Electrical and Electronic Diagnostics

For Vehicle Air Conditioning

Prepared for

WIRE & GAS 2013 Training Convention

Sam Nazarian

Jack Stepanian

Long Reef Garage

Circuit Diagrams Supplied with Courtesy of

All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior notice. ALL conditions prescribed under the copyright act are reserved. No

part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence

For Circuit diagrams, connector Location/end views and pin configurations please see

TAT, Rellim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, and Automotive Service Solution

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

2 of 54

Acknowledgement and references Authors wish to acknowledge that information gathered and collated for the purpose of research and development of this is training manual was based on actual measurements from a BA Ford Falcon vehicle

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Rellim, Bookworks, Repco Auto Tech Encyclopedia, Auto Data and Automotive Service Solution

Information contained herewith is limited to Engine management and CAN BUS. For more information regarding Pin configuration, Circuit Diagrams and location of connectors please kindly contact above mentioned organizations. Information contained within is NOT intended to be used as a ‘stand alone’ training manual and or a reference material– rather as a reference material (an adjunct) to be used during training session. Websites accessed to gain information regarding Engine management and CAN BUS Operation, Configuration and Topology please, see ‘References’ at end of this training manual. Special thanks to Jeff Smit (Technical editor TAT) and Ken Newton (TAT) for their implausible editorial assistance, encouragement and moral support.

Authors would also like to thank the following organization for their unparalleled support and assistance in providing information, access to data and use of their scan tools (herewith contained in this training manual);

The Automotive Technician

(TAT)

Repco

Auto Tech Encyclopedia

Auto Data PC Based

DATA Base

Hanatech G-Scan

Mount Auto EQ

Autel

MaxDas InterEquip

Automotive

Service Solution

Relim

Bookworks Wiring Diagrams

Pico-Scope

PC USB Mount Auto EQ

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

3 of 54

Technician A

Technician B

Starting point

Pool of Knowledge

Gained Knowledge

Gained Knowledge

The essence of diagnostics is to apply gathered knowledge to maximize honing-in skills and minimize guess-work, thus avoiding unnecessary replacement of components.

After all, it isn’t what you know but rather it is the application of knowledge that makes the difference in diagnosing symptomatic vehicles

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

4 of 54

Basic steps of Diagnosis Initial BASIC checks

1. Listen to customer’s complaint 2. Listen to car’s complaint 3. Carry out basic checks 4. Check battery supply, charge voltage (AC, DC waveform) 5. Check battery Grounds (disable car from start – Post to block, chassis, terminal) 6. Carry out basic Wiggle test (wiggle connectors and electrical cables for possible bad connectivity) 7. Listen for Vacuum leaks 8. Observe possible restriction (inlet, exhaust) 9. Extract OBD generic diagnostic Trouble codes

In-Depth Diagnostics

1. Inform Customer 2. Obtain budget commitment 3. Extract specific diagnostic Trouble codes from each and every control module on the CAN BUS 4. Interrogate Diagnostic trouble codes and identify frequent codes (common codes yet reported by differing control

units) 5. Determine whether symptom is due to ‘failing’ CAN BUS communication and or specific control unit (sensor/control) 6. If symptom is CAN BUS related: Obtain Block diagram of CAN BUS Topology 7. If symptom is specific control unit ( sensor/control) related: obtain circuit diagram 8. Measure supply and ground voltages of that specific ECM and Capture waveforms (of suspect component) 9. Keep customer informed of progress 10. Prepare Invoice (Diagnosis / Remove and replace) 11. Inform customer of final costing 12. Hand over (show photos, captured waveforms colored circuit diagrams and other supporting material)

PRE

POST

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

5 of 54

The Process of Diagnostics Triangulation Technique 1 – Carry out a system wide DTC check (note, each and every DTC) 2 – Communicate with each and every control unit and pay particular attention as to which control unit is ‘responsible’ for reporting the DTC (if any) and carry out actuation test based on customers’ concern/symptom 3 – Obtain circuit diagram and interrogate circuitry by:

Query the following: ‘should this component fail - what will the symptom be’?

And then carry out specific component tests based on customer symptom/complain.

