Automotive

Fault Diagnosis
AUT403
01
Diagnostic Techniques
Fault Finding Logic
▪ Understanding of the system in which the problem exists.

▪ The ability to apply a logical diagnostic routine.

▪ Clearly define the definition of :

Symptom(s) : What the user/operator/repairer of the system (vehicle or whatever) notices;

Fault : The error in the system that causes the symptom(s).

Root cause(s) : The cause(s) of the fault.

Diagnostic Process:
Six-stage Process:
By using this plan, you can minimize the amount of time spent diagnosing the
system by performing only the checks that you need to make, with an
emphasis on checks that are the easiest to make.
Step 1

Step 2

Step 3

Step 4

Step 6
Step 5
Verify the Evaluate Test,
Collect the Measure Fix the
After
Complaint Data Repair
Evidence & Fault
Compare Check
Collect
Data
Step #1 :
Verify the Complaint:
During this step you must do the following steps:

➢ Confirm customer complain.

➢ Confirm if it is normal behavior or not.
➢ Confirm if it is normal use or abnormal use.
➢ Confirm if it is permanent or intermittent.
Step #2 :
Collect Data:
In this step we will start to apply operational check for the system and
some main checks, as :

- Test drive.
- Visual and audible check
- Battery voltage and SOC check.
- Fuel level check.
- Smell check.
- Vehicle systems Healthy check.
- Diagnostic tool check.
Step #3 :
Evaluate the Evidence :
Stop and think about the evidence then analysis all this information
together to specifically define:

- Exactly which components/system are affected.

- What kind of problem you need to look for.
- Operating conditions under which the fault appears.
Step #4 :
Test, Measure & Compare :
Identify the origin of the fault by check, test and measurement for
everything that could have generated the fault or has relation to the
operating conditions under which the malfunction appears.

Then compare the test and measurement results with the stander value
or good known system results.
Step #5 :
Fix the Fault :
Correcting the fault is probably the most straightforward step in the
diagnostic process, but you must apply the manufacturer's procedures
during repair.

Step #6 :
After Repair Check :
After making the repair, you must confirm the following points:
- The system is working properly.
- No warning light illuminated.
- No fault in the computers.
- All systems specific configurations.
- Systems initialized.
Fault Finding Report:
The three Cs:
Concern, Cause, Correction
The three C's are how you can describe the diagnostic process in a
technical report., is another reminder that following a process for
automotive repairs and diagnostics is essential.

Six-stage process CCC

Verify the complaint Concern
Collect, Evaluate, Test Cause
Rectify Check Correction
02
Root Cause Analysis
(RCA)
Root Cause Analysis:
(RCA) is used to describe a range of problem-solving methods aimed at
identifying the root causes of problems or events, so that appropriate
measures can be taken to prevent the problem from arising again.

The 3Rs of Root Cause Analysis:

Recognize:
This first step is when you notice something’s not working quite right.
Rectify
Once you’ve recognized the root cause, it’s time to start a corrective
course of action.
Replicate
you’d need to replicate what happened during this period to ensure that
you got to the bottom of the issue.
Fundamentals of RAC:
• Safety-based RCA descends from the fields of accident analysis
and occupational safety and health.

• Production-based RCA has its origins in the field of quality control

for industrial manufacturing.

• Process-based RCA is like production-based RCA, but has been

expanded to include business processes.

• Failure-based RCA comes from the practice of failure analysis used

in engineering and maintenance.
RCA Techniques:
Fishbone Diagram technique:
The shape of the resulting diagram looks like a fishbone, which is why
it is called a fishbone diagram. This diagram is built on the idea that
multiple factors can lead to a failure/event/effect.

Option #1 Option #2 Option #3

Cause Cause Cause

Problem

Cause Cause Cause

Option #4 Option #5 Option #6

Fishbone Diagram Technique :
Construct a fishbone diagram:
• Problem Statement.
• Categorization process or procedure.
• Detect Contributing factors.
• Ask: Why? to find deeper causes

Benefits of the fishbone diagram:

• Good way to brainstorm within a defined structure.
• Helps to visually diagram a problem or condition’s root cause.
• Shows bottlenecks in the process.
• Find ways to improve the process.
RCA Techniques:
Fault tree analysis technique (FTA) : Top Undesired
Event

is a method for root cause

analysis that uses boolean Logic Gates
logic (using AND, OR, and
NOT) to figure out the cause
of failure. Fault tree analysis Intermediate Events Intermediate Events
tries to map the logical
relationships between faults
and the subsystems.

Basic Events
Fault Tree Analysis Technique (FTA) :

Undeveloped Event

AND gate the above output event occurs if all

of the input lower-level events occur

OR gate the above output event occurs if

either of the input lower-level events occur

TRANSFER gate transfer to/from another part

of the fault tree
Fault Tree Analysis Technique (FTA) :
Benefits of using a fault tree analysis:
• Use deduction to find the causes of each event, like the 5 whys
• Highlights the critical elements related to system failure
• Creates a visual representation for analysis
• Can focus on one area of failure at a time
• Exposes system behavior and possible interactions
• Accounts for human error
• Promotes effective communication
02
Tools and Equipment
Hand tools Spanners, hammers, screwdrivers and all the other basic bits

A collective term for items not held as part of a normal tool kit. Or items required
Special tools
for just one specific job.
Accuracy Careful and exact, free from mistakes or errors and adhering closely to a standard

Calibration Checking the accuracy of a measuring instrument

This device reads the ‘black and white balls’ mentioned above or the on–off
Code reader or scanner
electrical signals, and converts them into language we can understand
Now usually PC based, these systems can be used to carry out tests on vehicle
Combined diagnostic
systems, and they also contain an electronic workshop manual. Test sequences
and information system
guided by the computer can also be carried out
The main part of ‘scope’ is the display, which is like a TV or computer screen. A
scope is a voltmeter, but instead of readings in numbers it shows the voltage levels
Oscilloscope
by a trace or mark on the screen. The marks on the screen can move and change
very fast allowing us to see the way voltages change.
Accurate Measurement Process:

Step Example
Do we need to know that the battery voltage is 12.6 V
Decide on the level of accuracy required
or 12.635 V
Choose the correct instrument for the job A micrometer to measure the thickness of a shim
Most instruments will go out of adjustment after a time.
Ensure the instrument has been looked after and You should arrange for adjustment at regular intervals.
calibrated when necessary Most tool suppliers will offer the service or in some
cases you can compare older equipment to new stock
Study the instructions for the instrument in use and
take the reading with care. Ask yourself if the Is the piston diameter 70.75 or 170.75 mm
reading is about what you expected
Make a note if you are taking several readings Don’t take a chance, write it down
Multimeter (AVO)
Electric Circuit Test:
Voltage Current Resistant
Types of Circuit Filers:
Oscilloscope

1 5 6
2 3
1- Without a path to ground, when the circuit is off, the switched earth terminal voltage is the
same as the coil supply voltage, at or very close to battery voltage.

2- When the circuit is switched on by the supply of an earth path, the voltage decreases to 0 V.

3- The primary circuit remains on, at 0 V, for around 4 ms.

4- When the circuit is switched off, the primary voltage spikes, very briefly, around 400 V.

5- After it is switched off, the primary circuit mirrors the features within the secondary circuit.

6- There is a raised voltage, around 25 to 40 V, for about 2 ms after the voltage spike.

7- At the end of the raised voltage, there are 3 to 5 cycles of diminishing oscillation before it
stabilises back at the coil supply voltage, at or very close to battery voltage.
 Thanks!
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