Course Agenda: Body Electrical Diagnosis Course L652

BODY ELECTRICAL DIAGNOSIS COURSE - AGENDA
Body Electrical Diagnosis Course L652

Course Agenda
Lesson Time Duration Description
Day 1
1.00 9:00 10 Introduction
1.10 9:10 60 Review of Basic Electrical Theory
10:10 15 Break
1.20 10:25 60 Introduction to EWD
Worksheets 2-1 and 2-2
1.30 11:25 60 Following Current Flow in a Circuit
12:25 60 Lunch
1.40 1:25 30 Using Electrical Diagnosis Tools
1.49 1:55 30 The Six-Step Diagnosis Troubleshooting Plan
1.50 2:25 60 Using Repair Manual
3:25 90 Worksheets
Day 2
2.10 8:30 90 Open Circuit Diagnosis

Worksheet 2-4 Right Hand Mirror Does Not Go UP or DOWN
2.20 10:00 60 Short Circuit/Parasitic Load Diagnosis
2.25 11:00 60 On-Car/Simulator Short & Parasitic Load Diagnosis
12:00 60 Lunch
2.30 1:00 60 High Circuit Resistance Diagnosis
2.35 2:00 60 On-Car/Simulator High Resistance Diagnosis
2.40 3:00 60 Feedback Problem Diagnosis
4:00 60 Review
Day 3
5.00 8:30 120 Rotations/Body Electrical

6.00 10:30 30 Multiplexing Introduction
6.00 11:00 60 Rotations/Multiplexing Worksheets
12:00 60 Lunch
6.00 1:00 60 Rotation/Body Electrical or Multiplexing Worksheets
6.00 2:00 90 Rotation/Body Electrical or Multiplexing Worksheets
3:30 15 Break
6.00 3:45 75 Review and Final Test
LEXUS Course L 652 - Body Electrical Diagnosis 1

OVERVIEW
ES 300 Body Electrical Simulator Instructor Information

Overview
The ES 300 Body Electrical Simulator is a TMC produced training aid designed for use in body electrical courses.
Nearly all body electrical systems from an ES 300 are fully operational, and can be used to teach both system
operation theory and diagnosis.
The relative position of all parts (including wire harness routing) are approximately the same as on an actual ve-
hicle.
Fault Switches
• For convenience in the classroom, a set of twenty fault switches are provided. Sixteen of the switches are
pre-programmed with faults.
The following circuits have built-in “fault switches” for in-class practice of troubleshooting techniques:
Interior Light
Heater Blower Motor
Horn
CD / Radio
Headlight
Taillight
Power Window
Combination Meter
Remote Control Mirror
Turn Signals
Wireless Door Lock
• These circuits illustrate the 4 major types of electrical problems encountered on the vehicle: Open, short-to-
ground/parasitic load, high resistance, and feedback, with varying difficulty levels for each problem (see
table). The fault for each circuit is activated by moving the appropriate fault switch to the UP position.

LEXUS BODY ELECTRICAL SIMULATOR INFORMATION




LESSON OBJECTIVES SUMMARY
Body Electrical Diagnosis Course L 652
Summary of Lesson Objectives
Lesson 1.00 Objectives

1. Instructor introduction to technicians
2. Complete attendance records
3. Introduce technicians to program goals, and objectives
4. Familiarize technicians with technician handbook

1. Technician will know what subjects the L 652 course will be covering.
2. Through this review of L 622 course materials, the technician will be able to demonstrate an
understanding of the following concepts:
• Voltage
• Amperage
• Resistance
• An electrical circuit
• Series circuit theory
• Parallel circuit theory
3. Familiarize the technicians with EWD wiring diagram symbols.

After completing this section, the technician will be able to:
1. Find and use each of the sections of the EWD
2. Given a system circuit diagram in the EWD:
• Identify each of the symbols used on the system diagram.
• Understand the meaning of the labels that are used with those symbols.
• Apply basic current flow theory to diagram the path of current flow through the circuit.
3. Know how to apply the information in the EWD within the 6-step troubleshooting plan.

After completing this worksheet:
1. The technician will have demonstrated the use of all the sections of the EWD during a "typical"
diagnostic process.
2. Applied the concepts covered in lesson 1.1 on an actual system circuit diagram.
3. Demonstrated an understanding of the symbols used on the system circuit diagram.

1. Use the System Outline section of the EWD when available.
2. Configure the switches/relays to the appropriate position for the operating condition.
3. Follow the current flow path from the B+ source to ground in example EWD circuits.
4. Apply "what-if" problem simulation scenarios to the circuit.


In this section the technician will demonstrate the ability to:
1. Use the system outline section of the EWD.
2. Configure the switches/relays to the appropriate position for the operating condition.
3. Follow the current flow path from the B+ source to ground.
4. Determine the amount voltage that should be measured at given test points.
5. Apply "what-if" problem simulation scenarios to the circuit.
1. Use a voltmeter and measure voltage drops and open circuit voltage in a circuit.
• Understand what an acceptable voltage drop is
• Understand the concept of what creates a voltage drop
• Understand the proper way to connect a voltmeter in a circuit
• Know how to use a voltmeter for continuity check only
• Understand the voltmeter's application in diagnostics
2. Use an ammeter to measure current flow.
• Use a series type ammeter
• Use a inductive type ammeter
• Understand the concept of parasitic load
• Be able to apply parallel circuit current rules
• Understand the ammeter's application in diagnostics
3. Use an ohmmeter to measure the resistance of a component.
• Understand the need for circuit isolation when using an ohmmeter
• Understand the ohmmeter's application in diagnostics
4. Use a jumper wire properly for circuit diagnosis.
5. Apply basic circuit theory concepts with the use of an EWD on vehicle circuits.

1. Implement the 6-step diagnostic process on a typical body electrical problem.
2. Properly verify an electrical problem.
3. Use defined techniques to analyze the related symptoms.
4. Isolate and correct the trouble using the EWD and electrical diagnostic tools.
5. Perform wire, connector, and harness repairs according to proper procedures.


1. Successfully diagnose an open circuit problem in an electrical circuit.
2. Apply the 6 step diagnostic process.
3. Learn the diagnostic strategy for diagnosing an open circuit problem in which the entire circuit is
inoperative.
4. Learn the diagnostic strategy for diagnosing an open circuit problem in which part of the circuit is
still functional.

1. Successfully diagnose a high resistance electrical circuit problem.
2. Apply the 6 step diagnostic process for this type of problem.
3. Locate a high resistance problem in the ground circuit.
4. Locate a high resistance problem in the B+ circuit.

After completing this section, the technician will have:
1. Successfully diagnosed 3 high circuit resistance problems.
2. Practiced and applied the 6 step diagnostic process on these problems.
3. Extensively used the EWD support sections to locate electrical/wiring components and determine
power flow from the fuses and junction blocks.
4. Used the EWD System Circuit Diagrams to trace the path of current flow through circuits.

1. Diagnose a short-to-ground in an electrical circuit.
2. Diagnose an unwanted parasitic load problem.
3. Apply the 6 step diagnostic process for each of these problems.
4. Use the EWD to determine circuit power distribution through the various junction blocks and junction
connectors.

1. Successfully diagnosed 3 short-to-ground/excessive parasitic load circuit problems.
3. Extensively used the EWD support sections to locate electrical/wiring components and determine
power flow from the fuses and junction blocks.


1. Successfully diagnose an electrical feedback circuit problem.
3. Diagnose a feedback problem in a lighting circuit.
4. Diagnose a feedback problem in a general body electrical circuit.

1. Accurately diagnose open circuit problems.
2. Diagnose parasitic load problems.
3. Diagnose short to ground problems.
4. Diagnose high resistance problems.
5. Diagnose feedback problems.
This section will also:
1. Provide feedback on what the technician has learned from the course.
2. Enhance the technicians' confidence in their electrical diagnostic ability.

1. Define multiplexing and serial data.
2. Explain the need for standard.
3. Retrieve trouble codes (DTCs) from a multiplexing system.
4. Diagnose a simple system fault in a multiplexing system.

MATERIAL REQUIREMENTS AND APPROACH TO INSTRUCTION
Body Electrical Diagnosis

Course L652
Material Requirements and Approach to Instruction
Materials
• Instructor Guide
• Multimedia Presentation
• LCD Projector and Screen
• L 652 Technician Handbook
• L 622 Experiment Suitcase (Optional)
• Digital Multimeters
• ES 300 Body Electrical Simulator (Should be located in the front of the classroom)
• Assorted jumper wires
• 1998 ES 300 EWD (1 per technician)
• Spare body/engine wiring harness
• Assorted Lexus vehicles *
* The concept regarding vehicle usage is that any vehicle in the Lexus lineup can be used to teach these electri-
cal concepts. However, some of the bugs cannot be placed on all vehicles because of limitations regarding ac-
cess to bugged areas and/or the possible damage to related components. The ES 300 simulator should always
be considered as an extra vehicle and included in rotations whenever practical. In every case where the electri-
cal problem is not "system specific" an attempt has been made to make the bug generic. Instructors are encour-
aged to look at the concept of the bug (what the bug is designed to teach) and then try to install the bug on avail-
able vehicles with the least amount of time and trouble.
Approach
The course is built around the simulator as a means of showing how the theory of electrical trouble-
shooting can be applied to an automotive system. The multimedia presentation has been designed to
assist the instructor in the transition between theory and real world applications. Just as the instruc-
tor is free to use additional relevant examples to relate a concept during his presentation, he is also
encouraged to go beyond the confines of the outline to produce bugs and diagnostic scenarios which
work for him and his group of technicians. Another important consideration is the concept of "volt-
age drop" which has been used in a number of examples as a diagnostic approach that works and is
very useful. It is recommended that the instructor become familiar with this concept and make every
effort to convey this knowledge to the technicians.

ENROLLMENT AND INTRODUCTION 1.00
Lesson Title Enrollment and Introduction 1.00
Day Number One
Time Period 9:00 - 9:10 a.m.
Total Time 10 min.
Instructional Objectives
1. Instructor introduction to technicians
2. Complete attendance records
3. Introduce technicians to program goals, and objectives
4. Familiarize technicians with technician handbook
Lesson Key Points

• Use this time to take attendance and orient the technicians to the topics which will be covered each day of
the course. By using the time and topic, technicians will get a feel for what is to be covered throughout
the day.
• Discuss the technician incentive program depending on the make-up of the class.
• This is also a time to “break the ice” so the class gets to know each other. Have technicians introduce
themselves and hobbies they enjoy.
• Depending on your area policy you may wish to discuss technical problems and fixes at this time.
Required Material
• Multimedia presentation
• LCD Projector and Screen

ENROLLMENT AND INTRODUCTION 1.00
Slide / Activities / Ref.
I. Enrollment
A. Complete Attendance Record as indicated on back of form
B. Have each technician enroll with appropriate information on Atten-

dance Record
II. Introduction
A. Introduce yourself as instructor
B. Introduce course: Lexus Body Electrical Diagnosis L652
C. Prerequisites
1. Course L 622 - Electrical Fundamentals
D. Have technicians introduce themselves
1. Name
2. Dealership
3. Number of years as Lexus technician
4. Hobbies or interests
III. Problems (Optional)

A. Discuss Technician Incentive Program
B. Discuss recent technical problems and fixes

REVIEW OF ELECTRICAL CIRCUIT THEORY AND CONCEPTS 1.10
Lesson Title Review of Electrical Circuit Theory and Concepts 1.10
Day Number One
Total Time 60 min.
1. Familiarize the technician with the subjects to be covered during the course.
2. Through a review of L 622 course materials, the technician will be able to demonstrate an understanding of the
following concepts:
• Voltage
• Amperage
• Resistance
• An electrical circuit
• Series circuit theory
• Parallel circuit theory
3. Familiarize the technicians with EWD wiring diagram symbols.
Lesson Key Points

Use this section to review the materials that were covered in L 622. Heavily emphasize the practical on-car
applications of electrical theory, with less emphasis on concepts that are “nice to know.”
During the review of the concepts, try to get a “feel” for the knowledge and skill level of the technicians, and tailor
your instruction to fit their needs as much as possible.
Required Materials
• Computer Presentation
• L 622 Experiment Suitcase (Optional)
• Digital Multimeter
• ES 300 Body Electrical Simulator (Should be located in the front of the classroom)

After the general introduction/attendance matters have been finished,

proceed with the following.
NOTE: The instructor may feel the need to Assign Worksheet 1-1 and
go to the Worksheet 1-1 Presentation materials for review, or continue
forward with Slide 2. If students need a review of L622 this option
may be valuable.
Slide 1

I. Introduction to L 652 Course

A. Course Objectives
1. Solidify the concepts taught in L 622
a. L 622 concentrates on the theory aspects of electricity

and electronics
2. How to diagnose electrical circuits on the vehicle
Slide 2 a. Repairing body electrical problems can take too long, not
very profitable
b. Have a lot of guesswork and parts changing
3. “Real World” electrical
a. Some electrical problems are difficult to diagnose

b. Using proper techniques will eliminate any unnecessary
checks
c. The techniques in the course will make you faster and
more profitable
B. Sections of the L 622 course

1. Review
a. Concepts taught in L 622, emphasizing real world appli-

cations
Explain to the technicians that the review will be brief; later in this
course we will be applying the concepts covered in L 622 on an
actual body electrical troubleshooting.
2. Tools of Electrical Diagnosis
a. Explanation and practice with major tools for electrical di-

agnosis:
1) Electrical Wiring Diagrams
2) Digital Multimeters
3) BE section of the Repair Manual
b. Extensive lab/worksheet exercises for each of these

3. Electrical Troubleshooting
a. Explanation of the 6-step troubleshooting method

b. Diagnostic techniques for:
1) Open circuit problems
2) Short/parasitic load circuit problems
3) High resistance problems
4) Feedback problems
c. Extensive hands-on lab worksheets for each of these
problems
4. Final exam
a. 20 multiple choice questions, open book

b. Hands-on diagnostic problem
C. ES 300 Body Electrical Simulator
1. Nearly all of the body electrical systems of a 1998 ES 300
2. Systems are operational.
3. The location of components, harnesses, and connectors/

splices are in the approximate locations as they would be on
the car.
4. A set of bug switches will be used to create electrical prob-

lems for class case studies and worksheets
II. Basic Electrical Terms

A. Voltage
1. Definition
a. Electrical pressure differential

b. Pressure differential causes current flow if a complete
path is present.
2) Other terms
Demonstrate each of these voltage concepts on the Simulator using
the Dome Light circuit.
Slide 3

c. Open Circuit Voltage

1) Measured at any point in the circuit when there is no
current flow present
2) Used when diagnosing an inoperative or open circuit.
If you placed the negative probe of the DMM on the opposite side of
the connector, it should also read about 12.6 V if the ground path of
the circuit has continuity.
Slide 4
d. Voltage Drop
1) Measurement made with voltmeter connected in par-
allel to circuit or portion of a circuit that has current
flow through it:
2) Can measure exactly how much voltage the load is
getting.
a) Almost all body electrical components should
be receiving full battery voltage.
Slide 5
3) Used to track down high resistance problems.
Figure 1-8 illustrates a 0.1V drop across all the connections.
An additional explanation of voltage drop is to also call it an “I R”

drop. This application of Ohm's law can help the technician remem-
ber that for a voltage drop to occur, you need to have amperage and
resistance. If you are missing one of these components, you can’t
have a voltage drop.
B. Amperage or current flow
1. The rate of flow or “how much” electricity.
2. Multiplied by voltage tells you the amount of power being used.
3. Measured with meter in series or with accessory inductive

clamp.
4. Watts = electrical horsepower.