Minimum MUST HAVE arsenals (access to the following):

Scan Tool

Circuit Diagram (CAN BUS Topology, specific diagrams and so on)

Location of component’s (Sensors, Connectors, Control units)

Oscilloscope

1

System Wide Diagnostic Check

Communicate with each and every control unit

2

Obtain Circuit Diagram

3

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

6 of 54

1

System Wide Diagnostic Check

Perform system wide DTC check, note, each and every DTC

1

2

3

4

5

6

7

8

9

1 – 1

2005, Holden, Commodore VZ, 3.6, DLC

10

11

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

7 of 54

1

System Wide Diagnostic Check

1 – 2 Obtain diagram

2007, Holden, Commodore VE, 3.6, DLC

Air Conditioning Controls and CAN BUS (controller Area Network Bidirectional Universal system) Obtain CAN BUS Topology by accessing automotive data-base of CAN BUS diagram

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

8 of 54

1

System Wide Diagnostic Check

1 – 2 Obtain Diagram

2007, Holden, Commodore VE, 3.6, DLC

1

2

3

4

5

6

7

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

9 of 54

Plug Scan tool into DLC and make sure that scan tool ‘powers-up’ If not, measure supply (pin 16) and grounds at (pins 4 and 5) DLC

2007, Holden, Commodore VE, 3.6, DLC

1

System Wide Diagnostic Check

1 – 3

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

10 of 54

Plug Scan tool into DLC and make sure that scan tool ‘powers-up’ If not, measure supply (pin 16) and grounds at (pins 4 and 5) DLC

2 volt / div

1 second / div

100 mv / div

1 second / div

2007, Holden, Commodore VE, 3.6, DLC

1 – 4

1

System Wide Diagnostic Check

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

11 of 54

Identify and note each and every control unit in the diagram

Data BUS connector

DLC

TCM

ABS

Head Lamp Leveling control

ECM

AC

TPMS

Seat adj cont mod

Park contr

SRS

Alarm

NAV

Mobile

Ins PNL

Auto

SAS Multi -

Function Control

Unit

2007, Holden, Commodore VE, 3.6, DLC

1

System Wide Diagnostic Check

1 – 5

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

12 of 54

Identify resistor LOCATIONS of High speed CAN BUS (Controller Area Network Bidirectional Universal Signal) terminating resistors of 120 Ohms each.

Data BUS connector

DLC

TCM

ABS

Head Lamp Leveling control

ECM

AC

TPMS

Seat adj cont mod

Park cont

SRS

Alarm

NAV

Mobile

Ins

PNL

SAS Multi -

Function Control

Unit

Terminating resister 120

Terminating resister 120

2007, Holden, Commodore VE, 3.6, DLC

1

System Wide Diagnostic Check

1 – 6

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

13 of 54

Identify and trace High side of High speed CAN BUS

Data BUS connector

DLC

TCM

ABS

Head Lamp Leveling control

ECM

AC

TPMS

Seat adj cont mod

Park cont

SRS

Alarm

NAV

Mobile

Ins

PNL

SAS Multi -

Function Control

Unit

Terminating resister 120

Terminating resister 120

2007, Holden, Commodore VE, 3.6, DLC

1

System Wide Diagnostic Check

1 – 7

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

14 of 54

Identify and trace Low side of High speed CAN BUS

Data BUS connector

DLC

TCM

ABS

Head Lamp Leveling control

ECM

AC

TPMS

Seat adj cont mod

Park cont

SRS

Alarm

NAV

Mobile

Ins

PNL

SAS Multi -

Function Control

Unit

Terminating resister 120

Terminating resister 120

2007, Holden, Commodore VE, 3.6, DLC

1

System Wide Diagnostic Check

1 – 8

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

15 of 54

Measure resistance between High side of High speed BUS (pin 6) and Low side if the High speed BUS (pin 14) and since two 120 Ohm resistors are in parallel then the measured resistance MUST be 60 Ohms (approx..) Please note: for resistance measurements there must NOT be any voltage activities. The High speed BBUS must be ‘SLEEP’. Allow 3 minutes after Ignition key out of barrel to allow voltage activities to cease

