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2-2 Testing and Repairing WiringElectrical System
2-2 Testing and Repairing WiringElectrical System
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TABLE OF CONTENTS
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You have already some basic knowledge and skills covered in this module
because you have been working for some time; and already completed
training in this area.
If you can demonstrate competence to your teacher in a particular skill,
talk to your teacher so you don’t have to undergo the same training again. If
you have a qualification or Certificate of Competency from previous trainings
show it to him/her. If the skills you acquired are consistent with and
relevant to this module, they become part of the evidence. You can present
these for RPL. If you are not sure about your competence skills, discuss this
with your teacher.
After completing this module, ask your teacher to assess your
competence. Result of your assessment will be recorded in your competency
profile. All the learning activities are designed for you to complete at your
own pace.
In this module, you will find the activities for you to complete and
relevant information sheets for each learning outcome. Each learning
outcome may have more than one learning activity.
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INTRODUCTION:
LO1. test electrical system for open and short circuits to determine faults;
LO2. repair electrical system; and
LO3. test and repair starting system.
ASSESSMENT CRITERIA
PREREQUISITES
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TECHNICAL TERMS
BACK UP LIGHTS a light that illuminates the back of the car when the
transmission is shifted in reverse.
FUSE a replaceable circuit protection device that will melt. Should the
current passing through it exceeds its rating.
GROWLER test equipment used to test starter armatures for shorts and
grounds. It produces a very strong magnetic field that is capable of inducing
a current flow and magnetism in a conductor.
PARKING LIGHTS a light that marks the front of a parked vehicle and to
mark the front of a vehicle if a headlamp fails.
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Assessment Criteria
Resources
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LEARNING EXPERIENCES/ACTIVITIES
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Exterior Lights
Typically include the headlights, signal lights, stoplights,
parking lights, back up lights and side marker lights.
Interior Lights
Normally include the dome light, instrument light, in the dash
board, trunk light.
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Dimmer Switch- controls the high and low head lamp beam function.
This switch may be mounted on the steering column or flow board.
HIGH__________
LOW___________
BATTTERY________
Dimmer Switch
The turn light system basically consists of a fuse, switch, flasher, unit,
turn light bulbs, indicator bulbs and related wiring. The turn signal light
are used by the driver of an automotive vehicle to indicate his intention of
driving either to the right or to the left. A directional signal light switch is
used by the driver to operate the right signal lights if his intention is to drive
to the drive to the right, or the left signal lights if his intention is to drive to
the left side.
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The back lamp switch closes the light circuit when the
transmission is shifted into reverse, to illuminate the area behind the
car.
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_______ 2. The type of switch that control the high and low head
lamp beam function
a. signal switch c. dimmer switch
b. hazard switch d. stop light switch
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CONDITIONS:
Automotive wires
Tools
Electrical Pliers
Long nose plier
Test light
Screw Driver
Equipment
Battery 12 volts
Electrical mock-up/Vehicle
Plan/Working Drawing
PROCEDURE
2. Connect a wire to the lamp specified as the back-up light to the back-
up switch found on the transmission.
4. Connect a wire from the fuse box to the ACC terminal of the ignition
switch
.
5. Connect a wire from the fuse box to the AM terminal of the ignition
switch.
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ASSESSMENT CRITERIA:
1. Correct information is assessed and interpreted using appropriate
tools and equipment
2. Necessary repairs are carried out using appropriate tools, techniques
and materials
3. Electrical circuit is repaired without causing damage to the work
place, property or vehicle
Resources
LEARNING EXPERIENCES/ACTIVITIES
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SELF-CHECK No. 2
_________5. How many light bulbs and feet of wiring in the lighting circuits.
a.) 10 bulbs and 2 feet of wire
b.) 15 bulbs and 3 feet of wire
c.) 50 bulbs and hundreds of feet of wiring
d.) 20 bulbs and 5 feet of wires
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CONDITIONS:
Automotive wires
Tools
Electrical Pliers
Long nose plier
Test light
Screw Driver
Equipment
Battery 12 volts
Electrical mock-up/Vehicle
Plan/Working Drawing
PROCEDURE
2. Connect a wire to the lamp specified as the back-up light to the back-
up switch found on the transmission.
4. Connect a wire from the fuse box to the ACC terminal of the ignition
switch.
5. Connect a wire from the fuse box to the AM terminal of the ignition
switch.
7. Connect the negative terminal of the battery to the ground a part of vehicle body.
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CONDITIONS:
Equipment:
Battery (12 volts)
Electrical mock-up/Vehicle
PROCEDURE:
The teacher will discuss the procedure with the students with the aid
of diagram and pictures demonstration. Then the students will do the
procedure themselves.
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7. Coat the connector terminals and the prongs of the new headlight
with the dielectric grease to prevent corrosion.
8. Install the wire connector to the headlight prongs and place the
headlight into the shell assembly. When positioning the headlight, be
sure the embossed number is at the top.
