memory saver
                                                         9. Battery jump box
Notes:                                                   Notes:




                   Test Questions                                      Homework Assignment
1. True or False: Batteries should be load tested at     1. Research what a carbon pile is and how it is
   twice their CCA rating. Answer: False                    utilized in battery load testers.
2. Electronic battery testers measure a battery's        2. Explain why battery testing is done before
   _________. Answer: Capacitance                           performing any starting or charging system tests?
3. If a battery has been charged recently, the           3. Find one TSB related to battery testing
   _______ _______ should be removed before                 procedure.
   testing it. Answer: Surface charge                    4. Research why built-in state-of-charge indicators
4. True or False: A load test should be performed           are not considered to be accurate once a battery is
   on a battery that is 25% charged. Answer: False          placed into service.
                                                                                             50
                                            LESSON PLAN

                                           Battery Service
Chapter # 15 Lesson # 2      Meets NATEF Task: A6-B-4, 5, 6, 7, 13

            Classroom Content Outline                                       Lab Activities
Time Req’d      4-5 hours                               1.   Service and Replace the Battery worksheet
Text ref:                                               2.   Battery Charging worksheet
PowerPoint:                                             3.   Battery Cables and Connectors worksheet
Handouts:                                               4.   Jump Starting worksheet
Parts/Demo: Battery, battery charger, jumper            5.   Key-Off Battery Drain worksheet
                cables, battery jump box, battery
                service tools, DMM, low amp probe
Student CD:
Discuss:                                                Tools/Resources Needed:
1. Battery charging                                     1. Lab vehicles
2. Jump starting                                        2. Service information
3. Battery date codes                                   3. DMMs
4. Battery electrical drain testing                     4. Low amp probes
5. Battery troubleshooting                              5. Battery charger
                                                        6. Battery terminal post cleaners
                                                        7. Battery lifting tools
                                                        8. Baking soda/water solution
                                                        9. Parts brushes
                                                        10. Jumper cables
Notes:                                                  Notes:




                  Test Questions                                       Homework Assignment
1. True or False: Batteries will self-discharge even    1. Explain why electrolyte should never be added to
   when the cables are disconnected. Answer: True          a battery that has been put into service.
2. Maximum allowable battery electrical (parasitic)     2. Explain why the vehicle bumpers should never
   drain is _________. Answer: 50 mA                       touch when jump starting.
3. When jump-starting, the first connection should      3. Research the chemical nature of baking soda and
   be the positive terminal of the (running/disabled)      why it is useful for cleaning battery tops.
   vehicle's battery. Answer: Disabled                  4. Measure the diameter of the posts of a top-post
4. True or False: Battery temperature should not           battery. Are both of the terminals the same size?
   exceed 150 degrees F during charging. Answer:           Why were they designed this way?
   False
51
                                             LESSON PLAN

                                          Cranking System
Chapter # 16 Lesson # 1       Meets NATEF Task: A6-C-3, 5

            Classroom Content Outline                                   Lab Activities
Time Req’d      3-4 hours                            1. Starter Relays and Solenoids worksheet
Text ref:                                            2. Starter Control Circuit Components worksheet
PowerPoint:                                          3. Cranking System Identification worksheet
Handouts:
Parts/Demo: Starter motor components, starter
                relay, solenoid, complete starters
Student CD:
Discuss:                                             Tools/Resources Needed:
1. Cranking circuit                                  1. Lab vehicles
2. How the starter motor works                       2. Service information
3. How magnetic fields turn an armature              3. DMMs
4. Types of starter motors
5. Starter motor components (armature,
    commutator, field)
6. Gear reduction starters
7. Starter drives
8. Positive engagement starters
9. Solenoid operated starters
Notes:                                               Notes:




                   Test Questions                                  Homework Assignment
1. The two windings in a starter solenoid are the    1. Research starter motors that use compressed air
   pull-in and the _________ winding. Answer:           to turn them. What applications are these used
   Hold-in                                              in? What advantages and disadvantages do these
2. True or False: The starter field can be build        systems have?
   using permanent magnets. Answer: True             2. Find one TSB related to the starting system.
3. The starter drive pinion turns approximately      3. Explain why starter current increases when
   ______ times faster than the engine flywheel.        battery voltage drops.
   Answer: 18                                        4. Research the planetary gearsets used in starter
4. True or False: The starter armature begins to        gear reduction drives. What are the three parts of
   rotate just before the drive pinion engages the      any planetary gearset? Where else are planetary
   engine's flywheel. Answer: False                     gearsets used in an automobile?
                                                                                             52
                                          LESSON PLAN

                                   Cranking System Diagnosis
Chapter # 17 Lesson # 1     Meets NATEF Task: A6-C-1, 2, 4, 6

            Classroom Content Outline                                      Lab Activities
Time Req’d      4-5 hours                             1.   Starter Current Draw Test worksheet
Text ref:                                             2.   Starter Circuit Voltage Drop worksheet
PowerPoint:                                           3.   Remove and Install the Starter worksheet
Handouts:                                             4.   Cranking Circuit Problem Diagnosis worksheet
Parts/Demo: Battery jump box, starter motor,
                remote starter switch, DMM, high
                current probe,
Student CD:
Discuss:                                              Tools/Resources Needed:
1. Starting system troubleshooting                    1. Lab vehicles
2. Voltage drop testing                               2. Service information
3. Control circuit testing                            3. DMMs
4. Specifications for a starter amperage test         4. High amp probes
                                                      5. Battery/starter/alternator tester
                                                      6. Hand tools
Notes:                                                Notes:




                  Test Questions                                    Homework Assignment
1. True or False: Higher resistance in a conductor    1. Research the operation of an inductive amp
   will cause a higher voltage drop. Answer: True        probe. How does the probe determine the
2. In order to measure the voltage drop in a             amount of current flowing in the conductor?
   cranking circuit, _______ must be flowing in the   2. Research how a Digital Storage Oscilloscope can
   system. Answer: Current                               be used to test a cranking system. What other
3. When measuring voltage drop on a starter ground       instrument must be used in order to make this
   circuit, the DMM positive lead should be              work?
   connected to the __________ (battery               3.
   negative/starter frame). Answer: Starter frame
4. True or False: When performing a starter current
   draw test, the battery should be at least 50%
   charged. Answer: False
53
                                            LESSON PLAN

                                           Starter Service
Chapter # 17 Lesson # 2      Meets NATEF Task: None specified

            Classroom Content Outline                                      Lab Activities
Time Req’d      3-4 hours                               1. Starter Disassembly and Testing worksheet
Text ref:                                               2. Starter Solenoid Testing worksheet
PowerPoint:
Handouts:
Parts/Demo: Disassembled starters, growler,
                DMM
Student CD:
Discuss:                                                Tools/Resources Needed:
1. Starter overhaul                                     1. Starter motors
2. Testing starter armatures                            2. Growler
3. Growler testing                                      3. DMMs
4. Armature service                                     4. Hand tools
5. Testing field coils
6. Brush inspection
7. Bench testing
8. Starter drive-to-flywheel clearance check
Notes:                                                  Notes:




                  Test Questions                                      Homework Assignment
1. In order to check for shorted armature windings,     1. Research prices for starter parts from an auto
   a ________ must be used. Answer: Growler                electrical rebuilders catalog.
2. True or False: Armatures are replaced as a unit if   2. Research two different designs for starter drive
   they are found to be defective. Answer: True            overrunning clutch construction. Which do you
3. Any soldering of parts in a starter motor should        think would be the most reliable?
   be done using _______-core solder. Answer:           3. Research the materials used in starter bushing
   Rosin                                                   construction.
4. True or False: Commutator service could              4. Visit a local auto electrical rebuilder.
   involve ________ the mica between the
   commutator segments. Answer: Undercutting
                                                                                              54
                                             LESSON PLAN