Data BUS connector

DLC

TCM

ABS

Head Lamp Leveling control

ECM

AC

TPMS

Seat adj cont mod

Park cont

SRS

Alarm

NAV

Mobile

Ins

PNL

SAS Multi -

Function Control

Unit

Terminating resister 120

Terminating resister 120

2007, Holden, Commodore VE, 3.6, DLC

1

System Wide Diagnostic Check

1 – 9

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

16 of 54

DataBUS connector

DLC

TCM

ABS

Head Lamp Leveling control

ECM

AC

TPMS

Seat adj cont mod

Park cont

SRS

Alarm

NAV

Mobile

Ins

PNL

SAS Multi -

Function Control

Unit

Terminating resister 120

Terminating resister 120

2007, Holden, Commodore VE, 3.6, DLC

Measure waveform of High side of High speed BUS (pin 6) and Low side if the High speed BUS (pin 14) and observe ‘fidelity’ of the signal High side of high speed BUS should oscillate between from 2.5 volts up to 3.5 volts (approx.) Similarly the Low side of the high speed BUS should oscillates from 2.5 volts down to 1.5 volts (approx.)

1 volt / div

20 micro sec / div

1

System Wide Diagnostic Check

1 – 10

1 volt / div

20 micro sec / div

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

17 of 54

Identify the module that is assigned as Gateway Gateway is the ‘mediator’ and or the ‘translator’ (if you will) between High and low speed BUSs

Data BUS connector

DLC

TCM

ABS

Head Lamp Leveling control

ECM

AC

TPMS

Seat adj cont mod

Park cont

SRS

Alarm

NAV

Mobile

Ins

PNL

SAS

Multi -Function Control Unit is

THE GATEWAY

Terminating resister 120

Terminating resister 120

2007, Holden, Commodore VE, 3.6, DLC

1

System Wide Diagnostic Check

1 – 11

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

18 of 54

Trace Low Speed BUS

Data BUS connector

DLC

TCM

ABS

Head Lamp Leveling control

ECM

AC

TPMS

Seat adj cont mod

Park cont

SRS

Alarm

NAV

Mobile

Ins

PNL

SAS

Multi -Function Control Unit is

THE GATEWAY

Terminating resister 120

Terminating resister 120

2007, Holden, Commodore VE, 3.6, DLC

1

System Wide Diagnostic Check

1 – 12

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

19 of 54

Measure waveform of Low Speed BUS and observe fidelity of signal

Data BUS connector

DLC

TCM

ABS

Head Lamp Leveling control

ECM

AC

TPMS

Seat adj cont mod

Park cont

SRS

Alarm

NAV

Mobile

Ins

PNL

SAS

Multi -Function Control Unit is

THE GATEWAY

Terminating resister 120

Terminating resister 120

2007, Holden, Commodore VE, 3.6, DLC

2 volt / div 1 sec / div Insert Key IN, crank

and start engine

2 volt / div 1 sec / div

5 min after IGN OFF

2 volt / div 40 milli sec / div

Whilst engine running

2 volt / div 0.2 milli sec / div Whilst engine running

1

System Wide Diagnostic Check

1 – 13

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

20 of 54

Communicate with each and every control unit and pay particular attention as to which control unit is ‘responsible’ for reporting the DTC (if any) and carry out actuation test based on customers’ concern/symptom Log in-to Autodata

Select year, Manufacturer, Mode range, engine

Wiring Diagram

ADDITIONAL Circuit Diagram

Data Link Connector (DLC)

2 – 1

Communicate with each and every control unit and carry out actuation test unit

2

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

21 of 54

Trace and highlight supply (pin 16) and grounds at (pins 4 and 5) DLC

2005, Holden, Commodore VZ, 3.6, DLC

2 – 2

Communicate with each and every control unit and carry out actuation test unit

2

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

22 of 54

2005, Holden, Commodore VZ, 3.6, DLC

Identify and note each and every control unit in the diagram

TCM

ABS

SAS

ECM

Interface Module

Inst Contr Mod

AC

Seat Adj

Contr Mod

SRS

Audio

Multi Funct Contr Unit

DLC

2 – 3

Communicate with each and every control unit and carry out actuation test unit

2

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

23 of 54

2005, Holden, Commodore VZ, 3.6, DLC

TCM

ABS

SAS

ECM

Interface Module

Inst Contr Mod

AC

Seat Adj

Contr Mod

SRS

Audio

Multi Funct Contr Unit

DLC

Identify resistor LOCATIONS of High speed CAN BUS (Controller Area Network Bidirectional Universal Signal) terminating resistors of 120 Ohms each.

