Order of Parts of the Left Engine Cover and Starter

Figure 3.12. Order of details of the left starter and cover

3.2.2. Remove the belt.

- Remove the left engine cover then use the active pulley clamp (1) then remove the nut (2), bushing (4), starter ratchet guard (5) and drive belt (6)

- Remove the rear half of the driving pulley.

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Car body electrical practice - 8 zt2i3t4l5ee zt2a3gs zt2a3ge zc2o3n4t5e6n7ts If the voltage is out of specification, replace the wire or connector. If the voltage is within specification, install the front fog light relay and follow step 5. Step 5 Check the front fog light switch - Remove the D4 connector of the fog light switch - Use a multimeter to measure the resistance of the front fog light switch. Measurement location Condition Standard D4-3 (BFG) -D4-4 (LFG) Light switchFront Fog OFF >10kΩ D4-3 (BFG) -D4-4 (LFG) Front fog light switchON <1 Ω - Standard resistor D4 connector is located on the combination switch assembly. If the resistance is out of specification, replace the combination switch (the fog light switch is located in the combination switch). If the resistance is within specification, follow step 6. Step 6 Check wiring and connectors (front fog light relay-light selector switch) - Disconnect connector D4 of the combination switch assembly - Use a voltmeter to measure the voltage value of jack D4 on the wire side. Measurement location Control modecontrol Standard D4-3 (BFG) - (-) AQ TAIL 11 to 14 V D4 connector for the wiring of the combination switch assembly If the voltage does not meet the standard, replace the wire or connector. If the voltage is within standard, there may have been an error in the previous measurements. Step 7 Check the front fog lights - Remove the front fog light electrical connector. - Supply battery voltage to the fog lamp terminals Jack 8, B9 of front fog lamp on the electrical side blind first. Power supply location Terms and Conditions Battery positive terminal - Terminal 2Battery negative terminal - Terminal 1 Fog lightsbefore morning - If the light does not come on, replace the bulb. If the light is on, re-plug the jack and continue to step 8. Step 8 Check wiring and connectors (relay and front fog lights) - Disconnect the B8 and B9 connectors of the front fog lights. - Use a voltmeter to measure voltage at the following locations: Measurement location Switch location Terms and Conditions B8-2 - (-) AQ Electric lock ON TAIL size switchFog switch ON 11 to 14 V B9-2 - (-) AQ Electric lock ONTAIL size switch Fog switch ON 11 to 14 V B8 and B9 connectors on the front fog lamp wiring side Voltage is not up to standard, repair or replace the jack. If up to standard, there may have been an error in the measurement process. 2.2.4. Procedure for removing, installing and adjusting fog lights 1. Procedure for removing - Remove the front inner ear pads Use a screwdriver to remove the 3 screws and remove the front part of the front inner ear liner -Remove the fog light assembly + Disconnect the connector. + Use a screwdriver to remove 3 screws to remove the fog light cover 2. Installation sequence -Rotate the fog lamp bulb in the direction indicated by the arrow as shown in the figure and remove the fog lamp from the fog lamp assembly. -Rotate the fog light bulb in the direction indicated by the arrow as shown in the figure and install the light into the fog light assembly. - Use a screwdriver to install the fog light cover -Install the electrical connector Attention: Be careful not to damage the plastic thread on the lamp assembly. - Install the front inner ear pads Use a screwdriver to install the front inner bumper with 3 screws. 3. Prepare the vehicle to adjust the fog light convergence. Prepare the vehicle: - Make sure there is no damage or deformation to the vehicle body around the fog lights. - Add fuel to the fuel tank - Add oil to standard level. - Add engine coolant to standard level. - Inflate the tire to standard pressure. - Place spare tire, tools and jack in original design position - Do not leave any load in the luggage compartment. - Let a person weighing about 75 kg sit in the driver's seat. 4. Prepare to check the fog light convergence a/ Prepare the vehicle status as follows: - Place the car in a dark enough place to see the lines. The lines are the dividing line, below which the light from the fog lights can be seen but above which it cannot. - Place the car perpendicular to the wall. - Keep a distance of 7.62 m between the center of the fog lamp and the wall. - Park the car on level ground. - Press the car down a few times to stabilize the suspension. Note: A distance of approximately 7.62 m is required between the vehicle (fog lamp center) and the wall to adjust the convergence correctly. If the distance of 7.62 m cannot be achieved, set the correct distance of 3 m to check and adjust the fog lamp convergence. (Since the target area varies with the distance, please follow the instructions as shown in the figure.) b/ Prepare a piece of thick white paper about 2 m high and 4 m wide to use as a screen. c/ Draw a vertical line through the center of the screen (line V). d/ Set the screen as shown in the picture. Note: - Keep the screen perpendicular to the ground. - Align the V line on the screen with the center of the vehicle. e/Draw the reference lines (H, V LH and V RH lines) on the screen as shown in the figure.HINT: Mark the center of the fog lamp on the screen. If the center mark cannot be seen on the fog lamp, use the center of the fog lamp or the manufacturer's name mark on the fog lamp as the center mark. H line (fog light height): Draw a line across the screen so that it passes through the center mark. Line H should be at the same height as the center mark of the fog light bulb. Line V LH, V RH (center mark position of left fog lamp LH and right fog lamp RH): Draw two lines so that they intersect line H at the center marks. 