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PERFORMANCE CRITERIA
Workmanship/Performance POINTS
35 – Functional
25 – Not Functional
10 – None Functional
TOTAL SCORE
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ASSESSMENT CRITERIA:
1. Tests are carried out to determine faults using appropriate tools and techniques.
2. Faults are identified and preferred repair action determined.
3. Starting systems are repaired without causing damage to any workplace property or
vehicle.
Resources
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LEARNING EXPERIENCES/ACTIVITIES
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Major components of the starting system. The solid line represents the
starting circuit. The dashed line indicates the starter control circuit.
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The insulated circuit resistance test is a voltage drop test that is used to locate high
resistance in the starter circuit. An electrical resistance will have a different pressure or
voltage on each side of the resistance. Voltage is dropped when current flows through
resistance. Most manufacturers design their starting systems to have very little resistance to
the flow of current to the starter motor. Most have less than 0.2 volt dropped on each side of
the circuit. This means the voltage across the starter input terminal to the starter ground
should be within 0.4 volt of battery voltage.
Voltage drops are measured by connecting a voltmeter in parallel with the circuit
section being tested. In order to obtain a voltage drop reading, a load on the circuit must be
applied. The following is the test procedures:
1. Set the volt selector to the 3V position.
2. Connect the test leads depending the type of system being tested.
3. The voltmeter should read off the scale to the right until a load is put on the circuit.
If the meter reads zero, reverse the leads.
4. Disable the ignition system to prevent the vehicle from starting. This may be done
by removing the ignition coil secondary wire from the distributor cap and putting
it to ground.
This test for voltage drop in the entire circuit, so if voltage drop is excessive the
cause of the drop must be located. To locate cause of the excessive voltage drop,
move the voltmeter lead on the starter toward the battery. With each move of the test
lead, crank the engine while observing the voltmeter reading. Continue to test each
connection until a noticeable decrease in voltage drop is detected. The cause of the
preceding point.
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A ground circuit test is performed to measure the voltage drop in the ground side of
the circuit. If the starter motor connection to ground is broken or loose, the circuit would be
opened. This could cause an intermediate starter system problem, or a starter motor that will
crank the engine. To perform the ground circuit test, connect the voltmeter leads across the
ground circuit and read voltage drop while cranking the engine. Follow these directions:
Less than 0.2 volt indicates the ground circuit is good. If more than 0.2 volt is
observed, then there is a poor ground circuit connection. A poor ground circuit connection
could be the result of loose starter mounting bolts, paint on the starter motor case, or a bad
battery ground terminal post connection. Also check the ground cable for high resistance or
for being undersized.
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1. Always have a clean and organized work area. Prepare tools and materials needed
2. Clean the case and scribe reference marks at each end of the starter and housing
and the frame.
3. Disconnect the field coil connection at the solenoids terminal.
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4. Remove the two screws that attach the solenoid to the starter drive housing.
5. Rotate the solenoid until the locking flange of the solenoid is free, then remove
the solenoid.
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11. Remove the armature from the drive housing. Note: on some units it may be
necessary to remove the shift lever from the drive housing before removing the
armature.
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15. Remove bushing with a hammer and a special service tool (SST)
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BRONZE BUSHING
ARMATURE
PEAR HOUSING
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SHIFT LEVER
MAGNETIC SWITCH
CARBON BRUSH
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THROUGH BOLTS
Commutator Tests
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PERFORMANCE CRITERIA
Workmanship/Performance POINTS
35 – Functional
25 – Not Functional
10 – None Functional
TOTAL SCORE
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ASSESSMENT PERFORMANCE
Workmanship/Performance Points
35 – Exemplary
25 – Adequate
10 – Need improvement
TOTAL SCORES
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Answer each of the following answer with the word TRUE if the statement is
correct or FALSE if the statement is wrong. Answer before the number.
Direction: On the blank provided for, write the correct letter of your choice.
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b. resistance drop
c. voltage drop
d. heat drop
5. If the engine cranks slowly but does not start, a possible
cause _________
a. a discharged battery
b. low temperature
c. driver has row down the battery trying to start
d. any of the above
Direction: Select the one correct, best or most probable answer to each
question.
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Answer Key
LO1
No. 1
1. d – dome light
2. c – dimmer switch
3. b – stoplight
4. a – transmission
No. 2
1. B
2. D
3. D
4. D
5. C
LO3
Self Check No. 1
1. true
2. false
3. false
4. true
5. false3
1. a
2. b
3. a
4. c
5. d
1. b
2. d
3. a
4.
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ACKNOWLEDGMENT
Technology Teacher:
George C. Callanta
Don Alejandro Roces, Sr. Science-Technology High School
Quezon City
John M. Diego
Isabela School of Arts and Trades
Isabela
Robert S. Domingo
AFG Bernardino Malolos Trade School
Malolos, Bulacan
Lino A. Olit
Calapan Community Vocational HS
Calapan Mindoro
Nelson C. Señedo
Tagum National High School
Tagum, Davao del Norte
English:
Belen L. Tado
Tagum National High School
Tagum, Davao del Norte
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Facilitators:
Encoder:
Rowena S. Fonacier
4. Manufacturer’s Manual
By: Toyota Corporation
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