2 – 4

Communicate with each and every control unit and carry out actuation test unit

2

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

24 of 54

2005, Holden, Commodore VZ, 3.6, DLC

TCM

ABS

SAS

ECM

Interface Module

Inst Contr Mod

AC

Seat Adj

Contr Mod

SRS

Audio

Multi Funct Contr Unit

DLC

2005, Holden, Commodore VZ, 3.6, DLC

TCM

ABS

SAS

ECM

Interface Module

Inst Contr Mod

AC

Seat Adj

Contr Mod

SRS

Audio

Multi Funct Contr Unit

DLC

Identify and trace High side of High speed CAN BUS

2 – 5

Communicate with each and every control unit and carry out actuation test unit

2

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

25 of 54

2005, Holden, Commodore VZ, 3.6, DLC

TCM

ABS

SAS

ECM

Interface Module

Inst Contr Mod

AC

Seat Adj

Contr Mod

SRS

Audio

Multi Funct Contr Unit

DLC

2005, Holden, Commodore VZ, 3.6, DLC

TCM

ABS

SAS

ECM

Interface Module

Inst Contr Mod

AC

Seat Adj

Contr Mod

SRS

Audio

Multi Funct Contr Unit

DLC

Identify and trace Low side of High speed CAN BUS

2 – 6

Communicate with each and every control unit and carry out actuation test unit

2

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

26 of 54

2005, Holden, Commodore VZ, 3.6, DLC

TCM

ABS

SAS

ECM

Interface Module

Inst Contr Mod

AC

Seat Adj

Contr Mod

SRS

Audio

Multi Funct Contr Unit

DLC

2005, Holden, Commodore VZ, 3.6, DLC

TCM

ABS

SAS

ECM

Interface Module

Inst Contr Mod

AC

Seat Adj

Contr Mod

SRS

Audio

Multi Funct Contr Unit

DLC

Identify the module that is assigned as Gateway Gateway is the ‘mediator’ and or the ‘translator’ (if you will) between High and low speed BUSs

Interface Module

is THE GATEWAY

2 – 7

Communicate with each and every control unit and carry out actuation test unit

2

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

27 of 54

2005, Holden, Commodore VZ, 3.6, DLC

TCM

ABS

SAS

ECM

Interface Module

Inst Contr Mod

AC

Seat Adj

Contr Mod

SRS

Audio

Multi Funct Contr Unit

DLC

2005, Holden, Commodore VZ, 3.6, DLC

TCM

ABS

SAS

ECM

Interface Module

Inst Contr Mod

AC

Seat Adj

Contr Mod

SRS

Audio

Multi Funct Contr Unit

DLC

Interface Module is THE

GATEWAY

Trace Low Speed BUS

2 – 8

Communicate with each and every control unit and carry out actuation test unit

2

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

28 of 54

2005, Holden, Commodore VZ, 3.6, DLC

TCM

ABS

SAS

ECM

Interface Module

Inst Contr Mod

AC

Seat Adj

Contr Mod

SRS

Audio

Multi Funct Contr Unit

DLC

2005, Holden, Commodore VZ, 3.6, DLC

TCM

ABS

SAS

ECM

Interface Module

Inst Contr Mod

AC

Seat Adj

Contr Mod

SRS

Audio

Multi Funct Contr Unit

DLC

Interface Module is THE

GATEWAY

Trace Low Speed BUS

2 – 9

Communicate with each and every control unit and carry out actuation test unit

2

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

29 of 54

2005, Holden, Commodore VZ, 3.6, DLC

TCM

ABS

SAS

ECM

Interface Module

Inst Contr Mod

AC

Seat Adj

Contr Mod

SRS

Audio

Multi Funct Contr Unit

DLC

2005, Holden, Commodore VZ, 3.6, DLC

TCM

ABS

SAS

ECM

Interface Module

Inst Contr Mod

AC

Seat Adj

Contr Mod

SRS

Audio

Multi Funct Contr Unit

DLC

Communicate with each and every control unit

pay particular attention as to which control unit is ‘responsible’ for reporting the DTC (if any) and

carry out actuation test based on customers’ concern/symptom

Interface Module is THE

GATEWAY

2 – 10

Communicate with each and every control unit and carry out actuation test unit

2

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

30 of 54

Obtain circuit diagram and carry out specific component test based on customers’ concern/symptom and determine course of action!

