Automotive Electrical Diagnosis Course

Automotive Electrical Diagnosis
AED Course Guide 01 1



Course Guide Module
COURSE OVERVIEW The Automotive Electrical Diagnosis Course
provides you with the opportunity to increase your
ability and efficiency in testing, diagnosing and
repairing moderately complex electrical/electronic
systems and components.
In this performance-based course, you will

demonstrate your testing, diagnostic and repair
proficiency through intermediate to advanced level
hands-on, instructor supervised guided practices and
diagnostic scenarios including:
 Electrical circuit and component operation
and diagnosis
 Testing, diagnosis and repair techniques for Kia
wiring harnesses
 Battery, Charging, and Starting system operation
& diagnosis
COURSE GOAL Upon completion of this course, you will have the ability
to diagnose, troubleshoot, and repair basic to
moderately complex electrical systems and components
the first time, every time.
TARGET AUDIENCE Kia Dealership Technicians who have mastered the

fundamentals of automotive electrical principles and
diagnostic techniques.
PREREQUISITES You must complete the following:

 Introduction to Kia Automotive
Electrical Web Course
 Introduction to Kia Circuit Diagram
Analysis Web Course

ABOUT TRAINING Today’s complex automotive technology demands that

MODULES you stay up-to-date with the latest service information,
special tools and complex repair procedures. We have
adopted a modular training delivery system that
breaks-down the critical information into logical
groupings. First you will be presented with system
theory and operation, then given a chance to practice
what you have learned. Finally, we will test what you
have learned through a Performance Assessment.
REVIEW A Review Module gives the technician the opportunity

to demonstrate he/she has mastered the key objectives
from a prerequisite course. This module is only used
where appropriate.
THEORY A Theory Module explains the subject from basic to

complex. This allows you to obtain a working
knowledge of a component or system, which is a
prerequisite for successful diagnosis and repair.
GUIDED PRACTICE The Guided Practice Module affords you the

opportunity to familiarize yourself with a component or
system through hands-on experience. The guided
practices are to be instructor supervised and verified.
These exercises may include: the use of service
manuals or KSIS, accessing kdealer.net, lab
disassembly and reassembly, live vehicle activates and
much more.
PERFORMANCE The Performance Assessment Module provides the

ASSESSMENT opportunity for you to prove that you can perform the
subject matter related tasks and procedures. Each
technician must successfully complete this module,
which is designed to test your cognitive (knowledge)
and motor (hands-on) abilities. The module must be
completed individually, not as a team.

GETTING THE MOST OUT These modules are designed to be part of a structured
OF THIS COURSE training plan consisting of lecture, interactive classroom
discussion, and hands-on shop activities under the
direction of a trained Kia Instructor. After completing
the course modules your understanding of the material
will be verified through our Performance Assessment
Module, you must pass a written and hands-on
evaluation.
COURSE MANAGEMENT The course and its materials are here for you to learn.
Use them and your time in a way that will benefit you
when you return to your dealership.
TAKE NOTES Make drawings, jot down notes, and highlight these
materials to help you remember important details. Each
module is designed with ample margins for your
important notes.
ASK QUESTIONS If you do not understand something in this course, ask

your instructor for clarification. Asking questions is
strongly encouraged to help you get the most out of
this course.
TEAMWORK During the hands-on activities, you will often be

working as a team. By actively engaging in each
activity, you will maximize your learning experience.
While in the lab, feel free to ask the instructor
questions at any time.
LEARN AT EVERY This course is an opportunity for you to learn in a

OPPORTUNITY controlled environment under the guidance of a trained
Kia Instructor. Through active participation you can
build confidence in your abilities to diagnose customer
concerns right the first time, every time!

COURSE MATERIALS
Course Guide
Performance
Module Title
Assessment
Number
Practice
Module
Review
Guided
Theory
Day 1 AED.01 Course Guide X
AED.02 WBT
Prerequisite X
Review
AED.03 Electrical X
Circuits 1
AED.04 Electrical X
Circuits 2
Virtual
Breadboard Computer Simulation
Sims
AED.05 Electrical
Day 2 X
Components
AED.06 Wiring
X
Harness
AED.07 Electrical
Diagnosis X
Vehicle
Simulations Computer Simulation
AED.08 Battery,
Day 3 Starting, X
Charging
AED.09 Battery,
Starting, X
Charging
AED.10 Performance
X
Assessment

ICONS Throughout this course you will come across several

icons designed to keep you on track.
NOTE: Indicates additional information to help clarify a

particular point or procedure to help you perform your
job more efficiently.
FEEDBACK: Indicates a progress check meant to

provide you with feedback on your understanding of
the course material. Based on this information, we
recommend you review any areas where you have not
mastered the material.
COMPUTER SIMULATION:
CAUTION: Indicates a procedure must be done in a

certain way to avoid potential problems and possibility
of damaged tools, equipment or the vehicle.
GUIDED PRACTICE EXERCISE: Indicates an activity

that supports a critical learning objective. These
activities are offered to help you master the material.
WARNING: Indicates a procedure must be done in a

particular way to minimize the chances of an accident
that could result in personal injury or even loss of life.
VIDEO: Indicates there is a video segment

corresponding to the module information.
WAIT FOR FURTHER INSTRUCTIONS

PERFORMANCE The Performance Assessment Scorecard is used to

ASSESSMENT SCORECARD track your classroom participation, performance on
guided practices, performance on diagnosis &
troubleshooting, and any written knowledge
assessments.
COURSE ACHIEVEMENT A final score of 80% or higher is needed for

completion credit of this course.
SCORECARD ROUTING One copy of the scorecard is yours, and one copy is
used to update your Kia technical training records.
Should you not complete the course, the third copy is
forwarded to your Kia District Parts and Service
Manager (DPSM).

Automotive Electrical Diagnosis Review
MODULE GOAL Upon completion of this module you will demonstrate,

through discussion, your knowledge of:
 Relationship of current to resistance
 Power flow in an ETM schematic
 Determining unwanted circuit resistance
 Types of electrical circuits
 DVOM measurements
 Number Conversions
MODULE OBJECTIVES Given this module, and information learned from

successfully completing the prerequisite courses, you
will be able to participate in class discussions and
answer questions on the following:
 ETM Schematics
 DVOM Usage
 Circuit Operation
 DVOM Readings
MODULE INSTRUCTIONS During this review, participate in the discussion to get

the most out of this module while answering the
questions and recording your answers.
Questions are based upon the web courses that are

required prerequisites.
EXPECTATIONS It is expected that you passed the prerequisite web

course that supports this course, and will be able to
complete this review module, and participate in class
discussion on the information presented.
TIME TO COMPLETE Approximately: 60 minutes for review

WRITE IN YOUR ANSWER 1. Which of the following is not a load device?

BASED UPON THE a. Lamp
PREREQUISITE WEB
COURSE DISCUSSION b. Fuse
c. Solenoid
d. Motor
2. Which of the following is typically at the top of an

ETM schematic?
a. Ground
b. Load
c. Signal
d. Power
3. Which of the following best describes wire size on

an ETM schematic?
a. The wire size equals to the number of strands
that make up the wire
b. The larger the number the larger the wire size
c. The larger the number the smaller the wire size
d. Each number doubles in size
4. Which of the following best describes hyperlinks on

an ETM schematic?
a. They link to a photo of the component
b. They link to a view of the connector
c. They link to a view of the wiring harness
d. All the above
5. Which of the following is a characteristic of a series

circuit?
a. When circuit resistance increases, circuit current
flow decreases
b. When circuit voltage increases circuit resistance
decreases
c. Current is reduced as it passes through each
load
d. None of the above

6. Which method is the best for identifying unwanted

resistance in a circuit?
a. Measure circuit resistance
b. Measure circuit voltage drop
c. Measure circuit amperage
7. How is a DVOM connected in a circuit to measure

amperage?
a. In series with the load being measured
b. In parallel with the load being measured
c. Across the source of power
8. Convert the values listed in the chart below:

Mega Kilo Base Value milli
.869 KΩ
7.45 KΩ
2.2MΩ
50 mA
.208 A
1,086 mA
186mV
.450 V
3.3 V
9. What does an O.L reading on a DVOM indicate when

measuring resistance of a load device?
a. Shorted
b. Over Limit
c. Over Load
d. Continuity

10. Which of the following would cause a fuse in a

circuit to blow?
a. Decreased Total Circuit Resistance
b. Decreased Total Circuit Amperage
c. Decreased Applied Circuit Voltage
11. Which of the following would be considered a

control device?
a. Switch
b. An ECU
c. Relay Contacts
d. All the above
12. What do you need to do to the DVOM to measure

Amperage?
a. Move the selector switch to Amps position and
leave the Red lead in the Volt Jack
b. Move the Red lead to the Amps Jack and leave
the selector switch to Volt position
c. Move the Red lead to the Amps Jack and the
selector switch to Amps position
d. Move the selector switch to Volts and the Red
lead to Volts Jack

Use the schematic above for the next two (2) questions.
13. What is indicated in the box where the arrow is

pointing to on the ETM schematic above?
a. Power is available only when the ignition is ON
b. Power is available all the time
c. Power is available only when the RR HTD Relay
is ON
d. Power is available only when the Defogger
Switch is ON
14. What turns on the RR HTD Relay and Deicer Relay?

a. B-CAN Low pulled High
b. B-CAN High pulled Low
c. IPS Control Module applying voltage to the
relays
d. IPS Control Module grounding the relays

Connector A Connector B
15. Which connector shown above is a female?

a. Connector A
b. Connector B
c. Unable to determine from drawing
d. Varies depending on wiring harness configuration
16. What action is required when measuring the

resistance of a component installed in the vehicle?
a. Operate the circuit while testing
b. Turn Key ON Engine OFF while testing
c. Disconnect the battery negative cable while
testing
d. Isolate the component from the rest of the circuit
17. What will cause the amperage in a circuit to

decrease?
a. Resistance decreases
b. Voltage decreases
c. Resistance increases
18. What is the function of a load in a circuit?

a. Produce heat
b. Create light
c. Perform movement
d. All the above

Use the schematic above for the next three (3) questions.
19. What is the purpose of the Defogger Switch

a. Turn on the Indicator Lamp in the switch
b. Supply ground to the Rear Defogger Element
c. Directly ground the RR HTD and Deicer relay
coils
d. Indirectly controls the RR HTD and Deicer relay coils
20. Which fuse supplies voltage to the Power Outside

Mirror Defoggers?
a. HTD MIRR
b. RR HTD IND
c. RR HTD
d. Both a. and b.
21. What is the function of the IPS Control Module?

a. Supply voltage to the RR HTD and DEICER
relays
b. Control the B-CAN lines
c. Monitor the contact closing of the RR HTD and
DEICER relays
d. Supply ground to the RR HTD and DEICER relays

22. Under what conditions does Cooling Fan Motor-2

receive ground for Low Speed operation?
a. Rad Fan Relay (OFF) Cond Fan Relay-1 (ON)
b. Rad Fan Relay (OFF) Cond Fan Relay-2 (ON)
c. Rad Fan Relay (ON) Cond Fan Relay-1 (OFF)
d. Rad Fan Relay (ON) Cond Fan Relay-2 (OFF)
23. Which relay has a Normally Open (NO) and a Normally

Closed (NC) set of contacts
a. Cond Fan Relay-1
b. Cond Fan Relay-2
c. Rad Fan Relay
d. All the above

24. With the Headlamp Switch OFF & Daytime Running

Lamps ON, how is the DRL RESISTOR wired with the HI
BEAM HEAD LAMPS?
a. Series
b. Parallel
c. Series – Parallel
d. Parallel – Parallel
25. What is required to turn the LO BEAM HEADLIGHTS

ON?
a. Light Switch to HEAD, Dimmer Passing Switch to
LOW, and Ignition to OFF position
b. Light Switch to HEAD, Dimmer Passing Switch to
LOW, and Ignition to RUN position
c. Either a or b
d. Neither a nor b

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Electrical Circuits
TARGET AUDIENCE The target audience for this module consists of Kia
service technicians who have basic understanding of
automotive electricity.
MODULE GOAL Upon completion of this module, you will be able to list
expected measurements and measure voltage,
resistance, and amperage in different types of electrical
circuits.
MODULE OBJECTIVES Following the instructions in this module, and given a

Digital Volt-Ohm Meter (DVOM) and electrical
“breadboard”, you will be able to:
 Build series electrical circuits and accurately predict

and measure the following with 100% accuracy:
o Applied Voltage
o Voltage Drop
o Amperage
o Resistance
 Diagnose abnormal voltage readings in a series

circuit and list the root cause with 100% accuracy.
MODULE INSTRUCTIONS Carefully read through the material, take notes based
on the classroom discussion and study each illustration.
REQUIRED MATERIALS In order to complete this module, you will need the
following items:
 DVOM
 Electrical “breadboard”
 Colored highlighters (pink/red, yellow, green)
TIME TO COMPLETE Approximately 1.75 hours

Resistance
Voltage Current
Source Flow
WHAT IS ELECTRICITY? Electricity is a form of energy where electrons move

from one atom to another. Electricity exists when a
_____________________ creates a _______________
by _____________________ with enough force to
overcome the _______________ of the circuit.
Electricity itself is invisible but its effects can be seen in
the forms of light, heat, and motion, which is often
referred to as “work”.
CIRCUIT ELEMENTS In order to operate, all electrical circuits need three

items:
1. _______________________________________
2. _______________________________________
3. _______________________________________

Fill in the blanks. Most automotive circuits are made up of a:

 Power Source _______________________________
 Protection device to protect the wiring and
components ________________________________
 Control device to turn the circuit ON or OFF
__________________________________________
 Load ______________________________________
 Conductors to allow current flow from one element
to another _________________________________
 Ground ____________________________________
The ground path is created by connecting the negative

battery terminal to the engine, chassis and/or body.
This allows circuits to have a ground point at any metal
contact point on the vehicle.
An ECU can also provide a ground path by turning ON a
transistor that is connected to ground
It is critical that ground points and ground related
wiring are installed properly after vehicle service.

Source
Load
Ground
DIRECTION OF Conventional current flow is from positive to negative.

CURRENT FLOW In the automotive industry, we frequently “read” circuit
diagrams from the top “positive” to the bottom
“negative.”
To support conventional current flow, Kia’s wiring

diagrams generally flow from top to bottom through
three (3) sections:
1. The electrical source (positive) at the top (Power)
2. Circuit load is in the middle (Load)
3. The ground (negative) is shown at the bottom (Ground)

POWER FLOW DIAGRAMS You need a plan when diagnosing electrical concerns.
Begin by printing out the wiring diagram located in the

Electrical Troubleshooting Manual (ETM) in KGIS and
identify the components.
Assume that the circuit is in operation.
Next, using colored highlighters, identify the three
sections on the wiring diagram:
• Power in Red/Pink
• Load in Yellow
• Ground in Green

Using the wiring diagram above, color each circuit listed

below:
• Power side in Pink / Red
• Load in Yellow
• Ground side in Green

Using the wiring diagram above, color each circuit listed

below:
• Power side in Pink / Red
• Load in Yellow
• Ground side in Green

MEASUREMENT OF Voltage is produced by chemical action in the battery or

ELECTRICITY by magnetic induction in the alternator (generator).
Pressure _____________ is the pressure in an electrical circuit

and is measured in ____________________.
The symbol for voltage is V. You may see E used to
represent electromotive force.
Current Flow The movement or “flow” of electrons is called

____________ and is measured in ________________.
The symbol for amperage is A. You may see I used to

represent intensity.
Resistance Every electrical circuit or component has

___________________ which opposes current flow and
is measured in _____________________.
Resistance is what creates heat, light, or motion, and
does the work. The standard unit of resistance is the
ohm. The symbol for resistance is .

OHM’S LAW
Current Flow
Resistance
Voltage
Resistance
Current Flow
Voltage
Ohm’s Law Relationship Understanding the relationship between volts, amps
and ohms is important when performing automotive
electrical diagnosis.
This relationship is referred to as “Ohm’s Law”.
According to Ohm’s Law:

 When resistance ___________________________,
current flow _______________________________.
 When resistance ___________________________,

current flow _______________________________.
Ohm’s Law Application Complete the following statements for a better

understanding of how Ohm’s Law can help you in
electrical diagnosis.
Fuses blow when _____________________ is too high.
According to Ohm’s Law, _________________ goes up,
when _______________ goes down.
What causes a fuse to blow?
____________________________________________

Ohm’s Law Solving Circle While you generally don’t engineer electrical circuits,
the divided circle can help you to remember the
relationship between volts, amps and ohms.
Volts
Amps Ohms
Volts = Amps X Ohms

Amps = Volts ÷ Resistance
Resistance = Volts ÷ Amps
ELECTRICAL CIRCUIT In addition to Ohm’s Law, the following characteristics

CHARACTERISTICS are true of electrical circuits.
 Voltage is always ________________ when current

flows through resistance
 Voltage is _______________ used after the last

load, or other resistance, in a circuit
 Voltage will always take the path of ____________

resistance to ground
We’ll talk more about this later when we make circuit

measurements and look at electrical circuit diagnosis.

Mulitmeter Functions Most meters have a rotary selector switch that allows
you to set the function and range for the type of
reading that you wish to make.
Most meters will let you manually select the range, or

will set the range automatically (auto-ranging).
NOTE: Always look at the meter display to determine if

the range is set manually or auto-ranging.
Mistakes are often made by not reading the meter

reading correctly.

Setting up the Multimeter When setting up a multimeter:

 Set the mode selector switch to the measurement
you want to make
 Insert the meter leads in the terminals for the
measurement you want to make
 Select auto or manual range:
o Auto range can be used when you are not sure
what range your reading will be in, and to
protect the meter
o Manual range can be used when you know what
the expected meter reading is, for a more
accurate reading

Using the Multimeter Because digital multimeters are designed to measure

voltage, current and resistance, you must properly set
up the meter to avoid damaging the meter or the
circuit, and to ensure that you are making an accurate
measurement. Since there are a wide variety of meters
available, always review the operator's manual before
using a meter.
CAUTION: To ensure that the meter is used safely,

follow these instructions:
1. Never use the meter if the meter or test leads
look damaged.
2. Be sure the test leads and rotary switch are in
the correct positions for the desired
measurement.
3. Always insert the meter in the circuit in parallel
for voltage and in series for current
measurements.
4. Never use the meter in a circuit that has higher
voltage or amperage than the meter is capable of
measuring safely.
5. Always start measuring with the ammeter on the
highest scale and work your way down.
6. Never measure resistance in a circuit with power
applied. Be certain capacitors are discharged
before measuring.
7. Keep your fingers behind the finger guards on
the test probes when making measurements.
8. Keep meter leads in good condition.
9. Always test/check meter fuses.
10. Check battery display - meters will not read
accurately with a low battery.
11. Calibrate meter leads resistance by zeroing the
meter before doing resistance testing.

