E-learning

1. Job safety

. Personal Safety (head, eyes, mouth, clothing, gloves, shoes, remove personal accesories,
hygiene)

. Handling heavy object (never attempt to carelessly lift a heavy/big object)

. Hand tools

. Power tools (any tool that is activated by electricity, compressed air, or hydraulic pressure)

. Lifts and jacks (raising a vehicle using a lift or jack)

.Lift

.Jack (Never jack up a vehicle with a person inside it. never get under a vehicle that is
supported only by a jack.)

. Chain Hoist and Crane (removal of heavy vehicle parts such as engine or transmission
assemblies.)

. Vehicle batteries (batteries emit explosive gases. battery electrolyte is corrosive.)

. Workshop safety (safety in work area)

. Fire safety (Know locations of fire extinguishers. Never use water on a gasoline fire)

. First aid (know location of first aid kits)

. Disposal of harmful Wastes (there are many harmful chemicals in the workshop.)

2. Threaded Fasteners (Bolts and Nuts)

. Description of Bolt

. thread diameter "Nominal Diameter" - outside diameter of a male thread.

.Pitch - peak to peak distance between threads

. Width across flats (Bolt head Size)

. Bolt Length

. Types of threads

. Metric threads

. Other types of Threaded Fasteners

. Hegagon socket heads, Torx, Philips

. Torque Principle
 . may defor/not be able to return to original length if excessive torque is applied to the
required torque.

. Tightening Torque

. tightening torque is proportional to the bolt axial force

. Hex-head bolt strength marking

. Such locations are where the tightening torque is critical

. Plastic region tightening bolt

. used when precise tightening is required

. Fastener Loosening

. Fastener Locking Methods

. Service Rules for Threaded Fasteners

. Use appropriate tightening tools and tightening method

. Tighten each fastener to the torque which is specified by S/M

3. Understanding Repair Orders

. Introduction

. A repair order (RO) form informs a technician of the customer's wishes with respect to
servicing and repairs.

. Repair Order Contents

. Vehicle/customer information, repair autohorization, service information, repair

information, materials used,

labor charge information, charge calculation

. Vehicle/Customer Information

. Customer Name

. Current address

. Telephone Number

. VIN (Vehicle identification Number)

. Model/grade

. Model Year

. License plate number

. Delivery date
 . Exterior conditions or others

. Repair authorization

. essentially a contract to allow the customer to apply repair on vehice

. Statement of autorization

. Customer signature

. Service information

. RO date, Date completed, RO number, Odometer reading in and out, service advisor,
Hat number, Time in, Time pomised,

Time promised, Time started, Time completed

. Repair information

. Job number, Complaint, Cause, Correction

. Materials used

. labor charge information

. FRT

. Charge Amount Calculation

. Total Charges

. How to utilize informations

. First read the RO

4. Service Literature

. How to find applicable service literature

. always select the correct title and version

. Shop Manual (Service manuals) S/M

. published whenever a new vehicle or a full-model-change vehicle is released.

. How to find the applicable S/M

. simply select the S/M corresponding to the model year of the vehicle to be serviced.
Also use VIN or Vehicle identification Number

5. Job Quality

. Servicing

. Restoring a car to its original condition

 . to reinstate its performance and safety characteristics

. ensuring the serviced condition will last for as long as possible.

. Proper Servicing

. it is important that technicians have a good understanding of a wide range of the

modern technology

. It will be not possible to carry out servicing correctly if the car's system is not
understood

. Three Key requirements for job quality

. Do your work Safely

. Do your work correctly

. Do your work in time

. Do your work safely

. Careless work must never be allowed to cause the car to be damaged or cause injury to
self and others

. Do your work correctly (most important)

. Working correctly is reading the S/M carefully

. Do your work in time

. The customer's pleasure and confidence will not be gained if the car cannot be
returned at the pre-arranged date and time

6. Pre-delivery Inspection

. Pre-delivery inspection (PDI)

. final step to be performed before delivering a new honda vehicle to a customer

. PDI procedures (refer to picture)

. Protective wax

. Applied to protect vehicle exterioes from damage during transport from production
facility to the dealership.