                                           Charging System
Chapter # 18 Lesson # 1       Meets NATEF Task: None specified

            Classroom Content Outline                                      Lab Activities
Time Req’d      2-3 hours                                1. Generator (Alternator) Identification worksheet
Text ref:
PowerPoint:
Handouts:
Parts/Demo: Disassembled generators, generator
                cutaway, DMM
Student CD:
Discuss:                                                 Tools/Resources Needed:
1. Principles of generator operation                     1. Lab vehicles
2. Generator construction                                2. Service information
3. How a generator works
4. Wye and delta-connected stators
5. Generator output factors
6. Generator voltage regulation
7. Battery condition and charging voltage
8. Temperature compensation
9. A and B field circuits
10. Electronic/computer controlled voltage regulators
Notes:                                                   Notes:




                   Test Questions                                     Homework Assignment
1. True or False: Generators convert mechanical          1. On your personal vehicle, determine the speed of
   energy into electrical energy. Answer: True              the generator when the engine is at 2500 RPM.
2. The generator's brushes make direct contact with      2. Explain what effect a slipping accessory belt
   the ______ ______. Answer: Slip rings                    would have on generator output.
3. The type of stator that generates higher current at   3. Find one TSB related to the charging system.
   high RPM is the ________-connected stator.            4. Research mechanical point-type voltage
   Answer: Delta                                            regulators and explain their operation.
4. Batteries require a _______ (higher/lower)
   charging voltage at lower temperatures. Answer:
   Higher
55
                                              LESSON PLAN

                                    Charging System Diagnosis
Chapter # 19 Lesson # 1        Meets NATEF Task: A6-D-1, 2, 3, 4, 5

           Classroom Content Outline                                         Lab Activities
Time Req’d     5-6 hours                                 1. Starting and Charging Tests worksheet
Text ref:                                                2. Generator Fusible Link Check worksheet
PowerPoint:                                              3. Charging System Output Test worksheet
Handouts:                                                4. Charging System Diagnosis worksheet
Parts/Demo: Generators of various makes, DMM,            5. Generator (Alternator) Drive Belt worksheet
               high amp probe, test light, starting      6. Charging Circuit Voltage Drop worksheet
               and charging system tester                7. Remove and Install Generator (Alternator)
Student CD:                                                 worksheet
Discuss:                                                 Tools/Resources Needed:
1. Charging system testing and service                   1. Lab vehicles
2. Accessory drive belt inspection                       2. Service information
3. AC voltage check                                      3. DMMs
4. AC current check                                      4. High amp probes
5. Charging system voltage drop testing                  5. Battery, starting, and charging system tester
6. General Motors generator testing                      6. Test lights
7. Generator output testing                              7. Belt tension gauge
8. Determining minimum required generator output
Notes:                                                   Notes:




                   Test Questions                                      Homework Assignment
1. True or False: If a generator is charging, its rear   1. Research to find out what DTCs, if any, will set
   bearing should be magnetized. Answer: True               on your personal vehicle if system voltage drops.
2. In order for a generator to ______, current must      2. Explain how a scan tool can be used to check the
   be flowing through the field windings. Answer:           starting and charging system of the vehicle (hint:
   Charge                                                   what PIDs are related to these systems?)
3. ______ _______ is a method of bypassing the           3. Explain why many vehicle sensors operate at 5
   voltage regulator. Answer: Full fielding                 volts instead of at battery voltage.
4. True or False: A serpentine belt should be            4. Research an automotive diagnostic equipment
   changed at least once every ten years. Answer:           manufacturer's catalog to find their best charging
   False                                                    system tester and how it works.
                                                                                                   56
                                             LESSON PLAN