VOLTMETER When measuring applied voltage:

Applied Voltage  The voltmeter is connected in parallel
 Tests for voltage in a non-operating or operating
circuit.
When to Use: When verifying voltage values.
Readings:  Approximately source voltage before the load =

good power side
 Approximately 0 volts after the last load = good
ground
Drawbacks: Voltage values may be misleading when the load is

open in the circuit.
How to Measure Applied  Operate the circuit

Voltage:  Connect the meter in parallel
 One meter lead to B(-) the other at key points along
the circuit
Examples of When to Use:  Testing for open

 Testing for short
 Testing control functions
 Testing for excessive resistance

Voltage Drop When using a voltmeter for voltage drop

 The voltmeter is connected in parallel.
 Voltage drop test must be made when the circuit is
operating.
When to Use: When looking for excessive resistance.
Readings:  Across power side should show very low voltage. If

significant voltage, then there is resistance.
 Across ground side should show very low voltage.
If significant voltage, then there is resistance.
 Most voltage drop should be across the load(s).
Drawbacks: Not effective if the circuit does not operate.
How to Measure Voltage  Connect the meter in parallel across the section of
Drop: the circuit to be tested, usually source or ground
 Operate the circuit
Examples of When to Use:  Lighting circuits are unusually dim

 Motors operate more slowly than normal
 Specific circuit is operating strangely
 Abnormal Current Data values
 Testing for excessive resistance

OHMMETER When using an ohmmeter

 The circuit should be OFF
 The section being tested should be isolated from the
power source otherwise the meter can be damaged.
 Connect the DVOM across the part of the circuit, or
component, to be tested.
When to Use: Testing for continuity, or when there is a resistance

specification.
Readings:  No continuity/Infinity/Over Limit = OPEN circuit
 0 ohms = no resistance (good connection)
 An ohm reading = resistance
Drawbacks: Cannot measure the effective resistance in a circuit
under operating conditions.
How to Measure Ohms:  Power down the circuit
 Isolate the circuit or component to be tested from
the power source
 Place meter leads at each end of section
Examples of When to Use:  Testing for broken wire (open)
 Testing for short
 Resistance of a component (relay, solenoid or other
load)
 Continuity in switch or relay contacts

AMMETER When using an ammeter:

 The ammeter is connected to the circuit in series.
 Never substitute the ammeter for the load.
 The ammeter should be used the same way you
would use a fused jumper wire.
 The circuit must be ON in order to measure
amperage.
When to Use: When specified by the diagnostic process in the proper

service publication.
Readings:  Battery output

 Starting system draw
 Charging system output
 Parasitic draw
Drawbacks: Not able to pinpoint location of open, low resistance, or

high resistance.
How to Measure Amperage:  Connect the meter in series

 Operate the circuit
Readings:  No current = OPEN circuit

 Low current = high resistance
 High current = low resistance

INTERPRETING METER Volts, amps and ohm readings are given in:
READINGS
 Whole number (12 volts, 30 amps or 560 ohms)
 Milli = one thousandths of the whole number,
x0.001 (12mV)
 Kilo = whole number X 1,000 (12KV)
 Mega = whole number X 1,000,000 (10M)

Meter Reading Conversion

Tables
Meter
Value Multiply by Value Practice
Reading
mV 213mV = ___________V
12mV x 0.001 __________
(milli-volts)
V
12V x1 12V
Volts
KV 14.2KV = ___________V
1.2KV x 1,000 __________
(kilo-volts)
Meter
Reading
Ω
10Ω x1 10 Ω
Ohms
Ω 4.6kΩ =
10KΩ x 1,000 __________
(Kilo-ohms) _____________Ω
MΩ .63kΩ =
10MΩ x 1,000,000 __________
(Mega-ohms) _____________Ω
Meter
Reading
mA 31mA = __________A
125mA x 0.001 __________
(milli-amps)
A
125A x1 125A
(amps)

Multimeter Specification This exercise requires using information from KGIS. The
Exercise vehicle is the same for each question.
Interpreting Resistance  Using KGIS, select the Component Inspection for

Specifications 1 the vehicle and DTC assigned by the Instructor:
Vehicle: _____________________________
DTC: _______________________________
 Using the Specification Table for checking ECTS
resistance for the DTC, convert the k reading into
. Write your answers below.
Temp. Resistance k Resistance 

(°C)
-40
-20
0
20
40
60
80
Interpreting Resistance  Using KGIS, select the Component Inspection for

Specifications 2 the vehicle and DTC assigned by the Instructor:
Vehicle: _____________________________
DTC: _______________________________
 Using the Specification Table for checking the coil
primary and secondary resistances for the DTC,
answer the following questions.
 What is the range for the primary coil resistance?
__________________ to _________________
 What is the range for the secondary coil resistance?
__________  to __________ 
NOTE: When measuring low resistance values it is
necessary to zero your meter or take the resistance of
the leads into consideration for accurate measurements.

Interpreting Voltage  Using KGIS, select the Component Inspection for

Specifications the vehicle and DTC assigned by the Instructor:
Vehicle: _____________________________
DTC: _______________________________
 Using the Inspection/Repair W/Harness Inspection

Ground Circuit Inspection procedure for the DTC,
answer the following question.
What is the specification __________mV ________V
If the voltage “A” measured 5.12V and voltage “B”
measured 5.15V, what is the calculated value
______________V _____________mV
Would the measurement be within specification?
Yes _________ No _________
End of Exercise

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PREDICTING ELECTRICAL Predicting voltage in a circuit is one of the most

READINGS important diagnostic skills you develop. Analyzing the
circuit and predicting the voltage at critical test points
ensures the following:
• Your diagnosis is efficient
• Your testing is accurate
• Your understanding of proper circuit operation
• Confidence that you have isolated the problem
based on the DVOM readings made during circuit
testing
Whenever you make an electrical measurement, you

should know what results to expect if the circuit is
working properly.
SERIES CIRCUITS A series circuit has only one path for current to flow.
There are no branches to other loads.
The components of a series circuit are assembled on
the same path. A sample circuit is shown below.
Series Circuit Rules 1. Voltage – Voltage drops across each load, and the
sum of the voltage drops equals the source
voltage.
2. Resistance - The total resistance in the circuit is
equal to the sum of each resistance in the circuit.
3. Current - There is only one current path in the
series circuit. Current must be the same at every
test point in the circuit.

Circuit A Circuit B Circuit C

In the schematics shown above, record the following.
Circuit A B C
Current Paths
Loads
NOTE: Control devices in wiring diagrams/schematics

are shown in their normal state (open or closed) with
the ignition in the OFF position. When predicting circuit
measurements, you need to visualize the control device
is in both the OFF and ON position.

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SERIES CIRCUIT In the following exercises you will:

PREDICTING AND  Predict measurement results in a circuit
MEASURING
 Build the circuit using an electrical breadboard
 Confirm your predictions by making actual
measurements on the electrical breadboard
APPLIED VOLTAGE Set up your breadboard to match the circuit above.

EXERCISE 1 Work in teams as assigned by your instructor and build
the circuit shown using the following components
supplied in your Kia Electrical Workstation Kit:
• Power supply
• Jumper leads
• Fuse
• Lamp
• Switch (#1)
NOTE: The Kia Electrical Breadboard has built in wiring

from the power supply connectors to the positive and
ground connector terminals (view the bottom of the
Workstation to see this wiring if desired).

Switch OFF Switch ON
Predicting Applied Voltage On the schematics above:

 Predict and record the voltage readings you expect
to measure at each location (switch OFF and ON)

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Measuring Applied Voltage On the breadboard, build a series circuit as shown above:
 Turn the power supply on
 Turn the Main Switch ON
 Turn Switch #1 ON, the bulb should light!
If the bulb lights, continue on with the exercise.
If the bulb does not light, ask your instructor for

assistance.

Measuring Applied Voltage Measure the applied voltage as follows:
 Set the DVOM to measure Direct Current (DC)

Voltage
 Place the DVOM ground (black) lead to the ground

connection (J) at the bottom of the breadboard

 Place the DVOM positive (red) lead at each test

point
 Record the Applied Voltage (switch OFF and ON)

readings on the circuit schematics
Wait for further instruction.

APPLIED VOLTAGE On the circuit schematics above, predict the voltage

EXERCISE 2 readings you expect to measure at each location
(switch OFF and ON)
Predicting Applied Voltage
Each bulb has the same resistance value.

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Building the Circuit On the breadboard, build a series circuit with two lamps
as shown above.

Measuring Applied Voltage  Perform the applied voltage test.

readings on the wiring diagram above

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RESISTANCE Resistance measurements are made with the circuit

MEASUREMENT OFF and the component disconnected from the circuit.
You typically measure the resistance of a component

and compare your reading with the specifications in
Service Information.
Resistance tests can be used to determine if a

component is:
 Open (high resistance)
 Normal (within specification)
 Shorted (low resistance)
NOTE: A resistance test can be used to isolate shorts

in a circuit.
If a fuse blows, there is low resistance in the circuit

causing amperage to increase (Ohm’s law) beyond the
capacity of the fuse.
Using the meter to perform resistance / continuity

tests, set the meter so that it reads continuity to
ground, and then begin disconnecting connectors. At
the point that the meter changes to “O.L” (or Over
Limit) you may have isolated the short in the circuit.
VIDEO: Resistance

RESISTANCE Using the schematics above, predict if each component

MEASUREMENT has (switch ON and OFF):
EXERCISE 1
 NR = No Resistance (Near zero resistance – very low
Predicting Resistance resistance)
 R = Specific resistance (designed into circuit)
 O.L = Over Limit (Open)

Measuring Resistance Disconnect the power supply from the breadboard.
On the circuit you previously built (2 bulb series), using

a DVOM, measure the resistance in each segment of
the circuit, or circuit component, with the switch in both
the OFF and ON positions. Record your results on the
schematic.
 Measure the resistance of the complete circuit by

measuring at point A and point L with the power
supply cables disconnected from the workstation
and record your reading.
_______________________________ Ω

 Using the measurement you already made, add the

resistance of bulb 1 and bulb 2
Ω Bulb 1 + Ω Bulb 2 = _______Ω

 Does the resistance of both bulbs added together
equal total circuit resistance?
YES / NO (circle one)
Why or why not? ___________________________
__________________________________________

CURRENT MEASUREMENT Current is measured by selecting amperage using the

rotary switch and moving the red lead to the amperage
jack on the DVOM.
The meter is connected in series in the circuit. Think of

it as a fused jumper that measures current.
Most DVOMs can safely measure up to 10 amps of

current. Many automotive circuits operate at higher
current levels than 10 amps (note the fuse rating for
the circuit you are working on). If the amperage of the
circuit exceeds your DVOM’s measurement capabilities,
do not attempt to take the reading. Use a meter with
an inductive clamp. Most DVOM’s have a fuse for the
amperage section of the unit to protect you and the
DVOM when current exceeds DVOM measuring
capabilities. Failure to follow proper procedures can
damage vehicle components, the DVOM, and cause
injury.
NOTE: Measuring voltage with the test leads in the

amperage position may blow the internal fuse in the
meter.

Predicting Current Predict the amperage for each circuit at the locations
(Amperage) listed above.
Assume each circuit’s total amperage is 1.0 amp.

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CURRENT MEASUREMENT Measure amperage as follows:

EXERCISE 1
 Select DC amps on your DVOM
 Move the red lead on the DVOM to the amperage

jack (if there is more than one, always start with the
highest available)
 Create an open circuit on the breadboard by

removing the wire between point D & E
 Connect the red lead of the DVOM to point D
 Connect the black lead of the DVOM to point E
 Turn the power supply ON (the bulb should light)

If the bulb does not light, have your instructor check
the circuit and meter connections.
 With the bulb ON, record the amperage reading below:

________________A _______________mA
 Turn the circuit OFF
 Reconnect the wire between D & E
 Remove the wire between point F & G. Connect

the DVOM red lead to test point F (use an alligator
lead if necessary)
 Connect the black lead of the DVOM to the wire

going to point G
 Turn the power supply ON. What is the amperage

reading? _______________A ______________mA
Is this reading the same as the previous amperage

reading you made? YES / NO (circle one)
How many paths for current are there in a series

circuit? _______________
Is the current the same anywhere you measure in a

series circuit? YES / NO (circle one)

CAUTION: After completing your amperage

measurement, place the red lead back in the Volt/Ohms
jack on your DVOM. This is a good habit to practice. If you
leave the lead in the amperage jack on the DVOM, and you
then go to measure voltage, you will have a short circuit
through the meter. This can damage the DVOM, blow the
fuse in the DVOM, and cause vehicle damage or injury if
you cause a spark while measuring source voltage at the
battery.

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VERIFYING OHM’S LAW In this activity, you will observe the relationship
between current and resistance.
 Build the circuit shown above connecting R1 with
lead wires
 Measure and record the amperage below
 Repeat individual amperage measurements with R2
& R3
R1 (100) ____________A ____________mA

R2 (200) ____________A ____________mA
R3 (300) ____________A ____________mA
Explain what you discovered about the relationship

between voltage, current, and resistance in a circuit.
_____________________________________________
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VERIFYING OHM’S LAW In this activity, you will observe the relationship
between voltage and current.
 Build the circuit shown above connecting R1 with
lead wires
 Use the potentiometer to set the voltage at the top
of R1 to the value of V1 listed below
 Measure and record the amperage
 Repeat individual amperage measurement with V2 & V3
V1 (4Vdc) ______________A ____________mA

V2 (8Vdc) ______________A ____________mA
V3 (12Vdc) ______________A ____________mA
Explain what you discovered about the relationship

between voltage, current, and resistance in a circuit.
_____________________________________________
_____________________________________________

SERIES CIRCUIT SUMMARY In this section:

 You built series circuits using the breadboard.
 You predicted, measured, and verified the following
values:
o Voltage
o Resistance
o Amperage
Series Circuit Rules From your series circuit practice, you have verified the
following series circuit rules:
• The sum of the voltage drops equals source voltage
• There is one current path therefore current is the
same at every point in the circuit
• Total circuit resistance equals the sum of each
resistance in the circuit

PROGRESS CHECK 1. The three elements needed for an electrical circuit

are source, ___________ and ground.
A. circuit protection
B. load
C. switch
D. wiring harness
2. In an electrical circuit, what causes a fuse to blow?

A. Low resistance
B. High resistance
C. High current flow
D. Both A and C
3. Which of the following is the unit of measure for

resistance?
A. Volts
B. Amperage
C. Ohms
D. Watts
4. Voltage ___________ as it pushes through

resistance.
A. slightly increases
B. does not change
C. drops
D. doubles
5. When measuring amperage in a circuit, how should

the ammeter be connected?
A. In series
B. In parallel
C. Across the battery
D. From ground to the point being tested

PROGRESS CHECK 6. 125mV = _______ V

A. .125
B. 1.25
C. 12.5
D. 125
7. 25.5K = ________ 
A. 2.55
B. 255
C. 2,550
D. 25,500
8. In a series circuit, how many paths does current

have to flow?
A. As many paths as there are loads in the circuit
B. One path for current flow
C. Three separate sources and one ground
D. Current does not flow in a series circuit


Electrical Circuits
service technicians who have basic understanding of
automotive electricity.
MODULE GOAL Upon completion of this module, you will be able to list
expected measurements and measure voltage,
resistance, and amperage in different types of electrical
circuits.
MODULE OBJECTIVES Following the instructions in this module, and given a

Digital Volt-Ohm Meter (DVOM) and electrical
“breadboard”, you will be able to:
 Build parallel electrical circuits and accurately

measure the following with 100% accuracy:
o Applied Voltage
o Voltage Drop
o Amperage
o Resistance
 Diagnose abnormal voltage readings in a series and

parallel circuits and list the root cause with 100%
accuracy.
MODULE INSTRUCTIONS Carefully read the material, take notes based on the
classroom discussion, and study each illustration.
following items:
 DVOM
 Electrical “breadboard”
 Colored highlighters (pink/red, yellow, green)

Circuit A Circuit B Circuit C
PARALLEL CIRCUITS A parallel circuit is created when each load has an

individual source of power and ground, or path for
current. The paths for current are often called branches
(or legs).
Parallel Circuit Rules 1. Voltage - Each branch drops source voltage (some
loss expected due to connections).
2. Resistance - The total circuit resistance is always
less than the lowest individual resistance.
3. Current - The total circuit current is equal to the
sum of each of the individual branch currents.
Use the schematics above to determine and record the

number of current paths and loads in each circuit.
Circuit A B C
Current Paths
Loads

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PARALLEL CIRCUIT Begin your parallel circuit work by assembling the

MEASUREMENT parallel circuit on your breadboard as shown above:
EXERCISE 1
 Turn the circuit ON. Does each bulb light? YES / NO
Voltage (circle one)
 If NO, ask your instructor for assistance.
 Remove the wire going to one bulb.
 Does the other bulb remain ON? YES / NO (circle

one)

APPLIED VOLTAGE All loads in a parallel circuit receive source voltage. The
(PREDICT) voltage is not divided like in a series circuit.
On the schematics above:

 Predict and record the voltage readings you expect
to measure at each location (switch OFF and ON)

APPLIED VOLTAGE Measure the applied voltage as follows:

(MEASURE)
 Set the DVOM to measure Direct Current (DC)
Voltage
 Place the DVOM ground (black) lead to the ground

connection (K) at the bottom of the breadboard
 Place the DVOM positive (red) lead at each test

point

readings on the circuit schematics above

APPLIED VOLTAGE  Replace one bulb in the circuit with a (10 Watt
(PREDICT) bulb)
 Predict the available voltage at the points shown in

the circuit schematics

APPLIED VOLTAGE  Measure the available voltage with a (10 Watt

(MEASURE) bulb)
 Record your readings on the circuit schematics

above

In a parallel circuit, each load has its own path for

current. Total circuit amperage will equal the sum of
the current in each branch of the parallel circuit.
PARALLEL CIRCUIT Return the circuit back to normal with two five
MEASUREMENT watt bulbs
EXERCISE 2
Measure parallel circuit amperage at the points
Amperage indicated as follows:
 Set your DVOM to read DC Amps.
 Measure the current flow for the complete circuit

and record your reading below.
Total current flow: _________________________
 Measure the current flow at the fuse for each leg of

the circuit, record your readings below.
Current flow through bulb one: _______________
Current flow through bulb two: _______________

 Add the current flow through bulb one and bulb two
together
Does it equal the total current flow you measured?

Parallel Circuit Rule The total circuit current is equal to the sum of the
individual branch currents.