5. Check the fog light convergence a/ Cover the fog lamp or remove the connector of the other side fog lamp to prevent light from the unchecked fog lamp from affecting the fog lamp convergence test. b/ Start the engine. c/ Turn on the fog lights and make sure that the dividing line is outside the standard area as shown in the drawing. 6. Adjust the fog light convergence Use a screwdriver to adjust the fog light to the standard area by turning the toe adjustment screw. Note: If the screw is adjusted too far, loosen it and then tighten it again, so that the last rotation of the light adjustment screw is clockwise. 3. Self-study questions 1. Describe the operating principle of the lighting system with automatic headlight function 2. Describe the operating principle of the lighting system with the function of rotating headlights when turning 3. Draw diagram and connect lighting system on Hyundai Porter car 4. Draw diagram and connect lighting system on Honda Accord 1992 5. Draw the lighting circuit on a 1993 Toyota Lexus LESSON 3 MAINTENANCE AND REPAIR OF SIGNAL SYSTEM I. IMPLEMENTATION GOAL After completing this lesson, students will be able to: - Distinguish between types of signals on cars - Correctly describe common symptoms and suspected areas causing damage. - Connecting signal circuits ensures technical requirements - Disassemble, install, check, maintain and repair the signal system to ensure technical requirements. - Ensure safety in work and industrial hygiene II. LESSON CONTENT 1. General description The signal system equipped on cars aims to create signals to notify other vehicles participating in traffic about the vehicle's operating status such as: stopping, parking, braking, reversing, turning... Signals are used either by light such as headlamps, brake lights, turn signals….. or by sound such as horns, reverse music…. Just like the lighting system. A signal system circuit usually consists of: battery, fuse, wire, relay, electrical load and control switch. Only some switches of the signal system are on the combination switch. The switches of other signals are usually located in different locations such as in the gearbox or brake pedal…… 2. Maintenance and repair 2.1. Turn signals and hazard lights The installation location of the turn signal is shown in Figure 3.1. The turn signal control switch is located in the combination switch under the steering wheel. Turning this switch to the right or left will make the turn signal turn right or left. The hazard light switch is used when the vehicle has a problem while participating in traffic. When the hazard light switch is turned on, all the turn signals on the vehicle will light up at a certain frequency. The hazard light switch is usually placed separately from the turn signal switch (some old cars integrate the hazard and turn signal switches on the same combination switch cluster). Figure 3.1 Turn signal switch Figure 3.2 Hazard switch The part that generates the flashing frequency for the lights is called a turn signal relay. The turn signal relay usually has 3 terminals: B (positive power supply); E (negative power supply); L (providing the turn signal switch to distribute to the lamp) 2.1.1. Circuit diagram To generate the frequency for the turn signal, a turn signal relay is used in the turn signal circuit. The current from the turn signal relay will be sent to the turn signal switch assembly to distribute the current to the turn signal lights for the driver's purpose. Figure 3.3. Schematic diagram of a turn signal circuit without a hazard switch 1. Battery; 2. Electric lock; 3. Turn signal relay; 4. Turn signal switch; 5. Turn signal lamp; 6. Turn signal lamp; 7. Hazard switch Figure 3.4 Schematic diagram of turn signal circuit with hazard switch 1. Battery; 2. Combination switch cluster; 3. Turn signal; 4. Turn signal light; 5. Turn signal relay Today's cars no longer use three-pin turn signal relays (B, L, E) but use eight-pin turn signal relays (figure 3.5) (pin number 8 is used for hazard lights). For this type, the current supplying the turn signal lights is supplied directly from the turn signal relay to the lights. div.maincontent .p { color: black; font-family:"Times New Roman", serif; font-style: normal; font-weight: normal; text-decoration: none; font-size: 14pt; margin:0pt; } div.maincontent p { color: black; font-family:"Times New Roman", serif; font-style: normal; font-weight: normal; text-decoration: none; font-size: 14pt; margin:0pt; } div.maincontent .s1 { color: black; font-family:"Times New Roman", serif; font-style: normal; font-weight: normal; text-decoration: none; font-size: 13pt; } div.maincontent .s2 { color: black; font-family:"Times New Roman", serif; font-style: italic; font-weight: normal; text-decoration: none; font-size: 14pt; } div.maincontent .s3 { color: black; font-family:"Times New Roman", serif; font-style: normal; font-weight: normal; text-decoration: none; font-size: 14pt; } div.maincontent .s4 { color: black; font-family:"Times New Roman", serif; font-style: normal; font-weight: normal; text-decoration: none; font-size: 13pt; } div.maincontent .s5 { color: black; font-family:"Times New Roman", serif; font-style: normal; font-weight: normal; text-decoration: none; font-size: 13pt; vertical-align: 1pt; } div.maincontent .s6 { color: black; font-family:"Times New Roman", serif; font-style: normal; font-weight: normal; text-decoration: none; font-size: 11pt; } div.maincontent .s7 { color: black; font-family:"Times New Roman", serif; font-style: normal; font-weight: normal; text-decoration: none; font-size: 14pt; vertical-align: -9pt; } div.maincontent .s8 { color: black; font-family:"Times New Roman", serif; font-style: normal; font-weight: normal; text-decoration: none; font-size: 11pt; } div.maincontent .s9 { color: #008000; font-family:"Times New Roman", serif; font-style: normal; font-weight: normal; text-decoration: none; font-size: 14pt; } div.maincontent .s10 { color: black; font-family:"Times New Roman", serif; font-style: italic; font-weight: normal; te
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Figure 3.13. Brake and remove front clutch (pulley)

