Level 3 Diploma in Light Vehicle Maintenance and Repair

QUALIFICATION NO.500/9814/7 UNIT REF:AE06K

TITLE OF TEST :DIAGNOSIS AND RECTIFICATION OF AUTOMOTIVE AUXILIARY
ELECTRICAL FAULTS
LEARNER NAME Adeel Atcha NUMBER

DATE TEST TAKEN 19-11-23

ASSESSOR NAME Paul Branswood

SIGNATURE PIN NO.

RESULT % PASS REFERRED

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WRITTEN ASSESSMENTS
UNIT REF:
DIAGNOSIS AND RECTIFICATION OF AUTOMOTIVE AUXILIARY
AE06K
ELECTRICAL FAULTS

Pass Mark 60%

This assignment is allocated 100 marks (50 marks awarded for each of the two selected systems). Because of the nature of
the unit, acceptable answers may vary considerably. It is expected that the assessor will allocate marks accordingly.

This assignment is designed to show an understanding of diagnosis and rectification of vehicle auxiliary electrical systems
and their units. It also covers the evaluation of performance of the systems.

Assignment:

Select a vehicle from your normal place of work (e.g. college, training centre, or garage workshop).
Select one system from section A and one system from section B:

A. Electric Window B. Heater, Cooling and Air Conditioning

Electric Mirror Integrated Security/Warning
Wiper and Washer Lighting
Central Locking Supplementary Restraint and Airbag

For each of the two selected systems:

1. Provide a detailed description of the construction and operation. 10 marks AC (1.1, 1.2, 1.3, 2.2)

2. Analyse two different typical electrical faults - one for each of the systems chosen. Explain the symptoms and
causes of the faults.(10 marks) AC (1.1, 1.2, 1.3, 2.2)

3. Explain the systematic diagnostic techniques used to identify the faults. Include the complete process; from initial
inspection through to confirmation of the faults.(10 marks) AC (3.1, 3.3)

4. Explain the type of diagnostic measurements and readings expected to be found during the process, and how these
readings would compare to the manufacturer’s specifications.
(10 marks) AC ( 3.6)

5. Explain the rectification process to correct the faults; include the selection and preparation of any equipment used,
the correction procedure (unit replacement or adjustment) and the evaluation of the repaired system to confirm
performance. (10 marks) AC (3.4, 3.6, 3.7)

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Assignment guidance:
The assignment should:

 be all your own work and contain approximately 600-900 words for each of the two systems
 show in-depth knowledge of each system and a clear understanding of the diagnostic processes and rectification
activities

The assignment should include:

 at least one labeled diagram for each system

 at least one circuit diagram for each system
 supporting technical data
 vehicle details (make, model, VIN)

When completing this summative assignment you should refer to the following assessment criteria for the unit
AE06k:

1.1 Explain the principles of electrical inputs, outputs. voltages and oscilloscope patterns, digital and fibre optics
1.2 Explain the principles of sensor inputs, computer processing and actuator outputs
1.3 Identify sensor types (passive and active)
1.4 Identify the electrical principles that are related to light vehicle electrical circuits
2.1 Identify advanced automotive auxiliary electrical system components
2.2 Explain the construction and operation of automotive auxiliary electrical systems
2.3 Explain the interaction between electrical, electronic and mechanical components within the system defined
2.4 Explain the operation of the electrical and electronic systems for electric, hybrid and alternative fuel vehicles including regenerative
braking systems
2.5 Explain how electrical systems interlink and interact, including multiplexing and fibre optics
2.6 Compare automotiveauxiliary electrical system components and assemblies against alternatives to identify differences in
construction and operation
3.1 Explain the symptoms and causes of faults found in automotive auxiliary electrical systems
3.2 Explain systematic diagnostic techniques used in identifying automotive auxiliary electrical system fault
3.3 Explain how to examine, measure and make suitable adjustments to components
3.4 Explain how to carry out the rectification activities in order to correct the faults in the automotiveauxiliary electrical systems
3.5 Explain how to select, prepare and use diagnostic and rectification equipment for automotiveauxiliary electrical systems
3.6 Explain how to evaluate and interpret test results found in diagnosing automotiveauxiliary electrical system faults against vehicle
manufacturer specifications and settings
3.7 Explain how to evaluate the operation of components and systems following diagnosis and repair to confirm system performance