Slide 6
5. Knowing source voltage is key.

Slide 7

Fig. 1-10 illustrates the amount of power the light bulb is using: 650
ma X 12.5V drop (not the battery voltage) = 8.125 watts.
C. Resistance
1. Opposition to current flow.
2. Regulates the amount of current flow in a circuit.
3. Problems occur when resistance is excessive.

Slide 8
4. Measured in Ohms
a. When using an ohmmeter, isolate the component being

measured from parallel connections.
b. When using an ohmmeter, be sure the power is
disconnected.
Slide 9
D. Ohm’s Law
1. Allows you to predict how an electrical circuit will behave.
a. States that current flow in a circuit will always be propor-

tional to the voltage and resistance in a circuit.
1) E, I, and R in a circuit are always proportional and
maintain a fixed ratio with each other.
a) If you know the value any two of those compo-
nents, you can mathematically determine
what the third one is.
2. Because we deal with predominately 12 V only circuits, the rule

to remember is that when there is more resistance in a cir-
cuit, there is always less current flow.
3. On car applications of Ohm’s law.
Demonstrate each of these conditions on the Simulator as you talk

about them.
a. If a circuit is inoperative: infinite resistance or open
circuit.
b. Partially operative: excessive series resistance.
c. Fuse is blown: excessive current flow from too little
resistance.
Slide 10

1) Short-to-ground before the load

2) Too low circuit resistance from over-loading
Be sure to stress to the technician how these principles are time sav-
ers in the diagnostic process. Ohm's law allows them to eliminate
unnecessary checks and component changes. Application of Ohm's
Law allows you to quickly identify the type of problem (Open, short,
high resistance), and using the EWD, you can eliminate any guess-
work involved in identifying the potential problem areas.
NOTES ARE ON EACH SLIDE
Slide 11
Slide 12
Slide 13

III. Series Circuits

A. “True” definition has multiple loads with a single path of current flow
1. Example circuit is Lexus cooling fan circuit on most models.
Slide 14 EWD pg. 264
B. Resistance
1. Resistances add up to the total circuit resistance.
C. Current Flow
1. Same at any point in the circuit.
2. On-car application
a. A resistor either before or after the load still has the

same effect on current flow.
Use the inductive ammeter on the Simulator and measure the current
flow at the Blower Motor, and relay block. You can also measure the
current flow at the battery and have the class tell you the relationship
between that amperage and the amperage that is being used by the
fan.
Slide 15
D. Voltage
1. Divides proportionately between all the resistances.
2. The sum of the voltage drops will equal the source voltage.
You will always encounter a situation in class where the voltage

drops DO NOT add up EXACTLY to the source voltage. Small differ-
ences (usually less than 0.10 volt) can be attributed to meter inaccura-
cy, meter lead resistance, fluctuations in source voltage, and round-
ing error in the DMM.
a. Because of connections, the load usually receives a little

less than source voltage.
1) Max 0.2V drop across any switch, connection or re-
lay point.
Slide 16

b. High resistance problems can be identified by the voltage

drop. There should only be a voltage drop of significance
at the load.
c. The excessive resistance can be located anywhere in the
circuit and still have the same effect.
Demonstrate this using a wire wound resistor in series with the dome
light on the ES 300 BE simulator.
IV. Parallel Circuits

A. Defined as a circuit with multiple loads, but also multiple paths to
ground.
Never use the phrase “Current flow takes the path of least resistance!”
If you have a parallel circuit with a 2 and 4W resistor, current flow
does not just take the 2W path, the path of least resistance. If the
phrase was changed to “Current flow will always take a path of no re-
sistance and by-pass (short out) the rest of the circuit,” then it would
be correct.
Slide 17
B. Term “parallel” is also used to describe the connection of a voltmeter
when making a voltage drop check.
C. Voltage
Slide 18
1. Voltage to each branch will be the same as source voltage.
a. Everything that receives “12V” is connected in parallel to

the battery.
b. Number of parallel branches does not affect the voltage
(although the total load on the voltage source will).
c. If problem occurred in series to a set of power/grounds
that are connected in parallel, it will affect all of the cir-
cuits.
Slide 19

D. Resistance
1. Total resistance is less than the smallest resistor.
a. We tend to look at parallel circuits in terms of amperage.

b. The more components in parallel, more amperage flows.
c. (With voltage constant) If amperage is increased, Ohm’s
law says that it can only happen if there is a decrease in
resistance.
Most technicians find this concept very confusing to understand. As
long as they can see that current flow is increased when a branch is
added, that is all they need to know for this class.
Slide 20
E. Current Flow
1. Total current flow is equal to the sum of the current flow in
each branch.
a. Each branch works independently of each other.

b. The amperage that each accessory “draws” adds up to
total load on the charging system or fuse.
Slide 21
c. You can determine the amount of amperage a component
draws by measuring the change in amperage at the bat-
tery when the accessory is turned ON.

V. Series Parallel Circuits

A. Combination of elements of both series and parallel circuits together
in a single circuit.
B. Applications
1. Circuit control
a. A single switch in series can control a set of 12 V lamps

that are connected to it in parallel.
Slide 22
2. Power/ground distribution
a. Many unrelated circuits with many parallel branches are

connected to the same fuse/junction block or to the
same ground point.
b. If problem occurred in series to a set of power/grounds
that are connected in parallel, it will affect all of the cir-
cuits.
3. Connectors
a. Junction connectors in series with a fuse distribute

power to multiple circuits.
b. Series power supply
c. Parallel power connections at J12/J13
d. Parallel grounds at J5/J6
e. Series control through R5 rheostat.
VI. Electrical Circuit Concepts

This section is meant to provide a review of the basic EWD schematic
symbols as well as a theory review.
A. Components in a basic circuit

Emphasize that for the circuit to function properly, you need all of
these conditions present.
1. Load
a. What gets the work done in the circuit (the reason why
the circuit was built)!
b. Most loads typically require “12 V,” it is always the circuit
resistance which determines the amount of current flow.
Slide 25

2. Voltage source (power and ground)
a. Provided by the battery and alternator

b. Altenator provides AC
c. Battery provides DC
Slide 26
d. Other sources found on car:

1) Sensors (speed sensor)
2) Capacitors
3) Ignition Coils
Slide 27
3. Over-current protection
a. Prevent circuit damage from a short to ground or exces-

sive current flow condition.
1) Fuse
a) circuits are designed to carry only certain
amount of cuurents
2) Circuit breaker
a) Some types have a hole at the top to reset
Slide 28
the breaker.
3) Fusible link
How to examine a fuse to help diagnose a problem is discussed in
section 5, short-to-ground diagnosis.
4. Control device
a. Switch
1) Blower speeds change as resistance is added or
subtracted
2) Broken wires impact switch
b. Resistors
c. Transistors
Slide 29
1) Acts as a non-mechanical switch with “logic” fea-
tures

5. Conductor
a. A low resistance pathway for the current or amperage to

flow.
1) Items which affect the amount of resistance in a
conductor are
a) Diameter
b) Length
c) Material
Slide 30
d) Temperature
e) Physical condition
b. The amperage or electron flow occurs whenever there is
a complete pathway to ground.
6. Connectors
According to Field Technical Product Report Summaries, connector

and terminal problems are the #1 electrical problem, and account for
up to 75% of all electrical problems, depending on the model.
a. Aids in assembly and service of the vehicle
b. Typical problems
1) Disconnected
Slide 31 2) Terminal backed out
3) Terminal corroded
4) Terminal spread too wide
5) Improperly made splice
These terminal/connector problems can be illustrated on a scrap har-
ness. Demonstration of a terminal with too wide a spread can be use-
ful to illustrate how to inspect a terminal for this condition. Also,
show the Lexus Wire Repair SST to the class.
In L 652, we will not be discussing a lot of the theoretical aspects of

electricity such as the 2 current flow theories. This course will always
assume the use of the conventional theory of current flow (+ to -).
B. Requirements for current flow
1. A complete connection between the + and - sides of the volt-

age source.
a. The pressure differential causes the current to flow

through the conductor.
b. Using a voltmeter in parallel to the load, the voltage drop
should be about the same as the voltage drop at the
source.
2. The resistance in the load and in the control device
a. Regulates the amount of current flow.

b. When it will occur.
C. In actual application, voltage drop at the load is approximately the

same as the source voltage.
1. It will never be exactly the same because of the series resis-

tances that uses some of the pressure that is available to
push current through the load.
VII. Basic Diagnostic Tools

A. Electrical Wiring Diagram
Show the EWD/point out the actual EWD to the class.
1. The EWD is your #1 source for information to make repairs to

the electrical system.
2. You must know your basic circuit theory and all the concepts
talked about in L 622 in order to be able to use the EWD to fix
Slide 32 a problem.
a. Little information in it to guide you through problems.

b. You must be able to follow the paths of current flow in the
circuit:
1) If you cannot follow those current flow paths, you
will not know where to perform checks with a volt-
meter, or know what to look for (possible open,
short, or high resistance problem).
In short, using the EWD to diagnose and successfully repair the cir-
cuits brings all the L 622 concepts together!
B. Repair Manual
1. The BE section of the Repair Manual has some information

that is not contained in the EWD.
a. ECU controlled circuits

1) Look in the Repair Manual FIRST before using the
EWD.
2) The RM and NCF have information about the self di-
agnosis systems that are used in circuits such as
SRS, ABS, and the Cruise Control System.
2. Use the RM when
a. Diagnosing ECU controlled circuits.

b. You need guidance as to how to diagnose the circuit.
c. You need verification of something listed in the EWD that
does not match the actual vehicle.
C. Introduction to the RM Body Electrical Section

1. This is the last of the tools that will be covered in this course.
2. Very useful, especially in conjunction with the EWD.

3. Advantages over the EWD
a. Has information about the self-diagnostic systems

1). Trouble code system is not mentioned in the EWD
a) Code definition
b) How to access codes
c) How to clear codes
b. Diagnostic Assistance
1). Clear set of procedures for dealing with trouble
codes
2). Individual component inspection procedures
3). Tables which explain where each switch should be
under a given condition
a) Power door lock system “sensors”
4). Troubleshooting matrices
a) Direct you to check, given a particular
symptom, specific components in a spe-
cific order.
5). Troubleshooting “trees”
a) Tell you exactly what to do to test sys-
tem.
Explain to the class that this “laundry list” of possible causes is the
same thing that they would come up with while diagnosing using the
EWD. However, with the EWD, the order that you would make your
checks would be up to the technician's discretion.
The matrices in the RM may not take into account the accessibility of
components, or even the past history of failures, like the technician
would while diagnosing with the EWD alone. However, for a situation
where the technician is totally “lost”, it would be the resource to use.
(Although, after completing this course, that situation should not oc-
cur!)
c. Additional Specifications
1). Various resistance and voltage values
4. Disadvantages to using the RM Body Electrical Materials
a. Black and White only

b. Does not use the connector/component ID system used
in the EWD
1). Slowly is being integrated into the RM.
2). 1998 ES 300 BE section uses the EWD connector/
component ID system.

