Car Alarm

Installing Car Alarm in 2000 Honda Accord.


Alarm came with:
1. Module with built in shock sensor
2. 4-pin Relay
3. Horn
4. LED Light
5. Wiring loom
6. Two Remotes

Preparation
I decided to make all wiring one colour and installing additional Relay for better protection.


Tools and material required
1. Alarm
2. Soldering Iron
3. Insulation Tape
4. Solder
5. Multimeter and check-light
6. Knife
7. Set of screw drivers
8. Heat shrink
9. 2 x Automotive relay
10. Solder sucker

the first thing I got rid of the plugs on alarm unit.

my next step was to solder same colored wires to the board and label them.

now Alarm is ready to be installed into the car

WARNING: remove all fuses from alarm wiring harness to reduce risk of short circuit during installation process 

First step is find BAT+ and earth. with key off probe wires that go to EGN Switch. BAT+ should output 12V with engine off key out. Earth could be any metal surface of the chassis or dash frame.

next step is to find negative door trigger. normally it can be taken from dome light, because dome light in most cases is connected to all 4 doors or front 2.

then trace two wires for indicators. i left indicator flashing and probed wires that were coming out of indicator switch

Then one wire to IGN ON. Probe IGN switch with IGN ON until find live wire. make sure there is no voltage when key is OFF.

I had to configure the wiring to suit my application for locking and unlocking system, since the car uses negative trigger to lock and unlock the doors

Honda Accord has lock and unlock switch on the driver's door, so I traced two wires that if you apply negative to one- the doors would lock and to other- they would unlock. So I connected negative trigger wires coming from alarm unit to the door locking relay.

next step is to install immobiliser relay: find starter wire from IGN switch and cut it in the middle. Pin 30 and 85 will go to starter cable on the IGN switch side, 87 on other side of the Starter wire and 86 to Alarm Unit

Time to install the siren under the bonnet and connect it to the Alarm unit

when job is finished and it's a time to reinstall fuses and try the alarm

when check is finish and everything works fine, next step is reprogram alarm (change flashing indicators when door is open):

1. get inside of the car and close the door

2. switch IGN ON (but do not start the engine)

3. turn IGN SW to Acc and back to IGN ON

4. do it 12 times and leave IGN SW ON

5. siren will go off 3 times

6. turn it back to Acc and to ON again

7. siren goes of 2 times

8. Ign key to Acc and to ON

9. siren goes off 3 times

10. IGN key to Acc and to ON

11. siren goes off 4 times

12. press unlock to disable indicator blinking while doors are open

13. IGN key to OFF and wait for 5 seconds

Alarm is ready

Ignition systems

Ignition system is designed for igniting air/fuel mixture in combustion chamber of the engine. Most of the Ignition Systems consist of two main parts: LT (Low Tension) and HT (Hi Tension).
LT components: Battery, Alternator, IGN Switch, (Ballast Resistor), IGN Coil primary windings, Capacitor (Condenser) and contact braker (contacts, pulse generators)
HT components: IGN Coil Secondary winding, Distributor Cap and Rotor, HT leads, Spark plugs.


Mechanically Operated Ignition
Kettering  (points) Ignition System
 Ignition Coil is being switched with the contacts (or points). Since Coil primary winding resistance is low (around 0.8 Ohms), so LT current would be hi. Points switch this current directly and were out quickly.

Ignition Coil (or step up transformer) is made of two windings primary and secondary. primary windings is lower resistance and about few hundred windings. Secondary winding is higher resistance and consist of few thousands of windings. .

current from battery goes through IGN Switch powering up the Ignition Coil primary. As starter motor spins the engine, the distributor cam changes its position opening and closing the contacts. once contact is closed and LT circuit is complete, the coil creates the magnetic field. Distributor cam rotates more and opens the contacts. This coses magnetic field of LT collapse, sudden collapse of magnetic field in LT induces voltage in HT. then this high voltage passed to the centre of the distributor cap through the HT wire and then through rotor back to the correct contact at distributor cap, through the HT wire to spark plug electrode.

in some applications capacitor (condenser) is used to increase duration and quality of the spark. condenser is connected in parallel with contacts. so capacitor is charging when contacts are closed. when the contacts open then condenser discharging to the IGN coil, then back EMF of the coil is charging capacitor again. so it goes back and forth until it is depleted.

Resistors

Resistors

A linear resistor is a linear, passive two-terminal electrical component that implements electrical resistance as a circuit element. The current through a resistor is in direct proportion to the voltage across the resistor's terminals. Thus, the ratio of the voltage applied across a resistor's terminals to the intensity of current through the circuit is called resistance. This relation is represented by Ohm's law:

     (sorce: Wikipedia)

Axial-lead resistors (left side) and power resistors (right side)

Resistor Colour-code:

Electronic Symbol:

Testing:

Resistor can be tested with ohmmeter by connecting two terminals to the meter.