. Installing the Back-up Fuse and Erasing DTC

. Back-up fuse is used to prevent discharge of the battery due to storage over a period of
time,.

. Erase DTC's using HDS before delivery

7. Special Tools
 . provided to enable the safe, accurate, and efficient performance of service operations that are
difficult or impossible to perform

using common hand tools alone.

. special tools required for specific service operations will be shown in S/M

8. Engine Overview

. Role of the Engine

. power is needed to motor a vehicle

. A vehicle's engine is a powering system which converts fuel into energy to rotate its
wheels

. Engine Types

. Gasoline Engine - compresses gasoline and air into an air-fuel mixture and uses electric
sparks to ignite the mixture.

. Gasoline engines are compact and lightweight and engine-emitted vibration

and noice are minimal

. Passenger-carrying vehicles primarily use the gasoline engine

. Diesel Engine - compresses and heats air to heat temperatures and then injects fuel
into th compressed hot air

setting off natural combustion

. Cost-economical

. vibration, noise, and acceleration has greatly improved upon recent years

. Hybrid system (engine)

. combines 2 or more sources of power

. combination of electric motor and a gasoline engine, have high fuel efficiency

. Insight and Civic

. Basic operation of engine

. Intake - Compression - Combustion - Exhaust

. Classification of Engine

. By fuel (gasoline/petrol or diesel), by cylinder head arrangement (valve mechanism)

. Basic construction of an engine

. Valve train, Power train, Lubrication System, Cooling System, Fuel System, Intake
system, Exhaust system, Engine Electrical System
9. Engine Electrical Overview

. Introduction

. Consistes of battery, starting system, charging system, and ignition system

. Starting System

. Starting or Cranking system

. Consistes of battery, starter, and an ignition switch

. Ignition System

. comprises a distributor, ignition wires, and spark plugs

. distributor regulates current and direct it to spark plug via ignition wires

. Charging system

. consists of alternator, alternator belt, charging system light and battery

. Precautions when handling the electrical system

. check connections to battery

. re-connect the positive terminal first

10. Cylinder Head/Valve Train Overview

. cylinder head is mounted on top of the cylinder block and together with the pistons,

it encloses the engine's combustion chambers

. valve train controls the supply of air/fuel mixture

. SOHC and DOHC

. SOHC (single overhead camshaft) configuration

. DOHC (dual overhead camshaft) configuration

. Cylinder Head

. have a number of different passages to allow circulation of coolant and of lubricating

oil

. Valve train

. valve train controls the supply of air/fuel mixture, and removal of burnt gasses from
combustion chambers

. Maintenance

. Hydraulic Lash Adjuster

 . eliminates the necessity of valve clearance adjustment

. provided at the valve side end of each rocker arm

11. VTEC System Overview

. Variable Valve Timing and Lift Electronic Control (VTEC0

. DOHC VTEC, SOHC VTEC, VTEC-E, New VTEC

15. Intake and Exhaust System Overview

. Intake system supplies each clinderr with the air that is required for combustion

. air enters a port located near engine compartment, passes through a duct to the air cleaner.
then passes through the throttle body,

then to intake manifold chamber, then to the intake manifold straight to intake port of
cylinders

. Major components of intake systems

. Air cleaner (HONDA USES WETTYPE PAPER FILTER ELEMENTS - filter paper with oil to
hold dirt) - removes dust and foreign matters

. Intake manifold - pipe arrangement that connects carburetor (or throttle body) with
the intake ports of the cylinder head.

It divides the flow of air and direts it toward each intake port.

. Duct arrangement - connects them together

. (in fuel injected engine) throttle body and intake manifold chamber are connected and
fuel injectors are located near

the intake manifold outlets.

. Intake manifold chamber - fitted before pipes diverge. ensures equal amount of air is
supplied to each cylinder.

injectors are fitted near manifold outlet. it inject fuel toward the intake ports\

. Resonator - fitted before air cleaner. reduces intake noise

. Intake Control system - reduces intake noise and enhance engine performance.