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PARALLEL CIRCUIT  Connect the three (3) resistors in parallel as shown

MEASUREMENT on the breadboard above.
EXERCISE 3
 Disconnect power at points A & N.
Resistance
 Measure total circuit resistance using your DVOM at
points E and J: __________ Ohms
In a parallel circuit, each branch has its own path for
current. In the circuit above, the smallest resistance is
≈100 Ohms (Ω). The other two branches are ≈200 and
≈300 Ohms respectively
 Is the total circuit resistance more or less than the

resistance of any branch?
More / Less (circle one)
NOTE: When a branch is added in a parallel circuit the

total:
 Resistance decreases
 Current increases


Parallel Circuit Rule Total circuit resistance is always smaller than the
smallest individual resistance.
PARALLEL CIRCUIT In this section:

SUMMARY
You created a parallel circuit on the electrical
workstation.
You predicted the values, and then you measured and
verified those voltages.
Parallel Circuit Rules From your parallel circuit practice, you have verified the
following parallel circuit rules:
• Voltage - Each branch drops the approximate

source voltage (some loss expected due to
connections)
• Resistance - The total circuit resistance is always
less than the lowest individual resistance
• Current - The total circuit current is equal to the
sum of the current in each circuit branch

• Combines characteristics of
series and parallel circuits
• Some components are in series
and others are in parallel
• Loads are normally in parallel
SERIES-PARALLEL CIRCUITS Normally in a series-parallel circuit, the power source,

control and protection devices are in series and the loads
are in parallel.
If an open occurs in the series portion, the whole circuit

will lose current flow.
If an open occurs in a parallel branch, the current flow

will remain in the series portion and the remaining
parallel branches.
The instrument panel lighting circuit is one example of a

series-parallel circuit.
Series-Parallel Circuit Rules Electrical behavior in all series-parallel circuits is

governed by the rules shown in the illustration.
These rules apply to all series-parallel circuits regardless

of the type and number of load devices.
• Current in the series section equals sum of parallel

branch circuits
• Total circuit resistance equals parallel resistance plus
series resistance
 Voltage applied to the parallel portion equals applied
source voltage minus voltage drop across series
portion

VOLTAGE DROP The Voltage Drop test is a valuable test that you can
perform during electrical diagnosis. Voltage drop
measures the voltage used by resistance in sections of
the circuit.
This includes the:

• Power side of the circuit
• Load in the circuit
• Ground side of the circuit
Voltage Drop, tests the circuit while it is operating. The

Voltage Drop Test allows us to find any unwanted
resistance that may have been missed by other tests.
VIDEO: Voltage Drop
As we stated earlier in this module, the circuit uses (or

Example loses) voltage as current flows through resistance in the
circuit:
 We start with approximately 12.6V
• A minimal amount of voltage is used by the
resistance of connections in the power side of the
circuit as the current flows to the load
• The majority of the voltage is used by the resistance
to operate the load in the circuit
• The remaining voltage is used by the resistance of
the connections in the ground side of the circuit as
the current flows back to the battery
• Any unwanted resistance in the circuit will cause a
greater than normal voltage drop
NOTE: Voltage Drop is the voltage differential in a
portion of a circuit. This voltage differential is caused by
resistance in the circuit.

MEASURING VOLTAGE Voltage Drop test across the Power Side of the circuit
DROP would require that the Red Test Lead starts as close to
the power supply (positive terminal) and the Black Test
Lead on the positive side of the load device.
For example, to check for resistance between the

positive battery terminal and clamp, the positive meter
lead would go on the positive battery post, and the
negative meter lead would go on the terminal or clamp.
NOTE: The power and groundside of a circuit should

have a voltage drop near 0.0 volts. However, each
connection, fuse, switch, and splice may drop a small
amount of voltage. The integrity of any connections will
affect the amount of voltage dropped in a circuit.
A Voltage Drop test across the load would require the

Red Test Lead to be on the positive side of the load
and the Black Test Lead on the negative side of the
load. The reading should be close to source voltage.

A Voltage Drop test across the groundside of the circuit

requires the Red Test Lead to go to the negative side of
the load device and the Black Test Lead as close to
battery ground as possible. The reading should be as
close to 0.0V as possible. A voltage drop more than
0.5V may indicate a bad ground or resistance in the
circuit between the load device and the battery ground.
NOTE: It may not always be possible to reach to the

source from the load device unless long lead adaptors
are used.
NOTE: A Voltage Drop test can only be performed on a

circuit, which has a complete path for current to flow
from source to ground. Voltage cannot drop without
current flow. If current is not present the circuit is
open, such as when the switch is OFF, the load is open
or a wire is cut.
Typical Circuit Voltage Everything has resistance. The wires, connectors, and
Drops switch contacts that make up a circuit all have some
resistance. In an undamaged, properly designed circuit,
normal resistance is small enough that it does not keep
the load from working. If the circuit is functioning
properly, all voltage drops to and from the load will be
acceptable.
A general rule of thumb for voltage drop includes the

following:
 Starting and charging circuits (high current >20A)
0.5 volts
 Lighting and solenoid circuits (low current 1-20A)
0.1 volts
 Computer sensor circuits (very low current < 1A)
0.050 volts
The larger the wire, the larger the voltage drop limit.
Anything higher indicates a need for inspection and

possible repair.
Repair usually includes cleaning corrosion from

connections, repairing faulty terminal crimps, or
tightening connectors and ground terminals.
On a rare occasion, it is also possible that the wire size

is too small for the load.
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VOLTAGE DROP Assemble your breadboard to match the circuit above.

MEASUREMENT Prepare your DVOM to take Voltage Drop tests and
EXERCISE 2 complete the information in the schematic on the next
Measuring Voltage Drop page.
Measure the source voltage (circuit ON): __________
Measure the voltage drops in the circuit and use the

schematic on the following page to record your results.

VOLTAGE DROP Use the schematic above to predict the voltage drop in
MEASUREMENT the circuit. Remember, the circuit must be ON for any
EXERCISE 1 voltage to drop so you have to imagine the switch is
Predicting Voltage Drop closed.
What symptom would you expect to see if there was a

5V voltage drop between points G and H in the circuit?
_____________________________________________

1. Does the total voltage drop equal the source

voltage? YES / NO (circle one)
2. What is the voltage drop on the source side of the

circuit? _______________________
3. What is the voltage drop on the groundside of the
circuit? _______________________

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Building the Circuit On the breadboard, build a series circuit with two lamps
as shown above.

VOLTAGE DROP Assuming that the bulbs are the same wattage, predict
MEASUREMENT the Voltage Drop in the schematic above.
EXERCISE 3
Multiple Loads (Series)

 On the breadboard, measure the voltage drops as

indicated in the schematic and record your results.

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 Build the circuit above on the breadboard.

VOLTAGE DROP  Predict the Voltage Drop across each load in the
MEASUREMENT parallel circuit above.
Exercise 4

 Measure the Voltage Drop across each load and

record your readings in the provided spaces.
Does each voltage drop equal source voltage?
Parallel Circuit Rule Each load drops approximately source voltage.

OPEN CIRCUITS An open circuit does not have a complete path for
current. Since there is no current, there is no voltage
drop across the loads, and the components cannot
operate. Troubleshooting an open circuit is made using
the available voltage test.
 Turn the circuit ON (even though it is not operating)
and place your negative meter lead on a known
good ground.
 Place the positive lead at convenient test points in
the circuit.
 You will see source voltage up to the point of the
open circuit.
 After the open circuit point, you will see 0 volts.
VOLTAGE POTENTIAL Often referred to as Open Circuit Voltage. This is

voltage before doing any work. Measuring a battery
that is not connected is measuring Open Circuit
Voltage. If you measure identical voltage at multiple
points in a non-working circuit, you are seeing voltage
potential before the open.
FEEDBACK: Can you do a Voltage Drop test on an

open circuit? Why or why not?


SHORT TO POWER In some cases, there can be a short to power. This can
be caused by wire, connector, or component damage.
The symptom is an unrelated load operating when the
selected circuit is turned ON.
Components such as bulbs, motors, solenoids, and
relays have varying resistance determined by their
design. The service information provides the
component resistance value in the related
diagnostic section.
A short to power is when a wire in the circuit touches a
positive wire. If the short to power is in the control side
of the circuit, a load device such as a bulb may
illuminate unexpectedly.
If the short causes the load to be bypassed, the lower
resistance in the circuit will increase the amperage and
often blow a fuse or other circuit protection device.
NOTE: There are many useful tools (short detectors)

available from the aftermarket that can help you
diagnose shorts to power and shorts to ground.

SHORT TO GROUND The most common short circuit occurs when a damaged
wire touches ground. If this damaged wire is before the
load, the circuit resistance decreases to almost 0 and the
resulting increase in current results in a blown fuse or an
open circuit breaker.
WARNING: Never attempt to repair a circuit by

removing a blown fuse, fusible link, or circuit breaker,
and installing a jumper lead. Doing so could result in
vehicle damage and personal injury.
How do you diagnose a short circuit? Here is a method
that allows you to isolate the location of the short:
• Remove the fuse
• Use a 12V test light connected to the fuse holder of
the affected circuit (the test light should illuminate)
• Isolate sections of the affected circuit by
disconnecting harness connectors
• When the test light turns OFF, you have isolated the
section of the circuit with the short

EXCESSIVE RESISTANCE In a circuit, an increase in resistance results in an

increase / decrease in amperage.
Many circuit problems result from an excessive

resistance on the groundside of the circuit because:
• The vehicle chassis, frame and/or body serve as
the ground point for most circuits
• Many of the ground points are exposed to the
elements which can lead to corrosion
• Many grounds are made using a bolt which may
work loose over time
 Build breadboard circuit shown.

How does the high resistance on the groundside of
the circuit affect the operation of the circuit?
_________________________________________
 Power off the circuit and move the resistance to the

power side of the circuit to simulate corrosion in a
connector.
How is the circuit affected differently than the
resistance on the groundside of the circuit?
__________________________________________

POWER FLOW DIAGRAMS It is very important to diagnose electrical concerns with

a plan. When beginning on an electrical concern, the
first step is to print out the wiring diagram (also known
as Electrical Troubleshooting Manuals - ETMs).
Once you have the wiring diagrams printed, the next

step is to identify the three sections on the wiring
diagram:
• Power side of the circuit
• Load device
• Ground side of the circuit
Have 3 colored pens available for the following exercises.

With the Horn Circuit switch OPEN/OFF:

 Draw the power side of the circuit in Pink / Red
 Draw the load in Yellow
 Draw the ground side of the circuit in Green
What is the voltage at connector EM11, Pin 8?
__________________________________________
What is the voltage at E15, Pin 2? ______________

With the Horn Circuit switch CLOSED/ON:

What is the voltage at connector EM11, Pin 8?

_________________________________________
What is the voltage at E15, Pin 2? _____________
Discuss with your Instructor when completed.

With the Seat Warmer switch LH CLOSED/ON

(Key is in the ON Position):
What is the voltage at connector F13, Pin 1?

_________________________________________
What is the voltage at F13, Pin 3? _____________

With the Back Up Lamps switch OPEN/OFF

What is the voltage at connector R23, Pin 3?

_________________________________________
What is the voltage at FR21, Pin 4? ____________

With the Back Up Lamps switch CLOSED/ON

What is the voltage at connector R23, Pin 3?

_________________________________________
What is the voltage at FR21, Pin 4? ____________

With the Rear Defogger Switch Input OPEN/OFF*

What is the voltage at connector D08, Pin 10?

_________________________________________
What is the voltage at I/P-F, Pin 17? ___________
* The IPM activates the HTD Relay Control based on

the Rear Defogger Switch Input.

With the Rear Defogger Switch Input CLOSED/ON

What is the voltage at connector D08, Pin 10?

_________________________________________
What is the voltage at I/P-F, Pin 17? ___________
* The IPM activates the HTD Relay Control based on

the Rear Defogger Switch Input.

With the Engine Control Relay and Cooling Fan (High)

Relay (Non-Energized) OPEN/OFF:
What is the voltage at connector E32, Pin 2?

_________________________________________
What is the voltage at CLG-A, Pin 94?
_________________________________________

With the Engine Control Relay and Cooling Fan (High)

Relay (Energized) CLOSED/ON:
What is the voltage at connector E32, Pin 2?

_________________________________________
What is the voltage at CLG-A, Pin 94?
_________________________________________

CIRCUIT DIAGNOSIS
Electrical issues usually are caused by the following:

• An open circuit
• A short to power
• A short to ground
• Excessive resistance
When diagnosing a circuit, your plan should include

Split Circuit Theory and Common Point Analysis.
Split Circuit Theory - is finding the easiest access

point to perform a test and thereby cutting the circuit in
half. The load is a good place to start, if accessible, as
it separates the power supply portion of the circuit from
the ground portion.
Common Point Analysis - is understanding the circuit

and selecting a location that affects one or all branches
within a circuit. For example, if both tail lamps were
out, then Common Point Analysis would check the
circuit before it separates into two circuits. If only one
of the tail lamps were out, then check after the circuit
separates.

KIA’S 5-STEP 1. Confirm the Customer’s Concern

TROUBLESHOOTING
(Confirm)
PROCESS
2. Analyze & Diagnose the Customer’s
Concern (Diagnose)
3. Find the Root Cause (Troubleshoot)
4. Repair the Root Cause (Repair)
5. Verify the Repair (Verify)
1. Confirm It is essential you have an accurate description of the

customer’s concern and that you are able to Confirm
the Customer’s Concern. This includes what the
vehicle is doing, and the conditions it is doing it under
(i.e., hot, cold, accelerating, braking). Sometimes the
customer’s concern is a normal characteristic of the
vehicle. If so, it is important to have the service advisor
explain normal vehicle operation to the customer. If the
customer is describing an abnormal concern, confirm it
first-hand before continuing. Sometimes the customer
may describe the concern in a way that leads you down
the wrong diagnostic path. You must understand and
experience exactly what the concern is if you are to
repair it.
In many cases, you may have to road test the vehicle

to duplicate the symptoms they experience. During
your road test, look for related symptoms and
abnormalities. Are there any indicator or warning lights
lit? Are there any abnormal noises? Does the vehicle
handle in an unusual manner? Try to experience the
symptoms first hand. Note the symptoms, but do not
begin disassembly or testing until you have verified the
concern and narrowed down the problem.
Also, note what is working. This will help you to

performing a common point analysis.

2. Analyze Once you have verified a malfunction does exist, you

can now Analyze & Diagnose the Customer’s
Concern. First, determine whether it is related to some
other obvious problem such as a previous repair,
collision damage or from adding on an aftermarket
accessory (e.g. car alarm or audio system).
The malfunction may be in either the electrical

component or the circuit itself. At this time, you should
perform some preliminary checks. Based on the
symptoms and your understanding of how the system
operates, identify one or more possible causes. Use the
troubleshooting information in the Service Manuals and
ETMs as a guide.
There are other valuable resources like Technical

Service Bulletins (TSBs), Tech Times, and Pit Stop
newsletter materials. Be familiar with the latest
information and always check for TSBs before going
any further.
Locate and identify the appropriate wire diagram for

the circuit(s) in question and break the circuit into three
parts:
1. Power (source)
2. Load (accessory or electrical component)
3. Ground (return path)
Identify the possible causes for a particular

malfunction, and then consult the troubleshooting
section in the Service Manual. From this information,
create a logical procedure to diagnose the symptom.

Write out a list of possible causes and of tests you can

perform that will confirm or eliminate each item on your
list as the root cause. Now organize the list starting
with the most likely to the least likely. Here are some
key questions that help when analyzing a wiring
diagram:
• Which part of the circuit is most likely the source of
the malfunction, power, load, or ground?
• Are there other systems that are affected by the
malfunction?
• Which part of the circuit is common to both?
• Is there a system that is functioning properly which
shares part of the circuit?
• If so, what part of the circuit can be ruled out as the
cause?
 What are some easy points to begin troubleshooting
(i.e. easy to access connections, sensors, actuator,
fuse block, etc.)
3. Troubleshoot Now you will need to Find the Root Cause. Work
through your list starting with the most likely cause
first. Isolate electrical circuits, if possible, in your tests.
Look for the easy points to access the circuit and work
to the difficult access points as required. Following
these troubleshooting steps will save you valuable time
and help assure an accurate determination of the root
cause of the customer’s concern.
If you were unable to find the root cause, stop, go back

to step 2; analyze & diagnose the customer’s concern.
The last thing you want to do is just “throw parts at it”.
Have the concerns looked at by a fresh set of eyes, the
shop foreman, a fellow technician, or call the Tech Line.
NOTE: If you spend 30 minutes or more, or if it’s a

second warranty repair for the same concern, contact
Techline.

4. Repair After identifying the root cause of the malfunction,

Repair the Root Cause. Use the recommended repair
procedures described in the service manual and/or
ETM. Never take shortcuts that may cause personal
injury or damage to the vehicle. Be careful during the
repair not to create other concerns by damaging
connectors or components that may have lost some of
their elasticity over time.
5. Verify Most importantly, Verify the Repair. Be certain that it

has corrected the customer’s concern by performing the
system checks as documented by the repair order.
Operate any related systems and verify no new
malfunctions appear.
During your test drive, operate the vehicle under the

same conditions that caused the concern to occur and
verify the repair is complete. If the concern reoccurs,
go back to step 2 and walk through the process again
paying close attention to what may have been
overlooked. Occasionally, causes are missed and
concerns slip through unresolved. Skipping this step will
lead to dissatisfied customers, be certain the repair(s)
corrected the concern before returning the vehicle to
the customer.
Do not release the vehicle to the customer if you are

not sure it is fixed. If you need more time, get the
service advisor involved.
Make it your personal goal to fix-it-right the

first time, every time!

SUMMARY Vehicles contain many electrical circuits. The circuit

design may be series, parallel or series-parallel. It is
important that you are familiar with and have the ability
to recognize the circuit type. Having knowledge of
circuit types helps determine the circuit operation as
well as your approach in diagnosing a circuit problem.

PROGRESS CHECK 1. What happens to the total current in a parallel

circuit when one of the branches is removed?
a. Current stays the same
b. The current will always go up
c. The current will always go down based on
decreased resistance
d. Current changes to equal the remaining
resistance
2. The voltage drop in each branch of a parallel circuit

will equal:
a. source voltage
b. ½ of source voltage
c. twice the source voltage
d. the resistance in that branch of the circuit
3. In a parallel circuit, how many paths is/are there for

current flow?
a. One
b. There is an individual path for each load
c. There is an individual path for each control
device
d. One path for the source and multiple paths for
ground
4. What indicates a problem when performing a

voltage drop test?
a. low resistance
b. excess voltage
c. low current flow
d. unwanted resistance

PROGRESS CHECK 5. Total resistance in a parallel circuit is:

a. equal to the sum of the individual resistance in
each branch
b. always less than the lowest individual resistance
c. equal in each branch of the circuit
d. ½ the total circuit resistance in each branch
6. When tracing power flow diagrams, your first goal is

to locate:
a. source
b. load
c. ground
d. All of the above
7. What is a circuit that doesn’t have a complete path

to ground called?
a. Shorted
b. Open
c. Clipped
d. Incomplete
8. Corroded terminals in a wiring harness can cause

which of the following?
a. Short circuit
b. Excessive resistance
c. Excessive current flow
d. Blown fuse

Electrical Components
Theory Module
service technicians who have a basic understanding of
automotive technology.
MODULE GOAL Upon completion of this module, you will be able to

troubleshoot the following electrical system
components: fuse, relay, solenoid, lamp, horn, audio
speaker, and electrical motor.
MODULE OBJECTIVES  Given an electrical workstation, you will build a horn

and blower motor circuit, including the use of a
switch, relay, and resistor block, noting the function
of each component with 100% accuracy.
 Given an electrical workstation and a Digital Volt-
Ohm Meter (DVOM), you will identify normal voltage
readings in a horn and blower motor circuit with
100% accuracy.
 Given an electrical workstation and a Digital Volt-
Ohm Meter (DVOM), you will troubleshoot an open
or excessive resistance fault in a horn and blower
motor circuit with 100% accuracy.
MODULE INSTRUCTIONS Carefully read through the material, take notes based
on the classroom discussion and study each illustration.
Throughout the module there will be Progress Check
questions for you to answer. You may use the modules
to answer the questions.
following items:
• Digital Volt-Ohm Meter (DVOM)
 Electrical Workstation

ACRONYMS ATC – Closed Blade Fuse

ATO – Open Blade Fuse
ECU – Electronic Control Unit
EVAP – Evaporative Emission Control System
HVAC – Heating Ventilation & Air Conditioning System
LED – Light Emitting Diode
INTRODUCTION In an earlier module, we looked at the three types of

circuits. Now it is time to take a closer look at some of
the common components found in many vehicle circuits
including fuses, diodes, relays, solenoid, lamps, horns,
and gauges.
A solid understanding of the components that make up

the various circuits will enable you to quickly determine
the root cause of a customer concern. This module will
describe the operation, function, and diagnosis of the
most common circuit components and how they are
used in a circuit.
Electrical components typically fall into the following

categories:
• Circuit Protection Devices
• Conductors
• Control Devices
• Load Devices

CIRCUIT PROTECTION The function of a circuit protection device is to create

DEVICES
an __________________ in the circuit, which is the
result of __________________________________
caused by __________________________ in the circuit.