+ Disassemble the front clutch parts (active pulley). Remove the bushing (1), tilt plate (2), slide piece (3), swing arm (4), pulley plate (5)

Figure 3.14. Removable parts of the driving pulley

3.2.3. Remove the passive pulley (Rear clutch)

- Hold the outer face (1) of the pulley then remove the nut (2)

- Remove the drive belt (2) from the clutch and remove the ball bearing pulley (clutch) from the drive shaft. Before removing, hold the ball bearing clutch (1) and compress the active pulley jaw spring by turning the passive pulley jaw clockwise until it stops.

Figure 3.15. Locking and removing the rear cone nut

- Remove the parts of the passive clutch (rear clutch)

+ Install the clutch assembly into the spring pressure valve, then mount the clutch spring assembly on the vise and remove the frozen pulley nut (1) with a specialized tool.

+ Slowly remove the clamp and spring-loaded candle tool to remove the parts.

Figure 3.16. Removing the spring and clutch assembly

Figure 3.17. Disassemble the parts of the movable ball pulley

- Remove the clutch hammers (Clutch shoes): Remove the E-rings [1] and guide plate [2]; remove the clutch hammer springs; remove the shock absorber rubber

Figure 3.18. Remove the hammer cone and shock absorber rubber

- Disassemble the parts of the movable pulley

Figure 3.19. Order of disassembly of rear clutch parts

3.2.4. Repair check

* Check the pot in front of the car

– Clean and check the clutch plates and ball cups: If you find that the clutch balls are worn or dented, you should replace them. If you do not replace them, it will cause shaking when accelerating.

+ For the active pulley, measure the inner diameter of the bearing. The limit is 24.08 Air blade vehicles.

Figure 3.20. Pulley check position

– Clean and check the 6-ball bearing set: Check the ball cup, if the ball cup is found to be worn, replace it. When the ball cup is worn, the vehicle will shake at the front.

+ Ball bearing limit diameter is 19.5mm

– In addition, you also need to clean and check the battery (pot) and the vehicle's sliding clamp so that if there is any problem, it can be repaired promptly.

+ The outer diameter of the active clutch bushing is limited to 23.93mm

* Check the rear pot of the scooter

– Clean and check the 3-legged hammer: Check the 3-legged hammer if it is worn or burnt, replace it. This helps the bell catch better and the vehicle operate better.

– Clean and check the rear clutch bell: Determine the wear of the rim, if necessary, re-smooth it so that the 3-legged clutch can catch better and improve fuel consumption.

Figure 3.21. Checking the spring and the cone bell

– Clean and check the 3-pin spring: If it is uneven or loose, replace it to avoid jerking when running.

- Check wear of passive flange, ball clearance

* Check the drive belt.

According to the manufacturers' recommendations, the drive belt should be checked regularly after about 8,000 km and replaced after about 20,000 km. Users should regularly check, repair and maintain the vehicle to maintain good operating condition.

* Install the front drive components (active pulley)

- Install the active pulley (1) to hold the inclined plate (2) and the lining (2,3)

- Install the drive belt on the main pulley nose tube, install the main pulley nose (3) so that it fits the shaft, apply machine oil to the shaft (4)

Figure 3.22. Installing the front clutch

- Hold the driving pulley cheek and tighten the nut as specified.

* Install rear clutch.

- Install the parts of the passive pulley.

- Install shock absorbers and install hammers, springs and brakes.

Figure 3.23. Installing the pulleys and taper hammers

- Install the clutch assembly onto the driven pulley in order

Figure 3.24. Installing the taper hammer on the driven pulley

Use the valve to press the pulley spring and tighten the reverse nut.

- Install the drive belt onto the pulley and hold the driven cheek then install the clutch onto the drive shaft.

+ Clean grease, brake clutch and tighten lock nut

Figure 3.25. Installing the rear clutch

Cleaning the scooter's pot needs to be done periodically.

Clean the car for the first time after the first 1000km. This helps to remove dust generated by the car's operation. Moreover, this also helps you detect and fix any damage to the car early.

Lesson 4. Repairing the wheel brake system

1. Repair car brake system

1.1. Mechanical brake system.

1.1.1. Tasks.

- The braking system is used to control the speed reduction and stop of the vehicle as required by the driver on flat or sloping roads to ensure traffic safety when operating on the road.

1.1.2. Brake system structure