Advanced Automotive Fault Diagnosis



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Advanced Automotive Fault Diagnosis
LÔØI NOÙI ÑAÀU, ledklok
2.5.6 On and off load tests
On load means that a circuit is drawing a current.
Off load means it is not! One example where this
may be an issue is when testing a starter circuit.
Battery voltage may be 12 V off load but only
9 V when on load.
A second example is the supply voltage to the
positive terminal of an ignition coil via a high
resistance connection (corroded switch terminal
for example). With the ignition on and the vehicle
not running, the reading will almost certainly be
battery voltage because the ignition ECU switches
off the primary circuit and no volt drop will show
up. However, if the circuit were switched on (with
a fused jumper lead if necessary) a lower reading
would result showing up the fault.
2.5.7 Black box technique
The technique that will be covered here is known
as ‘black box faultfinding’. This is an excellent
technique and can be applied to many vehicle
systems from engine management and ABS to
cruise control and instrumentation.
As most systems now revolve around an ECU,
the ECU is considered to be a ‘black box’, in
other words we know what it should do but how
it does it is irrelevant! Any colour, so long as it’s
black [Henry Ford (1920s)]. I doubt that he was
referring to ECUs though …
Figure 2.3 shows a block diagram that could
be used to represent any number of automobile
electrical or electronic systems. In reality the
arrows from the ‘inputs’ to the ECU and from 
the ECU to the ‘outputs’ are wires. Treating the
ECU as a ‘black box’ allows us to ignore its com-
plexity. The theory is that if all the sensors and
associated wiring to the ‘black box’ are OK, all
the output actuators and their wiring are OK and
the supply/earth connections are OK, then the
fault must be the ‘black box’. Most ECUs are
very reliable, however, and it is far more likely
that the fault will be found in the inputs or 
outputs.
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