                                          Generator Service
Chapter # 19 Lesson # 2       Meets NATEF Task: None specified

           Classroom Content Outline                                         Lab Activities
Time Req’d      4-5 hours                                1.   Generator Disassembly worksheet
Text ref:                                                2.   Generator Rotor Testing worksheet
PowerPoint:                                              3.   Generator Stator Testing worksheet
Handouts:                                                4.   Generator Diode Trio Testing worksheet
Parts/Demo: Generators of various makes, DMM,            5.   Generator Rectifier Bridge Testing worksheet
                regulator tester,
Student CD:
Discuss:                                                 Tools/Resources Needed:
1. Generator disassembly                                 1. Service information
2. Testing the rotor                                     2. DMMs
3. Testing the stator                                    3. Air impact wrench and sockets
4. Testing the diode trio                                4. Generator pulley puller
5. Testing the rectifier bridge                          5. Paper clips (for brush installation)
6. Testing the GM internal voltage regulator             6. Arbor press and adapters
7. Brush holder replacement                              7. Scribing tool
8. Bearing service and replacement                       8. Hand tools
9. Generator assembly                                    9. Benchtop generator tester
10. Remanufactured generators
Notes:                                                   Notes:




                   Test Questions                                       Homework Assignment
1. Before removing a generator, always remove the        1. Research an automotive electrical parts catalog to
   ________ battery cable first. Answer: Negative           determine prices of generator parts.
2. True or False: An ammeter can be used to check        2. Explain why an arbor (hand-operated) press is a
   the rotor's field winding. Answer: True                  better choice for generator rebuilding than a
3. A shorted stator will _______ (reduce/increase) a        hydraulic press.
   generator's output. Answer: Reduce                    3. Research how a brushless generator works (hint:
4. The diode trio supplies current for the generator's      look up the Delco 25SI generator)
   _______ winding. Answer: Field                        4. Draw and label an exploded diagram of a
                                                            generator's rotor.
57
                                           LESSON PLAN

                             Lighting and Signaling Circuits #1
Chapter # 20 Lesson # 1      Meets NATEF Task: A6-E-1, 2

           Classroom Content Outline                                     Lab Activities
Time Req’d      3-4 hours                              1. Lighting System Diagnosis worksheet
Text ref:                                              2. Headlight Replacement and Aiming worksheet
PowerPoint:
Handouts:
Parts/Demo: Assorted bulbs, switches, sealed
                beams, composite halogen assembly,
                HID
Student CD:
Discuss:                                               Tools/Resources Needed:
1. Lighting                                            1. Service information
2. Bulb numbers                                        2. DMMs
3. Brake lights                                        3. Hand tools
4. Headlight switches                                  4. Optical headlamp aiming equipment
5. Sealed beam headlights                              5. Headlamp aiming light screen
6. Headlight aiming
7. Halogen sealed beam headlights
8. High intensity discharge headlights
9. Daytime running lights
10. Dimmer switches
Notes:                                                 Notes:




                  Test Questions                                     Homework Assignment
1. The amount of light a bulb produces is measured     1. Find one TSB related to vehicle lighting.
   in __________. Answer: Candlepower                  2. Research to find out if the interior lights in your
2. True or False: Many headlight switches contain         personal vehicle are module-controlled.
   a circuit breaker for circuit protection. Answer:   3. Research scan tool bi-directional controls. How
   True                                                   can this function be used to diagnose computer-
3. CHMSL stands for Center ______-Mounted Stop            controlled lighting circuits?
   Light. Answer: High                                 4. Explain what damage could occur if a
4. True or False: Interior dash lights are dimmed         manufacturer-recommended bulb was replaced
   using a potentiometer. Answer: False                   with one with a higher wattage.
                                                                                              58
                                              LESSON PLAN

                               Lighting and Signaling Circuits #2
Chapter # 20 Lesson # 2        Meets NATEF Task: A6-E-3