Potentiometers

Potentiometer is 3 terminal resistor with sliding wiper that forms an adjustable voltage divider. Potentiometer can be easily turned in to rheostat (or variable resistor) by using just 2 terminals: one side of the resistor and wiper. Applications: volume control in sterio systems, some car sensors (TPS, AFM). 

In time potentiometers wear out and become noisy. 

Electronic symbol: 

Oxygen Sensors

Oxygen Sensors

Oxygen Sensor is a feedback sensor that tells ECU if there is oxygen in exhaust gas, so ECU can adjust the mixture close to Lambda 1 (14.7:1). Oxygen Sensor is passive sensor which does not require power to run, it outputs its own voltage. Purpose of the sensor is to protect the CAT.
Ledded fuel will destroy O2 Sensor as well as some silicone gasket makers.
In time O2 sensors become "lazy" they become less responsive and don't switch voltage as fast as needed. It's recommended to change them every 60 000 km or whenever engine light comes on.

O2 is similar 1V Battery. depending on amount of oxygen in exhaust gas it outputs a range of voltages from 0V to 1V. So the leaner the mixture the closer to 0V:


0V is lean
0.45V is ideal
0.9V is rich



Bosch O2 sensor wires colour code:
1 wire: Signal (black)
2 wire: signal (black) and earth(grey)
3 wire: heater wires (white) and signal (black)
4 wire: heater wires (white), signal (black) and earth (grey)

3 types:
Zicronia
Titania
Wideband

upstream and downstream (before and after CAT)

most new cars have 2 Before and after CaT to see if CaT working

V engines got O2 sensor per bank, so most of V12 got 4 O2 sensors

need to be at 500-600 degrees to operate properly


Wideband:

1 cell: 4 wires
2 cell: 5-7 Wires

tells how rich the mix is

Fuel Injections - air flow meters

There are a few different types of how air flow getting represented to ECU.
Directly:    K-Jetronic - Mechanical
                 L-Jetronic - Flap (or Vane) controlled. air flow pushes the flap inside the airflow meter box and wider the flap opens it means more air pushing it, so it would need more fuel for Lambda one. Disadvantages: spring on the flap becomes loose, restricts air. most early European cars, early Toyotas have it. there are two types of Flap Air meters: the ones that output around +4.5 V when idle and ones that output close to 0 when idle. this one is from Toyota MR2 and it outputs around +4.5V when flap is fully closed (at idle).

Testing:

according toyota manual there are 4 terminals: VC (+5V in), E2 (earth), VS (sensor output) and THA (temperature sensor)

       check the resistance according the manual.
wire the AFM up to 5V power supply and check the output voltage.

        

the voltage goes down as flap opens

checking it with scope

H-Jetronic - Hot Wire. The air flow sensor has got a titanium wire inside.Titanium wire gets hot when ECU puts current through it and changes it's resistance
Indirectly:  D-Jetronic - Map Sensor. Measures pressure in plenum chamber.

Injector Circuit

For this assignment we were given this diagram 

according Motorola Datasheet current gain on BC547 transistors is 110 to 800

Voltage = 12V

choosing proper resistors for LEDs:

ILED = 30mA

VLED = 1.8V

RLED = (VSupply - VLED) / ILED

RLED = (12-1.8)/0.03= 340 Ohms

So I would use two 330R resistors for R14 and R15

β=Ic/Ib

Ib=Ic/β

Ib=30/110=0.27mA

R=(5V-0.7V)/0.00023A=18695.65 Ohms

so I choose to use 15K resistors for R13 and R16

Parts List:

BC547 transistor x 2

Green LED x 1

Red LED x 1

330R resistor x 2

15K resistor x 2

PC board 

Lochmaster Diagram

Video

O2 sensor Tester

Calculations:

R5
V=12V-9V=3V
I=5.6mA

V=IR
R=V/R
R5=3/0.0056=535.7 Ohms

====================================================================

Vtotal = 9V
V(R7)=0.23V
V(R8)=0.63V-0.23V=0.4V
V(R6)=9V - 0.63V = 8.37V
R6= 10 000 Ohms

I=V/R
I = 8.37/10 000 = 0.000837A =0.837mA

R8 = 0.4/0.000837= 477.9 Ohms
R7 = 0.23/0.000837 = 274.8 Ohms

====================================================================

R = (Vs-Vled)/Iled

R2 = (12-1.8)/0.0095= 1073.7 Ohms
R3/4 = (12-1.8-0.7)/0.0095 = 1000


=====================================================================



Part list:

3 x Diodes 1N4001
3 x Resistors 1K
1 x Zener Diode 9V1
1 x 3mm Green LED
1 x 3mm Yellow LED
1 x 3mm Red LED
2 x Capacitors 0.1uF
1 x Resistor 10K
1 x Resistor 270R
1 x Resistor 470R
1 x Resistor 540R
1 x IC LM324AM


====================================================================



Lochmaster Diagram:


top side:

Bottom Side:

Video:

Checking Alternators

On car check


Checking alternator on 1991 Toyota MR2. Make sure that the vehicle is in neutral (or park) and hand brake is applied firmly.
Check list:

1. Does Charge light work?  Yes
2. Visual condition of the connectors. OK
3. Alternator mounting. OK
4. Fuses and fusible links. OK
5. Condition of the drive belt (tension, cracks or rips). OK

Tools required: Hight rate discharge tester, multimeter, clamp amp meter.

No load test.
Battery OCV (Open Circuit Voltage) - 12.67V
for this test all doors need to be closed, all lights switched off and ignition key is out. Alternatively, Battery negative terminal can be disconnected. Using digital multimeter measure voltage of the battery.

Specified Regulator voltage - 14.9V 
voltage is found in service manual for the car. acceptable voltage is 13.5V to 15V


Regulator Voltage Reading - 14.89V
start the car. measure the voltage at the battery while engine is running.

No load Current output - 15A @14.7V
Clamp Amp Meter required for this test. place clamp over negative/positive battery terminal. readings for carburettered car should be 5A to 12A and for fuel injected - 10A to 18A.


Current output under the load - 80A@13.4V
High Rate Discharge Tester is required for this task. Dial 50 Amps on the Tester, start the engine and connect the tester terminals to the battery. Rev the car up to 2000 RPM and turn the tester ON for no more than 20seconds. Take the readings from Load Tester.


The Alternator has Passed all tests and it is fully functional.


OFF Car Check


Visual inspection: check the alternator for any Damage to back cover, bearings, terminals...

Disassembly:

<!--[if !supportLists]-->1.        <!--[endif]-->Unscrew the nut on “B+” terminal and insulator.

<!--[if !supportLists]-->2.        <!--[endif]-->Remove three nuts holding the back cover and take it off

3.        Remove the brush holder and voltage regulator.

4.        Remove the four screws that hold the rectifier, remove the rectifier.

5.        Remove the four screws that hold the voltage regulator, remove the regulator.

5 Volt Regulator/rectifier

For this assignment we have been given out the following parts:
4 x Diodes 1N4001
2 x Capacitors 100 uF
1 x Red LED
1 x Green LED
1 x Voltage regulator TS7805
2 x 1K Resistors
1 x Circuit board
different colored wires



The circuit diagram (updated)

Lochmaster printout

AC voltage coming from Neutral (N) and Phase (P) connectors is getting rectified by four diodes to DC voltage. then Red LED lights up indicating that rectifier works correctly. Green LED after voltage regulator indicates that voltage is 5V after regulator.


testing:
supplying 12V DC after rectifier, both LED lights should light up

Supplying AC Voltage to the rectifier

Red wire reads 17.35V DC

the white wire reads 4.9V DC

Mazda B5 Engine Head/Block

Removing Cylinder Head from Mazda B5 Engine

     1.  Disconnect all cables and hoses that connected to cylinder head

     2.       Remove exhaust and intake manifolds

     3.       Take rocker cover off 

     4.       Remove timing belt cover

     5.       Mark direction and position of the belt at #1 cylinder TDC

6.       

    6. Carefully pull the belt off the cam sprockets

    7.   Holding cam with size 24 spanner, remove the cam shaft sprocket screw on each cam (note I-for intake and E- for exhaust markings on sprockets)

    8.  Take the metal timing belt protecting cover off   

    9.   Loosen the head bolts in order:

             Intake Side      

              1 7  9  6 4

              3 5 10 8 2

            Exhaust Side

  

     

      10.   Carefully lift the Engine Head, do not use screw driver or similar, because it is really easy to damage the machined surface of Head and Block.

Disassembling Engine Head

1.      

    1.  Loosen the cam shaft holding bolts

    2.  Keep cam shaft holders in order (note, arrow imprinted on cam holders indicates towards the crankshaft pulley, Letter “I” – stands for Intake side and “E”- stands for Exhaust side, numbers on each holder represents the position of the holder starting from “1”- from crank pulley)

    3.  Mark each valve’s position (eg. E1, E2….E8) (Tip: cardboard box can be used to keep valves in order. Simply pop the valve through the cardboard and write the position of the valve on the box)

      4.  Using correct size valve spring compressor remove the valves (Tip: magnet or magnetic screwdriver can be used to remove the valve keepers)

5.       Note that some of the valve springs have top and bottom sides

Inspecting Cylinder Head

1.       Visual check of all components for any damage

2.       With metal ruler and filler gauge check the warp across, along and diagonal of the head surface. In my case it seems like head has been machined and it is 0mm warp in every direction.