FUSES Fuses are thin wires that melt very easily when
Function & Operation overheated by excessive current. They are built-in weak
spots in a circuit designed to protect circuit components
and wiring from damage.
Fuse ratings are based on the current flow needed to
operate the circuit while protecting it from excessive
current flow. For example, a circuit that would normally
draw 7 amps might have a 10 amp fuse to protect it.
TYPES Fuses come in a variety of shapes and sizes including:

 Low profile mini fuses
 Mini fuses
 ATO/ATC fuses
 Low Profile Slow Blow fuse
 Multi fuse
 Main fuse
“Low profile Mini” and “Mini” fuses are smaller size

version of the ATC fuse.
The fuse material is molded into plastic shells that are
also color-coded to indicate the current rating. The
current rating is molded on the top of the fuse. Never
replace a fuse with one of a higher rating; circuit
damage may occur.
ATC fuses are sealed to prevent accidental ignition of

any fuel vapors that may accumulate in the engine
compartment, from the arc created when the fuse
blows. Only ATC fuses should be used under the hood
and in areas where fuel vapors may accumulate.
ATO fuses are open on the bottom and should only be

used in the interior of the vehicle.

Low Profile JCASE “Slow Blow” fuses are used for

circuits that may have a current spike that exceeds the
fuse rating. This typically included circuits with
solenoids and motors.
Multi-fuses are more than one fuse in a single housing

and protect multiple circuits individually. The fuses in a
multi-fuse assembly cannot be replaced individually.
Main fuses are located at the battery positive (+)

terminal. Examples of these fuses include:
 Alternator
 Cooling Fan

A fusible link is simply a short piece of wire

approximately four (4) AWG sizes smaller than the wire
that is being protected.
For example, an AWG 16 fusible link might be used to

protect AWG 12 wiring. Electrical fusible links are common
in high-current automotive applications. The wire in an
electrical fusible link is encased in high-temperature fire-
resistant insulation to reduce hazards when the wire melts.
Fuses/Fusible links can fail due to the following:

• ________________________________________
• ________________________________________
• ________________________________________
• ________________________________________
• ________________________________________
The Power Distribution Schematic Diagrams, located in

the ETM, are a good place to determine which
fuse/fusible link protects which circuit.


INTELLIGENT POWER The Intelligent Power Switch (IPS) provides circuit

SWITCH protection by monitoring current flow. The switch is
integrated on printed circuit boards within various
modules on Kia vehicles. A circuit that is protected by
an IPS will feature “IPS” inside the module.
If the current flow exceeds preset limits, the IPS will

shut down the current flow to the affected circuit. If
there is no problem when the circuit is repaired, and
the ignition cycled OFF/ON, the IPS resets itself so the
load devices operate properly again.
Depending on the vehicle and the circuit, the IPS can

set a DTC if the circuit is open, shorted to ground or
both while the fault is present.
FEEDBACK: What would happen to the IPS if a

customer installed an aftermarket bulb in the vehicle?
How could a different wattage bulb affect the IPS
operation?

Programmable Current Limit Open Current Limit
TYPES OF IPS Programmable Current Limit (PCL)

A. Short to ground
B. Excessive current flow
C. Monitors current information
D. Prevents control while excessive current is detected
and record lamp status
Open Current Limit (OCL)

A. Open circuit when the turn signal lamps are
activated.
B. Current flow not detected.
C. Blinking rate on the remaining lamp changes
(example: turn signal lamps blink faster).

POSITIVE TEMPERATURE PTC resistor (or thermal resistor) is a special type of

COEFFICIENT RESISTOR circuit protection that increases resistance as its
Function & Operation temperature increases.
When the polymer material in the resistor is heated

from excessive current flow, it expands, causing the
circuit to “open”. The PTC remains “open” as long as
voltage is applied to the circuit. It resets when voltage
is removed and the polymer cools.
PTCs are soldered in place and cannot be serviced

separately. The component that contains the PTC must
be replaced if a PTC fails.

TROUBLESHOOTING If an electrical system is inoperative, use the power

distribution schematic diagram to determine the circuit
protection devices in the circuit.
If one system is inoperative, check the protection for

that device. If multiple circuits are inoperative, use the
diagram to determine the protection device that
protects all of the circuits.
Fuses, fusible links and PTC resistors can be checked

by:
________________________________________
________________________________________
________________________________________
Use the DVOM and a visual inspection to verify the

condition. Do not assume a circuit protection device is
good because it looks good.
NOTE: If a blown fuse is found, read the fuse. Inspect

the fuse to determine if the fuse wire is just broken due
to the load operating near it maximum capacity, or did
a major short cause the fuse wire to vaporize.

NOTES:___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________

CONDUCTORS Conductors are made of copper wire that allow current

to flow freely.
The insulation protects the wire from shorts or

grounding.
Twisted pairs of wires are often used in circuits to

reduce electro-magnetically induced voltages.

AWG-to-INCHES-to- Automotive wiring typically has multiple strands to

METRIC CONVERSION increase the wire’s ability to be flexible and conduct
TABLE
electricity.
AWG Size Metric Size
mm2
24 0.2
Two types of wire size charts are used in automotive
20 0.5 applications:
18 0.8  American wire gauge (AWG)
16 1 o The larger the number, the smaller the wire size
14 2
12 3  Millimeter Squared (mm2)
10 5 o The larger the number, the larger the wire size
8 8
6 13 For comparison purposes:
4 19
2 32  Standard automotive wiring is approx. 20 AWG or 0.5
0 52 mm2
 Average battery cable is approx. 4 AWG or 19 mm2

CONTROL DEVICES Control devices typically turn circuits ON or OFF. They

can also control a system function. For example,
changing the A/C mode or blower fan speed.
Control devices typically:

 Open the circuit to turn it OFF
 Close the circuit to turn it ON
Control devices may also limit the current in a circuit or

only allow current to flow in one direction.
Examples of control devices:

• Switch – Brake light
• ECU – Transistor to control an output device
(solenoid)
• Relay – Fog light
• Intelligent Power Switch (IPS)
Control devices can also be used as an ________________

or as an ____________________ device in computer
controlled circuits.

SWITCHES
Function & Operation
A switch is one of the most common control devices.

Switches vary from the simple, a door switch, to the
complex, a multi-function switch. The simplest switch
has two positions, OPEN - no continuity and CLOSED -
continuity. Switches can be opened and closed
manually, mechanically, electrically or by pressure.
Switches may be normally open or normally closed.
A switch is placed in a series position in the circuit.

When the switch is open, no current flows and the
circuit is OFF. When the switch is closed, there is a
complete circuit for current and the circuit is ON.
A switch may be used as an input to an Electronic

Control Unit (ECU) which in turn analyzes other inputs
and then decides when to turn the circuit ON or OFF.
Normally Closed (NC) Normally Open (NO)
Switches can be either Normally Open (NO) or Normally

Closed (NC) type. They are shown in circuit diagrams in
their “normal, at-rest” position.

TROUBLESHOOTING When diagnosing an electrical circuit with a switch,

depending on component accessibility, start at the load
where you can divide the circuit into two parts, power,
and ground. If the switch-controlled side of the circuit
is not providing the power or ground when the switch is
manipulated, test the switch itself.
You can test the switch for continuity by:

 Disconnecting the switch connector
 Using a DVOM, operating the switch through its
various positions while checking continuity at the
appropriate pins
Continuity should only exist when the switch is in the

ON position. Unless the switch pin-out chart indicates
resistance, the tests should have little or no resistance.

You can also test the switch using a voltage drop test.
The advantage of the voltage drop test is that you are

testing the switch under normal operating conditions.
 Using the appropriate ETM schematic and the switch

in the ON position measure the Voltage Drop across
the switch terminals.
 GOOD SWITCH: Voltage Drop of less than 0.2V

when the switch is closed.
 BAD SWITCH: Voltage Drop of more than 0.2V

when the switch is closed indicates excessive
resistance in the switch or the connector.
 Switch Open/OFF: Voltage Potential measured

across the switch contacts confirms the switch is
open.

Using the pin-out table above, record the switch

position when continuity is measured between the
following terminals?
1. Terminals 2 and 3 __________________________
2. Terminals 4 and 5 __________________________
3. Terminals 1 and 5 __________________________
4. Terminals 13 and 14 ________________________

ELECTROMAGNATISM Many automotive components use electromagnetism to

Inductors create a magnetic field to do work or control operation
of fluid flow.
How is this magnetic field created?

____________________ is the flow of electrons
The flow of electrons creates a ___________________
Coiling the wire concentrates the __________________
increasing its strength.
One example of this is the electro-magnet. Wrapping

an insulated wire around an iron core and then
connecting the wire to a power source. The coil of wire
becomes an inductor when connected to a power
source.
Examples of other inductive devices include:

 Coils
• Transformers (Step Up / Step Down)
• Solenoids
• Relays
• Fuel injectors
• Motors
 Stepper motors

Suppression Diode Suppression Resistor
Spike Suppression When an inductor is turned off, the magnetic field that
has built up collapses very rapidly. This creates a
voltage spike like an ignition coil. Many inductive
devices have a clamping diode or resistor in the circuit
to block this voltage spike from traveling back to an
electronic control unit (ECU). These diodes and
resistors are critical to proper circuit operation.
We will review diodes in more detail later in this

module.
NOTE: Sensitive ECUs must have spike suppression or

ECU damage may occur. Always check for aftermarket
or misplaced relays on circuits with sensitive electrical
components.
CAUTION: Relays should only be replaced with the

same type of relay. Never substitute a relay that has a
clamping diode with a relay not equipped with a
clamping diode or damage to the ECU may occur.

RELAYS A relay is a remote control switch that can control a

Function & Operation
_______________________ amount of current using a
_______________________ amount of current. A relay
contains an electro-magnetic coil that closes a set of
_______________________ when the coil is energized.
A relay is especially useful when controlling a high

current device. An ECU, using a small amount of
current, can energize the coil side of the relay with
about 500 mA or 0.5A of current can control circuits
that carry 20 to 40 times as much current.
Using a low current signal to control a high current

circuit not only allows an ECU to control the circuit, it
also reduces the need for heavy-duty control switches
and heavy gauge circuit wire to and from the switch.
NOTE: Like switches, relays are identified by their

“at-rest” position, normally open (NO) or normally
closed (NC)

INTERNAL RELAY Internal relays:

 Not serviceable
 No terminal numbers on ETM
 May have Actuation Test using GDS
EXTERNAL RELAY External relays:

 Serviceable
 Terminal numbers on ETM
 Typically has Actuation Test using GDS

(5) (1) (2) (5) (4)
(3) (2) (1) (3)
Example A Normally, pins 30 and 85 have source voltage applied

to them with the IGN key ON. Pin 86 is controlled by a
switch or an ECU and provides a path to ground. This
energizes the coil and closes the contact points. Now
the current can flow through the contact point side of
the relay, pins 30 and 87 to operate the load device.
Example B Shows a 5 pin relay. This is sometimes referred to as a

crossover relay. The current is directed to pin 87A (NC)
when the relay is OFF and to pin 87 (NO) when it is
ON. These relays are sometimes used on 2-speed
cooling fans.
Example C Notice that the top relay has a diode in parallel with the
coil, while the bottom relay has a resistor in parallel
with the coil. The diode and resistor are used to
suppress the voltage spike that is induced when power
is removed from the coil side of the relay. Do not
interchange these two types of relays. If polarity is
reversed across the relay with the diode, the diode will
be damaged and the relay will no longer suppress the
voltage spike.
NOTE: Relay pin numbers and how the relay is wired

into the circuit may vary. Always refer to the
appropriate service information when troubleshooting.


Troubleshooting
Relays are two separate circuits, control (coil), and

switch.
Whenever possible test the relay in the car, energized

and current flowing through the circuits.
Most relays have four terminals.
The coil side of the relay terminals are ____ and ____.
The switch side of the relay terminals are ____ and ____.
Step 1 - While turning the ignition switch ON or

activating the relay, a click should be heard coming
from the relay. A click would indicate that the control
side of the relay is functioning properly and to focus
your attention on the switch side of the relay (terminal
30 and 87).
NOTE: If the relay does not click, then go to Step 2. If

the relay clicks, then jump to Step 3.

Step 2 - No click indicates either a lack of power on

terminal 85, no ground control on terminal 86, the relay
coil is open, or the switch is stuck in the relay. To test:
 Measure the resistance of the relay coil. It should
measure between 50 and 100 ohms. If not, replace
the relay.
 Place a DVOM on terminal 85 with the ignition
ON and note the voltage (battery voltage should be
present here).
 No voltage would indicate an open on the power
supply of the relay control circuit.
 If voltage is present then check the voltage on the
ground side terminal 86 with the relay energized.
 If voltage is present, the ground control circuit to
the relay is open.
 If there is no voltage at terminal 86, and no audible
click from the relay when activated, then the coil
side of the relay is open and the relay must be
replaced.
 If the relay tests OK electrically, the switch may be
stuck. NO relay contacts, test for continuity at
terminals 30 and 87 with no power applied to the
relay. Continuity indicates that the switch is stuck.
Step 3 – If the relay clicks when activated, proceed to
check the voltage on terminal 30 when the relay is
activated.
 Battery voltage at this point shows that the circuit
from the battery feed to the relay is good.
 No voltage or low voltage indicates an open or high
resistance on the main battery feed to the relay
terminal 30 and the circuit will need to be repaired.
 If proper voltage is observed at terminal 30, then
check voltage on terminal 87 with the relay
energized.
 No voltage would indicate an open in the relay and
the relay should be replaced. Battery voltage would
indicate that the circuit from the relay terminal 87 to
the load (that the relay controls) is open and the
circuit needs to be repaired.
VIDEO: Relay



Horn Circuit Build the horn circuit as shown. Connect the power
source to the breadboard and turn ON the main switch.
1. What are the load devices in this circuit?

____________________________________
____________________________________
2. How many switches are in this circuit? Explain.

____________________________________
____________________________________
3. Is the switch in series with the horn?

YES / NO Explain:_____________________
____________________________________
____________________________________
4. Is this one or two circuits? Explain.

____________________________________
____________________________________

Predict Measure
Troubleshooting Relays Using the horn circuit you built on the previous page:
 Predict the voltage readings when the circuit is

CLOSED (ON) using the diagram above.
 Turn the circuit ON and use the DVOM to measure

the voltage readings and current flow. Note your
readings on the diagram.

DIODES A diode is a semiconductor device that allows current

Function & Operation to flow ______________________________________.
It can be compared to a ____________________ which

permits a fluid to pass in one direction and stops it in
the other.
Diodes are commonly used to control voltage spikes

and in the generator to rectify or change the AC voltage
into DC voltage. A diode is also used in the generator to
prevent the battery from discharging back through the
windings in the generator.
Other types of diodes include Zener diodes, which allow

current to flow in both directions above a certain
voltage, and Light Emitting Diodes (LEDs).

Troubleshooting Since current should flow through a diode in only one

direction, use the diode test feature of a DVOM to
verify its operation.
 Power down the circuit and isolate the diode from
the rest of the circuit.
 Select diode test and connect the leads.
 With most DVOM’s when the leads are connected in
one direction, the meter will beep and display the
forward bias voltage required to “turn on” the diode
i.e., the voltage required which will allow current to
flow in one direction.
 When the leads are reversed, the meter will display
O.L.
 If the diode measures no continuity or O.L in both
directions, it must be replaced.
The bias voltage for most diodes is around 0.5V.
NOTE: A diode is said to be “forward biased” when

current is allowed to flow and “reverse biased” when
current does not flow.
CAUTION: Diodes are directional. Installing a diode

backward will cause the circuit to malfunction, may
damage the circuit, and may damage the diode.

DIODE INSPECTION  Locate the diode in your workstation unit.
 Set your DVOM to the diode test function.
 Place the red lead on one end of the diode, and the
black lead on the other end. Record your reading
here:
__________________________________________
__________________________________________
 Reverse the DVOM leads and record your reading

here:
__________________________________________
__________________________________________
NOTE: A good diode will show approximately 0.5V

when forward biased and Over Limit when reverse
biased.

TRANSISTORS Transistors are an electronic switch.

 NPN used for ground side control
 PNP used for power side control
In a transistor, a small amount of current is used to

control the base (electronic switch) which allows a
much larger current to flow between the collector and
emitter terminals. Similar to a relay controlling a large
current.
Early transistors could not lower their resistance to

zero. This resulted in a voltage drop of 1.0 to 1.5 volts
dc. They required a relay to bypass the transistor to
reduce the voltage drop to zero. In this example, it
allows the blower to run at high speed.


MOSFET A MOSFET provides better control than the standard

transistor. It is able to lower its resistance to near zero
and does not require a bypass relay.
A MOSFET is typically found in Air Conditioning systems

in place of the blower transistor.

ECU The ECU is a control device capable of controlling outputs

Function & Operation based in the inputs it receives from system sensors.
While you cannot often diagnose the ECU itself, its

important that you identify the role it plays in the curcuit
so that you can properly diagnose the circuits the ECU
controls.
Powerside Controlled When you identify the load and it is connected directly to
ground, and the ECU is before the load, the ECU is
controlling the power side of the circuit.

Groundside Controlled When you identify the load and it is connected directly
to power, and the ECU is after the load, the ECU is
controlling the groundside of the circuit.

Sensor
Pulse
Reversible Modulated
Motor Solenoid
Power and Ground or If you identify a component with resistance in the

Sensor circuit, and both wires go to the ECU, either the circuit
is a sensor circuit, or the ECU is controlling the power
and ground as a reversible motor or pulse modulated
solenoid.

NOTES:___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________

LOAD DEVICES The load is the device that performs ______________,

and should have the most ________________, and the
largest _______________________ in the circuit.
The load converts electrical energy into light, heat or

motion that can be used for a specific purpose.
Examples of various load devices include:

• Lamps
• Solenoids
• Motors
• Resistors

LAMPS Lamps provide illumination throughout a vehicle. They

Function & Operation vary in sizes, and produce various amounts of
brightness depending on the requirement.
Light bulbs have a resistive wire encased in glass with

their circuit ends either connected to the metal base of
the bulb, or exposed in the glass tube.

Combination lamps (stop lamps/rear tail lamps) have

dual filaments that are essentially two circuits.