           Classroom Content Outline                                      Lab Activities
Time Req’d      2-3 hours                               1. Turn Signal and Hazard Lights worksheet
Text ref:                                               2. Bulb Trade Numbers worksheet
PowerPoint:
Handouts:
Parts/Demo: Flasher units, battery, jumper leads
                with aligator clips, light bulbs with
                sockets
Student CD:
Discuss:                                                Tools/Resources Needed:
1. Stop lamp and turn signals                           1. Service information
2. Flasher units                                        2. DMMs
3. Hazard lights                                        3. Hand tools
4. Courtesy lights
5. Illuminated entry
6. Fiber optics
7. Feedback
8. Lighting system troubleshooting
Notes:                                                  Notes:




                   Test Questions                                     Homework Assignment
1. True or False: Light-emitting diodes (LEDs) can      1. Find one TSB related to signaling circuits.
   be used in brake light circuits. Answer: True        2. Try to determine what type of flasher you have in
2. Bimetal flashers are similar in operation to a          your personal vehicle by removing one of the
   _______ ________. Answer: Circuit breaker               turn signal bulbs and operating the turn signals.
3. A hybrid flasher is also known as a _______             Does the flash rate change?
   relay. Answer: Flasher                               3. Explain what component is used to switch the
4. True or False: Solid state flashers have no             signal lights on and off in a solid state flasher
   moving parts. Answer: True                              unit.
                                                        4. Print out a wiring diagram of the signaling circuit
                                                           for your personal vehicle. Trace the power flow
                                                           with the turn signal switch in the right turn
                                                           position.
59
                                            LESSON PLAN

                                    Analog Dash Instruments
Chapter # 21 Lesson # 1       Meets NATEF Task: A6-F-1

            Classroom Content Outline                                       Lab Activities
Time Req’d     3-4 hours                                1.   Fuel Gauge worksheet
Text ref:                                               2.   Oil Pressure Gauge or Warning Lamp worksheet
PowerPoint:                                             3.   Coolant Temperature Gauge worksheet
Handouts:                                               4.   Gauges and Sending Units worksheet
Parts/Demo: Instrument panel components,
               sending units and switches
Student CD:
Discuss:                                                Tools/Resources Needed:
1. Analog dash instruments                              1. Lab vehicles
2. Computer-controlled instrument panels                2. Service information
3. Dash instrument diagnosis                            3. DMMs
4. Telltale lamps                                       4. Hand tools
5. Oil pressure warning devices
6. Temperature lamp diagnosis
7. Brake warning lamp
Notes:                                                  Notes:




                  Test Questions                                      Homework Assignment
1. A gauge that utilizes a bimetallic strip is known    1. Find one TSB related to analog dash instruments.
   as a _________ gauge. Answer: Thermoelectric         2. Research how module control works with dash
2. IVR stands for Instrument ________ Regulator.           instrument panels (ie; the Ford VIC). How is the
   Answer: Voltage                                         flow of information different from vehicles with
3. True or False: If resistance of the sensor is low,      analog instruments?
   an electromagnetic gauge will read high.             3. Research how oil pressure gauges work in late
   Answer: False                                           model vehicles. Why are some set up to only
4. The switch that operates the ______ warning             change readings with major changes in pressure?
   lamp is known as a pressure differential switch.     4. Explain the difference between a problem
   Answer: Brake                                           indicated by the brake warning lamp and a
                                                           problem indicated by the ABS warning lamp.
                                                                                              60
                                             LESSON PLAN

                                     Digital Dash Instruments
Chapter # 21 Lesson # 2       Meets NATEF Task: A6-F-2, 3, 4

            Classroom Content Outline                                       Lab Activities
Time Req’d      3-4 hours                                1. Gauge Printed Circuit Boards worksheet
Text ref:                                                2. Driver Information and Warning Devices
PowerPoint:                                                 worksheet
Handouts:                                                3. Electronic Instrument Circuits
Parts/Demo: Digital dash instrument components,          4. Dash Display Activity worksheet
                fuel level sending unit, vehicle speed
                sensor
Student CD:
Discuss:                                                 Tools/Resources Needed:
1. Digital electronic dash operation                     1. Lab vehicles
2. Electronic speedometers                               2. Service information
3. Electronic odometers                                  3. DMMs
4. Electronic speedometer and odometer service           4. Hand tools
5. Electronic fuel level gauges
6. Electronic dash instrument diagnosis and
    troubleshooting
7. Maintenance reminder lamps
Notes:                                                   Notes:




                   Test Questions                                      Homework Assignment
1. LCD stands for _________ Crystal Display.             1. Find one TSB related to digital dash instruments.
   Answer: Liquid                                        2. Explain how a scan tool can be used to diagnose
2. True or False: LCD displays perform the same at          problems in module-controlled instrument
   high or low temperatures. Answer: False                  panels.
3. Vehicle speed sensors are normally found near         3. Print out a diagnostic flow chart for an
   the _______ _______ of the transmission.                 instrument panel malfunction in your personal
   Answer: Output shaft                                     vehicle.
4. True or False: NVRAM is often used to retain          4. Research how to turn off the maintenance
   odometer information. Answer: True                       reminder lamps in your personal vehicle.
61
                                            LESSON PLAN

                                            Horn Circuits
Chapter # 22 Lesson # 1      Meets NATEF Task: A6-G-1

           Classroom Content Outline                                    Lab Activities
Time Req’d     2-3 hours                               1. Horn worksheet
Text ref:                                              2. Horn Operation worksheet
PowerPoint:
Handouts:
Parts/Demo: Horn, horn relay
Student CD:
Discuss:                                               Tools/Resources Needed:
1. Horns                                               1. Lab vehicles
2. Horn system diagnosis                               2. Service information
3. Horn service                                        3. DMMs
                                                       4. Hand tools
Notes:                                                 Notes:




                  Test Questions                                     Homework Assignment
1. True or False: High-pitched horns are marked        1. Find one TSB related to a horn circuit.
   with an "H." Answer: True                           2. Explain what a clockspring (related to
2. Horns are normally operated by ________                automotive electrical systems) is and how it
   contact switches. Answer: Momentary                    works.
3. True or False: Horn frequency can be adjusted.      3. Research the horn used in the original Plymouth
   Answer: False                                          Roadrunner and what made it unique.
4. What type of electrical instrument can be used to   4. Print the wiring diagram for the horn circuit in
   adjust a horn? Answer: Ammeter                         your personal vehicle.
                                                                                         62
                                         LESSON PLAN

                                         Wiper Circuits
Chapter # 22 Lesson # 2     Meets NATEF Task: A6-G-2, 3

           Classroom Content Outline                               Lab Activities
Time Req’d    2-3 hours                            1. Windshield Wiper worksheet
Text ref:                                          2. Windshield Washer worksheet
PowerPoint:
Handouts:
Parts/Demo: Wiper motor, washer pump and
              reservoir
Student CD:
Discuss:                                           Tools/Resources Needed:
1. Windshield wiper and washer system              1. Lab vehicles
2. Windshield wiper motors                         2. Service information
3. Windshield wiper diagnosis                      3. DMMs
4. Windshield wiper service                        4. Hand tools
5. Windshield washer diagnosis
6. Windshield washer service
Notes:                                             Notes:




                 Test Questions                                  Homework Assignment
1. Another name for variable delay wipers is       1. Find one TSB related to a wiper circuit.
   _______ wipers. Answer: Pulse                   2. Determine the type of wiper motor used in your
2. Most windshield wiper motors have ______           personal vehicle. Is it multiple-speed, or variable
   speeds. Answer: Two                                speed?
3. True or False: Wipers motors are replaced if    3. Research resistive multiplex switches and how
   defective. Answer: True                            they are used to control pulse wipe systems.
4. Washer pumps are either positive-displacement   4. Print a diagnostic flowchart for the wiper circuit
   or __________-type. Answer: Centrifugal            of your personal vehicle.
63
                                           LESSON PLAN