. air port has primary and secondary passages.

. Primary passage always open

. Secondary passage open at high engine speeds to boost rate of air intake
thereby enhance the engine's output

closes at low engine speeds to reduce intake noise

 . intake manifold consists of primary and secondary passages

. Primary always open (increases intake air flow velocity to enhance torque)

. secondary close in low engine speed. Open in high engine speeds to boost
intake air volume thus greater power.

. Chamber volume control system

. Operation: .low engine speeds: all valves are closed

.mid ranger engine speed: bypass-Lo control valves opened, reducing

length of the intake passage

.high engine speed: bypass-hi control valve is also opened. air flows to
whole chamber

. MAP (manifold Absolute Pressure sensor) - connected to intake manifold. enables

detection of the intake air volume

. Exhaust system overview - collects burned gases from cylinders and smoothly discharges them
outside the vehicle.

. Gases from cylinders flow through exhaust pipe by exhaust manifold. then pass
through muffler, which reduce exhaust noise

. Three-way catalytic converter (in exhaust pipe) - to cleance the exhaust gases

. can incorporate temperature sensor, oxygen sensor, and other divices

. Exhaust system major components

. Exhaust manifold - mostly cast iron. Stainless steel is used for certain vehicles since it is
relatively light and smoother inside surface

for smotther flow of gases

. exhaust pipe

. exhaust muffler - reduces exhause noise. made form sound absorbing materials

. Emission control system

. EGR or Exhaust gas recirculation system

. purge control system

. PCV or positive crankcase ventilation system

. TWC or Three-way calalytic converter

16. Cooling system overview

. Major components
 . Radiator - where cooling actually takes place. has radiator core fitted with cooling fins.

Coolant flows through tubes inside the core and releases heat to fins

. Radiator cap (contains relief valve and vent valve) - serves to regulate the pressure in the
cooling system

Relief valve open when pressure increases beyond level

Vent valve open to pressure decreases to not create vacuum in cooling system

. Reservoir - connected to radiator cap. regulates amount of coolant in the cooling system

. Cooling fan (HONDA USES ELECTRIC MOTOR and controlled from thermo sensor on radiator) -
maintain the required flow of air through the radiator

. Thermostat - prevent overcooling of the engine. located in coolant outlet or coolant inlet.

.closes when engine starts cold to reach optimum performance quickly

prevents coolant from entering the radiator while closed. coolant circulate inside engine
instead of radiator

.opens when temperaute exceeds. coolant flows through radiator for cooling

. Water Pump - keeps coolant moving around the cooling system

. Heating core - located inside heater unit. hot coolant flows thorough it.

Coolant's heat passes through the core. air is warmed by coolant's heat

. Coolant - water with anti-rust and anti-freeze. HONDA engine have aluminum components.
coolant should be appropriate.

17. Coolant Overview

. All engine in HONDA is water-cooled which prevents overheating

. Water has low boiling point. Boiled water cannot transfer heat efficiently

It freezes readily

freezing increases the volume of water which rupture the cylinder block or other cooling
system parts

becomes cause of rust and scale formation

ethylene glycol-based liquid is uded an an additive

.lowers freezing point and has higher boiling point than water

. GENUINE HONDA ANTIFREEZE/COOLANT in 50/50 mixture with water

. full coolant is not advisable since it will produce pre wear in the engine
18. PGM-FI System Overview

"Programmed Fuel Injection (PGM-FI)" HONDA's fuel injection system

. PGM-FI system supplies fuel to the engine via a set of fuel injectors. allows more precise fuel
supply control than carburetor

.ECM or engine control module controls fuel injectors

. Improved fuel economy

. improved emissions

. improved response

. higher power output

. Carburetor system - volume of fuel supplied is controlled by amount of air passing through the
carburetor

air volume is regulated by throttle valve which is operated by the accelerator pedal

. Fuel injection system is developed to allow suitable control under all engine conditions for
more accurate fuel supply volumes

. ECM determines the current engine conditions from sensors and calculated required
fuel volume

. Basic construction of pgm-fi

Intake system:

control volume of air supplied to engine

fuel-supply system:

delivers pressurized and regulated fuel to the injectors

control ystem

uses ECM to control fuel volume and injection timing based on signals from
various sensors.