Troubleshooting Lamps Troubleshooting a lamp circuit should be based on the

symptom:
 If the lamp doesn’t light, check:
o The fuse
o The bulb
o Source voltage
o Ground
o The switch
 If the fuse is blown, there is a short to ground that

is bypassing the load, or a short at the load. Test
the bulb for resistance as they can short internally.
 If the lamp lights but is dim, there is unwanted
resistance in part of the circuit. Use a voltage drop
test to determine if the resistance is in the source or
ground portions of the circuit, and isolate to the
fault.
 In most cases, except with dash lamps that are on a
dimmer circuit, the bulb should drop close to system
voltage. If the voltage drop is less, then measure
the voltage drop on the power and ground side of
the circuit. The power and ground side should drop
less than 0.3V each.

Assemble your breadboard as shown in the example

above. Perform a Voltage Drop test across each load
device (lamps). What are your readings?
Bulb 1: __________________________________
Bulb 2: ________________________________
Add a resistor in between one of the lamps and

the ground side switch. Perform a Voltage Drop test
across each load device (lamps). What are your
readings?
Bulb 1: _____________________________
Bulb 2: ________________________________

SOLENOID A solenoid uses an _________________________ to

Function & Operation move a mechanical plunger. Current flows through a
coil of wire to form the electro-magnet. The plunger
positioned inside the coil of wire moves when current
passes through the windings.
Examples include the purge control solenoid, oil control

valve, and fuel injectors.

Troubleshooting Solenoids are electro-mechanical devices and both the

electrical part and mechanical parts need to be tested.
Electrical
The coil winding can be checked with an DVOM for
continuity, opens and shorts. The appropriate service
information will contain resistance specifications. Some
components, like fuel injectors, have a hot and cold
specification (i.e., cold 12-14 ohms; hot 16-19 ohms).
Mechanical
Verify the plunger moves when energized. Apply 12V
and a ground while verifying plunger movement.
Movement can be verified:
 Listening for a clicking sound
 With a vacuum solenoid this can be done by
supplying vacuum to one of the ports. See service
information for proper operation and testing.
CAUTION: Do not leave a solenoid connected to a

constant 12V source. Doing so can damage the
component since most are designed for duty cycle or
short periods of ON time operation.

MOTORS Motors are electro-magnetic devices that convert

Function & Operation electrical energy into rotational motion.
Several types of motors are used in Kia vehicles:
 DC brush type
 DC brushless
 AC brushless
When current is applied to the armature, a magnetic

field is created and the armature is free to spin within
the motor housing. Attached to the housing are either
permanent magnets or electro-magnets, called field
magnets. As the armature poles react with the field
poles, like poles repel, unlike poles attract, causing the
armature to spin.
Some motors such as those used in power windows

and sunroofs must rotate in two directions. Changing
the direction a motor rotates is accomplished by using a
switch that changes the polarity (current direction)
through the motor.

Troubleshooting Start troubleshooting with a thorough visual inspection.

 Is there excessive end play or movement in the
armature?
 Is there corrosion on the terminals?
 Do the bearings feel smooth?
Follow the service information procedures when testing

motors.
Motors can be bench tested by supplying B(+) and

ground to the correct terminals. Larger motors have
higher current draw. Be certain you have a large
enough power source and the correct gauge jumper
wires for the motor being tested.
WARNING: Do not test a fuel pump outside of the fuel

tank. When the pump is outside the tank it may ignite
the fuel vapors surrounding it.
NOTE: Any force working against the electric motor will

cause the amperage draw to increase. This can be
caused by a tight motor, bearings, or accessories that
require excessive force to rotate.

RESISTORS A resistor is placed in a circuit to limit, or control,

Function & Operation current flow.
A resistor _______________ the voltage by converting

some of the electrical energy into heat.
Resistors can be fixed or variable and are available in a

variety of different ratings.
Because resistors oppose current flow, voltage

____________________ as current flows through the
resistor leaving _______________ voltage to operate the
load.
The blower motor resistor uses this resistance to

operate the blower motor at different speeds. At each
setting, the voltage that operates the motor is
controlled by a different resistor(s).

Terminal 2 1 4 3
Ohms (Ω)
Speed MH ML HI LO
Measure O O
between O O
terminals O O
1 2
3 4
Troubleshooting As with most circuits, the troubleshooting approach to

the blower motor circuit would depend on the
symptom.
 If the blower motor operates at some speeds and
not others, the problem is most likely the blower
motor resistor. If the resistor checks out good, the
switch may be bad.
 If the blower motor does not operate at all, check
for source voltage and continuity to ground,
including the fuse. Note: Ground circuit resistance
will change based on the position of the blower
motor switch.
 If the blower motor turns slowly at all speeds, there
is either unwanted resistance in the source or
ground circuit, or the motor is malfunctioning.
Use the service manual specifications and procedures

when diagnosing a blower motor malfunction.
Using the blower motor resistor provided by your

instructor, measure the resistance between the
terminals and write the resistance in the table above.

Blower Motor Circuit Build the motor circuit as shown. Connect A & L to the
power source and turn ON the main switch.
What is the load device in this circuit?
____________________________________
If the resistors were placed on the groundside of
the motor, would they still control motor speed?
____________________________________
 Turn on your DVOM and move the leads to the
Amperage setting. Connect the DVOM and record
the Amperage reading.________________________
 Next, apply gentle pressure to the tip of the motor

and record the Amperage reading.______________
 Finally, remove the resistor block and record the

Amperage reading __________________________
* Reinsert the resistor block as in the Power Point. Set

the DVOM to test Voltage.

Predict Measure

Troubleshooting Using the blower motor circuit you built on the previous
page:
1. Predict the voltage readings when the circuit is

CLOSED (ON) using the above diagram.
2. Turn the circuit ON and use the DVOM to
measure the voltage readings and current flow.
Note your readings on the diagram.
GAUGES Instrument cluster gauges display critical engine

Function & Operation operating parameters to the driver; engine speed,
vehicle speed, engine temperature, and fuel level.
Based on the gauge readings, the driver can make
informed decisions.
There are two parts to a gauge circuit:
Gauges:
 Magnetic balance coil
 Microprocessor controlled gauge
 Microprocessor controlled display.
Sending Unit:
 Variable resistor
The tachometer uses a signal from the ECM while the

speedometer uses a signal from the vehicle speed
sensor.

Magnetic Balance Type with sending units

Microprocessor controlled with Engine Temperature Sending Unit
Microprocessor controlled Engine Temperature via CAN

Troubleshooting A thorough visual inspection is the best way to start your

troubleshooting. Are there any damaged wires, terminals,
or components? Next, isolate the circuit at a logical test
point. Locate the appropriate circuit diagram and
determine if the sending unit is on the power or ground
side of the circuit.
In the illustration above the fuel sending unit is in the

ground side. Follow the service information instructions to
test the gauge portion.
To troubleshoot a sending unit, measure the resistance of

the unit as shown in the appropriate service information.
If the resistance is out of specification, the root cause
may be the sending unit.
NOTE: To quickly check the wiring and processor in a

gauge circuit:
 Disconnect the sensor connector from the sending
unit. The gauge should go to one end due to the
high resistance in the circuit.
 Jump the sensor circuit at the sensor connector using
a fused jumper wire. The gauge should go to the other
end due to the low resistance in the circuit.
It may take up to 30 seconds for the fuel gauge to change

position due to the circuit damping effect that keeps the
gauge from moving as the fuel sloshes in the tank.

DC/DC CONVERTOR The DC/DC converter is used on vehicles with an Idle Stop
Function & Operation & Go (ISG) system to compensate for voltage dips caused
by more frequent engine starting. The DC/DC convertor
supplies the by pass relay with a constant voltage during
starting, keeping accessories and other electrical
systems operating. Based on battery voltage, the CPU
decides whether power is supplied by the bypass relay
(normal battery voltage) or by the DC/DC convertor.
If the audio system turns OFF during ISG “Auto Start”

or “Idle Start”, the DC/DC convertor should be
replaced.

ELECTRICAL OIL PUMP The automatic transaxle (A/T) on Idle Stop & Go (ISG)
Function & Operation vehicles includes an Electric Oil Pump (EOP) in addition
to the Mechanical Oil Pump (MOP).The EOP provides
the oil pressure needed to keep the A/T hydraulic
system pressurized for normal operation when the
vehicle comes to a stop and the engine shuts off and
during low speed driving.
The system uses an oil pump inverter to control EOP

operation based on vehicle speed.

HORNS, BUZZERS AND Buzzers, horns and audio speakers use electricity to
AUDIO SPEAKERS reproduce sounds. Buzzers and horns contain a plate or
Function & Operation flexible diaphragm that vibrates as the electro-magnetic
circuit is closed and opened.
An audio speaker contains a voice coil and cone

assembly. The cone is attached to a moveable core
inside a wire winding. When current from an audio
amplifier is sent through the windings, a electro-
magnetic field, aided by large permanent magnets,
causes the cone to vibrate and create various pressure
waves (sound).

Troubleshooting
Since these components use electro-magnetism to

operate, use a DVOM to check the continuity of the coil
windings. An open or grounded circuit will reduce the
magnetic field strength and prevent proper operation.

SUMMARY Basic electrical components can be grouped as circuit

protection, circuit control and load devices.
Understanding the function and operation of
components like resistors, relays, switches, motors, and
gauges is critical to properly diagnose and troubleshoot
electrical malfunctions.

PROGRESS CHECK 1. The Intelligent Power Switch is an example of a

_______________ device.
e. load
f. input sensor
g. circuit protection
h. ground
2. Technician A says that if a “click” can be heard

when a relay is energized, the relay is good.
Technician B says that you should check resistance
across the switch side when the relay is energized.
Who is correct?
e. A only
f. B only
g. Both A and B
h. Neither A nor B
3. If a circuit consists of a load device, power source

and an ECU, what is the ECU doing?
e. Reading the load device as a sensor
f. Providing circuit protection
g. Controlling the power side of the circuit
h. Controlling the ground side of the circuit
4. What needs to be done when testing a solenoid?

e. Test for proper mechanical operation
f. Test for proper electrical operation
g. Test the current flow in the circuit
h. Both A and B

PROGRESS CHECK 5. What is the most likely cause of a blower motor that
operates at some speeds and not at others?
e. High resistance in the ground circuit
f. A blown fuse
g. A bad blower motor resistor
h. Low resistance in the blower motor switch


Theory Module
automotive technology.

diagnose basic to moderately complex wiring harness
malfunctions.
MODULE OBJECTIVES Upon completing this module and Module 7 (Electrical

Diagnosis Guided Practice), you will be able to:
 Identify the elements of a wiring harness while
diagnosing a vehicle with an electrical problem, with
100% accuracy
 Identify wire position in a connector based on wiring
schematics and harness diagrams while diagnosing a
vehicle with an electrical problem, with 100%
accuracy
 Properly test electrical readings on wires in a wiring
harness and connector while diagnosing a vehicle
with an electrical problem, without damaging the
connector
 Identify proper wiring harness repair procedures
bases on vehicle diagnosis, with 100% accuracy
classroom discussion, and study each illustration. At the
end of the module, there will be Progress Check
following items:
 Kia Electrical Repair Kit II
 Terminal Removal Tools
ACRONYMS CPA – Connector Position Assurance

SRS – Supplemental Restraint System
TPA – Terminal Position Assurance

INTRODUCTION The wiring harness is an important part of any electrical

PURPOSE circuit. The harness provides a current path to, from
and between electrical components as well as to the
battery and chassis ground connections.
Wiring harnesses are bundles of separate wires
wrapped together with tape and/or protected by plastic
tubing. A vehicle has several wire harnesses. Individual
sections can be conveniently diagnosed, repaired, or
replaced. Harness sections attach to each other using
connectors, which keep the individual wires separate.

APPLICATION The table above illustrates the number of harnesses in

a typical vehicle. The number of wiring harnesses varies
depending on the vehicle and how the vehicle is
equipped. Refer to the applicable service information
for specific vehicle information.

COMPONENT OVERVIEW Every wire in a vehicle terminates or ends with a

terminal or a ground point. Connectors are used to
house the terminals, and sometimes a group of ground
wires, which is referred to as a ground block.
TERMINALS
A terminal is a metal device mechanically attached

(crimped, soldered) to the end of the wire. “Male” and
“female”– shaped terminals in each connector half join
to continue the current path.
A loose fitting terminal can cause intermittent concerns.
A pin tension gauge can help determine if a
terminal is too loose.
STABILANT 22A Stabilant 22A improves conduction of electrical

terminals in harness connectors. Follow the
manufacturer’s instructions when using this product.
When a connection is suspect, Stabilant 22A can be
used to provide a good connection. Use it sparingly; a
small amount is very effective in providing a positive
connection.
WARNING: Do not use Stavilant 22A on SRS or O2

sensor terminals or connectors.
Stabilant 22A can be sourced from the following:


GROUNDS A ground point consists of one or more wires usually

connected to an eyelet terminal bolted to the body or
frame assembly. In some cases, multiple wires come
together into a grounding connector and joined to a
single common eyelet. Grounds may also be numbered.
A harness ground symbol is different from a unit
ground.

CONNECTORS A connector is a plastic block that houses and protects

a group of wire terminals. Two halves make up a
connector. The terminal and connector halves allow a
point to separate for testing and replacement.
Harness connectors provide an excellent access point

for circuit diagnosis, but be careful. Connectors can be
damaged if handled or tested improperly. Separate
connector halves by pressing and releasing the lock
lever. Do not pull the wires to separate the connector.
Hold each connector housing while separating them.

TERMINAL NUMBERING When looking at the harness side of the connector:

 The male terminals are numbered left to right
starting in the upper left hand corner
 Female terminals are numbered right to left starting
on the upper right corner
 When facing each other, the terminals are a mirror
image and each terminal number will match
All terminal passages in the connector are identified

even though some may be empty. Always refer to the
appropriate service information for correct numbering.
The terminal number (39), and connector number

(M01) are given in the wiring schematic.


LOCATING HARNESSES, In KGIS, ETM, Schematic Diagrams you can view:

CONNECTORS AND  An image of the connector
COMPONENTS
 A picture of the connector location
 The wiring harness for the connector


Wiring Colors Color coded wires provide a convenient (and obvious)

method to identify circuit wires. Two-color wires are
indicated by a two-letter symbol. The first letter
describes the base wire color; the second letter is the
stripe color.
The wire size (0.5mm) and color (Red) is also shown in

the wiring schematic.
SPLICES A splice is where two or more conductors meet at a

common connection point in a circuit. Do not confuse
the splice symbols in a wiring diagram for two
conductors crossing over each other (no electrical
connection).

WIRE
Comprised of a core of conductive metal, usually

copper strands, and covered with electrical
resistant insulation.
TERMINAL
The terminal is metal piece attached to the end of the

wire that is plugged into a connector. Connection to a
mating terminal or device will complete an electrical
connection (Terminal is often used incorrectly to
describe a connector).
The lock tangs are part of the terminal that locks it into
a connector. Some terminal designs feature multiple
lock tangs.
The core wings are part of the terminal that is crimped

over the wire core and provides the electrical path
between the terminal and the wire core.
The insulation wings are part of the terminal that is
crimped over the insulation (and seal if present).

Terminal Seal
The terminal seal is designed to help prevent

contamination from the environment after the terminal
is plugged into
the connector.
CONNECTOR
A connector is the plastic component which contains

one or more terminals and provides a mechanical
connection to another connector or component such as
a switch, relay, sensor, etc.
Entry Canal Canal(s) in the connector is where a removal tool is

inserted to depress the terminal lock tang(s) in order to
remove the terminal. (Some connector designs have
plastic lock features used with terminals that do not
have tangs. The plastic lock is raised to remove the
terminal.)
Terminal design (series) determines removal tool to
be used.


Connector Seal The connector seal is used to protect the terminals

from debris and moisture.
Terminal Position Designed to help prevent contamination from the

Assurance (TPA) environment after the connector is mated, and prevent
the terminal(s) from backing out of the connector.
CAUTION: When connecting and disconnecting

connectors, always make sure that the connector seals
and TPA are in place to help protect the terminals.
Connector Position
Assurance (CPA)
A device that is inserted after the connector is mated in

order to prevent disconnection.

Pigtail
A replacement part consisting of wire(s) that are bare

at one end with a connector or device attached to the
other.

Wiring Repair Kit II
Wiring Repair Kit III Upgrade
Wire Harness Repair The Wiring Repair Kit II and Wiring Repair Kit III
Upgrade are designed so that you can repair certain
wiring harnesses instead of replacing the whole
harness.


T-CONNECTOR Wiring Repair Kit II contains T-Connectors, which are a

set of molded wires that allow you to test live circuits.
Each T-Connector has male and female terminals that
are inserted into the terminals of a connector. Once
connected, the circuit can be powered up and tested.
Each kit is equipped with 3 T-Connectors. T-connectors
can be purchased separately through Kia parts
department.
CAUTION: Remove the negative battery cable (B-)

from the battery before performing wire repairs.
WARNING: Never repair SRS connectors and

terminals. Replace the complete harness if repairs are
required.

Harness Repair Overview When replacing a damaged wire, verify the wire size is the
same or larger than the existing wire. If possible, use the
same color wire.
1. When replacing terminals, identify the connector by

name, location of locking clip, and the direction to
unlock the plug from vehicle charts.
2. When replacing terminals, check the condition of
the other terminals.
3. Do not use excessive force on the terminal and do
not pry on the terminal with a pick.
4. If the new length of wire that is replacing the old
wire is not approximately the same length, problems
may occur.
a. Too short of wire may cause additional strain on
the splice, terminal, or the connector.
b. Too long of wire may cause the wire to get
pinched or damaged, causing a short circuit.
5. If heat shrink tubing is to be used, install tubing
before putting connector on end of wire. Make sure
heat shrink tubing is kept away from any area to be
soldered as tubing is very sensitive to heat and will
shrink prematurely before it can be properly placed.
6. When reinserting terminals into the plug, make sure
terminals are locked in the connector.
7. Not all terminals will give a noticeable click.
8. When putting both ends of plugs back together,
make sure that both ends are locked in place.

SUMMARY A wire harness is a group of circuit wires that are

bundled together. Wire harnesses are joined to other
harnesses for ease of assembly, service and diagnosis.
They are joined by plastic connectors containing metal
terminals inside that allow a continuous circuit path
when the connectors are joined.

PROGRESS CHECK 1. Place a check next to each item that is part of a

wiring harness:
___ Terminal
___ Actuator
___ Connector
___ Ground eyelet
___ ECU
___ Splice
___ Stranded wire
2. Connectors join which of the harness elements?

A. Grommets
B. Terminals
C. Fuses
D. Grounds
3. The wiring schematics found in the ETM include:

A. The wire color
B. The connector number
C. The pin number of the wire in the connector
D. A picture of the location of the connector
E. All of the above
4. How are male terminals numbered?