D. Digital Multimeter
1. This course concentrates on the DMM only. Analog meters
have their place, but in general, the DMM provides many ad-
vantages:
a. Highly accurate
b. Additional features such as min-max, peak hold
c. Low cost models available
Slide 33
d. Good models are highly durable
e. Many meters provide an analog bar graph to view volt-
ages that are changing rapidly (acts like a mini-oscillo-
scope)
f. Can be used with confidence on solid state ECU con-
trolled circuits.
1) Some older or inexpensive analog meters have
voltmeters with a low internal impedance.
a) The meter itself loads (uses power from) the

circuit you are testing.
b) The additional current flow demand on an
ECU’s power supply can artificially “pull down”
the circuit voltage.
c) Leads to an inaccurate measurement.
E. Test Lights
1. Not emphasized in this class
2. have limited usefulness
3. can cause a number of problems
a. ECUs
Slide 34 4. If hooked up in parallel becomes a load
5. Logic probe better for voltage testing
F. Fused Jumper Wire

1. Should be used in place of straight jumper
2. Need to know the current before hookup.

USING THE ELECTRICAL WIRING DIAGRAM 1.20
Lesson Title Using the Electrical Wiring Diagram 1.20
Day Number One
Total Time 60 min.
1. Find and use each of the sections of the EWD.
• Identify each of the symbols used on the system diagram.
• Understand the meaning of the labels that are used with those symbols.
• Apply basic current flow theory to diagram the path of current flow through the circuit.
Lesson Key Points

Use the EWD to walk the technician through each of the sections thoroughly. Answer any questions that they
may have about each of the sections, and add any additional information that you have about your experiences
in using the book.
Although the sections of the EWD are illustrated in the Technician Handbook, it is recommended that you simply
use the 1998 ES 300 EWD while talking about each of the Sections. In this way, the technician will get practice
in using the actual tool that he has to work with in the shop.
Component and parts location, and other information that is included with the system circuit diagrams will be
discussed later. In this section, keep the technician focused on the schematic only.
Use the ES 300 Body Electrical Simulator’s electrical circuits to illustrate what is being shown in the EWD.
Required Materials
• L652 Technician Handbook
• Spare body/engine wiring harness
• ES 300 Body Electrical Simulator

Although each of these sections is illustrated in the Technician Hand-

book, it is recommended that you have the technicians find and exam-
ine each of these sections directly in the 1998 ES 300 EWD.
I. Using the EWD
Slide 35
A. Sections of the EWD
1. Section A: Introduction
a. Defines what is in each section
2. Section B: How to use this manual
a. Small explanation of diagnosis using the manual

b. Definition of symbols and labels that are used on the
system circuit diagram
c. Explanation of each of the auxiliary sections of the sys-
tem circuit diagram
3. Troubleshooting
a. Techniques for measuring voltage

b. Continuity and resistance checks
c. Finding a short circuit
d. Disconnecting male and female connectors
Slide 36
e. Terminal removal techniques
4. Section D: Abbreviations
a. A short list of some of the abbreviations that are used

on the system schematic
5. Section E: Glossary of terms and symbols
a. Defines many of the schematic symbols that are used

on the system circuit diagrams
6. Section F: Relay Locations
a. The first section that deals with the specific vehicle the
EWD was written for
b. Physical location of relay blocks and relays
c. Junction Block diagrams and schematics
d. Junction block connector and fuse information
e. Relay block fuse and connector information
1) Relay and junction blocks are grouped together and
numbered consecutively

7. Section G: Electrical Wiring Routing
a. Component location
b. Wire harness routing
c. Connector locations
d. Wire harness to wire harness connector pin information
e. Wire harness to wire harness connector locations
f. Splice points
g. Ground points
8. Section H: Power Source (Current Flow Chart)
a. Power distribution to the each of the fuses and some

major components
1) Not all components are covered. Not entirely helpful
for short-to-ground diagnosis
b. Power distribution from each of the fuses
1) Helpful in diagnosing short-to-ground or parasitic
load problems
2) Gives page number of schematic, part name, and
location code
9. Section I: System Circuit Diagrams
a. Color schematics and additional information that is the

heart of the EWD
10. Section J: Ground Point
a. Gives ground point schematics and location tables

b. Use to help find circuits that are connected to each other
through shared ground points
11. Section K: Overall Electrical Wiring Diagram
a. Condensed version of “map” style wiring schematic

b. Still useful to some technicians because “you can see
everything at once”.
c. Because of increased circuit complexity, seeing every-
thing at once is not necessarily an advantage anymore.
d. The new style circuit diagrams are easier to follow.
The type of schematic a technician prefers many times depends on
the type of schematic that he learned first. For some technicians who
have been in the business a long time, there may be some resistance
to the EWD schematics. They are not used to turning pages to find
the (power/fuse, ground, location) circuit information that is covered
in the different sections of the EWD.

II. System Circuit Diagram Features

A. Breaks the vehicle electrical system into individual system circuits.
B. Provides identification code numbers for cross referencing to Service

Hints and location charts.
C. Lists all splices in harness wiring.
1. Older versions of the EWD did not do this.
Slide 37 EWD p. 264 D. Provides references to circuits which share common wiring/compo-
nents.
E. Provides all wires in color for easy identification.
F. Uses colors and grey shading to identify different components.

G. Fuses (power) are at the top, ground at the bottom.
1. When a battery or fusible link is used in the circuit, it is located
on the lower left of the schematic.
III. Parts of the System Circuit Diagram Section I

Recommend to the technicians to use the table of contents at the front
of the EWD to help locate the system circuit diagram that they are
looking for. It definitely helps speed up the process of finding the
right circuit.
A. System Title
1. Always at the top corner of the page.
2. Power Source, Starting/Charging circuits are always first.
3. The easiest way to find the circuit you need is to use the table
of contents either at the front of the book, or at the beginning
of section I.
Slide 38 EWD p. 98 & 118 4. Asterisks * / Parenthesis ( )
a. Indicates different wiring and connector for different mod-

els or equipment specification (S/D) = Sedan, etc.

B. Wire Color
1. Wire colors are indicated by abbreviation of the wire color:
a. B=Black
b. BR=Brown
c. G=Green
d. GR=Gray
Slide 39 EWD p. 160
e. L=Blue *
f. LG=Light Green
g. O=Orange
h. P=Pink
i. R=Red
j. V=Violet
k. W=White
l. Y=Yellow
m. SB=Sky Blue
* This is different from other manufacturers
2. If the wire has a stripe or “tracer” on the wire, the color is rep-
resented by a dash (-) and a second letter.

C. Junction Block
Using the spare body/engine wiring harness, show an actual Junction
Block and Junction Connector. If possible, disassemble a Junction
Block to show how it is constructed.
This slide is taken from the Moon Roof circuit on page 238 of the
1998 ES 300 EWD.
1. Always shaded grey
2. Different shading to differentiate the different junction blocks
3. ID number is always in an oval
a. Number indicates the J/B number

b. Letter indicates a specific connector
c. Number next to the oval indicates the pin number in the
connector.
Slide 40 EWD p. 238
Many times, you need to look at 2 or more different system circuit

schematics to find a specific component, wire or connector. An exam-
ple of this would be all the schematics that have the Integration Relay
in it. In order to know about all the terminals at the Integration Relay
on a 1998 ES 300, you need to look at the headlight, tailight, Illumina-
tion, Interior Light, and Tail Light wiring diagrams.
Slide 41 EWD p. 25

D. Relay Block
Using a Body or Engine harness, show the technicians an actual Re-
lay Block. If that is unavailable, use the ES 300 Body Electrical Simu-
lator.
1. Relay blocks are not shaded.
2. ID numbers in an oval symbol indicate which relay block the

component is located in.
This slide is from the Headlight (Canada) schematic page 98 of the

1998 ES300 EWD
Slide 42 EWD p. 98

E. Components/Parts
1. Parts are always shaded Blue.
2. ID numbers usuaully begin with the first letter of the name of

the component.
3. Use the parts location table found in the support section usu-
ally found behind the system circuit diagram to locate compo-
nents.
Slide 43 EWD p. 126
4. Component ID number corresponds to the ID number on the

schematic
a. Pin numbering system is different for male or female ter-

minals:
1) Female - left to right, with #1 in the upper left corner.
2) Male - right to left, with #1 in the upper right corner.
Slide 44 b. View of the connector is from the terminal side of the

connector lock tab up.
5. Explains cavities that are not used in the particular circuit

have a “•” in them, and those cavities that are left empty and
marked by an X.
It is usually helpful to match the wire color on the schematic to verify

the correct pin on the connector when doing any pin/voltage inspec-
tion.

F. Multiple Connectors
1. Letter in a circle is used to designate which connector.
2. ID Numbers
a. E for Engine.
b. I for Instrument Panels. B for Body.
The Integration Relay on the headlight, tail light, interior light, and
auto shut-off circuit schematics is shown in varying degrees of detail
on each system circuit diagram.
G. Parts label
1. All parts are labeled and are colored sky blue.
Slide 45 EWD p. 114
H. Wire harness to wire harness connectors

1. On harness-to-harness connectors, the connector symbol indi-
cates which terminal is the male or female terminal.
2. Most connectors are white in color. If the connector is a differ-

ent color, the color will be noted above the illustration.
3. Harness-to-harness connectors use an I, E, or B as the first

digit in the ID number to indicate approximate location.
Slide 46 EWD p. 126
a. I = Instrument panel
b. E= Engine
c. B= Body
Use an appropriate engine or body harness to illustrate all of these

points about connectors.

I. Locating a Harness to Harness Connector

1. Use ID number on the location table.
2. Column to the right of number gives page number.
3. Find location of connector on designated page.
Slide 47 EWD p. 36
J. Switches and Relays
1. Switches shown in Normal position.
2. Multi-pole switches (Combo Switch, Heater Fan, etc.)
a. Circle and line show connections at various switch posi-

tions.
b. Gang type switch has dotted line inside switch connect-
ing the arms.
Slide 48
Optional: Go to worksheet 2.1
K. Shielded Cable
1. Dotted line around a section of the wire indicates a wire that is
shielded
a. A shielded wire is a wire that has a grounded wire sur-

rounding the insulation of the wire to absorb electro mag-
netic interference.
b. Used on low current flow ECU sensor circuits.
Slide 49 EWD p. 74 2. Intermittent or erratic operation of ECU controlled systems
could be caused by the failure of the shielding.
L. Splice point
1. Uses same ID codes as the harness to harness connector in

an octagon.
a. E=Engine Room
b. I=Instrument panel
c. B=Body
2. Splice points connect additional wires and systems together in

Slide 50 EWD p. 109
parallel.
a. When diagnosing problems where a number of different

circuits are not working, a splice (or power feed to a
splice or ground side splice) could be a cause.

b. Section G gives the general location of the splice.
M. Power and Ground Distribution
1. Shows entire circuit with fuses and grounds.
2. Section K contains Power Source.
N. Section H Shows Current Flow
1. Use to find other components that use same fuse.

Slide 51 EWD p. 40
2. If no B+ is available trace back to fusible links.
3. Lists every load on the vehicle
a. Good for diagnosing parasitic draw

b. Also good for feedback issues
Slide 52 EWD p. 126
O. Ground Point
1. Represented by a triangle.
2. Which lights are affected if BN ground is lost?
a. license plate
b. rear side marker, etc.
Slide 53 EWD p. 109

c. Section J shows shared grounds.
2. Use support section and ID number to locate ground on

vehicle.
3. Grounds always located at the bottom of the schematic.
4. Uses the I, E, and B location designations that were used for

harness to harness connectors, and for the splice points.
Slide 54 EWD p. 278
P. System Outline
1. Gives path of current flow
2. Describes operation of circuit
3. Found after individual system circuit
4. Some circuits do not have system outline
Slide 55 EWD p. 127
Q. Service Hints
1. Contains information not found in RM.
2. Provides pin voltages and resistance values.
3. Larger diagrams may replace “System Outline” with “Service

Hints.”
Slide 56 EWD p. 76
R. Overall Wiring Diagram (Section K)

1. Can be used as a back up for other diagrams.
a. Helps to verify possible errors.

b. Sometimes faster to use.
Slide 57 EWD p. 282

S. Troubleshooting (Section C)
1. Gives general hints in diagnostics.
Slide 58 EWD p. 10
T. Section L
1. Contains part numbers of connectors in newer vehicles.
2. Consult parts department for availability.
a. some connectors not available.
3. Power source section moved to back of book in newer

manuals.
Slide 59
Slide 60
** Introduce Worksheet 2-2 Tracing Current Flow. Use multime-

dia presentation to demonstrate how the tracing should be
done and to introduce the concept of Voltage Drop.

FOLLOWING CURRENT FLOW IN A CIRCUIT 1.30
Lesson Title Following Current Flow in a Circuit 1.30
Day Number One
Time Period 11:25 am - 12:25 pm
Total Time 60 min
• Understand the usage of the system outline section of the EWD when available
• Be able to configure the switches/relays to the appropriate position for the operating condition
• Follow the current flow path from the B+ source to ground in example EWD circuits
Lesson Key Points

Use the Technicain Handbook to walk the technician through the process of tracing current flow using the supplied
example circuits. Illustrate the current flow tracing with the use of the circuit on the ES 300 Body Electrical
Simulator.
Integrate what-if problem scenarios with the two example circuits.
Perform the 2 worksheets on Radiator fan and Remote Control Mirror Circuits. Integrate the problem switches on the
Simulator with what-if problem scenarios.
Required Materials
• 2 Different Color Highlighters for each Technician

FOLLOWING CURRENT FLOW IN A CICUIT 1.30
NOTE: Do the students understand the following concepts which are

used in subsequent exercises?
I. The importance of being able to trace the path of current flow

through a circuit diagram
A. The EWD does not tell you a procedure to diagnose a circuit.
1. Relies on the technician’s ability to use the EWD
B. The EWD is useless without this skill.

1. You will mis-diagnose everything unless you know where cur-
rent flow is going.
II. Procedure for tracing current flow

A. Determine which fuses are “hot” and at what times.
B. Move the switches into the proper open or closed position.

1. The system outline tells you a terminal-by-terminal description
of the current flow.
2. If the circuit does not use an ECU or an electronic control de-

vice, there will not be a system outline in the EWD.
a. An example of this would be the Remote Control Mirror

Circuit, Turn Signal Circuit, or Horn Circuit.
C. Starting from the fuse at top of the page, apply the series and par-
allel circuit laws to determine all the paths to ground in the circuit.
D. Break the circuit up into separate individual circuits.

1. Just about all the systems on the vehicle are made up of a
combination of separate, individual circuits.
a. This is important because in diagnosisng a circuit, you

want to identify the portions that are working and those
that are not.
II. Hints on finding all the paths to ground

A. Current flow will take any path to ground it can get.
1. Current does not necessarily flow “down” (it goes up and side-
ways, too) the page, but will find as many paths to ground as
possible.
a. Visually on the page, it will flow up, down and sideways

b. With all of the splices, especially on the ground side of
most circuits, the current flow can find a ground through
circuits that don’t seem to be related.
1) This is a feedback type problem.
The feedback problem can be demonstrated with the use of switch 27
on the simulator.

B. Current flow will bypass a load or resistance only if it can go directly

to ground.
1. This is a statement to replace that misconception of “Current
flow takes the path of least resistance.”
C. There is a difference between where there is voltage present and

where there is current flow.
1. Current flows only when there is a complete connection or cir-
cuit between the B+ source and ground.
2. Voltage will be present anywhere there is an unbroken connec-

tion between a location and the B+ source.
The measurement of voltage at certain locations can be of help in de-

termining CONTINUITY in circuit while diagnosing a problem. How-
ever later in the course, we will try to explain the difference between
making a voltmeter in series measurement and making an actual
VOLTAGE DROP measurement in a LIVE circuit, with current flow go-
ing through it.
D. Use a highlighter on a photocopy of the wiring diagram.