3.       Make sure that valve guides are not damaged, visually check every valve guide. They all in OK condition (no cracks, no rust, no carbon built ups)

Valve Stem Measurement

Three measurements need to be taken per valve. Top (A), Middle (B) and Bottom (C) of the stem.

	Cylinder 1		Cylinder 2		Cylinder 3		Cylinder 4
A on Valve 1	5.975mm	5.98mm	5.98mm	5.98mm	5.98mm	5.975mm	5.98mm	5.975mm
A on Valve 2	5.975mm	5.975mm	5.975mm	5.975mm	5.98mm	5.97mm	5.975mm	5.97mm
B on Valve 1	5.975mm	5.975mm	5.975mm	5.975mm	5.98mm	5.97mm	5.98mm	5.975mm
B on Valve 2	5.975mm	5.975mm	5.975mm	5.97mm	5.975mm	5.97mm	5.975mm	5.975mm
C on Valve 1	5.975mm	5.97mm	5.975mm	5.97mm	5.975mm	5.97mm	5.975mm	5.975mm
C on Valve 2	5.975mm	5.97mm	5.975mm	5.975mm	5.975mm	5.975mm	5.975mm	5.97mm
	In	Ex	In	Ex	In	Ex	In	Ex
Average Reading 1	5.975mm	5.975mm	5.976mm	5.975mm	5.978mm	5.972mm	5.978mm	5.975mm
Average Reading 2	5.975mm	5.973mm	5.975mm	5.973mm	5.977mm	5.972mm	5.975mm	5.972mm

Unable to measure valve guides, therefore cannot calculate Valve Stem to Guide clearance. Specified clearance is 0.03mm – 0.04mm for Intake side, 0.04mm – 0.05mm for exhaust side.

Valves Condition

Examine all valves for any damage

Cylinder 1

Cylinder 2

Cylinder 3

Cylinder 4

Ex1

Ex2

In1

In2

Ex1

Ex2

In1

In2

Ex1

Ex2

In1

In2

Ex1

Ex2

In1

In2

Damage to the tip

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

Damage or wear in collet grooves

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

Pitting or erosion of valve stem

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

Marks on stem that have sharp edges

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

Signs of scuffing or seizure

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

Cracks or erosion in fillet area

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

Stretching of the stem

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

Straightness of the stem

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

Mechanical damage to the head, erosion or cupping

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

Valve Margin

1.5

1.2

1.0

1.0

1.6

1.5

0.8

0.8

1.2

1.2

0.9

0.9

1.2

1.5

0.5

0.5

Since minimum Valve margin is 1mm then 6 Valves need to be serviced/replaced.

Visually check the Valve seats for seat width, angle, thickness of remaining material and any sort of damage (cracks, erosion..)

Inspecting Valve Springs

Put a spring upright on flat surface and place a combination square next to it. Rotate the spring and measure the distance between a combination square and top of the spring with feeler gauge. It should not be more than 1/16 inch (1.59mm). The spring that is not square would cause uneven wear on Valve stem and Guide.

Cylinder #				Ok	Fail
1	In	1mm	1mm	V
	Ex	1mm	1mm	V
2	In	1mm	1mm	V
	Ex	0mm	1mm	V
3	In	0mm	1mm	V
	Ex	1mm	1mm	V
4	In	1mm	1mm	V
	Ex	1mm	1mm	V

Check the free length of the Valve Spring

Note all springs must be within 1.5mm of each other

Cylinder #				Ok	Fail
1	In	47mm	47mm	V
	Ex	47mm	47mm	V
2	In	47mm	47mm	V
	Ex	47mm	47mm	V
3	In	47mm	47mm	V
	Ex	47mm	47mm	V
4	In	47mm	47mm	V
	Ex	47mm	47mm	V

Valve Spring Tension

Valve Spring Pleasure tester is required. Place the spring in to the tester and compress the spring to 40mm and record the result. All springs should be within 5kg range.

Cylinder #				Ok	Fail
1	In	16.7kg	16.6kg	V
	Ex	17.2kg	17.5kg	V
2	In	17.1kg	17kg	V
	Ex	17.6kg	17.2kg	V
3	In	16.5kg	16.9kg	V
	Ex	17.1kg	16.9kg	V
4	In	17.5kg	17.1kg	V
	Ex	17kg	17.2kg	V

Inspecting camshaft for wear and general condition

Using micrometer measure camshaft lobes

Tightening sequence is....

intake side
8 6 2 4 10
9 3 1 5 7
exhaust side