. PGM-FI system types

. Multi-point injection (MPI) system

most widely used. Fuel order is 1-3-4-2 for in-line 4 cylinder

. Groupwise fuel injection (GFI) system

used in 4-cylinder engines. injectors are split into two groups. fuel order 1&4-
2&3

. Dual-point injection (DPI) system

 simplified type of fuel injection system similar to carburetor.

Two injectors (primary and secondary) are fitted into throttle body. fuel is
injected same as carburetor

primary injector injects fuel during normal operation

secondary injector operates to add fuel during highspeec o high-load situations

. MPI system

. Air intake system

idle air control (IAC) fitted in throttle body to control air-intake volumes during
idling

. Fuel Supply System

. fuel pump > fuel tank > fuel feed pipe > Fuel filter > pressure regulator > Fuel
injector > fuel return pipe

. Control System

. ECM (engine control module) - determines current condition of each cylinder.

monitors the engine, the transmission, electric load among other current
conditions

19. Idle Control System Overview

. engine's idle control system adusts idling adling speed in response to changes in the engine;s
operating temperature, electrical loading, and other factors

by changng the volume of intake air.

Thus the system maintains the optimum idling speed over a wide range of operating
conditions

. Major components

. Idle adjusting screw - used to adjust the base idle speed

. Fast idle thermo valve - controls idling speed according to engine's operating
temperature

. Idle Air control (IAC) Valve #1 - operated by a signal from ECM. valve of the air bypass
passage is opened to control the idling speed according

to engine loading.

EACV or electronic air control valve - functions only as an IAC valve

RACV or rotary air control valve - functions as fast idle thermo valve

. Locations
 . Fast idle thermo valve - bottom of throttle body

. Idle adjsuting screw: Top of throttle body

. RACV: on throttle body

. EACV: On intake manifold

20. Fuel Supply System Overview

. PGM-FI Engine

. Fuel Tank - This component stores the engine's fuel

. Fuel pump - takes in fuel from fuel tank and delivers it to the injectors at high pressure

. Fuel filter - removes foreign bodies and impurities from the fuel

. Pressure regulator - ensures pressure of fuel delivered is kept constant level

. Pulsation damper - absorb slight variations in fuel pressure when fuel is discharged bt
injectors

. Fuel injectors - spray fuel into the intak port

. Outline

Fuel tank > fuel pump > fuel filter > pressure regulator > injectors

. in fuel return-less system

excess fuel from the pressure regulator is directly returned to the fuel tank.

22. Cluch System Overview

. Clutch - located between the engine and the manual transmission

functions to transfer or cut-off the power output of the engine to the manual
transmission

-to be cut - clutch disconnect the engine from the transmission

-to be started - engine and transmission engage gradually

-securely connected - clutch must transfer power without any loss or slippage

. Clutch assembly

. Flywheel - connected to the crankshaft to ensure smooth rotation of engine.

flywheel and pressure plate combines to bind clutch disc between them

so the engine and transmission engages

. clutch disc - spline-fitted to the transmission shaft.

 engages with the friction surfaces on both the flywheel and the
pressure plate

. pressure plate assembly - bolted to the flywheel. they rotate in unison. comprises of
clutch cover, diaphragm spring, pressure plate

Pressure plate - held inside the clutch cover outside the diaphragm spring

. Clutch control system (cable type and hydraulic type)

. clutch pedal

. clutch cable or clutch hydraulic system

. clutch release mechanism

. Cable-type clutch control system

. clutch pedal

. clutch cable

. clutch release arm

. Hydraulic type clutch control system

. clutch pedal

. master cylinder

. slave cylinder

. clutch damper

. clutch release arm

. clutch release mechanism

- contains the hydraulic clutch control system's release bearing and release fork.