Ford focus 2005

K77 SBY

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Electrical window

1. Provide a detailed description of the construction and operation.

Lift down
Lift up

Construction

The window lift uses a linkage to lift the window glass while keeping it level. A small electric motor is attached
to a worm gear and other gears to create a larger gear reduction, giving it enough torque t lift the window. The
linkage has a long arm, which attaches to a bar that holds the bottom of the window. The end of the arm can
slide in a groove in the bar as the window rises. On the other end of the bar is a large plate that has gear teeth
cut into it, the motor turns a gear that engages these teeth.

Simple power window system – The power is fed through a 20 amp circuit breaker. The power comes into the
window – switch control panel on the door and is distributed to a contact in the center of each of the four
window switches. Two contacts, on either side of the power contact, are connected to the vehicle ground and to
the motor. The power also runs through the lockout switch to each of the doors. When the driver pressed one of
the switches one of the two side contacts is disconnected from the ground and connected to the centre power
contact, while the other one remains grounded. This provides power to the window motor. If the switch I
pressed another way then power runs through the motor in the opposite direction.

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Advanced power window system

The power window work in a complete different way, instead of the power for the motor going through the
switches directly, the switches are connected to one of many electronic modules in the car. If the driver presses
his window switch, the door module closes a relay that provides power to the window motor.

2. Analyse two different typical electrical faults - one for each of the systems chosen. Explain the symptoms and causes of
the faults.

No power supply, when a power fails to operate a short checklist helps to narrow the possible causes. If all the windows
stopped working at once, a loss of power of the system is likely, when all windows quit working simultaneously, first
check for a blown fuse or bad relay.

Certain power window function switch not functioning

When a certain power window fails to operate, a possibly cause to the particular switch or wiring harness. It
may lose connection or damage the switch.

3. Explain the systematic diagnostic techniques used to identify the faults. Include the complete process; from initial
inspection through to confirmation of the faults.

Electric power window

Symptoms – electric power window malfunction.

Possible cause will be, if all unit not operating open circuit in the main supply, main fuse blown, relay coil or
contacts open circuit or high resistance.

Possible cause will be fuse blown, control switch open circuit, motor seized, open circuit, back – off safety
circuit signal (windows)

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Auxiliary systems diagnostic chart

4. Explain the type of diagnostic measurements and readings expected to be found during the process, and how these
readings would compare to the manufacturer’s specifications.

Voltage drop testing

Finding current at the motor, below system voltage. High resistance in the circuit. If the system voltage is 12 volts, we
have resistance in the circuit. This may cause the motor to run slowly or not at all. High resistance can also cause repeat
motor failures.

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Testing analogue power window switches

When we are not using the window switch, it is in the rest state, no current will flow to the motor on either wire. If we
check the connector at the motor, neither of the leads will show current when we check to ground. Both leads may show
continuity to ground, depending on the design of the switch.

Switch at window down

Pressing the switch to lower down a window, directs current to one wire and grounds the other wire. Direct current flow
in this position causes the motor to rotate and lower the window. The connector will show 12 volts between their two
wires and -12 volts if you reverse the tests.

Switch at window up

To raise the power window, push the switch in the opposite direction. This reverses the current flow within the switch.
The terminal which has 23 volts in the lowering position has become the ground in the raising position. The lead that
grounds the motor when lowering the window becomes the current source when the window is raised. By reversing the
current flow to the motor, which causes it to rotate and change the opposite direction, turning one way will lower the
window and rotating in the other direction will raise the window.

5. Explain the rectification process to correct the faults; include the selection and preparation of any equipment used, the
correction procedure (unit replacement or adjustment) and the evaluation of the repaired system to confirm performance.

Electrical window: After going through the diagnosed with symptom no power supply to the window motor. Possible
cause will be blown fuse or relay. So we can verify it with several tests on the fuse or relay with the help of a multimeter
for resistance test for both fuse and relay unit for electric windows.

Lighting.

1. Provide a detailed description of the construction and operation.

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