Obtain Circuit Diagram

3

3 – 1

2000, Holden, Commodore VX, 3.8, AC

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

31 of 54

3 – 2 Access Circuit Diagram and analyze the operation

Obtain Circuit Diagram

3

2000, Holden, Commodore VX, 3.8, AC

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

32 of 54

AC Heater Blower

Heater Blower speed resistor

AC Heater Function Control

AC Comp clutch

AC Heater Clutch Relay

DLC

AC Refrgrnt

pressure sensor

Engine Coolant Blower Motor 1

Engine Coolant Blower Motor 2

Multi Func Contr Unit

Engine Control Relay

AC Master Switch

Engine Coolant Blower Motor Relay 1

3 – 3 Label each and every component

ECM

Heater Blower relay 2

Heater Blower relay 1

2000, Holden, Commodore VX, 3.8, AC

Obtain Circuit Diagram

3

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

33 of 54

AC Heater Blower

Heater Blower speed resistor

AC Heater Function Control

AC Comp clutch

AC Heater Clutch Relay

DLC

AC Refrgrnt pressure

sensor

Engine Coolant Blower Motor 1

Engine Coolant Blower Motor 2

Multi Func Contr Unit

Engine Control Relay

AC Master Switch

Engine Coolant Blower Motor Relay 1

3 – 4 Highlight Supply

ECM

Heater Blower relay 2

Heater Blower relay 1

2000, Holden, Commodore VX, 3.8, AC

Obtain Circuit Diagram

3

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

34 of 54

AC Heater Blower

Heater Blower speed resistor

AC Heater Function Control

AC Comp clutch

AC Heater Clutch Relay

DLC

AC Refrgrnt pressure

sensor

Engine Coolant Blower Motor 1

Engine Coolant Blower Motor 2

Multi Func Contr Unit

Engine Control Relay

AC Master Switch

Engine Coolant Blower Motor Relay 1

3 – 5 Highlight Grounds

ECM

Heater Blower relay 2

Heater Blower relay 1

2000, Holden, Commodore VX, 3.8, AC

Obtain Circuit Diagram

3

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

35 of 54

AC Heater Blower

Heater Blower speed resistor

AC Heater Function Control

AC Comp clutch

AC Heater Clutch Relay

DLC

AC Refrgrnt pressure

sensor

Engine Coolant Blower Motor 1

Engine Coolant Blower Motor 2

Multi Func Contr Unit

Engine Control Relay

AC Master Switch

Engine Coolant Blower Motor Relay 1

3 – 5 Scenario 1 Clutch does not cut in. In order to identify component that may be the cause of symptom! One MUST consider the conditions that need to be met so that the system works properly. So, let’s assume that the compressor is NOT cutting in! And let’s assume that we do have good grounds and good supplies as highlighted.

ECM

Heater Blower relay 2

Heater Blower relay 1

2000, Holden, Commodore VX, 3.8, AC

Obtain Circuit Diagram

3

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

36 of 54

AC Heater Blower

Heater Blower speed resistor

AC Heater Function Control

AC Comp clutch

AC Heater Clutch Relay

DLC

AC Refrgrnt pressure

sensor

Engine Coolant Blower Motor 1

Engine Coolant Blower Motor 2

Multi Func Contr Unit

Engine Control Relay

AC Master Switch

Engine Coolant Blower Motor Relay 1

3 – 6 Scenario 1 Clutch does not cut in. As ignition switch is turned to the position one (ignition ON) the heater blower relay will become energized and pull the contacts in – and by doing so the relay now provides ground potential to the AC heater function control

ECM

Heater Blower relay 2

Heater Blower relay 1

2000, Holden, Commodore VX, 3.8, AC

Obtain Circuit Diagram

3

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

37 of 54

AC Heater Blower

Heater Blower speed resistor

AC Heater Function Control

AC Comp clutch

AC Heater Clutch Relay

DLC

AC Refrgrnt pressure

sensor

Engine Coolant Blower Motor 1

Engine Coolant Blower Motor 2

Multi Func Contr Unit

Engine Control Relay

AC Master Switch

Engine Coolant Blower Motor Relay 1

3 – 7 Scenario 1 Clutch does not cut in. However, AC system will NOT work until the AC heater function control is turned ON to have the heater blower operating! Indeed by doing so, all positions of AC heater function control (naturally other than off position) will provide near zero volts to the Multi-Function Control unit. (pin 3)