1. Drawing the paths to ground is one of the best ways of visually
seeing where the possible trouble areas are.
a. In the diagnostic process, based upon your operational

checks, you can draw in all the parts of the circuit that
you have observed to be operating.
b. The areas that you have not marked then become the
areas that you need to check. It is here that you can
apply the split-half methodology to help locate the prob-
lem.
2. In the beginning, it is possible to be a little confused in drawing

the lines; Therefore in this class, use one highlighter for
drawing and the other highlighter for making corrections only.
3. Add arrows if necessary for clarity.
4. For effective diagnostics, you must become CONFIDENT at

doing this.
III. First Example: The Horn Circuit

A. Found on Page 250 of the 1998 ES 300 EWD
While working on this circuit, a test light may be substituted for a
horn to make the noise level more tolerable.
Point out to the techncians that on simple schematics such as this,

there is no system outline section given in the manual.
B. Use the copy of the diagram in the Technician handbook.

C. This circuit does not have a system outline in the EWD.
D. Sample questions.

Even if the answer may seem easy, it is a good introductory use of the
EWD features. Make the student find the answers out.
1. When is the Haz-horn fuse “hot?” All times
2. What should the positions of the Horn Relay contact and Horn
Switch be? Both Open, until the Horn is depressed by the
driver; Normally Open.
Normally open means the switch position when the vehicle is parked,
all the doors closed.
3. In what sequence does this circuit operate? The Horn Switch

is depressed, completing the circuit for the relay coil; B+ is
then applied to the horns. The horns are connected in parallel;
Both receive 12V and provide ground from their housing.
4. Have the techicians trace the current flow in the two circuits
that are involved in making the horns work.
Other questions can be asked in conjunction with the ES 300 Body

Electrical Simulator.
What is the location of the horn relay, horn fuse?
What are the J/B connector numbers?
What would happen if there was an open in the G-B wire?
What would happen if there was an open in the G-W wire?
Proceed to the TRACING CURRENT FLOW worksheets.

USING THE ELECTRICAL DIAGNOSTIC TOOLS SECTION 1.40
Lesson Title Using the Electrical Diagnostic Tools Section 1.40
Day Number One
Time Period 1:25 - 1:55 p.m.
Total Time 30 min.
1. Use the System Outline to determine system operation.
2. Locate and use the diagnosis information to check connectors.
3. Perform a wire harness inspection.
4. Use jumper wires to aid in diagnosis.
5. Use DVOM to diagnose a circuit.
6. Use a digital ammeter to diagnose a circuit.
Lesson Key Points

The primary goal of this module is to familiarize the technician with the information available in the EWD.
Required Materials
• 1 DMM
• 1 1998 ES 300 RM

I. Introduction to the EWD System Outline
Slide 61
A. Shows how the system operates

B. Very useful diagnostic aid
C. Helps narrow down on paper the problem on the vehicle
Slide 62 EWD p. 137
1. Connectors are critical element
a. Typical Problems
1) connectors not locked
2) terminal pins backed out
3) terminals spread
Slide 63
2. Harness Inspections
a. wire chafing or rubbing

b. harness stretched too tightly
c. abnormal kinks or bends
3. Visual Inspections
a. Know how the system operates.

Slide 64 b. Check the easiest items first.
c. Use your experiences from the past to judge what should
be looked at first.
1) Tell you exactly what to do to test system.

4. Jumper Wires
a. Help to bypass certain sections of wiring harness

b. Should use only a fused jumper wire
c. Never by-pass a load
Slide 65
II. Digital Multimeters

A. Features of Multimeters
1. Accurate
2. Not sensitive to polarity
3. Durabale
Slide 66
4. Batteries last long time
5. Other features are min-max
6. Analog bar graph
Slide 67
B. Digital Voltmeter
1. Connect negative probe to ground
2. Connect positive probe to pin (source voltage)
Slide 68

C. Voltage Drop
1. Turn circuit ON
2. Connect leads
3. Measurement of 0 volts can mean two things
4. circuit is OFF or Open
Slide 69 5. There is vitually no resistance (load) in that part of circuit.
D. Digital Ammeter
1. Used in checking the starting and charging systems.
2. Used in diagnosing parasitic load problems.
3. Fuel pump check shown
a. Normal = 4.0A
b. Excessive = 6.0A
c. Warm pump = 3.0A or less
Slide 70

4. Types of Digital Ammeters
a. Series (Fluke)
b. Clamp (VAT40/60)
c. Maximum ECU draw 50mA
d. Battery generally rated at 50AH
e. Below 12V on battery is unacceptable for load test
must change
Slide 71

E. Digital Ohmmeter
1. Measures Resistance
Slide 72
2. Diode Check
a. Diode check is a separate function

b. Determines resistance one way and then the other
Slide 73
3. Continuity beep 0 - 100W
a. Only checks continuity

b. Does not determine resistance
c. Good for checking a wire from one end to the other
Slide 74
4. Ohmmeter checks
a. Highly accurate
b. Good for limited checks
c. Voltage checks still most accurate
Slide 75

III. Worksheets for Section Three

A. Worksheet 3-1 / Voltage Drop
1. Trace current flow when door is opened using markers.
2. Use voltmeter to determine current at fuse.
B. Worksheet 3-2 / Measuring Amperage
1. Section 2 / use clamp attachment or series to measure

seats
2. Section 3 / Inductive type or series
C. Measuring Resistance
1. Use this to measure resistance in relays.

THE SIX-STEP DIAGNOSTIC PROCESS 1.49
Lesson Title The Six-Step Diagnostic Process 1.49
Day Number One
Total Time 30 min.
1. Implement the 6-step diagnostic process on a typical body electrical problem.
2. Properly verify an electrical problem.
3. Use defined techniques to analyze the related symptoms.
4. Isolate and correct the trouble using the EWD and electrical diagnostic tools.
5. Perform wire, connector, and harness repairs according to proper procedures.
Lesson Key Points

This section applies the skills developed in Day 1 to diagnose and successfully pinpoint electrical problems.
The six-step troubleshooting plan applies to all electrical problems in general. Each of the six steps is broken into
specific actions that should be performed. Specialized techniques for troubleshooting opens, short-to-grounds,
parasitic loads, high resistance, and feedback problems are covered in the lessons which follow.
Have the technicians think strategically about the problem through the use of the six-step plan. Show him/her
that they can save a lot of time by working on paper first before going to the vehicle.
Work to build the Technician's confidence in the use of the diagnostic tools, and in his/her own abilities.
Stress that these techniques will help them to repair electrical problems faster, and make electrical problems
more profitable overall.
Required Materials
• 1998 ES 300 EWD
• Lexus Body Electrical Simulator
• 1 DMM for every 2 technicians minimum; 1 DMM per technician optimal

I. Introduction
A. You have now covered all the necessary “tools” to perform the diag-
nostic process.
1. Use of the EWD
2. Being able to follow the current flow in a circuit
3. Use of the DMM/Jumper wires

Slide 76
B. Some problems can be fixed quickly without any wasted effort.
1. Repeatedly seen problem on certain model
2. Therefore you can go to the problem area immediately
C. Problems where there is no trend to follow are not as easy.

1. Need to follow a six-step troubleshooting plan
a. Provides a structured approach

b. Will help you to fix problem in the least amount of time
II. Six-step Troubleshooting Plan

A. Verify the Complaint
Slide 77
B. Determine the Related Symptoms
C. Analyze the Symptoms

D. Isolate the Trouble
E. Correct the Trouble
F. Check for proper operation

G. These steps will minimize diagnosis time.
1. You will make only the checks that you need to make.
2. Emphasis on those checks that are the easiest to make.
3. Organizes the all of your checks.
H. Finding the cause of an electrical problem will depend on your skills

and not luck.
The definitions of each of these steps are a little different than the
definitions that are found in the L 622 course. In general, we are
trying to define each of these steps a little more clearly than in the
L 622 book. The diagnostic worksheets that you will be using will
follow these revised definitions.
III. Verify the complaint

A. Identify the problem.
1. Must understand what the customer is talking about.
a. Customer is not technically oriented.

b. Technician usually does not interface with customer.
The example that is used to illustrate this process is a Stop Light
Slide 78
problem on 1998 ES300. The stop light wiring diagram is found on
page 126 of the ES300 EWD.
2. Does a problem actually exist?
a. Must know how the circuit is supposed to operate.

1) Use the System Outline, New Car Features or
Owner's manual as reference.
Slide 79
Show the Technicians a copy of an owner’s manual, and how the in-
formation can be used with a customer.
b. May not be a problem.
1) Not being operated properly.
2) Operating condition that the customer is not aware
of causing the system to go into a "fail-safe" mode.
A good example of this would be to demonstrate the operation of
Slide 80 the Cruise Controls System on the ES300 Body Electrical Simulator
with the parking brake only slightly engaged.
c. Characteristic of the vehicle
1) No fix possible for a non-problem
2) Compare vehicle to a known good vehicle.
B. Intermittent or Continuous
1. If problem is intermittent
a. Duplicate exact conditions which caused problem to oc-

cur.
1) May require additional customer input.
b. Typical Causes (triggers)
Slide 81 1) temperature/weather
2) vibration
3) type of driving
4) How it is operated by customer

c. If you cannot duplicate problem

1) Perform thorough visual inspection.
a) Pay attention to terminal spread problems.
2) Simulate vibrations on harness.
a) Keep in mind that disconnecting and moving
the harness can temporarily “fix” a problem.
3) Never consider a vehicle’s problem fixed if it hap-
pens to “magically” fix itself.
4) If the situation warrants it, call Technical Assistance.
d. Repair Manual Troubleshooting section has inspection
procedures for tracking down intermittents.
B. Only if a problem exists should you go on to the next step.

1. You cannot accurately fix a problem that you cannot duplicate.
IV. Determine the Related Symptoms

A. After problem is verified
B. Operational check to determine
1. How much of circuit is affected?
2. Find clues to the location of the problem by operating other cir-

cuits which have parallel connections to the problem area.
Slide 82
C. Circuits are “related” through Parallel connections

1. Two or more loads connected in parallel within a single circuit
2. Entirely different circuits that are related through a shared

power source or ground point
3. Shared switches/sensors
a. For example, the door courtesy light switches are

Slide 83 EWD Pg. 126 shared by both the interior light circuit and the key
buzzer circuit.

To do this requires a strong general knowledge about the different

systems which share the same sensors or switches.
D. How much of the circuit is affected

1. Entire system is dead.
a. Possible power or ground problem.

b. Load or component is bad.
E. If the whole circuit is inoperative

1. Check for a blown fuse.
2. This can be done by checking the operation of other circuits

which use the same fuse or ground point.
a. This information is in Section H, Power Source Current

Flow Chart, and in Section J, Ground Point Information.
b. If the circuit works, it proves that the fuse or ground
point is OK.
c. If the circuit doesn't work, it means that a fuse or ground
point needs to be checked.
Slide 84 EWD Pg. 126 1) This check then becomes a time saver to help de-
fine the exact problem you are dealing with.
3. Part of the circuit operates
a. You can assume that the main power and main ground
are OK.
1) Not 100% true, especially in circuits with multiple
fuses and multiple ground points.
2) But the odds are in your favor—need to play the
odds if speed is a concern.
Slide 85 EWD Pg. 126

F. If part of the circuit is still operating

1. Because part of the circuit works, it tells you that:
a. The power source to those parts of the circuit are OK.

b. The ground point to those parts of the circuit are OK.
c. The conductors and connections in that part of the circuit
are OK.
Slide 86 EWD Pg. 126 2. If you know which parts of the circuit are OK, you can then
only concentrate on the parts of the circuit that could be
causing the problem.
a. No wasted time on unnecessary checks.

b. More profitable.
G. If the circuit has an ECU with self diagnostic ability:
1. The New Car Features and BE section of the RM are the best
places to look for information.
a. The EWD can help you to locate and understand the type
of problem better as a supplement to the RM.
b. RM has information on using the self diagnostic system.
c. Guides you to specific inspections to make for a given
Slide 87 code.
d. Symptoms matrix for driveability problems that do not set
trouble codes.
H. Using Diagnostic Trouble Codes (DTC)
1. Always check for codes first, and write them down.
a. If there are no codes, use the symptoms table.
2. Clear code to see if the problem occurs continuously or is

intermittent
a. If intermittent, you may need to simulate the conditions

in which the problem occurs by moving/causing vibra-
Slide 88
tions to the harness or connectors.
3. If a trouble code is present, follow diagnostic tables in the RM.
4. If there is no code, but there is a problem present, refer to the

Symptoms matrix in the RM.
5. While performing your diagnostics on the vehicle, use the

EWD to help locate connectors, components, etc.

V. Analyze the Symptoms

A. Make sure you have an exact description of the problem and all
related symptoms.
B. You must define the exact nature of the problem.

1. Which circuits overall are affected?
2. What kind of problem you are probably looking for
Slide 89 a. Open
b. Short-to-ground
c. Parasitic Load
d. High Resistance
e. Feedback
3. Difference between what is on the RO, and what the symptoms

of problem actually are.
C. Trace the known “good” current flow paths.
1. Use a photocopy of the page and a highlighter.
2. Gives you an easy to follow picture.
3. Shows you the areas that you don’t need to check (ones that
have confirmed current flow).
4. Shows you all of the potential problem areas (areas that you
Slide 90 EWD Pg. 126 did not trace over).
D. All the up front will result in less time spent making checks on the car.