                                     Blower Motor Circuits
Chapter # 22 Lesson # 3      Meets NATEF Task: A6-H-1

           Classroom Content Outline                                  Lab Activities
Time Req’d    2-3 hours                               1. Blower Motor Current Draw worksheet
Text ref:                                             2. Blower Motor Circuit worksheet
PowerPoint:
Handouts:
Parts/Demo: Blower motor, resistor pack, blower
              speed control switch
Student CD:
Discuss:                                              Tools/Resources Needed:
1. Blower motor operation                             1. Lab vehicles
2. Blower motor diagnosis                             2. Service information
                                                      3. DMMs
                                                      4. Low amp probes
                                                      5. Hand tools
Notes:                                                Notes:




                  Test Questions                                    Homework Assignment
1. True or False: One blower motor handles the        1. Find one TSB related to a blower motor circuit.
   A/C, heat, and defrosting functions. Answer:       2. Print the wiring diagram for the blower motor on
   True                                                  your personal vehicle. How is blower speed
2. Blower motors normally use _______ magnets.           controlled on this unit?
   Answer: Permanent                                  3. Research Electronic Automatic Temperature
3. When power bypasses the resistor pack and goes        Control as found on Ford vehicles. Does the
   directly to the blower motor, ______ speed has        driver control blower speed in the automatic
   been selected. Answer: High                           mode?
4. True or False: A slower-turning blower motor       4. Explain how a pulse-width modulated (duty
   can draw more current than a faster-turning one.      cycle) signal can be used to control blower speed.
   Answer: True
                                                                                        64
                                         LESSON PLAN

                                    Accessory Circuits #1
Chapter # 23 Lesson # 1    Meets NATEF Task: A6-H-2, 4

           Classroom Content Outline                                 Lab Activities
Time Req’d     3-4 hours                           1. Cruise Control worksheet
Text ref:                                          2. Heated Glass Operation worksheet
PowerPoint:
Handouts:
Parts/Demo: Cruise control module, vacuum
               servo unit,
Student CD:
Discuss:                                           Tools/Resources Needed:
1. Cruise control                                  1. Lab vehicles
2. Cruise control operation                        2. Service information
3. Troubleshooting cruise control                  3. DMMs
4. Heated rear window defoggers                    4. Low amp probes
5. Troubleshooting heated rear window defoggers    5. Hand tools
Notes:                                             Notes:




                 Test Questions                                  Homework Assignment
1. True or False: Stepper motors can be used as    1. Find one TSB related to cruise control systems.
   actuators in a cruise control system. Answer:   2. Determine the type of actuator used for the cruise
   True                                               control in your personal vehicle. Does it use a
2. Most cruise control systems only operate at        stepper motor, or a vacuum servo?
   _____ MPH and above. Answer: 30                 3. Time the rear window defogger cycle in your
3. The resistance of rear window defogger grids       personal vehicle. How long does the first cycle
   __________ as temperature decreases. Answer:       take? How long does a second cycle take?
   Decreases                                       4. Print the wiring diagram for either the front
4. True or False: Broken grid wires cannot be         defroster (under the windshield wipers) or the
   repaired in rear window defoggers. Answer:         rear window defroster circuit in your personal
   False                                              vehicle.
65
                                            LESSON PLAN

                                       Accessory Circuits #2
Chapter # 23 Lesson # 2      Meets NATEF Task: A6-H-1, 8

           Classroom Content Outline                                     Lab Activities
Time Req’d     3-4 hours                                1. Power Windows worksheet
Text ref:                                               2. Door Panel worksheet
PowerPoint:
Handouts:
Parts/Demo: Power window motor, window
               regulator, power seat components
Student CD:
Discuss:                                                Tools/Resources Needed:
1. Power windows                                        1. Lab vehicles
2. Troubleshooting power windows                        2. Service information
3. Power seats                                          3. DMMs
4. Troubleshooting power seats                          4. Low amp probes
                                                        5. Door panel removal tools
                                                        6. Hand tools
Notes:                                                  Notes:




                  Test Questions                                      Homework Assignment
1. True or False: Permanent magnet motors can           1. Find one TSB related to power seats.
   only be wired to rotate in one direction. Answer:    2. Research to determine how resistive multiplex
   False                                                   switches are used to control power window
2. DPDT stands for Double Pole, Double _______.            operation (hint: look at a power window system
   Answer: Throw                                           that is controlled by a module).
3. The lower back part of a seat is called a _______.   3. Research memory seats and explain their basic
   Answer: Lumbar                                          operation.
4. True or False: Power seats are normally powered      4. Print a wiring diagram for a heated seat circuit.
   directly from the battery. Answer: True                 How is the temperature of the seat controlled?
                                                                                           66
                                           LESSON PLAN

                                      Accessory Circuits #3
Chapter # 23 Lesson # 3      Meets NATEF Task: A6-H-3, 11

            Classroom Content Outline                                   Lab Activities
Time Req’d      3-4 hours                            1. Power Door Locks worksheet
Text ref:                                            2. Anti-theft System Diagnosis worksheet
PowerPoint:
Handouts:
Parts/Demo: Power door lock switches and
                actuators, remote keyless entry
                module, examples of antitheft keys
                and components
Student CD:
Discuss:                                             Tools/Resources Needed:
1. Electric power door locks                         1. Lab vehicles
2. Keyless entry                                     2. Service information
3. Keyless entry diagnosis                           3. DMMs
4. Programming a new remote                          4. Scan tools
5. Antitheft systems                                 5. Hand tools
6. Antitheft system testing and service
Notes:                                               Notes:




                  Test Questions                                   Homework Assignment
1.                                                   1. Find one TSB related to power seats.
                                                     2. Research to determine how resistive multiplex
                                                        switches are used to control power window
                                                        operation (hint: look at a power window system
                                                        that is controlled by a module).
                                                     3. Research memory seats and explain their basic
                                                        operation.
                                                     4. Print a wiring diagram for a heated seat circuit.
                                                        How is the temperature of the seat controlled?
67
                                           LESSON PLAN

                              Airbag and Pretensioner Circuits
Chapter # 24 Lesson # 1      Meets NATEF Task: A6-H-5, 6

            Classroom Content Outline                                  Lab Activities
Time Req’d      4-5 hours                             1. Airbag Diagnosis worksheet
Text ref:                                             2. Disarm and Enable Airbags worksheet
PowerPoint:
Handouts:
Parts/Demo: Spent airbag inflator modules, airbag
                sensors, spent pretensioners
Student CD:
Discuss:                                              Tools/Resources Needed:
1. Airbags                                            1. Lab vehicles
2. Airbag operation                                   2. Service information
3. Airbag sensors                                     3. DMMs
4. Airbag wiring                                      4. Scan tools
5. Airbag diagnosis tools and equipment               5. Airbag diagnostic tools/equipment
6. Airbag testing and service                         6. Hand tools
7. Safety when manually deploying side airbags
8. Pretensioners
9. Occupant detection systems
10. Side and curtain airbags
Notes:                                                Notes:




                  Test Questions                                   Homework Assignment
1. True or False: Two sensors must be triggered at    1. Find one recall notice related to an airbag or
   the same time in order to deploy an airbag.           pretensioner circuit.
   Answer: True                                       2. Determine how the passenger side airbag works
2. The heating element used to deploy the airbag is      in your personal vehicle. Must there be a
   known as the _______. Answer: Squib                   passenger in the seat for it to deploy in a
3. True or False: Self-powered test lights can be        collision?
   used around airbag circuits. Answer: False         3. Research a DTC related to the airbag system in
4. The arrow on an airbag sensor should always           your personal vehicle.
   point towards the _______ of the vehicle.          4. Research to determine the explosive material
   Answer: Front                                         used in seatbelt pretensioners.

								
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