ECM

Heater Blower relay 2

Heater Blower relay 1

2000, Holden, Commodore VX, 3.8, AC

Obtain Circuit Diagram

3

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

38 of 54

AC Heater Blower

Heater Blower speed resistor

AC Heater Function Control

AC Comp clutch

AC Heater Clutch Relay

DLC

AC Refrgrnt pressure

sensor

Engine Coolant Blower Motor 1

Engine Coolant Blower Motor 2

Multi Func Contr Unit

Engine Control Relay

AC Master Switch

Engine Coolant Blower Motor Relay 1

3 – 8 Scenario 1 Clutch does not cut in. Having the blower fan ON will only blow ‘HOT AIR’. And in order to activate the compressor clutch, the AC Master switch MUST be turned ON And by doing so, the AC Master Switch will now provide 12 volts signal supply to the Multi-Function control Unit (pin 9)

ECM

Heater Blower relay 2

Heater Blower relay 1

2000, Holden, Commodore VX, 3.8, AC

Obtain Circuit Diagram

3

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

39 of 54

AC Heater Blower

Heater Blower speed resistor

AC Heater Function Control

AC Comp clutch

AC Heater Clutch Relay

DLC

AC Refrgrnt pressure

sensor

Engine Coolant Blower Motor 1

Engine Coolant Blower Motor 2

Multi Func Contr Unit

Engine Control Relay

AC Master Switch

Engine Coolant Blower Motor Relay 1

3 – 9 Scenario 1 Clutch does not cut in. And should BOTH conditions be satisfied by the Multi-function Control Unit (12volts on pin 9 and 0 volts on pin 3) Then, the Multi-function Control Unit will put a serial data bus communication (via its pin 2) to Electronic Control Module informing it those conditions to apply the compressor clutch solenoid have been met. Same information is also available on DLC pin 9 (for scan tool interrogation)

ECM

Heater Blower relay 2

Heater Blower relay 1

2000, Holden, Commodore VX, 3.8, AC

Obtain Circuit Diagram

3

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

40 of 54

AC Heater Blower

Heater Blower speed resistor

AC Heater Function Control

AC Comp clutch

AC Heater Clutch Relay

DLC

AC Refrgrnt

pressure sensor

Engine Coolant Blower Motor 1

Engine Coolant Blower Motor 2

Multi Func Contr Unit

Engine Control Relay

AC Master Switch

Engine Coolant Blower Motor Relay 1

3 – 10 Scenario 1 Clutch does not cut in. ECM however is programmed NOT to apply the compressor clutch unless there is adequate R143A refrigerant present in the system Should it be higher or lower than threshold levels of the Feed Back information provided by the Air conditioning refrigerant pressure sensor, then the clutch will not be activated. Whilst there are many other ECM sensors that can affect the operation, the ACP sensors operation varying voltage information is paramount to the operation of AC clutch

ECM

Heater Blower relay 2

Heater Blower relay 1

2000, Holden, Commodore VX, 3.8, AC

Obtain Circuit Diagram

3

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

41 of 54

AC Heater Blower

Heater Blower speed resistor

AC Heater Function Control

AC Comp clutch

AC Heater Clutch Relay

DLC

AC Refrgrnt pressure

sensor

Engine Coolant Blower Motor 1

Engine Coolant Blower Motor 2

Multi Func Contr Unit

Engine Control Relay

AC Master Switch

Engine Coolant Blower Motor Relay 1

3 – 11 Scenario 1 Clutch does not cut in. And should the ECM be satisfied by the operation voltage range of 1.8volts and 4.5volts, ECM will then provide an earth return path to the coil of the relay (will ground the relay)

ECM

Heater Blower relay 2

Heater Blower relay 1

2000, Holden, Commodore VX, 3.8, AC

Obtain Circuit Diagram

3

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

42 of 54

AC Heater Blower

Heater Blower speed resistor

AC Heater Function Control

AC Comp clutch

AC Heater Clutch Relay

DLC

AC Refrgrnt pressure

sensor

Engine Coolant Blower Motor 1

Engine Coolant Blower Motor 2

Multi Func Contr Unit

Engine Control Relay

AC Master Switch

Engine Coolant Blower Motor Relay 1

3 – 12 Scenario 1 Clutch does not cut in. And as the ignition switch is turned ON [position one - ignition ON) the relay will be triggered and the grounding path provided by the ECM’s earth will enable the relay to be pulled in. And by doing so, the compressor clutch solenoid will now be energized and turned on.