VI. Isolate the trouble
Slide 91
A. Circle all potential problem areas on the wiring diagram.
1. Anywhere there is no confirmed current flow
2. Gives a good visual reference
Note: There are two hotspots. Have students list the probable areas
for this failure
B. Determine where to begin based upon

1. Accessibility
2. If the inspections can be done visually
3. A known history of failures at a certain point
4. If multiple components or circuits are involved, parts of the cir-

cuit that are common to each.
Slide 93

C. Make initial inspections of the potential problem causes.

2. Tools
a. Visual
b. Voltmeter
c. Ammeter
d. Ohmmeter
Slide 94 c. Jumper Wire
D. If the initial checks do not find the problem, make additional checks.
1. The initial checks should have verified that a section of the cir-
cuit was either good or bad.
2. Based upon this information, perform further checks to pinpoint

the cause of the problem.
a. Continue to look for the easiest areas to get to based

upon the location information in the EWD.
b. The Split Half method
1) Go to the middle of the bad section and determine
which half is OK.
2) On the bad half, go to the middle of that circuit .
3) Continue to narrow down the possible causes until
you find the exact location of the circuit problem.
3. Remember that Diagnosing any problem is simply a process

of elimination.
E. The specific techniques for finding an open, short to ground/para-

sitic load, high resistance problem, and feedback will be discussed
later.
VII. Correct the trouble

A. Will involve the following
1. Repair or replacement of component(s)
Slide 95

2. Wiring Repair
3. Service to a circuit connection
a. Connectors
b. Terminals
c. Ground point
VIII. Component Service Hints

Slide 96
A. When disconnecting components, make sure the power is off or bat-
tery disconnected.
B. Refer to the Repair Manual for special service instructions.
1. SRS requires up to 90 seconds after the battery has been dis-

connected.
2. SRS also requires the squib (steering wheel pad) to be discon-

nected.
C. Before disconnecting battery, write down radio station presets.
IX. Lexus Wire Repair SST

A. Wire Repair SST
B. Contains
1. Splices
2. Terminals w/ wire pigtail
C. Hints
1. Cuts in the insulation should be covered with silicon tape or

heat shrink tubing, with 1/2" overlap on each side.
2. When replacing wires, use same or larger diameter wire.
3. Make sure the circuit is OFF while you are servicing it.
X Check for proper operation

A. Verify that the system is working properly.
1. Watch for circuits with multiple problems.
This can happen especially in areas of the country where corrosion

from road salts is a problem.
B. In ECU controlled circuits with Self diagnosis systems

Slide 97 1. Clear trouble code memory.
2. Verify that the trouble code does not return.

XI. Example of application of 6 six step process: Horn does not work
Have a technician from the class come up to do the checks on the
simulator. He should only do the checks, etc. that he is instructed to
do by the class.
A. Verify the problem

1. Depressing the Hornbutton; Horn does not work.
B. Determine the Related Symptoms

1. Find the circuit in the EWD and determine how the circuit is
supposed to operate.
2. Determine if it affects all or part of the circuit.
a. All of the circuit
3. Determine if the condition is intermittent or continuous.
4. Operational Checks
Since the problem seems to affect the entire circuit, our technique
suggests that you always check fuse and ground. This gives a stan-
dard pattern of “attack” that the technician can remember and follow.
a. Based upon the EWD, the fuse used is the Haz-Horn
Fuse.
1) This fuse is also used by the Hazard Warning Lights.
2) Using Section H, you find the Hazard Lights use this
fuse.
3) Hazard Lights are OK; therefore, fuse is OK.
4) When the horn button is depressed, the relay does
not click.
a) Indicates the first part of the circuit you
should be trying to repair--The Relay coil
circuit.
C. Analyze the Symptoms

1. Based upon the related symptom checks, you know that the
problem is isolated to the Horn Circuit only.
2. Using the System Circuit Diagram, trace the paths of current

flow in the circuits that are working.
3. Problem Description
a. Horn does not work; relay also inoperative.
D. Isolate the Trouble

1. List of possible causes
a. No B+ to pin 2 at horn relay

b. Open Horn Relay

c. Open between pin 1 of Horn Relay and pin 2 connector

2E of JB #2
d. Open in G-B wire
e. Bad Horn Switch
f. Open ground at Horn Switch
2. Inspect the possible causes
a. Go to the ones that are the easiest to access.

b. Will tell you the most information at once.
c. Most probable cause based upon experience
1) Diagnosis is a process of elimination.
2) You try to get to the problem area FIRST. But be-
cause there are many causes for a given set of
symptoms, this not always possible.
a) A certain amount of “luck” involved in getting
to the problem area first.
b) But using the strategy as presented will get
you there quicker overall. There are no
wasted steps, no wasted time.
Whenever inspecting for possible causes there are a number of differ-
ent approaches you can take. However, in this instructor guide we
will list only one example approach for each case study.
a. With a Jumper wire, ground pin 4 at connector 2E.
1) Horn Works
b. Check Horn Switch for continuity to ground at pin 10 of
the Combination Switch.
1) Continuity
E. Correct the trouble
1. Open in G-B wire between pin 4, J/B 2, connector E and Pin

10 of the combination switch.
This particular problem can probably be diagnosed faster using

only a jumper wire. The example in the book is there to illustrate
one possible approach, and to demonstrate how to fill-in the
worksheets that will be used for the entire day.
Stress to the technicians that this structured approach is the best way
to diagnose electrical problems. If done properly, you can eliminate
any unnecessary checks and accurately fix a problem right the first
time.

OPEN CIRCUIT DIAGNOSIS 2.10
Lesson Title Open Circuit Diagnosis 2.10
Day Number Two
Total Time 90 min.
1. Successfully diagnose an open circuit problem in an electrical circuit.
2. Apply the 6 step diagnostic process.
3. Learn the diagnostic strategy for diagnosing an open circuit problem in which the entire circuit is inoperative.
4. Learn the diagnostic strategy for diagnosing an open circuit problem in which part of the circuit is still
functional.
Lesson Key Points

This section is designed to demonstrate the strategy and techniques that can be used on open circuit problems.
There is no “one” way to diagnose a problem. Discuss with the class the different approaches that could be used.
Stress how the skills practiced in the previous sections of the course are combined to diagnose these problems.
Work to develop a “diagnostician’s mindset” into the technician throughout the case studies. Be consistent when
applying the diagnostic approach. The actions that the technician should make in “Step 2: Determine the Related
Symptoms” are of special attention, since this is one of the least used/understood checks.
Required Materials
• 1998 ES 300 Body Electrical Simulator
• Fused Jumper Wires

I. Introduction
A. In step 3 of the diagnostic plan, you analyzed all the symptoms
B. Based upon these you should be able to make a conclusion as to the

type of problem.
1. Open Circuit
2. Unwanted parasitic load
Slide 98 3. Short-to-ground
4. High resistance problem
5. Feedback problem
II. Diagnosing open circuit problems

A. The circuit is entirely inoperative or parts of the circuit appear to be
“dead”.
1. No visible signs of operation
2. Most common type of problem
B. Typical causes of an open circuit

1. Open connector
2. Cut wire
3. Inoperative switch
4. Poor terminal contact
5. Defective fuse
A bad ground point may not cause a circuit problem if there are splice con-
nections to other redundant ground points.
III. Open Circuit Diagnosis Strategy

Continue to repeat for each problem the method that was laid out in section
4.
A. Determine if the open affects entire circuit or just part of it.
1. Entire circuit
a. Possible open in the power feed or ground.

b. Check operation of circuits that share the power feed or
ground.
2. Part of the circuit
a. Determine which parallel branches are inoperative.

b. If it is operating you don’t have to inspect it.

B. Look at the EWD

1. Based upon your related symptom check, determine where the
circuit is verified as OK, and which parts of the circuit could be
possible causes of the problem.
2. Based on the parts locations and your own experience on the

vehicle, find locations that you can perform continuity checks
at.
a. Continuity checks
1) Voltmeter
2) Ohmmeter
3) Jumper wire to bypass a portion of the circuit
There is no one BEST tool to use in a given situation. The technician also will
probably have a personal favorite that he has more confidence in. Stress
proper tool use, and that the technician understands the limitations of each
of these tools.
3. In this course you will be asked to plan the first 2 checks that
you will make on the vehicle.
4. Then write down any other checks that you need to make in
order to “nail down” the problem.
C. Perform your checks

1. Use your diagnostic tools, make checks to the circuits.
a. It is a process of elimination.
IV. Using the Voltmeter on Open Circuit Problem

A. Open circuit voltage measurement
1. Positive probe at the terminal.
2. Negative probe to a known good ground.
3. Will not tell you if there is any series resistance in the circuit.
Slide 99
4. If you connect the meter in series, a voltage reading will indi-
cate continuity on both the power and ground sides of the cir-
cuit.
B. Procedure
1. Use EWD
a. Determine where to make the checks.

b. Circuit ON.
c. Negative probe to ground, use positive probe to pins.
1) EWD does not give most pin voltages.
2) Need to apply your circuit/current flow tracing
knowledge.
C. Notes
1. Go to the easiest places to access first.
2. Remember that an open circuit voltage is a continuity check

only--does not find series resistances.
D. Advantages to using a Voltmeter
1. Easy to use.
2. Can never cause any circuit/fuse damage.
E. Disadvantages
1. Open circuit inspection will not detect high resistance prob-

lems.
2. Would have to disconnect the ground circuit to check continu-

ity in those wires.
V. Using an Ohmmeter on Open Circuit Problems

A. Used to check continuity in the circuit.
B. Procedure
1. Use EWD to determine appropriate test points
a. No parallel connection to affect measurement
2. Turn circuit OFF.
3. Connect ohmmeter to each end of the section/component you

want to test.
C. Advantages
1. Will detect resistance problems for average circuit.
2. Easy to use and understand.
D. Disadvantages
1. Power must be off in the circuit.
2. Need to isolate the area you want to test.
3. Difficult to detect small resistances.
a. If circuit has current flow above 3-4 amps, even a small

resistance of .5 ohms is significant.
Slide 100 1) Voltage drop the best test for finding this.
b. But if problem is strictly an open circuit problem, ohmme-
ter is OK.

VI. Using a Jumper wire

A. A simple but effective tool.
B. Use a fused jumper wire as recommended in section 3.

C. Procedure
1. Use the EWD to determine sections that can be bypassed.
a. The wrong position can blow a fuse or damage a compo-

nent.
b. Never bypass a load.
2. Connect the jumper wire.
D. Advantages
1. Simple and effective means of bypassing parts of the circuit in
diagnosis.
2. You can bypass
a. Switches
b. ECU/Transistor control
1) Some Injector or Duty Cycle controlled circuits ex-
cluded. The ECU performs current limitation to
prevent the actuator coil from being damaged.
c. Wiring harness/connectors
E. Disadvantages
1. Could be difficult to use depending on component or connec-
tor location.
2. If you bypass a load can damage switches or other compo-

nents. At least will blow a fuse.
F. Caution
1. Never bypass a load--short-to-ground could cause circuit
damage.
Slide 101
2. Do not bypass series resistors in some circuits.
a. In the case of fuel injectors, the resistor is required for

over current protection for the injector coils.

VII. Open circuit case study: Right Mirror Does Not Go Up or Down
WS 5-11 SH251 (Switch #12)
For all of the Hands -On Worksheets in this course, ask 2 technicians to per-
form the troubleshooting actions by having one person read the EWD, one
person measures/checks). These technicians should only do what the class
tells them to do. The responsibility should be rotated.
To introduce this problem set Switch 12 to the "ON" position and explain that
the Right Hand Mirror does not operate properly.
A. Verify the complaint.
1. Demonstrate that this is in fact true. Ask what might have been
said on an RO.
The technicians will have to verify this problem. The problem descriptions
that are used in this course are purposely vague to force the technician to
investigate the operation of the particular circuit thoroughly.
2. Determine if the problem is intermittent or continuous.
a. Problem is continuous.
B. Determine the related symptoms.

1. Find the circuit in the EWD and determine how the circuit is
supposed to operate
2. Determine if all or just part of the circuit is affected.
a. Only part of the circuit is affected.

b. Other mirror functions work properly.
1) This confirms that much of the circuit is OK.
C. Analyze the symptoms

1. Define the Problem Accurately.
a. Right hand mirror does not have UP/Down function.
2. Define what parts of the circuit are OK.

a. Using the System Circuit Diagram, trace the paths of cur-
rent flow in the circuits that are working.
D. Isolate the trouble.

In our worksheets and case studies, instead of “listing” the possible causes,
the technicians are supposed to just circle or mark the possible problem ar-
eas on the copy of the wiring diagram in the technician handbook. This way,
we won't waste the technician’s time with unnecessary writing.

1. List of possible causes.
a. Open circuit in the following locations

1) Between IO2 / pin 14 and R17 / pin 3
2) Between R4 / pin 2 and IO2 / pin 14
3) Internal failure in Mirror Switch R4
a) All of the other locations are confirmed OK.
2. Inspect the possible causes.
a. In this case, it’s not too difficult because there are not
many possible causes for this problem.
b. Using the diagnostic tools, inspect the circuit.
1) In this case, it is fairly easy to get to the mirror
switch.
a) voltage is present at R4 / pin 2
b) list other possible checks
2) Could jumper from R4 / pin 2 to IO2 / pin 14
E. Correct the Trouble.
1. If jumper causes operation then open exists on LG-B.
2. On the simulator, this is as far as you can go. The actual prob-
lem is created by the switches which are in series.
3. This is how you would do the worksheets on the simulator

when we are doing the on-car worksheets.
F. Check for proper operation.

1. Make sure the system works properly after you make the re-
pair to the circuit.
Proceed to On-car Diagnosis Worksheets or go on to next section.

HIGH RESISTANCE PROBLEM DIAGNOSIS 2.20
Lesson Title High Resistance Problem Diagnosis 2.20
Day Number Two
Time Period 10:00 - 11:00 am
Total Time 60 min.
1. Successfully diagnose a high resistance electrical circuit problem.
3. Locate a high resistance problem in the ground circuit.
4. Locate a high resistance problem in the B+ circuit.
Lesson Key Points

Emphasis must be placed on being able to distinguish High Resistance Circuit problems from Open Circuit
problems. The primary difference is that there is NO current flow in an open circuit. With high resistance in a
circuit, there will still be continuity, but not enough to fully operate the load in the circuit.
The open circuit voltages that were useful when diagnosing an open circuit are not useful when diagnosing a
high resistance problem.
You must always identify either by observation (i.e., dim light bulb, partial operation) or by the presence of a
voltage drop whether the circuit has current flow or not.
Stress how easy it is to use the concept of voltage drop to isolate the location of any high resistance problem.
Required Materials
• 1 DMM for every 2 technicians minimum; 1 DMM per technician recommended
• Inductive Amperage Clamp for DMM
• 10 ohm wire wound resistor (optional)

I. Symptoms of a high resistance circuit problem

A. Lack of sufficient current flow/available voltage drop for the compo-
nent to operate properly.
1. Most components are designed to operate with 12 V.
2. Anything substantially less will cause the component to be in-

operative or operate erratically.
B. Component is partially operating, or operating weakly.