- In a cable-type clutch control system, the release fork is attached to the release shaft.

- release bearng slides axially on the transmission main shaft and is held by the release
fork.

- release fork - to hold and support the release bearing. connected to the clutch cable or
alternatively, the slave cylinder's push rod at one end

. main component of the clutch

.flywheel, clutch disc, pressure plate, diaphragm spring, clutch cover, release bearing,
release fork, clutch pedal

23. Manual Transmission (M/T) overview

 . basic functions:

- to transfer engine output power to the final driven gear

- to provide sufficient torque while starting, ascending, accelerating, engine braking, etc.

- To provide low to high speed driving capability

- To cahnge the direction of whheel rotation

. Flow of power in a drivetrain

. gear ratio @ speed = driver/driven, @ teeth = driven/driver

. reverse idler gear

24. Automatic transmission (A/T) Overview - was devised to allow the vehicle to automatically perform
gearshift operations in response to load, speed, and other relevant conditions

. Three major components:

. Torque converter - transfer the engine's output power to the gear through the action
of a special fluid. It must increase engine torque in a set ourput range.

. gear unit - implements the necessary gear change when the vehicle is driven in reverse

. hydraulic control unit - converts engine load, speed, and other similar variables into
hydraulic signals

and controls gear shifting according to hydraulic pressure. This also

performs control of the lock-up clutch

. Torque Converter - a fluid coupling that transfers torque through the action of the fluid which
it contains.

As speed of turbine increases, amount of fluid redirecte by stator to accelerate pump

will decrease and torque-increase effect is reduced.

If speed of turbine exceeds, fluid is discharged from this component, will effect the rear
of the stator where it promotes reverse rotation of the pump

and torque increase effect is further reduced.

Speed ratio = turbine speed / pump speed

torque ration = turbine axle torque / pmp axle torque

Transmission efficiency = (Output power / Input Power) *100

ratio speed is 0 = stall point, the turbine will not rotate and the torque will reach its
maximum value of 2.

. most fundamental difference between the gear units of A/T and M/T
 is the fact that the A/T have hydraulically-controlled multiple-disc clutches instead of
synchronizers.

These clutches are used to connect gears to the shafts to carry put gearshifts.

In the case of reverse gear, hydraulic pressure is used to actuate a shift fork so that the counter
shaft

and counter reverse gear can be engaged.

. Hydraulic control unit

. hydraulic pressure is supplied by an ATF pump which is driven by the pump drive gear
in the torque converter housing.

. hydarulic control unit receives signals relating to the driver's desired operation, current
condition of the vehicle,

and other similar factors these signals having been converted into hydraulic
form.

. Differential valves - hydraulic pressure applied to a differential valve causes the valve to
actuate.

. The direction of activation depends on differences in the amount of the area to which
pressure is applied.

. Shift change method

. Engine loading is detected using throttle valve A. Hydraulic pressure is generated

corresponding to the current degree of throttle opening

. Detection of vehicle speed - governor valve regulates line pressure in accordance with
vehicle speed.

When vehicle speed is low, the governor valve opens slightly. When speed is
high, it opens widely.

.1-2 > 2-3 > 3-4, each valve have different diameter and each have integrated springs
which varies from valve to valve.

. ATF or Automatic Transmission Fluid

used in automatic transmissions. functions as hydraulic fluid inside both the torque
converter and hydraulic control unit

and as a lubricant inside the gear unit.

ATF is directed to all parts of the automatic transmission by an ATF pump.

. E-AT or Electronically-controlled Automatic Transmission

. E-AT combines the operation of an automatic transmission with electronic control.

 . Throttle opening and vehicle speed signals are detected electrically.

32. Brake System Overview

. The brake system s the most safety-critical system in any vehicle.

. A malfunction in the brake system could cause a serious accident.\

. Introduction

. A vehicle's brakes cause the vehicle to decelerate or stop by converting the vehicle's
kinetic (motion) energy into heat energy through frictio

. Heat is dissipated to the atmosphere.