ECM

Heater Blower relay 2

Heater Blower relay 1

2000, Holden, Commodore VX, 3.8, AC

Obtain Circuit Diagram

3

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

43 of 54

AC Heater Blower

Heater Blower speed resistor

AC Heater Function Control

AC Compressor clutch

AC Heater Clutch Relay

DLC

AC Refrgrnt pressure

sensor

Engine Coolant Blower Motor 1

Engine Coolant Blower Motor 2

Multi Func Contr Unit

Engine Control Relay

AC Master Switch

Engine Coolant Blower Motor Relay 1

3 – 13 Scenario 1 Clutch does not cut in. Observe High pressure manifold pressure either by using an A - Oscilloscope (waveform) or B - Displayed in KPA and varying voltage in data list on the Scan tool ECM

Heater Blower relay 2

Heater Blower relay 1

2000, Holden, Commodore VX, 3.8, AC

Obtain Circuit Diagram

3

500milli volt / div 40 sec / div

As AC is turned ON, pressure builds up

1Amp / div 1 sec / div

Switching AC On & OFF

Built up of AC Pressure can be simulated

with the use of 5Killo Ohm variable resistor

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

44 of 54

AC Heater Blower

Heater Blower speed resistor

AC Heater Function Control

AC Compressor clutch

AC Heater Clutch Relay

DLC

AC Refrgrnt pressure

sensor

Engine Coolant Blower Motor 1

Engine Coolant Blower Motor 2

Multi Func Contr Unit

Engine Control Relay

AC Master Switch

Engine Coolant Blower Motor Relay 1

3 – 14 Scenario 1 Clutch does not cut in. Current flowing through the AC compressor clutch can be measured by placing 0. Ohm Ceramic 5 Watt resistor and note the voltage drop across the resistor (which is proportional to current flow)

ECM

Heater Blower relay 2

Heater Blower relay 1

2000, Holden, Commodore VX, 3.8, AC

Obtain Circuit Diagram

3

1Amp / div 1 sec / div

Switching AC On & OFF

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

45 of 54

Scenario 2 Should this component fail! What will the symptom be!

Obtain Circuit Diagram

3

3 – 15

2005, Holden, Commodore VZ, 3.6, DLC

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

46 of 54

AC Control Unit

IGN main relay

Side lamp relay

Eng CLT relay

AC Comp clutch relay

AC Comp clutch solenoid

Engine coolant blower motor

Engine coolant blower motor relay `2 and 1

Multi function control module

Inst Panel

AC SUN light

ACP

ECT

Interface module

Heater Blowerrelay

AC Heater BlowerMotor

Mix Flap

AC Heater Blower Motor control module

Heated rear window relay

In Car

Temp sens

Out Side Temp sens

Evap Temp sens

AC Air Mix

Obtain Circuit Diagram

3

3 – 16 Identify and label each component

2005, Holden, Commodore VZ, 3.6, DLC

ECM

Scenario 2

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

47 of 54

AC Control Unit

IGN main relay

Side Park lamp relay

Eng CLT relay

AC Comp clutch relay

AC Comp clutch solenoid

Engine coolant blower motor

Engine coolant blower motor relay `2 and 1

Multi function control module

Inst Panel

AC SUN light

ACP

ECT

Interface module

Heater Blowerrelay

AC Heater BlowerMotor

Mix Flap

AC Heater Blower Motor control module

Heated rear window relay

In Car

Temp sens

Out Side

Temp sens

Evap Temp sens

AC Air Mix

2005, Holden, Commodore VZ, 3.6, DLC

Obtain Circuit Diagram

3

3 –17 Should this component fail! What will the symptom be!