Slide 102
1. Light bulb appears dim
2. Motor operates slowly
3. Relay contact “buzz”
C. Component operates intermittently.

1. Lack of sufficient voltage/current flow causes the component
to work only sometimes.
D. Component appears to be totally inoperative.

1. Lack of sufficient voltage/current flow causes the component
to appear to be dead.
II. Causes of High Resistance Problems

A. Dirt/Corrosion on terminal/connection
B. Wire strands cut
C. Excessive heat
D. Poor terminal to pin connection

Note that amount of resistance required to cause a problem in a cir-
cuit depends on the amount of amperage that is flowing through the
circuit. For example, 0.1 ohm is insignificant to most body electri-
cal circuits on the vehicle. However, to the starter motor circuit, 0.1
ohm could cause the motor to be virtually inoperative. Likewise, a
10 ohm resistance in series with a light bulb circuit that usually has
0.3 amps of current flow will be greatly affected, while 10 ohms will
make virtually no difference in an extremely low current flow circuit
such as an ECU type sensor circuit.
III. High Circuit Resistance Diagnosis Strategy

A. In determining the related symptoms:
1. Determine if there is at least some current flow in the circuit if
it is an open circuit problem.
a. Look for partial operation

b. Any voltage drop around the load
B. Isolating the trouble

1. Measure the voltage drop across the component.

a. In most cases, should be about battery voltage.

1) If the voltage drop OK, then the problem would have
to be with the internal resistance in the component.
Ohm's law comes into play here. Whenever you have a voltage drop,
and a complete circuit, you know that you will have current flow. If
there is sufficient voltage drop according to your measurement at the
component, and yet the component does not function, Ohm's law
tells you that there must be excessive resistance that is limiting the
flow of current through the component.
b. Cases that the component would not be receiving 12 V
or more yet would be OK.
1) If the circuit used a dropping resistor in series.
a) AC blower fan
2) If another component is connected in series.
a) Radiator cooling fan circuit
3) If the source voltage is less than 12 V.
a) 5 V reference voltage sensors from the ECU
2. If the component does not have the correct voltage drop, mea-
sure the voltage drop across the ground side of the circuit
a. Put the voltmeter in parallel from the ground terminal of

the component to a known good body ground.
1) V drop should be less than 0.5 V.
2) If this measures less than 0.5 V, then the problem
must be on the Power side of the circuit.
This is an application of the series voltage drop rules that were
studied in 622. If the source voltage is 12 V, but the voltage drop
around the load is less than 12, then you know that there must be
some series resistance in the circuit. By process of elimination, if
the excessive voltage drop is not on the ground side of the load, then
it must be on the B+ side.
3. Isolate the high resistance area.
a. Use the voltmeter in parallel across the connectors or

wires in the circuit, measure for unwanted voltage drop.
At this point, the operation becomes simply a process of elimination.
V. High Resistance Switch # 17 BE simulator WS S-16, SH 271

A. Verify the complaint.
1. Customer complaint
a. Interior light is dim.

2. Inspection
a. You find a problem in only the Interior lamp—Dim bulb.
B. Determine the Related Symptoms.

1. Other courtesy lights are OK.
2. No other problems could be detected.
C. Analyze the symptoms.

1. Problem Definition
a. The Interior lamp is not bright enough.
2. Define what parts of the circuit are OK.
a. All parts of the circuit are OK except for exclusive parts

of Interior light circuit.
D. Isolate the problem.

1. List the possible causes.
a. High circuit resistance possible in the following locations:

1) From IF grnd. to I16 2
2) Splices B3 or B2
3) From I14 pin 2 to J/B 1F pin 2
4) From J/B 1F pin 2 to I16 pin 1
5) From II2 to pin 9, J/B#1, connector K
6) High resistance in the Integration Relay/JB
7) Switch ground
2. Inspect the possible causes.
a. Look at the EWD page 102.

1) A direct ground is provided by manual switch.
b. If bulb is still dim at manual ON setting
1) Problem is probably in component or upstream.
2) Disconnect I16 pin 2 from other lights.
c. Are other lights normal ?
1) Check at I16/pin 2 of the Interior lamp to ground.
a) less than 12v is NG
2) If practical jumper I16 pin 1 to I14 A pin 2.
E. Repair the Problem.

1. High resistance between I16 pin 1 and Integration Relay I14 pin 2.
Go on to the On-car diagnosis module.

ON-CAR RESISTANCE DIAGNOSIS WORKSHEETS 2.25
Lesson Title On-Car Resistance Diagnosis Worksheets 2.25
Day Number Two
Total Time 60 min.
1. Successfully diagnosed 3 high circuit resistance problems.
3. Extensively used the EWD support sections to locate electrical/wiring components and determine power flow
from the fuses and junction blocks.
Lesson Key Points

In this and all hands-on diagnosis worksheets, the major objectives are to allow the technician’s an opportunity to
apply the techniques that were covered in class on live vehicles, and to build the technicians confidence in his/her
diagnostic skills.
If the technician understands the concept of voltage drops and knows how to measure them, high circuit
resistance problems are easy to diagnose.
This section should make the concept of series circuit resistance come “alive” to the technician. The theory
of voltage drops really become applicable to a technician in electrical diagnosis when working on resistance
problems.
Class Preparation
Break the class into small groups (2 per group desired; 3 maximum) with 1 vehicle or the Simulator prepared for
each group. Each group should finish a each diagnosis worksheet in about 20 minutes. After all the groups are
finished, have them rotate between the vehicles/Simulator so that each group has worked on 3 problems (2
vehicles + Simulator).
If the class size is over 10 students or more, 3 vehicles + the Simulator will be required. If time permits, have the
technicians work on all four problems. You will need to provide an additional photocopy of a worksheet and wiring
diagram to accommodate the additional vehicle.
Required Materials
• 2 vehicles minimum with high resistance problems
• Back-up/Combination light harnesses bugged with 15 - 20 ohm 5 watt resistors (optional)
• Bugged wires with 470 ohm 1 watt series resistor (or 2 parallel 1K ohm resistors) and appropriate male and
female terminals
• 1 EWD for each specific vehicle used
• 1 photocopy of the appropriate System Circuit Diagram for each of the vehicles (one per technician unless
xerox machine is readily available)

ON-CAR RESISTANCE DIAGNOSIS WORKSHEETS 2.25
• 1998 ES 300 EWD

• Fused Jumper Wires
Vehicle Preparation
• Installing a “good” high resistance bug can pose some logistical challenges. Not only must the bug create the
desired symptom, but it must also “look” good so that the technician does not easily detect it. In lighting circuits,
the amount of current flow requires a bulky 5 or 10 watt wire wound resistor be used as series resistance. If a
lower current flow circuit is selected or if a high resistance series resistor (470 ohms or higher) a 1 watt resistor
can be used.
• The recommended bugs all specify the use of about 470 ohms of resistance. This amount of resistance will
cause the component to be inoperative. Through the use of a voltage drop test, the technician will find that
there is still current flow through the circuit. If the technician uses just an open circuit voltage check, he will
measure battery voltage—a circuit that seems to be OK. (A test light in this particular case would be OK—
the light will be inoperative or dim depending on the resistance of the test light bulb.)
• After the one group of technicians has found the bug, make sure that they restore the bug so that the next
group can work with the vehicle. The last group can restore the vehicle to normal.
High Resistance Worksheet

• Install bugged dummy wire harness into any of the vehicles.
• Remember that this bug can be located in series to any of the light bulbs -- Stop, turn signal, parking, or with
their ground wire. (The problem descriptions are intentionally vague) Be sure to use a dummy wire of the
correct wire color and correct terminals.
High Resistance Worksheet

• Install bugged dummy wire into the back-up light harness/combination light harness into any of the vehicles.
• This circuit is a good circuit to work with in class because of the large number of connections used.
Optional High Resistance problem #1

• Install 470 ohm 1 watt resistor in series with remote control mirror circuit or headlight relay coil.
• Install resistor on a substitute wire of correct wire color. Install correct male and female terminals to each
end of the wire. Install in series at any accessible connector.
Optional High Resistance problem #2

• Install 470 ohm 1 watt resistor in series with any load. The load will be inoperative. However, an open circuit
voltage check will show that there is “12V” getting to the light bulb.
• Install resistor on a substitute wire of correct wire color. Install correct male and female terminals to each
end of the wire. Install in series at any accessible connector.
• This bug can be adapted to a variety of circuits.

SHORT CIRCUIT/PARASITIC LOAD DIAGNOSIS 2.30
Lesson Title Short Circuit/Parasitic Load Diagnosis 2.30
Day Number Two
Time Period 1:00 - 2:00 pm
Total Time 60 min.
1. Diagnose a short-to-ground in an electrical circuit.
2. Diagnose an unwanted parasitic load problem.
3. Apply the 6 step diagnostic process for each of these problems.
4. Use the EWD to determine circuit power distribution through the various junction blocks and junction
connectors.
5. Apply basic circuit theory concepts with the use of an EWD on vehicle circuits
Lesson Key Points

Because the process of finding a short to ground and a parasitic load is similar, they have been combined in this
section.
The major thrust of this section is to apply a logical procedure to the process of tracking down a short circuit/
parasitic load problem. Again, we want to take the “magic” out of electrical, and make it as simple as possible.
While the power distribution tables in the EWD may seem quite extensive, there is one major shortcoming. There is
no easy way to track the power distribution after the fuse through the junction blocks and junction connectors.
Instead, you must look at every system circuit diagram in which the fuse is used, and note all the junction blocks
the fuse feeds into. The alternative to this is to make an “educated guess” as the problem component/harness
location based on your past experiences. Both of these methods are discussed in this section.
Required Materials
• Test Light
• Sealed Beam Headlight (optional)
• Inductive Amperage Clamp or equivalent
• Snap-On Short Finder or equivalent
• 20 Amp Fuses (for Gauge Fuse Replacement)

I. Diagnosing Parasitic Load Problems

A. Parasitic load definition
1. Continuously draws current from the battery, even when the

key is off.
2. ECU’s with a memory need this.
3. Maximum allowable is up to about 50 to 100 mA.
a. More on-board computers = higher milliamps draw

b. Average around 20 mA
B. Unwanted parasitic loads

1. Drains battery after the car sits overnight.
a. Verify that the battery and charging system are OK.
2. Caused by a short in the control of a circuit.
a. Shorted or closed switch, or switch bypassed

b. Short internally in a load which bypasses the switch
II. Parasitic Load Diagnostic Procedure

A. Turn all accessories on the vehicle OFF.
1. Make sure the doors are closed, dome light OFF, and key out
of the ignition, with illuminated entry lighting OFF.
B. Connect ammeter in series or use an inductive ammeter with low am-

perage measurement capability on the battery cable to determine the
amount of parasitic load.
1. Up to 100 mA is acceptable but borderline.
C. Remove fuses one at a time to determine the circuit that is causing

the draw.
D. Using a process of elimination, open the circuits that use that fuse
1. At harness to harness connectors, junction blocks, and at the
components themselves to determine the location of the short.
2. Use the Section H, Power Source Current Flow Chart to see

which circuits you need to check.

III. Amperage Measurement Caution

A. Some aftermarket alarms will “honk the horn” when the battery is re-
connected.
B. This will blow the ammeter fuse on many meters.

C. To avoid this
1. Use a jumper wire first to connect the battery post to the bat-
tery cable.
a. This should trigger any alarms if used.
2. With jumper wire still connected, connect the ammeter to the

battery post and cable.
3. Remove the jumper wire.
A blown fuse in a DMM causes 2 major headaches: 1) The fuses in a

Fluke DMM are quite expensive and 2) When the fuse is blown the cir-
cuit you are testing won’t work. (And you waste time trying to figure
out why!)
IV. Determining the location of a Parasitic Load

A. A process of elimination
B. Open circuits to find where the draw is coming from
C. Use the EWD to determine where the fuse feeds into
D. Two Methods- With ammeter connected:
1. Begin disconnecting components that are fed by that fuse.
a. Use your experience on common locations/component

failures.
b. If too many components are fed by that fuse, you will be
disconnecting a lot of items.
1) Use Power Source Current Flow Chart to determine
which components to disconnect.
Slide 103 Show this section of the EWD to the technicians.
c. Possibility of “forgetting” components - not as systematic
as mapping through the J/Bs
2. Follow current flow through the junction blocks.
a. Find which circuits use that particular fuse.

b. On each wiring diagram, note the junction block connec-
tors and junction connectors that are used with the spe-
cific pin numbers.
1) You must look at virtually every wiring diagram in
the EWD to do this.
Slide 104 2) Surprisingly, doesn’t take a lot of time—about 10

minutes.

c. Disconnect specific J/B connectors until the unwanted

parasitic load drops to normal.
d. If necessary, disconnect individual pins to further isolate
the location of the problem.
e. Strategically continue to disconnect connectors to iso-
late the exact location.
f. Make the repair.
Of the 2 methods, the “educated guess” is probably the one a techni-
cian will choose. But if it does not find the problem, mapping out the
current flow through the J/Bs is a very logical and “textbook” method
that will find the problem.
V. Diagnosing Short-to-grounds
A. A short-to-ground occurs when a circuit finds a path to ground before
the load.
1. Current flow is not regulated by the load
B. Causes blown fuse/circuit breaker or possible harness/component

damage.
C. Diagnostic strategy
1. Similar to parasitic load except for:
Slide 105
a. You know which fuse the problem is connected to .
b. You need to connect a load in place of the fuse.
c. You know that the problem is either at or before the load.
D. Typical causes of a short-to-ground:
1. Pinched wire
2. Chafed wire rubbing to ground
3. Defective wiring inside of a component
VI. Selecting the load

A. A “standard” test light does not work for many short-to-grounds
1. If you cannot isolate the problem circuit from other circuits that
are ON.
a. For example, the gauge fuse circuit.
B. Connect a load that requires more amperage to operate.
1. Use a sealed beam headlight.
C. Use a Short Finder.
1. Basically a 30 amp circuit breaker in a package.
a. Keeps you from touching the HOT circuit breaker.