. Brakes can be disc or drum brakes.

. Disc brake - pads squeeze a disc that rotates together with the wheel.

. Drum brake - shoes expand onto the inside surface of a drum that rotates together
with the wheel.

. HONDA use disc brakes on front, and disc or drum on rear

. Brake discs and drums are made from cast iron.

. Friction materials were originally made from asbestos. Now made from sintered alloy
substances.

. Brake system consists of servce brakes and a parking brake

. Service brakes are activated hydraulically by the brake pedal and are used while
moving

. Parking brake is activated mechanically by a parking brake lever or pedal. Used to hold
in position

. Service brake

. Master Cylinder - converts pedal force into hydraulic pressure

. HONDA utilize tandem master cylinder (has two independent hydraulic lines)

. Fitted with a brake fluid reservoir

. Disc brake - consistes of a brake disc, brake caliper, and two brake pads.

. The brake disc is sandwiched by the brake pads and the pads are held inside
the brake caliper.

. Most brake disc are solid

. Some utilize vetilated discs (contains radial vanes between its rubbing surfaces
fr optimum cooling performance.
 . Used on front brakes for heavy loading. Certain models for rear brakes

. Drum brake

. drum brake consistes of brake drum, wheel cylinder, two brake shoes and
backing plate.

. Proportional Control Valve (PCV)

. Adjusts the brake pressure supplied to the front and rear brakes

. Since locking of the rear wheels would cause instability and could cause to spin

. HONDA utilize dual PCVs

. Brake booster

. reduces the amount of force required when depressing the brake pedal.

. HONDA uses diaphragm-type vacuum servo brake booster.

. This type boosts the force applied to the brake pedal. Boosted force is
applied to master cylinder's pistons

. brake hose and pipes

. Metal pipes are used to connect brake system components that are fixed to a
vehicle's chassis.

. Rubber hoses are used to connect components that move vertically due to
operation of the suspention system.

. HONDA uses an X-split divided-line connecton arrangement. To prevent brakes

from failing in the event of fauly in one line.

. One line serves the front-right and rear-left brakes

. and other line serves the front-left and rear-right brakes.

. Parking Brakes

. Activation mechanism

. HONDA utilizes mechanical parking brake arrangement

. the rear-wheel parking brake mechanism is activated from the cockpit via
cables.

. can be lever-activated or pedal-activated.

. Lever-Activated Parking brake

. the parking brake cables are connected to a lever

. the driver pulls the lever upward to activate the mechanism.

 . the leber s then held by a rachet.

. Consists of parking brake lever (or pedal), parking brake cable, and rear wheel brakes.

. Pedal-Activated Parking brake

. used on certain automatic transmissions.

. the parking brake cable are connected to a pedal near the driver's feet.

. Parking Brake-proper

. Parking brake arrangement can be combined type or independent type

. Conbined type - the rear service brakes are used by the parking brake
mechanism

. Independent type - dedicated parking brake are fitted independently of the

service brakes.

. utilizes dedicated parking drum brakes that are fitted inside the disc
hubs of rear disc brakes.

. Operation Flow

. Service brake

depress>pedal force to brake booster>boosted force to the pistons in master cylinder

>pressure transmitted to wheel brakes via fluid-filled brake lines>causing pistons to

press pads against the discs.

. Parking Brake

lever pull>cables transmit pullng force to rear brake calipers>causing pistons to press
the pads against the discs.

33. Brake Fluid Characteristics

. brake fluid is used i nthe hydraulic circuits of brake and clutch systems.

. non-mineral subtance; it is not a type of oil.

. Main Requirements:

. High Boiling Point - To prevent vapor locking (caused by overheating), brake fluid must
have high boiling point.

. Low viscosity - must flow smoothly over wide temperature range

. Compatibility with Rubber and Metal Components

. brake fluid is highly hyfroscopic.

. it absorbs moisture from the atmosphere.