A. Right to left starting in the lower right hand
corner
B. Exactly the opposite of the female terminals
C. Left to right starting in the upper left hand corner
D. It changes by connector type
5. What color is a wire labeled (Br) on the wiring

schematic?
A. Brown
B. Blue with a red stripe
C. Black with a red stripe
D. None of the above


Guided Practice Module
service technicians who diagnose vehicles with
automotive electrical concerns.
MODULE GOAL Completing this module prepares you to diagnose and

troubleshoot automotive electrical concerns using the
appropriate diagnostic tools.
MODULE OBJECTIVES Upon completion of this module, you will be able to

perform the task in each guided practice.
MODULE INSTRUCTIONS Carefully read through the material and take notes
based on the classroom discussion. Throughout the
module there will be activities for you to participate in.
following items:
• Pen or Pencil
 Safety Glasses
 Digital Volt-Ohm Meter
 Vehicles as assigned by your instructor

GUIDED PRACTICE 1 The instructor will assign the vehicle and tell you what
the customer’s concern is.
Vehicle: ______________________________________
Symptom: ___________________________________
__________________________________________
 Go to the vehicle assigned by your instructor.
  What where the results when you verified the

concern?
__________________________________________
__________________________________________
__________________________________________
__________________________________________
  List any codes using the GDS:

_________________________________________
_________________________________________
 Using KGIS, print the schematic and highlight the

power flow for the suspected circuit.
 On the wiring diagram, identify the test points you

would check to diagnose the concern, and indicate
what results you would expect when performing the
test.
 Show the Instructor your wiring diagram with power

flow illustrated and your test points.
 After the instructor has reviewed your test points,

perform the tests on the vehicle. DO NOT perform
any additional tests without your instructor’s
approval.
 Based on your test results, identify on your wiring

diagram the suspected area of concern.

 Answer the following questions:

Based on your test results, what is the cause of the
problem?
__________________________________________
__________________________________________
__________________________________________
__________________________________________
What additional tests (if any) do you need to
perform to further diagnose the problem?
__________________________________________
__________________________________________
__________________________________________
__________________________________________
What would you do to repair the problem?
__________________________________________
__________________________________________
__________________________________________
__________________________________________
How would you verify that your repair fixed the
problem?
__________________________________________
__________________________________________
__________________________________________
__________________________________________
 Review the answers to the above questions with
your instructor. Reset your test area and keep your
wiring diagrams for scoring later in the classroom.
Instructor’s Initials ____

Vehicle: ______________________________________
Symptom: ___________________________________
__________________________________________
 What where the results when you verified the

concern?
__________________________________________
__________________________________________
__________________________________________
__________________________________________
 List any codes using the GDS:

_________________________________________
_________________________________________


test.


approval.



problem?
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
problem?
__________________________________________
__________________________________________
__________________________________________
__________________________________________

Vehicle: ______________________________________
Symptom: ___________________________________
__________________________________________

concern?
__________________________________________
__________________________________________
__________________________________________
__________________________________________

_________________________________________
_________________________________________


test.


approval.



problem?
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
problem?
__________________________________________
__________________________________________
__________________________________________
__________________________________________

Vehicle: ______________________________________
Symptom: ___________________________________
__________________________________________

concern?
__________________________________________
__________________________________________
__________________________________________
__________________________________________

_________________________________________
_________________________________________


test.


approval.



problem?
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
problem?
__________________________________________
__________________________________________
__________________________________________
__________________________________________

Vehicle: ______________________________________
Symptom: ___________________________________
__________________________________________

concern?
__________________________________________
__________________________________________
__________________________________________
__________________________________________

_________________________________________
_________________________________________


test.


approval.



problem?
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
problem?
__________________________________________
__________________________________________
__________________________________________
__________________________________________

Vehicle: ______________________________________
Symptom: ___________________________________
__________________________________________

concern?
__________________________________________
__________________________________________
__________________________________________
__________________________________________

_________________________________________
_________________________________________


test.


approval.



problem?
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
problem?
__________________________________________
__________________________________________
__________________________________________
__________________________________________

NOTES:___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________


Theory Module
automotive electrical.

diagnose basic battery/starting/charging system
malfunctions.
MODULE OBJECTIVES  Given this module and a multiple-choice test, you will
identify the operation of the
battery/starting/charging system components with
100% accuracy
 Given this module and a multiple-choice test, you will
identify the function(s) and variation(s) of the
100% accuracy
 Given this module and a multiple-choice test, you will
identify the diagnostic procedures related to
100% accuracy
classroom discussion, and study each illustration.
Throughout the module, there will be Progress Check
REQUIRED MATERIALS None
ACRONYMS AC – Alternating Current

BCM – Body Control Module
CCA – Cold Cranking Ampere
EPMS – Electrical Power Management System
IBSM – Intelligent Battery Sensor Module
PCM – Powertrain Control Module
SOC – State of Charge

INTRODUCTION The battery, starting, and charging systems are the

foundation of the vehicle’s electrical system.
 The battery is the source of electrical energy
 The starting system rotates the crankshaft when
starting the engine
 The charging system charges the battery and
provides a power source once the engine is running.
In this module, we will look at the function, operation,

troubleshooting, and diagnosis of these systems and
key components. Knowing how these systems operate
will help you diagnose system malfunctions quickly and
more efficiently.
PURPOSE The purpose of the battery is to supply electrical energy

to:
 Operate electrical accessories when the engine is
not running
 Crank the engine
 Provide electrical energy to run the fuel, ignition,
and accessory systems while the engine is running.
APPLICATION The physical size and location as well as the amount of

energy produced/used by the systems varies from
vehicle to vehicle based on the size of the engine and
the amount of electrical accessories on the vehicle.

Closed Advance
Maintenanc d Glass
e Free Mat
BATTERY FUNCTION The battery performs the following major functions:

1. When the engine is OFF, the battery provides
energy to operate the lighting and accessory
systems.
2. When starting the engine, the battery provides the
electrical energy to operate the starter motor and
the ignition system.
3. When the engine is running the battery acts as a
voltage stabilizer to even out voltage spikes within
the electrical system.
Battery Types Kia uses two types of sealed batteries:

 Closed Maintenance Free (CMF) lead-acid type, also
called a wet-cell battery
 Advanced Glass Mat (AGM)

LEAD ACID The CMF lead-acid battery

 Uses lead peroxide and sponge lead plates housed
separately in a plastic container
 Each group of plates is called “cells”
 The cells are submerged in an electrolyte solution
consisting of water and sulfuric acid
 The chemical reaction between the electrolyte and
the plates in each cell produces voltage
 Each fully charged cell generates 2.11 volts
 Six cells connected in series produce a total of 12.66
volts
ADVANCED GLASS MAT Advanced Glass Mat

AGM  Used in Idle, Stop & Go (ISG) vehicles, and vehicles
with large electrical loads such as power sliding
doors, and power lift gates
 Electrolyte is absorbed into glass mats held in place
by capillary action
 Keeping the plates "moist" with electrolyte, reduces
gassing
 Delivers higher power and efficiency than other
battery types
Cold-Cranking Ampere CCA rating - Number of amperes the battery can

(CCA) deliver at 0°F for 30 seconds while maintaining a
voltage of 7.2 or greater.
Reserve Capacity (RC) RC rating - The length of time in minutes that a fully
charged battery can deliver 25 Amps while maintaining
a minimum of 10.5 volts at 80°F.
Amp-Hour (AH) AH rating - The amount of current in amperes times

20 hours that a battery can deliver while maintaining a
voltage of at least 10.5 volts at 80°F. Example 54 Amp
Hours:
 2.7 Amps x 20 hours = 54 Amp Hours
 54 Amp Hours/20 hours = 2.7 Amps

TROUBLESHOOTING & There are a number of tests to run when troubleshooting

DIAGNOSIS the battery to determine its state of charge and its ability
to supply current. The state of charge test checks the
battery’s overall condition while the current test
measures the battery’s ability to deliver adequate
cranking power.
Visual Inspection The first step in diagnosing a battery related concern is

a visual inspection. The chart below describes the parts
of a good visual inspection.
Inspection Item Solution

Cracks in case Replace battery
Distorted case
Lose or broken terminals
Cracked or broken cables or Replace as needed

connections
Corrosion on terminals Clean with wire brush
Dirt or acid on top of case Clean with a mixture of water and baking soda
Rubber protector on positive Check for proper coverage

terminal
Loose battery hold down Tighten as needed

Loose cable connections

Open Circuit Voltage Test The open circuit voltage (OCV) test checks the available
voltage supplied by the battery.
Using a DVOM:
 Place the positive red lead on the positive battery
terminal (B+)
 Place the negative black lead on the negative
battery terminal (B-)
 If the battery has just been charged, turn the
headlamps ON for one minute to remove any
surface charge, turn the headlamps OFF, then wait
5 - 10 minutes and retest
 A fully charged battery should produce about
12.66 volts.
CAUTION: Always wear safety glasses when working

around batteries. Hydrogen gas may be expelled during
charging or testing and is highly explosive! Keep all
sparks away from the battery and never smoke near a
battery.

OPEN CIRCUIT VOLTAGE STATE OF CHARGE

12.80 REMOVE SURFACE CHARGE
12.70 AND RETEST
12.66 100%
12.58 90%
12.51 80%
12.45 70%
12.35 60%
12.28 50%
12.20 40%
12.11 30%
12.04 20%
11.97 10%
11.89 0%
Results The OCV values should be about 12.66 volts. If the

reading is below 12.45 volts possible reasons include:
• Vehicle sitting for extended period of time
• Insufficient battery charge prior to testing
• Corroded battery terminals
• Potential low charging voltage condition
• Parasitic draw (Ignition-Off Draw) condition exists
• Defective battery
VIDEO: Open Circuit Voltage Test

Parasitic Draw All vehicles have a constant small amount of parasitic

current draw due to computer memories and other
electronic components and circuits.
A parasitic draw is excessive when the current draw is

too high and discharges the battery over a short period
of time.
This is usually caused by a circuit or component that

remains powered up when it should not be.
Parasitic Current Inspection and Specifications can be

found in:
 Engine Electrical System
 Charging System
 Battery
 Repair Procedure
With the key out of the ignition and all loads off, there
should be less than a 50mA draw after 20 minutes.
If a specification is not available, the follow equation

can be used to calculate an approximate maximum
parasitic draw in mA.
Reserve Capacity x .25 = Maximum Parasitic Draw
CAUTION: Use the A (amps) range on the DVOM to test
parasitic draw then convert the reading to mA (milliamps).
You may blow the fuse in the DVOM if you use the
milliamp input and you get a higher current flow than
expected. This may be due to the amount of time it
takes for some computers to go to “sleep.”


To test for excessive parasitic draw:

 Turn all accessories and the ignition OFF, then
remove the key and key fob from the vehicle
 Close all doors. This will allow all the on-board
computers to go into “sleep” mode
 Disconnect the hood switch to allow the BCM or PCM
to go to sleep
 Disconnect the negative (B−) battery cable from the
battery post
 Connect a jumper wire between the negative terminal
(B−) and the negative clamp
 Connect a DVOM set to measure AMPS in series
between the negative cable and the negative post
 Wait up to 20 minutes to allow the computers to
enter sleep mode and all circuits to power OFF
 Remove the jumper wire and read the amperage
draw
 Compare measured value with service information
specifications
NOTE: To prevent accidently disconnecting the battery

while connecting the ammeter:
 Attach a “Jump Box” not a battery charger to the
positive (B+) and body ground
 Connect the ammeter between the battery negative
terminal and the negative cable
 After the DVOM is connected, remove the Jump Box
If the parasitic draw is excessive, a load device is on or

a computer is not going to sleep.
Check the obvious first, interior lamps, glove box lamp,
and trunk lamp.
If the root cause is not found, use the Power
Distribution wiring diagram in the ETM to determine
which fuse (load protection devices) provide power to
which circuits.
Start with the fuse that controls the most circuits and
disconnect them one at a time, to narrow down which
circuit is causing the excessive parasitic draw.
Use the wiring diagrams in the ETM to continue to
narrow down the circuit causing the draw.
VIDEO: Parasitic Draw

System Ground Voltage Using the voltage drop method for checking system
Drop grounds is useful for finding a component or circuit with
excessive resistance.
Unwanted resistance in the ground circuit changes

voltage and amperage values.
Multiple sensors and actuators often rely on common

grounds, which may affect their operation.
System ground voltage drop readings are normally less

than 0.10 volts.
To perform the system ground voltage test:

 Place the DVOM negative black test lead on the
battery negative post (B−)
 Place the positive DVOM red test lead on an area
near the ground connection (typically body sheet
metal or the engine block
 Next, turn the Key On Engine Running and turn on
the following:
o High beam headlights
o Windshield wipers
o Radio
o HVAC blower on high
• The DVOM should read 0.10 volts or less.
A voltage drop more than 0.10 volts indicates possible

corrosion in the ground connections or in the ground
cable. Clean all connections and re-test.


STARTING SYSTEM
Overview The starting system consists of the battery, starter

motor, and electrical control components.
 The ignition switch remotely energizes the starter
motor through the start relay.
 Vehicles with an automatic transaxle/transmission,
the A/T range switch allows the starter to run only in
the Neutral (N) or Park (P) positions.
 Vehicles with a manual transaxle/transmission have
a switch on the clutch pedal that allows the starter
to energize only when the clutch pedal is
depressed.
 When the starter is engaged, pull-in and hold-in
windings in the solenoid pulls in a plunger which
causes a pinion gear to mesh with the ring gear on
the flywheel.
 When the plunger is pulled in it closes a set of
contacts which supplies power to the motor to
crank the engine

STARTER RELAY

Function The starter relay is used to control the current to the

starter solenoid. As with any relay, the starter relay is
used to control a large amount of current with a small
amount of current.
Operation When the driver operates the ignition switch to the

START position:
 Current flows from the switch through either the
range switch or the clutch pedal position switch
when the contacts are closed
 Current then flows to the control side of the relay to
ground.
 The small amount of current on the control side
energized an electro-magnet that closes contact on
the switch side of the relay.
 These contacts carry a large amount of current from
the battery to the starter solenoid through the
battery cables.
 This current energizes the starter solenoid and
supplies current to the starter motor to crank the
engine.

Battery Cranking Voltage The Battery Cranking Voltage Test checks the condition
of the battery while cranking the engine.
To perform the battery cranking voltage test:

 Connect the DVOM
o Red test lead to the positive battery terminal
post (B+)
o Black test lead to the negative battery terminal
post (B−)
 Remove the fuel pump relay and run the engine
until it stalls
 Crank the engine for 5 seconds and record the
lowest readings from the DVOM.
Good 10.0 – 11.5 vdc

Marginal 9.6 – 9.9 vdc
Test Battery * < 9.6 vdc
* Test battery using the GR8 Multitasking Battery and

Electrical Diagnostic Station

Engine Positive The Engine Positive Voltage Drop test checks for
Voltage Drop unwanted resistance between the battery and battery
cable terminal on the starter solenoid.
To complete the test:

o Red test lead on the positive battery post (B+)
o Black test lead on the positive post of the starter
solenoid
 Remove the fuel pump relay and run the engine
until it stalls
 Crank the engine and record the DVOM readings.
Good 0.10 – 0.30 vdc

Requires Further Testing * > 0.50 vdc
* Run voltage drop tests on each part of the circuit to

isolate the source of unwanted resistance.
NOTE: It is possible to see an initial starter “voltage

spike” over 0.50 volts, it should drop while the starter
motor is cranking.

Engine Ground The Engine Ground Voltage Drop test tests for
Voltage Drop (Cranking) unwanted resistance in the groundside of the starter
circuit.
To perform the test:

o Black test lead on the negative battery post (B−).
o Red DVOM test lead onto the engine block or
head (do not use the fuel rail or bolts
attached to plastic cam cover).
 Remove the fuel pump relay and run the engine until
it stalls
 Crank the engine and record the DVOM readings
Good 0.10 – 0.30

vdc
Marginal 0.30 – 0.50
vdc
Requires Further Testing > 0.50 vdc
*
* Run voltage drop tests on each part of the circuit to

isolate the source of unwanted resistance.
NOTE: It is possible to see an initial starter “voltage

spike” over 0.50 volts but it should drop while the
starter motor is cranking.

CHARGING SYSTEM The Charging System consists of the battery and a

belt driven generator that provides the vehicle’s
electrical energy needs when the engine is running.
When the engine is running, the drive belt rotates the
generator rotor to produce electricity.
The generator converts mechanical energy into
electrical energy by rotating electro-magnets to
produce electricity.
A voltage regulator limits the output of the generator.
A charging indicator (warning) lamp displays the status
of the charging system.
The voltage and current produced by the generator
keeps the battery charged and provides the electrical
energy to operate the vehicle electrical systems.
The amount of current and voltage produced is limited
by the voltage regulator.
The regulator may be located in the generator or in the
PCM.
When the generator is not producing enough electricity
(belt broken or other malfunction), the warning lamp
goes ON to alert the driver.

ELECTRICAL POWER
MANAGEMENT SYSTEM
The Electrical Power Management System (EPMS)

changes the way the generator is managed.
It takes full use of the battery’s capacity, engine power,

and braking performance while maximizing battery life
and increasing fuel economy.
The battery uses the existing technology of a lead-acid

battery, and a generator that is specific to EPMS and is
controlled by the ECM/PCM.
The EPMS fully charges the battery and stops charging

during heavy acceleration for improved performance.
During braking, the EPMS increases the charging rate

from the generator.
This increases the load on the crankshaft, which helps

with engine braking as well as increasing the charge
rate to the battery.

INTELLIGENT BATTERY The EPMS uses an Intelligent Battery Sensor Module

SENSOR MODULE (IBSM) located on the negative battery terminal.
It monitors the following to determine the battery’s

State Of Charge (SOC):
 Battery temperature
• Available Voltage
• Current Flow
Since the battery’s State Of Charge is a measure of how

full the battery is charged, the EPMS controls the
charge rate to best optimize battery efficiency and
engine performance.
A vehicle without an EPMS typically maintains only an

80% charge on the battery.
With EPMS, a 95%-100% charge can be achieved.
FEEDBACK: What possible effects could battery

corrosion have on the Intelligent Battery Sensor
Module?

HOW EPMS WORKS The generator’s output voltage is controlled by the

EPMS, which minimizes battery gassing during the
charging stages.
Each State Of Charge zone requires a different charging

strategy. By controlling the battery current, the EPMS
limits gassing and provides a deeper charge compared
to a conventional system.
Reducing battery gassing minimizes the need for

battery maintenance and maximizes battery life.
The EPMS takes action on the following thresholds:

• 95% ~ 100% - is considered fully charged.
Charging voltage and current are minimized in a
condition known as Float Charging. This action
reduces fuel consumption and battery gassing.
• 90% ~ 95% - is the Absorption Charging stage.
During this stage, the charging voltage is
moderated to provide a deep charge while
minimizing gassing.
• 0% ~ 90% - is the Bulk Charging stage. Charging
takes priority over fuel economy and the EPMS
provides high charging current to the battery. The
IBSM monitors battery temperature and charging
current. When the battery warms up in
temperature, the voltage remains high but the
current is limited to protect the battery plates from
too much current.

EPMS Disable Under most circumstances, the EPMS controls the

Conditions battery charge rate.
There are conditions when the EPMS does not control

the charge rate.
These include the following:

 Headlights On – The EPMS does not cycle the
charge rate of the system because drivers might
notice a fluctuation in the headlight intensity as
the charging voltage is reduced.
 HVAC Blower On Max – Float charging is
disabled as varying the charge rate would affect
blower fan speed operation.
 Excessively High/Low Battery
Temperature – Excessive temperatures affect
the operation of the battery. Low temperatures
reduce the battery’s capacity (Amp Hours). Hot
temperatures can create an excessive load on
the system that may create a hazardous
condition.
 EPMS Error – When a calculation error is
determined within the EPMS, the system will
not cycle the charge and will default to
conventional charging.