2. Allows 30 amp bursts of current flow.
a. Momentary peaks of current flow are in excess of 50 -

100 amps.
b. May exceed the capacity of the wiring and cause dam-
age.
An additional advantage of the short finder is that as the circuit

breaker pulses, it will allow voltage to go to each branch that is
connected to the fuse. This means that by looking at the “lights” or
with a voltmeter you can check each branch up to the load. The
branch with the short in it will NOT get voltage while the circuit
breaker is closed.
3. Supplied with an inexpensive inductive ammeter
a. Equivalent to using a compass

b. Not useful if the harness is not easily accessed
4. Recommend using a good quality inductive ammeter to trace

the wire/harness which contains the short-to-ground (high
amperage flow).
a. Clamp-type ammeter takes all the guesswork out of find-

ing the location.
b. Keep in mind that the clamp will be measuring current
flow in both directions when clamped around a single har-
ness.
1) One current flow can cancel the other.
D. The Best Tool

1. The safest tool to use is the headlight.
To get the headlight amperage to “pulse” (making it easier to identify)

use a turn signal flasher in series.
2. The short finder has some risks because of potential overload,

but if the wiring can handle it, it is the fastest way to isolate
the problem.
Slide 106
a. But use the good quality clamp type inductive ammeter.
VI. Short-to-ground Diagnostic Procedure

A. Locate the blown fuse and inspect its condition.
1. Fuse appearance can tell you why the fuse is blown.
a. Direct Short to ground

1) Clean break
b. Melted
1) Excessive load in the circuit
Slide 107

c. Appears normal, but open

1) Probably defective fuse
2) May need a voltmeter or ohmmeter to check the
fuse.
B. Determine if the short is intermittent or continuous.

1. See if and when another fuse blows.
C. Replace the blown fuse with a test light or other load.

1. Use circuit breaker/short finder, headlight.
D. Using a process of elimination, open the circuits that use that fuse at
the various harness to harness connectors, junction blocks, and at
the components.
1. Use the Section H, Power Source Current Flow Chart to see
which circuits you need to check.
Slide 108
E. Mapping Current Flow through the J/Bs
1. One fuse can feed a large number of circuits.
a. The Guage fuse feeds into 38 different components on

the 1998 ES 300.
Slide 109

2. Procedure
a. Find which circuits use that particular fuse.

b. On each wiring diagram, for that circuit note the junction
block connectors and junction connectors that are used
with the specific pin numbers.
1) On some problems you must look at virtually every
wiring diagram in the EWD to do this (remember
the gauge fuse).
Slide 110
2) Surprisingly doesn’t take a lot of time—about 10
minutes.
c. Disconnect specific J/B connectors until the unwanted
Short-to-ground load drops to normal.
d. If necessary, disconnect individual pins to further isolate
the location of the problem.
e. Strategically continue to disconnect connectors to isolate
the exact location.
Slide 110
3. Intermittents
a. You need to duplicate the problem.

1) Shake the harness in different points:
a) May cause the problem to go away
temporarily.
b) A real hit and miss proposition
2) If a replacement fuse will not blow out, operate the
different components that are connected to the fuse.
a) If the fuse blows, it will pinpoint the problem
circuit quite quickly.
b. If the problem can't be duplicated
1) Make a general visual inspection of the potential
problem harnesses.
2) Verify the customer's description of when the fuse
actually blows, with attention to circuits that are
turned ON at the time.
3) Inspect the fuse to see if it is “melted” or if the fuse
is cleanly blown.
a) A melted fuse would indicate that fuse is
being overloaded.
4) It is virtually impossible to fix a problem that you
cannot duplicate.
5) Short circuits are always on the power side or at the load.
Go to Simulator Switch #7 (Interior light parasitic load), Switch #16 (Wireless
Door Lock short) or any short to ground or parasitic load problems you may
have installed in a vehicle. Use a generic worksheet for vehicles you may
have bugged. You may wish to demo one problem with entire class on the
simulator then go into full rotations in the shop. Remember: the simulator
is always available as a rotation vehicle.

ON-CAR SHORT-TO-GROUND/PARASITIC LOAD DIAGNOSIS WORKSHEETS 2.35
Lesson Title On-Car Short-to-Ground/Parasitic Load Diagnosis Worksheets 2.35
Day Number Two
Time Period 2:00 - 3:00 pm
Total Time 60 min.
1. Successfully diagnosed short-to-ground/excessive parasitic load circuit problems.
3. Used the EWD support sections to locate electrical/wiring components and determine power flow from the
fuses and junction blocks.
Lesson Key Points

In this and all hands-on diagnosis worksheets, the major objectives are to allow the technicians an opportunity to
apply the techniques that were covered in class on live vehicles, and to build the technicians confidence in his/her
diagnostic skills.
Short-to-grounds can be one of the most difficult electrical problems to diagnose. But through the use of
structured approach, the problem becomes at least manageable.
Allow the technicians to use the tool of their choice to find the short-to-ground (headlight or short finder). Be sure to
emphasize the cautions on using the short finder.
Stress the use of the EWD and the technique of narrowing down the possible problem locations by through
disconnecting JB, harness to harness, and component connectors.
Class Preparation
Break the class into small groups (2 per group desired; 3 maximum) with 1 vehicle or the Simulator prepared for
each group. Each group should finish each diagnosis worksheet in about 20 minutes. After all the groups are
finished, have them rotate between the vehicles/Simulator so that each group has worked on 3 problems (2
vehicles + Simulator).
If the class size is over 10 students, 3 vehicles + the Simulator will be required. If time permits, have the
technicians work on all four problems. You will need to provide an additional photocopy of a worksheet and wiring
diagram to accommodate the additional vehicle.

Required Materials
• 1 Snap On short finder
• 1 EWD for each specific vehicle
• 1 photocopy of the appropriate System Circuit Diagram for each of the vehicles (one per technician unless xerox
machine is readily available)
• 1998 ES 300 EWD (for the Simulator)
• Jumper Wires
• 1 vehicle minimum with an excessive parasitic load problem
• 1 vehicle minimum with a short-to-ground problem
Vehicle Preparation
• After the one group of technicians has found the bug, make sure that they restore the bug so that the next group
can work with the vehicle.
Parasitic Load Worksheet - Battery Dies Overnight; Charging System OK

• The bugs for this worksheet are easily implemented. They consist of:
1. Misadjusting the trunk light switch so that the trunk light is ON at all times.
2. Connect a 100 ohm 5 watt resistor (or two 270 Ohm 1 watt resistors in parallel) across the electrical connector
at the stop light switch or any other unswitched circuit.
Short Circuit Worksheet - Fuse Blown

• Remember to have the short to ground located before any switches if possible. Some switches (such as the
headlight switch) will be damaged if a short to ground occurs after the switch.
• Have the technicians use the DMM inductive ammeter to track the current flow through the harness when
using the short finder.
• The recommended bugs are listed in the following table. Because vehicle availability will vary, you may have
to devise similar bugs on different vehicles. Concentrate on the implementation of proper diagnostic
technique and the use of the EWD.
Parasitic Load Worksheet - Battery Dies Overnight; Charging System OK (Simulator Switch #7)
• Be sure that the technicians make an accurate measurement of the parasitic load before beginning, and use
the EWD to isolate the circuit that is causing the problem.

Recommended Bugs for Parasitic Load Diagnosis Worksheet
VEHICLE LOCATION SYMPTOM NOTES

LS 400 Misadjusted Trunk Light Trunk Light stays ON at
GS 300/400 Switch all times
ES 300
Any Vehicle 2/240 ohm resistors in Shorted Stop Light

parallel across Stop Switch
Light Switch
Recommended Bugs for Parasitic Load Diagnosis Worksheet
VEHICLE LOCATION SYMPTOM NOTES

Any SUV with trailer Jumper wire short-to- Blown Stop Fuse
harness wiring ground on load side of
connector
Any Vehicle Easiest access point in Blown Fuse Gauge fuse A quick check of the
Back-Up circuit according EWD should reveal a
to EWD suitable location. Trailer
connectors will work on
SUVs
Any Vehicle Taillight assembly/two Circuit has feedback There are a number of
terminal light bulb has symptoms when current possible symptoms since
solder bead placed flows, check Combo feedback can flow
between terminals/ Meter illumination during through several related
reinserted into connector. current flow. circuits

FEEDBACK PROBLEM DIAGNOSIS 2.40
Lesson Title Feedback Problem Diagnosis 2.40
Day Number Two
Total Time 60 min.
1. Successfully diagnose an electrical feedback circuit problem.
3. Diagnose a feedback problem in a lighting circuit.
4. Diagnose a feedback problem in a general body electrical circuit.
Lesson Key Points

This is the shortest of the 4 sections covered today. Due to the nature of feedback problems, they are usually very
difficult to figure out in the first glance at the System Circuit Diagram. But there is an explanation for every feedback
problem.
In this course we will concentrate on the GENERAL causes of feedback problems, and give a fairly simple approach
to diagnosis.
The diagnostic approach used here is centered on immediately inspecting the typical causes of a feedback problem.
Tracing the flow of current to figure out how the feedback is actually occurring is not the fastest way to fix the
problem and is not essential.
Because of the time consuming nature of isolating the cause of a feedback, if the techniques outlined in this section
fail to find the problem, the technician should be encouraged to use the Technical Assistance Hotline.
Required Materials
• 1 DMM for every 2 technicians minimum; 1 DMM per technician recommended

I. Symptoms of a Feedback Problem

A. When you operate one component, other components operate when
they are not supposed to
1. Parking lights flash when turn signal operates
2. High Beam indicator flashes when the horn is operated
3. All the “strange” problems

II. Causes of Feedback Problems
A. Short to voltage
1. Light bulb filament blows and shorts across to other filament
2. Wire Harness is pinched with two bare wires touching
B. Open grounds
C. Blown fuses
D. Improper light bulb wattage/type
III. Feedback Diagnosis Strategy

A. Don’t try to figure it out first
1. Current flow paths won’t seem logical
2. There are a few usual causes to feedback—check them first
Remember: There must be both a shared power and shared ground
B. Always check:
1. Fuse condition—power must be shared to create problem
2. If in a lighting circuit, check condition and type of bulbs that

are used in the circuit
a. Often, customers will install the wrong type of light bulb
3. Grounds—Must be shared to create problem
4. Find all the affected circuits or components
IV. Quick Checks for Lighting Circuits

A. If the feedback occurs when a lighting circuit is operated, check for
1. Short light bulb filament
2. Incorrect light bulb installed
a. Improper wattage
b. Incorrect type
Slide 112

An entirely wrong light bulb installed by the customer is a

common occurrence.
3. Open in light bulb ground
a. Inspecting light bulb grounds

1) If multiple bulbs share a single ground, remove all
the bulbs and then check countinuity to ground
2) This way you will not be measuring continuity to
ground through one of the light bulb filaments
V. Quick Check for General Feedback Problems

A. Check the fuses
1. A single blown fuse can cause feedbacks
B. Check for open ground wires

1. Simple problem
2. Less common because of redundant grounds used on most

circuits
a. You would have to disconnect 3 or 4 separate ground

points to cause a noticeable problem
C. Check for an open isolation diode

1. Many circuit use it; Check system circuit diagram
You will find one in the Interior Light circuit. Have the techni-
cians find the location of the diode and check it with a DMM di-
ode check if they have not already.
2. Be sure to use Diode Check DMM function when testing
VI. If the Quick Checks Do Not Find the Problem

A. Concentrate on individual circuits
1. Isolate each of the problem circuits from each other, verify
that ground side of the circuits are OK
2. Measure resistance between the ground terminal of the com-

ponent and body ground
a. If on a lighting circuit, remove all the light bulbs on a

particular side and check each bulb’s ground path.
1) You need to remove the bulbs to prevent the ohm-
meter from feeding back through another light bulb.
2) Ground is found on the walls of the light bulb
socket
C. When in doubt, call technical assistant hotline

1. Because of the infrequent nature of this type of problem, it
helps to have a little experience

a. Possibly, the problem occured somewhere else in the

US
b. Technical assistance will have a record of it on the
database
2. Before calling technical assistance
a. Make sure you have a very exact knowlege of what hap-

pens when the feedback occurs
1) What lights operate, what does NOT operate on the
vehicle
b. Have a list of all the inpections you have done so far,
and any measurement if possible.
D. Remember that there is no magic; There is a specific, ohm’s law

governed, cause for even feedback problems.
VII. Feedback Summary

A. Don’t spend an exessive amount of time trying to figure out a feed-
back
B. Make the quick checks to the fuses, grounds, and if applicable,
lightbulbs
C. Concentrate on making one circuit electrically correct, and working
properly
D. If you get stuck, use the Technical Assistance Hotline for advice
E. Use T.I.S. to get appropriate diagram after verification of problem.

DIAGNOSING BODY ELECTRICAL PROBLEMS 5.00
Lesson Title Diagnosing Body Electrical Problems 5.00
Day Number Three
Total Time 120 min.
1. Accurately diagnose open circuit problems.
2. Diagnose parasitic load problems.
3. Diagnose short to ground problems.
4. Diagnose high resistance problems.
5. Diagnose feedback problems.
Required Materials
• 1 DMM
• 1 1998 ES 300 RM

General Instructor Notes for Diagnostics in Section 5
I. Introduction
A. Diagnosing Open Circuits
1. disconnected connectors
2. bad switches
3. poor terminal contacts
4. cut wires
5. blown or defective fuses
B. Voltmeter Checks
1. Inspect areas that are easy to get to.
2. Checks are good because easy.
3. Downside is that high resistance may not be found.
C. Ohmmeter Checks
1. Circuit must be OFF to perform check.
2. Sometimes there are specs for resistance.
3. Jumpers wires can be used to by-pass suspect areas.
a. jumpers can be a problem because of short to ground

possibilities.
D. Parasitic Load Problems
1. These loads continually draw current from battery.
2. Before beginning diagnosis turn off all known loads.
3. Hook up meter in series and set to milliamps.
a. Isolate the fuse which feeds the parasitic load.

b. Disconnect each fuses one by one.
c. Disconnect the components that are fed by the fuse.
E. Mapping Current Flow
1. Determine which J/B connectors are fed by suspect fuse.
2. Disconnect each J/B connector individually.
3. If a single J/B has two or more pins which branch isolate sepa-
rately.
4. Look at the list of J/B connectors to find pins.
5. Isolate individual components until parasitic load drops.