 . Moisture in the brake fluid lowers the fluid's boiling point and make the system prone
to vapor locking

. Brake fluid must be replace regularly because of gradual absorption of moisture.

. Brake fluid are manufactured to conform with United States Department of Transportation
(DOT)

Federal Motor Vehicle Safety Standard (FMVSS).

. There are three grades: DOT 3, DOT 4, and DOT 5

. The higher the DOR number, the higher the boiling point.

. HONDA uses DOT 3 or DOT 4

. DOT 5 damage rubber components in HONDA vehicles. It is not hygroscopic

34. Antilock Brake System Overview

. Antilock brake system (ABS) prevents a vehicle's wheels from locking when the brakes are
applied, thereby maintaining steerability.

. Locking causes driver to lose directional control and vehicle will continue to move in its current
direction.

. ABS automatically controls the brakes to keep the wheels in this condition.

. When ABS malfunction, ABS warning lamp illuminates

. Components and Function

. consists of control unit, modulator, and set of wheel speed sensors

. Control unit - controls the system's operation

. Modulator - controls the brake fluid pressure

. Types of ABS

. HONDA-developed ABS - hydraulic control and regular braking circuits are independent
of each other

. OEM ABS - unlike HONDA-developed ABS. dependent of each other.

brake hydraulic pressure is controlled directly using soilenoid valves and a

pump.

35. Traction Control System (TCS) Overview

. TCS significantly reduces the work required from the driver during standing starts and rapid
acceleration on slippery road surfaces

and during cornering operations at high speeds.

36. Body overview

. HONDA bodies use unit construction

. Before this, frams constructon is used. Major components such as the engine, transmission,
and suspension were mounted onto

bare bones of the vehicle - the frame.

. Unit construction vehicles do not have special frames.

They are composed of body panels to provide the required body strength without the
use of a frame.

. Unit Constructon

. These use thin, press-formed steel panels of about 1 or 2 mm in thickness. Spot

weldings is used.

Locations of engine and suspension are required to have extra strength and
rigidity.

Improve strength: adding rids, recesses, and other similar indentations.

welding stiffening material and by addition of smaller, individual

sub-frames.

. It provides increases ability to absorb impact forces.

37. Heater Control System Overview

. used to warm the interior of the passenger compartment. Incorporates vents so that outside
air may be introduced in the compartment.

. used to maintain a comfortable temperature with the passenger compartment and to keep the
windows clear of fog or frost.

. Functions

. Intake of air from outside the vehicle or the recirculation of air within compartment.

. Passing of air over the heater core so that it may be heated.

. Directing the air to air-vent outlets in cmpartments.

. Regulating the strength of the air flow using blower-fan control.

38. A/C System Overview

. It blows cool and dry air into the passenger compartment to keep the interior at the desired
temperature

. It uses refrigeration system similar to that found in household refrigerators

 . The refrigerant must be evaporated to provide cooling as it absorbs heat from the
objects with which it is in contact

. HFC-134a is used as a refrigerant since it does not contain chlorine and

environmentally friendly

. Four major components: compressor, condenser, evaporator, and receiver/dryer

. The blower will blow air through the evaporator and into the cabin

. Compressor receives low-pressure and low temperature vapor from the evaporator
and changes this into high-pressure and high temeprature vapor

. Upstream- low pressure side

. Downstream - high pressure side

. Condenser is a heat exchanger that carries heat away from the vapor

. Receiver/Dryer filters and stores liquid refrigerant. It has a "desiccant" that absorbs
moisture present in the system

. Evaporator is also a heat exchanger and boils the liquid refrigerant

39. Battery Construction and Function

. Battery converts chemical energy into electrical energy. It serves as the power source for
electrical components in a vehicle.

. Batteries do not "store" electrical energy; instead, they contain potential. They convert
chemical into electrical energy when load is present

. Functions:

. Supply electricity to the starter during starting

. Dampen spikes from electricity such as from the alternator

. Supply electricity to vehicle systems when the engine is off

. Battery Construction

. "Wet multi-plate" type composed of lead plates immersed in an acid solution

. made up of following cells

. Positive and Negative Plates

. Negative plates: deposits of porous lead

. Positive plates: deposits of spongy lead peroxide

, Micro-Porous Separators
 . Plates are arranged alternately w/ porous plastic separators in bet.
since positive and negative plates must not touch one another.