ECM

Scenario 2

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

48 of 54

Scenario 3 AC Heater Blower Motor Inoperative Pulse Width Modulated (PWM) amplifier circuit(s) Identify main components

Obtain Circuit Diagram

3

3 – 18

AC Control Module

AC Heater Blower Control module

AC Heater Blower Motor

98, BMW/3 Series (E36), 2.5 323i, wiring diagram, AC control)

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

49 of 54

Obtain Circuit Diagram

3

AC Control Module

AC Heater Blower Control module

AC Heater Blower Motor

Scenario 3 AC Heater Blower Motor Inoperative Pulse Width Modulated (PWM) amplifier circuit(s) Identify main components

3 – 19

2 volt / div 1 sec / div

2 volt / div 1 sec / div

98, BMW/3 Series (E36), 2.5 323i, wiring diagram, AC control)

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

50 of 54

Scenario 4 AC Engine Blower Motor Inoperative Pulse Width Modulated (PWM) amplifier circuit(s) Identify main components

ABS

ECM

ECT Switch

AC Heater Blower Motor

Engine Collant Blower Motor

ACP

ECT

AC Control unit

Digital Multifunction Display (Gateway)

Obtain Circuit Diagram

3

03, Citroen, C3 I/II/First class, 1.6/AC, MY-2005 (auto temp control)

3 – 20

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

51 of 54

ABS

ECM

ECT Switch

AC Heater Blower Motor

Engine Collant Blower Motor

ACP

ECT

AC Control unit

2

3 4

1

Obtain Circuit Diagram

3

2 volt / div 2 milli sec / div

2 volt / div 2 milli sec / div

Scenario 4 AC Engine Blower Motor Inoperative Pulse Width Modulated (PWM) amplifier circuit(s) Identify main components

03, Citroen, C3 I/II/First class, 1.6/AC, MY-2005 (auto temp control)

3 – 21

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

52 of 54

Abbreviation, acronyms and references: Abbreviations: CAN BUS – Controlled Area Network Bidirectional Universal System BEM – Body Electrical Module PCM – Power Control Module HIM – Heater and air conditioning Integrated Module SRS – Supplementary Restraint System INS – Instrument Cluster Panel ICC – Interior Command Centre DMM – Digital Multi meter OSC – Oscilloscope ICU – Immobilizer Control Unit YRS – Yaw Rate Sensor SAS – Steering Angle sensor APPs – Accelerator Pedal Position sensor TPS – Throttle position Sensor ECTS – Engine coolant temperature Sensor CKPS – Crankshaft position Sensor Web sites: (these are only a few of sites visited)

References:

http://www.chevyavalanchefanclub.com/cafcna/index.php?topic=26444.0;wap2

http://ikwilthepiratebay.org/thepiratebay.se/torrent/3591423/GM_Techline_eSI

http://forums.justcommodores.com.au/ve-holden-commodore-2006-2013/194506-ve-sv6-ute-work-shop-manual.html

http://aurorah.proboards.com/index.cgi?board=Gen&action=print&thread=16952

http://www.ebay.com.au/itm/GM-CHEVY-ESI-ELECTRONIC-SERVICE-INFO-SYSTEM-MANUAL-/230605688505

http://www.ebay.com.au/itm/GM-CHEVY-ESI-ELECTRONIC-SERVICE-INFO-SYSTEM-MANUAL-/230605688505

DLC - Diagnostic Link Connector TCM - Transmission Control Module PNL - Park Neutral Lever Auto Unit Ins - Instrument panel NAV - Navigation Park contr - Parking control TPMS - Tyre pressure monitoring system ABS - Anti Lock Braking SAS - Steering Angle Sensor SRS - Supplementary Restraint System MFCU - Multi-Function Control Unit (often referred to as BCM) BCM - Body control Module)

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

53 of 54

CARS

SYMPTOMS

REMEDIES

Prepared for WIRE & GAS 2013 Training Convention Electrical & Electronic Diagnostics for Vehicle Air conditioning Authors: Sam Nazarian & Jack Stepanian

All Rights Reserved Long Reef Garage PTY LTD All recorded measurements are believed to be true representation of and are based on unproblematic motor vehicle management. ALL rights are reserved to make changes without prior

notice. ALL conditions prescribed under the copyright act are reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical without prior expressed written notice, it is an offence – All intelectuall materials are the property of the authors.

For Circuit diagrams, connector Location/end views and pin configurations please see TAT, Relim Bookworks, Repco Auto Tech Encyclopedia, Auto Data, Automotive Service Solution

54 of 54