2005 Suzuki Cary join gear box

Dry cleaners little van developed a grinding noise in gear box. Its 700cc van,  manual gearbox with 120000km on the clock.
Turned out that oil came out and bearings ran dry for a while.
Most bearing were easy to source, one had to come from Japan.
Replaced all 5 main bearings and 2 seals And all noise was gone.

2003 Peugeot 206 cc (Roland Garros) project

Few days ago got myself a new project. Will see how it's going to turn out.
Here we have 206 cc (Roland Garros edition). Had an impact on left front, from left side, so moved frame and engine to the left. Air bags haven't deployed. All electrical and mechanical seems to be intact (apart of headlights).
Donor chassis is 206 (non convertible) looks like front on this two is identical.
So front left rail will be taken from 206 if panel beater can't straighten the green one.

Received 4 wheels today.

9/10/12 R J Don panelbeaters.

10/10/12 R J Don decided to charge more :/ as they just realized that its gonna take longer to reassemble

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.