F. Diagnosing Short-to-Ground Problems

1. Occurs when current goes to ground before load.
2. Circuit is obvious because fuse is blown.
3. Connect a test light, short finder, or headlight.
a. Remember on many circuits the test light will not go out.
G. Diagnostic Procedure
1. Locate the blown fuse and inspect.
a. blown clean or charred = direct short

b. melted = overload
c. fractured fuse = defective part
2. Disconnect components or connectors until problem area is

discovered.
H. High Resistance Problems

1. Corrosion at connectors
2. Cut/chaffed wiring
3. poor grounding point
4. Place a voltmeter in parrallel with the load
a. one probe on B+ side / one on ground side
5. With circuit on measure the voltage drop
a. If drop exceed 0.5 V; problem is on ground side

b. If drop reading is OK then problem is on B+ side
6. When problem is know use the EWD to isolate the probable lo-
cations.
I. Feedback Problems
1. Considered the most unusual of electrical problems.
a. Operating the right side turn signal causes marker lights

to flash.
2. Diagnosing Feedback problems
a. Use quick checks.

1) shorted light bulb
2) incorrect light bulb
3. Generally check the fuses, open ground, open circuit diodes.

4. If quick checks don't work then check:
a. TSBs
b. each circuit individually
c. Ask for technical assistance.
d. Do not proceed without help or a plan.

GENERAL DEVELOPMENT OF MULTIPLEXING 6.00
Lesson Title General Development of Multiplexing 6.00
Day Number Three
Total Time 180 min.
1. Define multiplexing and serial data.
2. Explain the need for standard.
3. Retrieve trouble codes (DTCs) from a multiplexing system.
4. Diagnose a simple system fault in a multiplexing system.
Required Materials
• Lexus Diagnostic Tester
Note: This section is designed to be used by the instructor as time permits. If the class is
moving rapidly through the material in Day 1 and Day 2 then more time should be spent on
Multiplexing. This section is designed only as an introduction to the subject and therefore
extensive and in depth coverage should occur at some other level of instruction. Worksheets
developed for the section are generic to some degree in an effort to make them useful over a
longer period of model years.

I. Introduction
Slide 113
A. General Development
1. Network time division is multiplexing.
a. done to save cost of point to point wiring.
2. Data transmission to modules using a serial data bus
a. Serial data means digital codes transmitted in a series or

one after another.
3. Information is digitized into bytes 1 byte = (8 bits)
a. Rate of transmission is called the baud rate (bits per

sec.).
b. Baud rate is determined by multiplying the number of
parameters by the number of bits transferred in one sec-
ond 12 parameters x 8 bits (per word) = 96 baud.
4. Benefits of multiplexing
a. Decreased number of dedicated wires / saves money.

b. Common sensor data can be shared.
c. Increased flexibility by making software changes only.
Slide 114

B. Manufacturers find benefits in several system uses

1. suspension adjustments
2. power seat operation
3. audio systems
4. power window operation
Slide 115
C. Diagnostic Trouble Codes
1. Oscilloscopes are used in the research and development of

multiplexing systems.
a. Diagnosis is possible using an oscilloscope but known

good patterns and references are necessary.
b. Because of these limitations it is best to use the Lexus
Diagnostic Tester for determining system faults.
Slide 116 2. Types of Codes
a. SAE controlled codes

b. Manufacturer controlled codes
3. Diagnostic Tester
a. Use tester to identify trouble codes

b. Always consult Repair Manual to identify codes and
procedures.
c. Pay careful attention to the number of components
(subsystems) on the network.
4. Interpreting Codes
a. Know what will trigger a code.
5. Two opens along the data lines of a subsystem

will trigger a code / One will not:
6. two opens typically generate a (no communication) code.
7. shorts will typically generate a "malfunction" code.

D. Typical System
1. Power Bus line from battery
a. Provides power to components
2. Multiplex unit sends signal to CPU for processing.
a. Signal is coded to match a given command.

b. The command is specific to a given component.
Slide 117
3. As in " L / R window down"
E. Actions taken by component ECU

1. The message or signal travels along the data line to the com-
ponent ECU.
2. the component ECU receives signal and supplies power for

action.
3. The action is confirmed by component ECU and sent to CPU.
4. CPU verifies that command signal has been executed and logs
position of component.

F. Circuit Operation Tilt & Telescopic

1. Multiplexing system has layers.
2. Switch (like simple combo switch) sends signal to ECU.
3. Signals, communication lines, harness, and ECUs are potential

problem areas.
4. DTCs are logged when communication in interrupted.
a. DTCs can be tracked using Freeze Frame data.

b. Both are critical when troubleshooting.
c. first get the DTCs then go to the Freeze Frame.
1) Look for irregular match ups of data.
2) Use EWD and Repair Manual read carefully.
5. Problems with multiplexing systems are subtle.
Slide 118

G. Diagnostic Procedure
Do Worksheet on "Diagnosing the Multiplexing System"
Note: The ES 300 Body Electrical Simulator can be used as a second

rotation. Since the Audio system uses a Multiplexing system, a bug
is easy to introduce by creating a short or an open in one of the au-
dio circuits. Switch # 5 will give an open and should generate a
code. However, there are other possible scenarios available for in-
structor bugging in which a generic (blank) worksheet could be used.
Slide 119 The instructor sets his own bug, the technicians use the Six Step pro-
cess to find the problem.
1. After each full rotation (all stations) a debrief should take

place.
a. Ask each group to describe what they found.

b. Try to discover successful diagnostics from each group.
c. Look for errors which groups make that can serve as ex-
amples of what "not to do."
2. Optional Rotations
a. Have each group create a multiplexing bug in a vehicle.

1) Each bug should be non invasive.
b. Each groups complaint should then be noted and written
on a worksheet.

ADDENDUM
Appendix Wire Repair Using SST
I. Splicing Wires
Review of procedure in Wire Repair Manual
A. Procedure
1. Strip insulation.
a. Add heat shrink tubing if used.
2. Choose splice clip.
a. Small (16 - 22 ga) 00204-34130
b. Medium (14-16 ga) 00204-34137
c. Large (10-12 ga) 00204-34138
3. Insert wires in clip.
a. Overlap wires in the splice.
4. Use non-ins position of the crimping tool.
5. Use Rosin Core Solder to solder the splice.
6. Insulate the splice.
7. Secure the harness.
II. Connectors
All the information on connectors is meant to provide a general over-
view of connectors. Connectors will be continually evolving every
model year. Be sure to point out any new designs on a scrap harness
if possible.
A. Every repair will require working with connectors.

B. Connector Features
1. Improved connector to connector locking mechanisms
2. Improved weather sealing
3. Improved secondary locks on terminals
C. Disconnecting connectors
1. Look for lock tab.
a. Pull up.
b. Push down.
2. SRS Twin Lock connectors
a. Push tab to release the secondary lock.

b. Push tab to release primary lock.

ADDENDUM
3. Low Insertion Force Connectors (LIF)
a. Uses a lever to separate and join the connector halves.
D. Reconnecting connectors
1. Make sure secondary terminal lock is secure
a. Many connectors will not lock if the secondary lock is

not secure.
2. Listen for positive click.
III. Secondary Terminal Locking Mechanisms

A. Cause of a lot of frustrations when you don't see them.
B. You should never have to force a terminal out of a connector.
1. Too many different models to memorize but can be classified
into 3 categories.
C. Types
Use the terminals/connectors listed in this lesson’s material list to il-
lustrate proper terminal techniques. Pass these connectors around
the class with a T-pin for terminals removal practice.
1. Removable Terminal Retainer
a. Pulls forward out of the connector.

b. Look for a different color plastic.
3 different examples are illustrated in the handbook.
2. Hinged Latch
a. Always at the back of the connector.

b. Look for a latch on both sides of the connector.
3. Built-in terminal retainers
a. Do not separate from the connector.

b. Many different looking connectors use this type.
c. Look for different color plastic.
d. Release technique.
1) Push out.
2) Push Down.
3) Pull up.

ADDENDUM
Connectors to demonstrate different locking mechanisms on

would be:
1. Combination Meter
2. Pressure Sensor
3. TCCS ECU
4. SRS front sensor
5. Wire Harness to Wire Harness Connector
If you have the Technicians remove the terminals from these connec-
tors in class, be sure to move to different pin locations for each class
to prevent wear/damage to the connector/terminal. The terminals are
not designed for repeated in-out cycles. If available, use a spare wir-
ing harness for this demonstration.
IV. Releasing the primary terminal lock

A. Terminal Removal Techniques
1. Most current terminals have plastic locking lug built into the
connector.
2. Use a Pick Tool to lift up on the lug.
a. Macrame T-needle
b. “smashed” paper clip
The exact specifications for a pick tool are found in the EWD and in
the Technician Handbook.
V. Re-inserting the terminal

A. Make sure the terminal is oriented properly to the connector.
B. Listen for a positive click when the terminal is seated in the
connector.
C. Gently tug on the wire to make sure the terminal is seated.
D. Secure the secondary terminal lock.
VI. Other Types of Terminals

A. “Old” style terminals have a metal lock tang
1. To release
a. Use a pick tool in channel in connector to bend lock tang

down.
2. Re-inserting the terminal
a. Use the pick tool to bend the lock tang UP.

b. Orient terminal correctly to the connector.
c. Re-insert terminal. Listen for lock tang to click.

ADDENDUM
d. Lightly tug on the wire to make sure the terminal is

seated.
VII. Replacing Damaged Terminals

A. Use the Toyota Terminal Repair Kit SST.
1. Measure the diameter of the wire.
2. Measure the terminal dimensions and determine part number.
a. Wire Repair Manual visual guide

1) Terminals categorized by application
2) Additional Information
VIII. Connector Replacement

A. Use Wire Repair Manual.
1. Based upon terminal type and number of cavities
2. Not every terminal is listed
B. Use Number that is cast into connector body.

1. Add 90980- prefix to numbers.
2. Look in parts pricing catalog to see if terminal is carried in the

system.
If ordering a replacement connector, have technicians pay close atten-

tion
to the index grooves/slots on the connector body. If the pattern of

these
grooves is not exactly the same, the connector will not work.
C. If correct connector is not available

1. Use same family male and female connectors with additional
terminals.
2. Replace all of the terminals and use another set of connectors

that are available.
3. Get another connector from a “scrap” wiring harness.

Course Agenda: Body Electrical Diagnosis Course L652

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Course Agenda: Body Electrical Diagnosis Course L652

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BODY ELECTRICAL DIAGNOSIS COURSE - AGENDA

Body Electrical Diagnosis Course L652

2.10 8:30 90 Open Circuit Diagnosis

5.00 8:30 120 Rotations/Body Electrical

LEXUS Course L 652 - Body Electrical Diagnosis 1

ES 300 Body Electrical Simulator Instructor Information

LEXUS Course L 652 - Body Electrical Diagnosis 2

LEXUS Course L 652 - Body Electrical Diagnosis 3

LEXUS Course L 652 - Body Electrical Diagnosis 4

LEXUS Course L 652 - Body Electrical Diagnosis 5

LEXUS Course L 652 - Body Electrical Diagnosis 6

Lesson 1.00 Objectives

Lesson 1.10 Objectives

Lesson 1.20 Objectives

Lesson 1.25 Objectives

Lesson 1.30 Objectives

LEXUS Course L 652 - Body Electrical Diagnosis 7

Lesson 1.40 Objectives

Lesson 1.49 Objectives

LEXUS Course L 652 - Body Electrical Diagnosis 8

Lesson 2.10 Objectives

Lesson 2.20 Objectives

Lesson 2.25 Objectives

Lesson 2.30 Objectives

Lesson 2.35 Objectives

LEXUS Course L 652 - Body Electrical Diagnosis 9

Lesson 2.40 Objectives

Lesson 5.00 Objectives

Lesson 6.00 Objectives

LEXUS Course L 652 - Body Electrical Diagnosis 10

Body Electrical Diagnosis

LEXUS Course L 652 - Body Electrical Diagnosis 11

Lesson Title Enrollment and Introduction 1.00

Day Number One

Time Period 9:00 - 9:10 a.m.

Total Time 10 min.

Lesson Key Points

LEXUS Course L 652 - Body Electrical Diagnosis 12

B. Have each technician enroll with appropriate information on Atten-

B. Introduce course: Lexus Body Electrical Diagnosis L652

1. Course L 622 - Electrical Fundamentals

D. Have technicians introduce themselves

3. Number of years as Lexus technician

III. Problems (Optional)

B. Discuss recent technical problems and fixes

LEXUS Course L 652 - Body Electrical Diagnosis 13

Lesson Title Review of Electrical Circuit Theory and Concepts 1.10

Day Number One

Time Period 9:10 - 10:10 a.m.

Total Time 60 min.

Lesson Key Points

LEXUS Course L 652 - Body Electrical Diagnosis 14

After the general introduction/attendance matters have been finished,

LEXUS Course L 652 - Body Electrical Diagnosis 15

I. Introduction to L 652 Course

1. Solidify the concepts taught in L 622

a. L 622 concentrates on the theory aspects of electricity

2. How to diagnose electrical circuits on the vehicle

3. “Real World” electrical

a. Some electrical problems are difficult to diagnose

B. Sections of the L 622 course

a. Concepts taught in L 622, emphasizing real world appli-

2. Tools of Electrical Diagnosis