CHARGING VOLTAGE TEST This quick test allows you to determine if the charging
system is charging the battery.
 Perform an open circuit voltage test. An ideal
battery voltage should be 12.66 volts
 Start the vehicle and raise the engine rpm to about
2000 rpm
 The result should be 1.0 - 2.0 volts above the Open
Circuit Voltage test results
 If the reading is less than 1.0 volt above the
recorded Open Circuit Voltage test, then further
charging system testing is needed
NOTE: Charging voltage should only be measured at

the posts of the battery, not on the clamps or the B+
Terminal at the back of the generator.

Positive Side Voltage Drop The positive side voltage drop test checks for unwanted
resistance from the positive battery post to the B+
terminal on the generator.
To perform the test:

 Connect DVOM
o Black lead on the positive battery post (B+)
o Red lead on the B+ Terminal on the back of the
generator
 With the engine running, raise the engine to 2000
RPM.
 A voltage drop of greater than 0.25 volts indicates
that there is resistance on the B+ side of the
charging system
 Inspect and clean connections and inspect the wire
itself for excessive resistance
NOTE: If the voltage drop is still greater than 0.25

volts after the connections have been cleaned and the
wire inspected, then the battery may be drawing
excessive charging current. This could be caused by an
internal battery failure that may pass a GR8 battery
test. The excessive current causes heat in the
generator, which may ultimately create generator
failure. Check the vehicle’s prior history to see if
generators have been recently replaced on the vehicle.

Voltage Drop Ground Side Another quick check that can be performed after
checking the voltage drop on the positive side of the
charging system is to check the groundside of the
charging system.
To perform this test:

o Black lead from the DVOM to the negative
battery terminal
o Red lead to the case of the generator
 Raise the engine to 2000 rpm
 Test results should be less than 0.15 volts
 Readings greater than 0.15 volts indicate unwanted
resistance in the groundside of the charging system
circuit
 Check all electrical wiring and connections, clean the
generator mounting-bracket and mounting bolts to
the engine block, and retest

CHARGING VOLTAGE TEST To measure the charging system’s capacity there must
FOR UNDERCHARGE be a heavy load placed on the system. This test is
useful to determine if the generator is capable of the
charging demands of the vehicle.
To perform this test:

 Connect DVOM
o Black lead on the negative post
o Red lead on the positive post
 With the engine running, raise the RPM to 2000
 Turn on the headlamp high beams, the radio, the
HVAC blower motor on high, and the wipers on a
High-speed
 The reading should be greater than 13.4 volts
 A reading less than 13.4 volts may indicate that the
charging system wiring or generator is faulty
Charging Voltage Test An overcharge condition may cause considerable

For Overcharge damage to the vehicles battery, electrical circuits, and
components, including sensitive circuits inside
computers.
 To check for an overcharge condition:

 Start the engine and keep the engine RPM at 2000
 Turn off all electrical loads
 Place the DVOM leads onto the battery
o Black lead on the negative post
o Red lead on the positive post
 If the reading is above 15 volts, then an overcharge
condition may exist
 An overcharge condition may indicate that the
voltage regulator may be defective

Trouble Symptom Probable Cause Remedy
Charging warning Fuse blown Check fuses

indicator does not
light with ignition Light burned out Replace light
switch “ON” and Wiring connection loose Tighten loose connections
engine OFF
Electronic voltage regulator faulty Replace voltage regulator
Charging warning Drive belt loose or worn Adjust tension or replace

indicator does not go drive belt
out with engine
running (Battery Battery cables loose, corroded or worn Repair or replace cables
requires frequent Fuse blown Check fuses
recharging)
Fusible link blown Replace fusible link
Electronic voltage regulator or Test generator
generator faulty
Wiring faulty Repair wiring
Overcharge Wiring connection loose or open circuit Tighten loose connection

or repair wiring
Fusible link blown Replace fusible link
Poor grounding Repair
Electronic voltage regulator or Test generator. If faulty
generator faulty repair or replace
Worn battery Replace battery
Electronic voltage regulator faulty Replace voltage regulator
Voltage sensing wire faulty Repair wire
Service Information Refer to the latest service information for additional

charging system diagnosis procedures. Here is an
example of a trouble symptom chart:

Recharging Rate Chart (for fully discharged batteries)

RC AH
5A 10A 20A 30A 40A
Rating Rating
less less Not
10 hrs 5 hrs 2.5 hrs 2 hrs
than 75 than 48 Recommended
75-115 48-75 15 hrs. 7.5 hrs 3.25 hrs 2.5 hrs 2 hrs
115-160 75-100 20 hrs. 10 hrs 5 hrs 3 hrs 2.5 hrs
100-
160-245 30 hrs 15 hrs 7.5 hrs 5 hrs 3.5 hrs
150
Battery Recharging To recharge a battery, current must be applied to the

battery in the opposite direction of the discharge flow.
This restores the imbalance of electrons in the battery.
There are three methods of charging the battery:

 Fast charging
 Slow charging
 Trickle charging
Fast charging applies a high current rate to the battery

for a short period of time. Fast charging should not be
used on a completely discharged battery to prevent
damaging it.
Slow charging recharges a battery by using a reduced

current level for a longer period of time. The maximum
charging current should be less than 1/10th of the
battery capacity.
Trickle charging is a very low rate of charging used to

maintain a battery in a fully charged condition.
NOTE: A battery may lose its charge while the vehicle

sits on the lot waiting to be sold. To avoid customer
embarrassment or wrongfully replacing a battery, be
sure to periodically start and run the engine to maintain
full battery charge.

Jump Start Occasionally, it may be necessary to jumpstart a vehicle

with a discharged battery using a vehicle with a good
battery. Follow these procedures to reduce the risk of
personal injury and/or damage to the vehicle(s):
1. Position the vehicle so the jumper cables can reach
both batteries. Do not allow the vehicles to touch
each other.
2. Turn all accessories OFF in both vehicles.
3. Turn the ignition OFF in both vehicles before
connecting the jumper cables.
4. Connect one end of the positive jumper cable to the
positive terminal of the discharged battery. Connect
the other end of the positive jumper cable to the
positive terminal of the booster battery.
5. Connect one end of the negative jumper cable to
the negative terminal of the booster battery.
Connect the other end of the negative jumper cable
to the engine ground of the vehicle with the
discharged battery.
6. Start the engine of vehicle with the booster battery
and allow it to idle.
7. Start the vehicle with the discharged battery.
8. Remove the jumper cables in the reverse order they
were connected; negative jumper cables first, then
positive cables.
CAUTION: Personal injury or vehicle damage can

occur if jumpstarting is done incorrectly.

GR8 MULTITASKING Kia currently uses the GR8-1299 to test batteries,

BATTERY AND ELECTRICAL starting, and charging systems. The GR8 uses two
DIAGNOSTIC STATION methods to test a battery
 Conductance test, determines the battery’s ability to
store electricity
 Load test, determines the battery’s ability to provide
a specific open circuit voltage under a resistance
type load
In most cases, the GR8 can test a battery as received

without recharging it for testing.
Here is a brief overview of the testing procedure.

Before testing:
 Make sure all vehicle accessory loads are OFF and
the ignition is OFF
 If the battery is not installed, clean the battery posts
with a wire brush

__________________ ______________________
_____________________
Use the content of the classroom discussion, and the

GR8-1299 Instruction Manual on your computer
to fill in the blanks in the following section of this module.
•
GR8 COMPONENTS AND• The GR8-1299 has 3 sets of clamps, label the type of
CONTROLS clamp shown above.

CONNECTING TO THE Connect the charging clamps to the battery.

BATTERY
Do not connect either clamp to the ________________.
If you connect the clamps in the wrong polarity
(red to negative or black to positive),
the analyzer__________________________________,
and displays __________________________________.
Make sure ________________________ of the clamps

are gripping the terminals.
Poor connections will prevent testing, and the analyzer

displays the message __________________________.
DIAGNOSTIC CHARGE The diagnostic charge determines the internal condition

of the battery before attempting to charge it.
The charger applies a(n) ________________________

at a known frequency across the terminals and
measure the ____________________________to
determine the battery health.
The diagnostic charge is the most thorough test and
should always be performed when the battery is
questionable.
All Diagnostic Charge tests must include:

 ______________________________
 ______________________________
 ______________________________
 ______________________________

CHARGING MODES Diagnostic Charging has four modes.
 ____________________ – to determine if the

battery is good or needs replacement.
 ____________________ – to determine of the

battery can be recovered if the initial analysis is
negative.
 ___________________ – Once the GR8 determines

that the battery is good, needs charging, and is safe
to charge, it proceeds to the diagnostic charge
mode. During the diagnostic charge, the battery is
charged and the GR8 applies an electrical load to
the battery and measures the CCA to determine if
the battery needs replacing.
 ____________________ – occurs at the end of the

charge cycle to charge a good battery to capacity.

DIAGNOSTIC CHARGING BATTERY DECISION (list the three battery decisions)

TEST RESULTS  _________________________
 _________________________
 _________________________
RATED
 the battery’s rated CCA
VOLTAGE
 battery voltage
MEASURED
 measured CCA
AMP HOURS
 An indication of the total amount of energy the
battery will deliver at a constant rate of discharge
before it drops below 10 volts
CHARGE TIME
 time needed to completely charge the battery
STATE OF HEALTH The battery state of health shows general condition of

the battery and its ability to deliver the specified
performance as compared with a fresh battery.


BATTERY CODE The last six digits of the VIN and battery code for
warranty purposes.
NOTE: A REPLACE BATTERY result may also mean that

there is a poor connection between the battery and the
vehicle. If you tested the battery using the System
Test, disconnect the battery cables and retest the
battery using the Battery Test before replacing it.

ECM Re-Flash The ECM Re-Flash mode maintains the battery voltage
at _____________ volts using the _________________
clamps allowing for uninterrupted power during
programming of computers or retaining vehicle system
settings.
The message above will be displayed if the battery

needs to be charged before entering the ECM Re-Flash
Mode.

Battery Test The battery test performs the Conductance Test using
the test clamps. It is a shorter test then the diagnostic
charge and does not load test or charge the battery.
The battery test guides you through the steps of

selecting test parameters and interpreting the results.
During the battery test, the GR8 may display Additional

Test Requirements which are messages and
instructions to complete analysis of the battery’s
condition.
Additional Test Requirements include the following

(provide the title for each requirement):
 _________________________:
o Computer or ignition noise is present or a
parasitic draw has been detected.
o The battery will need to be retested.
o Be sure that all electrical loads and the ignition
are OFF.
o The tester will automatically retest the battery
when the noise is no longer detected.
 _________________________:
o The battery is weak or has just been charged
o A fully charged battery should stabilize quickly
o Weak batteries should be charged and retested
 _________________________:
o Runs automatically when further analysis is required

Test results include:
 _________________________
 _________________________
Based on the test results, the following battery decision

table indicates the recommended action.


Battery Condition Recommended Action

GOOD BATTERY Return the battery to service
GOOD−RECHARGE Fully recharge the battery and return it to service
CHARGE & RETEST Fully charge the battery and retest. If CHARGE AND
RETEST appears after fully charging the battery,
replace the battery.
REPLACE BATTERY A REPLACE BATTERY result may also mean that there
is a poor connection between the battery and the
vehicle. If you tested the battery using the System
Test, disconnect the battery cables and retest the
battery using the Battery Test before replacing it.
NOTE: When you start a new battery test, the last test
results in memory are overwritten. Record or print the
previous test results if you need to retain them.
CAUTION: Never connect both sets of clamps to the

battery at the same time. Only the test clamps (large
clamps) would be connected to the battery terminals
when performing a battery test.

System Test The system test tests the following systems:

 __________________________
 __________________________
 __________________________
It uses the ___________Clamps to perform all the

tests.
Battery test results are the same as those for the

diagnostic charge and/or battery test.
Starter test results include:

 Average cranking voltage
 Average cranking current (if Amp Clamp connected)
 Cranking time during the test in seconds
 System performance cranking voltage


 Starter code for warranty purposes

 Cable drop test reminder
Based on the test results, the following starter decision

table indicates the recommended action.
Starter Test Results Recommended Action

The starter voltage is normal and the battery is fully
_________________________ charged.
The starter voltage is low and the battery is fully

_________________________ charged.
The starter voltage is low and the battery is

_________________________ discharged. Fully charge the battery and repeat the
starter system test.
Replace the battery before testing the starter.

_________________________
The engine did not start and the test was canceled.
_________________________
The GR8 did not detect the vehicle’s starting profile
_________________________ and skipped the starter test.
Test data was inconclusive using the side post. Retest

_________________________ using side post adapters.
Data was inconclusive using the jump-start post.

_________________________ Retest at the battery terminals.
NOTE: In some cases, the GR8 may not detect the

vehicle’s starting profile and will display the options
STARTED and NO START. Select STARTED to continue
with an alternator test. Select NO START to end the
test.

CHARGING SYSTEM TEST To complete the charging system test you will need to:
 Raise rpm
 Return to idle
 Turn loads ON and OFF
It is easier if you are in the vehicle to follow the test

procedures and instructions on the GR8 to complete the
test.
Charging system test results include.
Load on and off current is displayed when amp clamp is used
 Charging Decision
 Charging voltage, no load
 Charging voltage, load
 Amps, not load (if amp clamp used)
 Amps, loaded (if amp clamp used)
 Bar graph of normal voltage range and NO

LOAD/LOAD test results

 Diode waveform
 Charger code for warranty

 Cable drop test reminder
Based on the test results, the following charging

decision table indicates the recommended action.
Charging System Test Recommended Action

Results
NO PROBLEMS The system is showing normal output from the
generator. No problem detected.
NO VOLTAGE The generator is not providing charging voltage to the

battery.
 Check the generator drive belt and belt tension
 Check all system electrical connections
 Check the voltage regulator (if equipped)
 If all checks out good, replace the generator
LOW VOLTAGE The generator is not providing enough voltage.

 Check the generator drive belt and belt tension
 Check all system electrical connections
HIGH VOLTAGE The voltage output exceeds the normal limits.
 Ensure that there are no loose connections and
that the ground connection is normal
 Check the voltage regulator (if equipped)

CABLE DROP TEST If the starter or charging system tests indicates a

potential problem, you can perform a cable drop test
to determine if the condition is caused by unwanted
resistance in the system’s circuits.
The cable drop test is a voltage drop test. There is no

need to run the engine as the GR8 sends a signal
through the circuit being tested and calculates the
voltage drop based on the results.
The preset tests are:

 ____________________
 ____________________
 ____________________
 ____________________
DO NOT USE THE CHARGING CLAMPS!!!
The cable drop test requires both sets of test leads to

be connected:
 _____________________ connected to the circuit
being tested
 _____________________ across the battery
terminals

After entering the required data and pressing “NEXT”,

the GR8 will display TESTING and a stopwatch while it
evaluates the circuit.
Test results include:

 Circuit Tested
 Circuit Drop (voltage drop total)
 PASS/FAIL
 + Drop (voltage drop on the positive side of the
circuit)
 − Drop (voltage drop on the negative side of the
circuit)
 Code (needed for a warranty claim)

MANUAL CHARGING The GR8 can manually charge the battery using the
Charging Clamps based on your input.
If the battery is safe to be charged, the battery can be

charged at selected levels.
You can set limits for __________________________
If you select CURRENT, what is the available range?

___________________________________________
If you select VOLTAGE, what is the available range?

____________________________________________
What is the minimum charge duration?_______________

What is the maximum charge duration?_______________
What do you select if you want to charge longer than the
maximum charge duration?_________________________
When the manual mode ends, the GR8 displays the

final charge status based on the selected charge
criteria.
An alarm sounds every 30 seconds until the clamps

are disconnected, or the “NEXT” key is pressed.

GR8 TESTS The GR8 Multitasking Battery and Electrical Diagnostic

can perform the following tests.
Data input required for each tests can be found in the

GR8 Data Input table.
GR8 Data Input Table

Data to be Last 6 Battery Vehicle Battery CCA Amp Type of
Entered of VIN IN/OUT of Type Type Clamp Test
vehicle Option
GR8 Test
Diagnostic
Test
      
ECM Re-
Flash

Battery Test     
System Test      
Cable Drop
Test * 
Manual
Charge
 **
* Rated amperage of the circuit being tested

** Set charging voltage or current limit

NOTES:___________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________

Load Testing A battery load test checks the battery’s ability to deliver
voltage under a load. Always follow the service manual
information when testing a battery. To perform a
battery load test:
 Apply a 300A load for 2 seconds to remove any
surface charge.
 Connect a DVOM to the battery terminals to monitor
battery voltage
 Use a load tester and apply a load equal to 1/2 the
Cold Cranking Amps (CCA) rating of the battery for
15 seconds. CCA specs can generally be found on
the battery’s label
 Record the DVOM reading at the end of the 15
second test with the load still applied
 Disconnect the load
The voltage should be above 9.6V with ambient

temperature above 68° F (acceptable voltage is based
on ambient temperature, see appropriate service
information).
CAUTION: Never apply a load to the battery for more

than 15 seconds as it may damage the battery or the
load tester.

Starter Draw Test If you experience a starter motor cranking slowly,

perform a starter current draw test.
To complete the test:
 Connect the positive and negative cable leads from
the tester unit to the vehicle’s battery, and place
the inductive clamp onto the positive cable that
leads to the starter motor
 Remove the fuel pump relay and crank the engine
until the engine stalls
 Set the tester timer on the tester with enough time
to safely enter the vehicle. Crank the engine until
the tester completes the test. Record your results.
Although Kia does not publish starter draw test results,

a reading between 160 - 190 Amps is normal on a cold
engine. Results will be affected by engine size
(cylinders, compression and displacement), and the
temperature at which the test is performed
If the reading is below 160 Amps, look for high

resistance in the starter cables and wring by performing
voltage drop tests on the positive and groundside of
the starter system.
If the reading is above 190 Amps, the starter motor

may be encountering mechanical resistance such as a
tight engine or defective starter motor components.
VIDEO: Starter Draw Test

Current Output Test A series of more traditional load tests may be

performed if the GR8 Multitasking Battery and Electrical
Diagnostic Station is not available.
To perform a generator load test:

 Connect the tester leads to the battery
 Connect the amp probe to the generator output
cable (at least 6 inches from the generator if
possible)
 Set the timer on the tester and press the Generator
Output Test button
The tester will begin to test the generator and the

results will be displayed on the screen.
The reading for a good generator will be within 10% of

the manufacturer specification
If the results are greater than 10%, suspected
components include the generator, regulator, wires, or
connections.
Always refer to the latest service information for exact

procedures and specifications.
NOTE: Some Kia vehicles are regulated internally

within the ECM and are not regulated externally.

SUMMARY The battery, starting, and charging systems are an

important part of the vehicle electrical system. The
battery supplies the source voltage to operate the
starter motor and all electrical accessories when the
engine is OFF.
The starting system relies on the condition of the

battery and the starting system circuits in order to
crank the engine under different operating conditions
and temperatures.
When the engine is running, the charging system must

recharge the battery and carry the electrical load of all
vehicle circuits.
System diagnosis is made easier using the GR8

Multitasking Battery and Electrical Diagnostic Station
which can be used to troubleshoot the condition of the
battery, starting and charging systems.
Helpful troubleshooting charts and procedures can be

found in the service information.
This information can make your troubleshooting steps

more efficient in pinpointing the root cause of an
electrical malfunction in these circuits.

PROGRESS CHECK 1. Which of the following is an advantage of testing a

battery using the GR8?
A. Indirectly checks battery capacity by measuring
circuit resistance
B. The meter reads battery electrolyte directly to
determine state of charge
C. Current output is read directly on the display
D. It can determine how much life is left in the
battery, which is measured by months.
2. What does a battery’s Cold Cranking Amps (CCA)

refer to?
A. The lowest temperature under which the battery
can still start the vehicle
B. The temperature under which the battery stops
providing voltage
C. The amps the battery can deliver at 0° F for 30
seconds while maintaining a voltage ≥ 7.2V
D. The amps the battery can deliver at 0° F for 30
seconds while maintaining a voltage ≥ 12.66V
3. Typically, a parasitic draw test should not be greater

than 0.050A.
A. True
B. False
4. What component completes the circuit between the

battery and the starter motor as well as engages the
pinion gear to the engine flywheel?
A. Overrunning clutch
B. Ignition switch
C. Ignition switch relay
D. Starter solenoid

PROGRESS CHECK 5. The GR8 Multitasking Battery and Electrical

Diagnostic Station can be used to:
A. test the battery
B. test the charging system
C. Test the starting system
D. All of the above
6. The battery converts chemical energy into electrical

energy.
A. True
B. False
7. What is the minimum open circuit voltage reading

on a fully charged battery?
A. 12.00
B. 12.22
C. 12.45
D. 12.66

NOTES:___________________________________________________________________
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__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________


Guided Practice Module
TARGET AUDIENCE The target audience for this diagnostic module consists
of Kia service technicians who have a good
understanding of automotive electrical and have
completed the Battery, Starting, and Charging Systems
Theory Module.
MODULE GOAL This module will give you the opportunity to
demonstrate the skills required to diagnose and
troubleshoot battery, starting, and charging system
concerns.
MODULE OBJECTIVES Given a Digital Volt-Ohm Meter, the GR8-1299, and a
GDS Station, you will perform battery, starting, and
charging system tests with 80% or greater accuracy.
Optional Given a Digital Volt-Ohm Meter, and a load-
type electrical system tester, you will perform battery,
starting, and charging system tests with 80% or greater
accuracy.
MODULE INSTRUCTIONS Follow all shop safety rules
Working in teams of two, each technician will perform
each test.
 The first time through technician 1 will perform the
test and technician 2 will assist and record the
results.
 The second time through technician 2 will perform
the test and technician 1 will assist and record the
results.
following items:
• Digital Volt-Ohm Meter (DVOM)
• GR8 Battery and Electrical Diagnostic Station
• Load Type Electrical System Tester (if available)
 Pen or Pencil
 1 Soul (AM), 1 Optima (TF), 1 Sedona (VQ), 2
Sorento (XM)

GUIDED PRACTICE 1 Assigned Vehicle: _____________________________
Battery State of Charge  Locate a DVOM and bring it to your assigned vehicle
 Confirm that all loads are OFF and that the

ignition is in the OFF position
 Set the DVOM to Volts DC then place the test leads

in their appropriate ports
 Place the DVOM red test lead on the battery

positive terminal and the DVOM black test lead
on the battery negative terminal
 Record your results

__________________________
 What is the battery’s state of charge?

__________________________
Are these results acceptable?
YES NO
 Have the second technician in your team perform

the test
OPEN CIRCUIT VOLTAGE STATE OF CHARGE

12.80 REMOVE SURFACE CHARGE
12.70 AND RETEST
12.66 100%
12.58 90%
12.51 80%
12.45 70%
12.35 60%
12.28 50%
12.20 40%
12.11 30%
12.04 20%
11.97 10%
11.89 0%

Parasitic Draw Test  Use GDS to answer the following questions:
What is the maximum parasitic draw specification?
_________________________________________
How long should you wait before recording your test

results? _________________________________
 Locate a DVOM and bring it to your assigned vehicle
 Confirm that all loads are OFF and that the

ignition switch is in the OFF position
 Set the DVOM to DC Amperage and place the test

leads in their appropriate ports to test for AMPS
CAUTION: If a voltage reading is taken with the meter

leads in the amp ports, the meter’s fuse may blow.
 Loosen the clamp on the negative battery terminal
 1. Place the DVOM black test lead on the

negative battery post
2. Place the DVOM red test lead on the
negative battery clamp
3. Lift the clamp off of the negative battery post
 Record the results __________________________

What are the results in mA? __________________
Are these results within an acceptable range?
YES NO

the test

System Ground  Locate a DVOM and bring it to your assigned vehicle

Voltage Drop
 Confirm that all loads are OFF and that the ignition
switch is in the OFF position
 Set the DVOM to DC Voltage and set the test leads

to measure voltage
 With the Key ON and Engine Running, turn on

the vehicle’s loads including the Electric Defroster,
HVAC Blower set to HIGH speed, Windshield Wipers
on HIGH, and High Beams ON
 1. Place the DVOM black test lead on the

ground terminal of the battery
2. Place the DVOM red test lead on the vehicles
engine ground
 System ground voltage drop readings are normally

less than 0.10 volts
 Record your results __________________________
What are the results in mV? __________________
Are these results within an acceptable range?
YES NO
 Turn the Key OFF and all loads off
Have the second technician in your team perform

the test

Battery Cranking  Locate a DVOM and bring it to your assigned vehicle

Voltage Test
is in the OFF position
 Set the DVOM to DC Voltage and place the test

leads in their appropriate ports
 Remove the fuel pump relay
 Start the car
 Let the engine stall
 1. Connect the DVOM to the battery
2. Place the DVOM black test lead on the

3. Place the DVOM red test lead on the positive

terminal of the battery
 Have your teammate crank the engine for

10 seconds and record the lowest reading
_________________________
Was the reading within an acceptable range?
YES NO

the test
 Do not replace the fuel pump relay
Battery Cranking Voltage Test
Good 10.0 – 11.5 vdc

Test Battery* < 9.6 vdc

Engine Ground (Cranking)  Locate a DVOM and bring it to your assigned vehicle
Voltage Drop

Fuel pump relay should already be removed from the

previous test. If not.
 Start the car
 Let the engine run until it stalls

3. Place the DVOM red test lead on the metal

surface of the engine
This test is performed with the engine cranking.
 Crank the engine for 10 seconds and record the

lowest reading _________________________

(specifications on next page)
YES NO


the test
 Do not replace the fuel pump relay
Engine Ground Voltage Drop
Good 0.10 – 0.30 vdc

Requires Further Testing* > 0.50 vdc

Engine Positive (Cranking)  Place the vehicle on a lift

Voltage Drop
 Locate a DVOM and bring it to your assigned vehicle
Fuel pump relay should already be removed from the

previous test. If not:
 Start the car


positive cable terminal on the starter
 Crank the engine for several seconds and record the

lowest reading _________________________

YES NO

the test
 Replace the fuel pump relay and start the engine,
turn the engine off
Engine Positive Voltage Drop
Good 0.10 – 0.30 vdc

Requires Further Testing* > 0.50 vdc


Charging Voltage Drop  Place the vehicle on a lift

Positive Side  Locate a DVOM and bring it to your assigned vehicle
leads in their appropriate ports on the DVOM
 1. Connect the DVOM
positive terminal of the battery
3. Place the DVOM red test lead on the B+
terminal on the generator
 Start the engine and raise the engine speed to
2000 RPM
 A voltage drop of greater than 0.25 volts indicates
that there is unwanted resistance on the B+ side of
the charging system

YES NO
 Turn the vehicle off
the test

Charging Voltage  Locate a DVOM and bring it to your assigned vehicle

at Battery Posts
 Set the DVOM to DC Voltage and set the test leads
to measure DC voltage on the DVOM


terminal

2,000 RPM
 The result should be 1.0 - 2.0 volts above the Open

Circuit Voltage test results
 Record the results from the Open Circuit Voltage

Test that was performed earlier in this module
_________________________________________
YES NO

the test

Charging Voltage Drop  Locate a DVOM and bring it to your assigned vehicle
Ground Side

negative terminal of the battery
3. Place the DVOM red test lead on the case of

the generator

2,000 RPM
 Test results should be less than 0.15 volts
YES NO

the test

Charging Voltage  Locate a DVOM and bring it to your assigned vehicle

Overcharge/Undercharge

negative terminal of the battery


2,000 RPM
 Turn on the vehicle’s loads such as the

Defroster, Blower (set to high speed), Windshield
Wipers, and High Beams
 Results should be:

 15 volts or lower without a load
 Greater than 13.4 volts with a load
YES NO

the test


 Locate a GR8 and bring it to your assigned vehicle
Diagnostic Charge
 Record the following information:
Last six digits of VIN ________________________
CCA ________________________
 Turn the GR8 ON
 Connect the GR8 Charge clamps to the battery

to the same battery at the same time. Only the charge
clamps of the GR8 should be connected to the battery
when performing the diagnostic charge.
 Use the GR8 Instruction Manual to fill in the

blanks. After you have filled in the blanks, complete
the test
 Select DIAGNOTIC CHARGE from the main menu
 Enter ____________________________ VIN and

press NEXT
 Enter the location of the ______________and press

NEXT
 Enter the ___________________ and press NEXT
 Enter the ___________________ and select NEXT
 Use the keypad to enter the _________________

and press NEXT to start the diagnostic charge
 While the test is running, record the following

information:
Volts _________________
Amps _________________
Amp Hours _________________
Max Time _________________
(Max Time is the time needed to fully charge the
battery)

 Press and hold the STOP button to abort the

diagnostic charge
 Disconnect the charge clamps and turn the GR8 Off

the test

ECM Re-Flash  Locate a GR8 and bring it to your assigned vehicle
 Turn the GR8 ON

to the same battery at the same time. Only the charge
when performing the ECM re-flash.
 Select ECM RE-FLASH from the main menu
 While the ECM re-flash is running, write down the

following information:
Volts _________________
Amps _________________
Voltage Setting _________________
 Press and hold the STOP button to to stop the ECM

re-flash
 Disconnect the charge clamps and turn the GR8 OFF

the test

Battery Test  Locate a GR8 and bring it to your assigned vehicle

CCA ________________________
 Make sure all vehicle accessories are off, the key is

not in the ignition (if applicable) and the doors are
closed
 Turn the GR8 ON
 Connect the GR8 Test clamps to the battery

to the same battery at the same time. Only the test
when performing the battery test.
 Select BATTERY TEST from the main menu
 Enter the last six digits of the VIN and press NEXT
 Enter the location of the battery and press NEXT
 Enter the vehicle type and press NEXT
 Enter the battery type and select NEXT
 Use the keypad to enter the battery rating (CCA)

 Follow the instructions and use the GR8 control

module to get the battery temperature. When the
temperature is entered, press NEXT to start the test.
 After the test has completed, print out the test results
 Press END after you have printed the test results
 Disconnect the Test clamps and turn the GR8 OFF

the test


System Test  Locate a GR8 and bring it to your assigned vehicle

CCA ________________________
 Make sure all vehicle accessories are off, the key is

not in the ignition (if applicable) and the doors are
closed
 Turn the GR8 ON
 Connect the GR8 Test clamps to the battery

to the same battery at the same time. Only the test
when performing the system test.
 Select SYSTEM TEST from the main menu
 Enter the last six digits of the VIN and press NEXT
 Enter if you are using the Amp Clamp option of not

and press NEXT
 Enter the location of the battery and press NEXT
 Enter the vehicle type and press NEXT
 Use the keypad to enter the battery rating (CCA)

 Follow the instructions and use the GR8 control

module to get the battery temperature. When the
temperature is entered, press NEXT to start the test.
 Follow the instructions on the GR8 screen to

complete the test


NOTE: If the GR8 displays “CHARGE & RETEST”

during the system test, press the NEXT key to continue
the test.
 After the system test is complete, print out the test

results
 Disconnect the Test clamps and turn the GR8 OFF

the test

Manual Charge  Turn the GR8 ON
CAUTION: Only the charge clamps of the GR8 should

be connected to the battery when performing a manual
charge.
 Select MANUAL from the main menu
 Select LIMIT VOLTAGE and press the NEXT key to

continue
 Set the voltage limit to 13.5 volts
 Set the charge time to CONTINUOUS and press

NEXT to start the manual charge
NOTE: Let the battery charge for the next group.


(OPTIONAL)
 Locate the AVR and bring it to your workstation
Load Testing a Battery
 Follow the tester instructions for the battery load
(Load Type Electrical System test, or instructions provided by your instructor
Tester)
 Complete the test and answer the following
questions
What is the CCA for the battery being tested?
__________________________________________
What was the voltage reading during the test?
__________________________________________
Did the battery pass the load test? YES NO

the test


(OPTIONAL)
 Locate the AVR and bring it to your workstation
Starter Draw Test
(Load Type Electrical System
Tester)  Start the car
 Follow the tester instructions for the starter draw

test, or instructions provided by your instructor

questions
 Record your results __________________________
YES NO
 Replace the relay. Start the engine and idle for 60

seconds then shut OFF engine.

the test


(OPTIONAL)
 Locate the ARV and bring it to your assigned vehicle
Current Output Test
 Follow the tester instructions for the current output
test, or instructions provided by your instructor

questions
YES NO
 Turn the vehicle OFF

the test

GUIDED PRACTICE The following questions are designed to help you

determine how you would use the tests you performed,
and the results you obtained, when actually diagnosing
a vehicle.
Answer the questions using:
 Information from KGIS
 Content from the theory module (AED.07)
 Your own knowledge
Your instructor will tell you which vehicle information to

use when answering the questions.
Vehicle: _____________________________________
BATTERY 1. When would you perform an open circuit voltage

test?
__________________________________________
__________________________________________
2. An open circuit voltage test result of 12.58 volts

would indicate that the battery is __________ %
charged.
3. When would you load test a battery?
__________________________________________
__________________________________________
4. According to the service manual, what are the four

steps to diagnosing a battery in a 2012 Optima?
1. _______________________________________
2. _______________________________________
3. _______________________________________
4. _______________________________________

5. If the battery state of charge was too low, what

would you do next if you were diagnosing a vehicle
that won’t start after sitting for three days?
__________________________________________
__________________________________________
6. According to the service manual, how long should

you wait for all electrical systems to go to “sleep”
before performing a parasitic draw test?
__________________________________________
7. According to the service manual, when performing a

parasitic draw test the maximum draw should be:
__________________________________________
8. If the results were not within specifications, what

would you do to diagnose the cause of the parasitic
draw?
__________________________________________
__________________________________________
SYSTEM GROUND VOLTAGE 9. When you perform a system ground voltage test,
DROP TEST
you are testing for __________________________
from the __________________________________
to the ____________________________________.
10. What symptoms might you see if the system ground

voltage drop were 0.03 volts?
__________________________________________
__________________________________________

STARTER 11. A battery cranking voltage test result of 8.9 volts

indicates the _______________________ needs
further testing.
12. When would you perform a starter draw test?
_________________________________________
_________________________________________
13. If the result of a starter draw test was 146 amps,

which test would you perform next?
__________________________________________
__________________________________________
14. If a technician was checking the voltage between

the negative battery post and engine block, what
would they be testing?
__________________________________________
__________________________________________
15. An engine positive cranking voltage drop test result

of 0.94 volts would indicate:
__________________________________________
__________________________________________

CHARGING SYSTEM 16. What is a quick way to determine if a charging

system voltage is normal?
__________________________________________
__________________________________________
17. The proper way to perform a current output test is

to test the output with no load, then turn on the
lights, blower and A/C to provide a load and recheck
the output.
True False (circle one)
18. If the charging system had high voltage drop when

testing the ground side, what would you test next?
__________________________________________
__________________________________________
19. According to the service manual, the standard

voltage drop for the alternator output wire is:
__________________________________________
20. What would be the most likely cause of charging

system overcharge?
__________________________________________
__________________________________________
GR8 21. Which GR8 test provides the most thorough battery
test?
__________________________________________
__________________________________________

22. The GR8 Battery Test should be used to confirm

that a battery that is suspected to be
_____________ is actually ______________.
23. What systems does the GR8 System Test test?
__________________________________________
__________________________________________
24. If you get a REPLACE BATTERY result from the

system check, what do you need to do before
replacing the battery?
__________________________________________
__________________________________________
25. The GR8 Manual Charge will charge the battery

based on:
__________________________________________
__________________________________________
__________________________________________

NOTES:___________________________________________________________________
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Automotive Electrical Diagnosis Course

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Automotive Electrical Diagnosis Course

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Automotive Electrical Diagnosis Course

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What does the course aim to teach technicians?

What does the course aim to teach technicians?

What are the different modules covered in the training?

What are the different modules covered in the training?

Automotive Electrical Diagnosis

AED Course Guide 01 1

AED Course Guide 01 2

Automotive Electrical Diagnosis

In this performance-based course, you will

TARGET AUDIENCE Kia Dealership Technicians who have mastered the

PREREQUISITES You must complete the following:

AED Course Guide 01 3

ABOUT TRAINING Today’s complex automotive technology demands that

REVIEW A Review Module gives the technician the opportunity

THEORY A Theory Module explains the subject from basic to

GUIDED PRACTICE The Guided Practice Module affords you the

PERFORMANCE The Performance Assessment Module provides the

AED Course Guide 01 4

ASK QUESTIONS If you do not understand something in this course, ask

TEAMWORK During the hands-on activities, you will often be

LEARN AT EVERY This course is an opportunity for you to learn in a

AED Course Guide 01 5

AED Course Guide 01 6

ICONS Throughout this course you will come across several

NOTE: Indicates additional information to help clarify a

FEEDBACK: Indicates a progress check meant to

CAUTION: Indicates a procedure must be done in a

GUIDED PRACTICE EXERCISE: Indicates an activity

WARNING: Indicates a procedure must be done in a

VIDEO: Indicates there is a video segment

WAIT FOR FURTHER INSTRUCTIONS

AED Course Guide 01 7

PERFORMANCE The Performance Assessment Scorecard is used to

COURSE ACHIEVEMENT A final score of 80% or higher is needed for

AED Course Guide 01 8

Automotive Electrical Diagnosis Review

MODULE GOAL Upon completion of this module you will demonstrate,

MODULE OBJECTIVES Given this module, and information learned from

MODULE INSTRUCTIONS During this review, participate in the discussion to get

Questions are based upon the web courses that are

EXPECTATIONS It is expected that you passed the prerequisite web

TIME TO COMPLETE Approximately: 60 minutes for review

AED Course Guide 01 9

WRITE IN YOUR ANSWER 1. Which of the following is not a load device?

2. Which of the following is typically at the top of an

3. Which of the following best describes wire size on

4. Which of the following best describes hyperlinks on

5. Which of the following is a characteristic of a series

AED Course Guide 01 10

6. Which method is the best for identifying unwanted

7. How is a DVOM connected in a circuit to measure

8. Convert the values listed in the chart below:

9. What does an O.L reading on a DVOM indicate when

AED Course Guide 01 11

10. Which of the following would cause a fuse in a

11. Which of the following would be considered a

12. What do you need to do to the DVOM to measure

AED Course Guide 01 12