. Cell Connectors

. Electrolyte or sulfuric acid/water mix (63% water and 37% sulfuric acid when
charged) (83% water and 17% sulfuric acid when discharged)

. Connector posts for battery cable connection

. Battery Ratings

. Cold Cranking Amps - number of amps a fully charged battery can deliver at -18C for
30s without having a voltage drop of 7.2 volts

. Cranking Amps - number of amps a fully charged battery can deliver at 0C for 30s
without having a voltage drop below 7.2 volts

. Reserve Capacity - number of minutes that a fully charged battery can supply 25 amps
at 27C before voltage drops to 10.5 volts

. Ampere-hour rating- amount ofn current flow a fully charged battery can supply for 20
hours without having a voltage drop of 10.5 volts

. Battery Use and Discharging

. As electrical loads in the vehicle are switched on

. H2S04 -> H2 and S04 (Sulfate)

. S04 + Pb = PbSO4 (lead sulfate)

. 02 from positive plates + H2 in the electrolyte = H20

. Chemical reactions occur as the electrical current flows from negative to positive
plates. It continues:

. Load is present

. Until acid concentration becomes too weak

. Battery is discharged when:

. Plates are mostly lead sulfate (PbSO4)

. Electrolyte is mostly water

. Cells no longer produce the desired voltage

. Batter Self-Discharge

. Doubles with every 10C increase in temperature

. Increases when battery cables are corroded/dirty

 . . Parasitic draw is a small amount of current that is required to operatre various
electrical systems or components

. ECM/PCM

. Radios

. Security Systems

. Battery Charging

. Lead Sulfate (PbSO4) is separated into lead and sulfate

. SO4 leaves both of the plates and combines with hydrogen in the electrolyte to form
sulfuric acid

. Oxygen in the electrolyte combines with lead on the positive plate to form PBO2

. Negative plate returns to original form of Pb

. Overcharging causes excessive gassing which leads to water consumption and raises
the temperature of the electrolyte causing the battery to explode

. Battery State of Charge Indicator "Eye"

. Equipped with "Hydrometer" or a state of charge indicator "eye".

. Electrolyte is 1.27 times heavier than water (Higher SG means thicker)

. Green means sufficiently charged for testing; Dark means insufficiently charged for
testing

. Purpose of Battery Testing is to determine:

. Starting power of the battery

. Condition of the battery

. Charge level of the battery

. Voltage level of the battery

. Open Circuit Voltage is obtained by using Digital Multi-meter across the battery terminals

. Battery Testing

. Surface Charge on a battery should be removed and it is

. A result of charging/discharging

. Mixture of H20 and H2S04

. Can cause inaccurate test reslt

. To remove surface charge

 . Turn on the high beam headlamps for a few minutes

. Internal Resistance (Impedance), Voltage, and ability to Current should be factored into
diagnosis

. If repeated "charge and retest" -> Replace the battery

. Battery Failure

. Sulfation: plates slowly develop and retain lead sulfate, reducing their ability to react in
the electrolyte. It is caused by lack of use, lack of water, and undercharging

. High Heat: Heat speeds up sulfation. It is caused by high underhood temperatures,

overcharging

. Vibration

. Age

. Deep Discharging

. Battery Maintenance

. Maintenance Free: sealed that require no periodic top-off distilled water

. Low-Maintenance: require periodic top-off distilled water

. Adding Water

. Use Distilled Water

. Never use tap water

. Do not add directly electrolyte to the battery

. Important to extending battery life

. Maintain correct electrolyte levels

. Tighten loose hold-down clamps and terminals, but not over-tighten battery
cable terminals

. Remove corrosion from both ends of each battery cable and terminal

. Keep the battery top clean

. Check alternator belt tension

. Battery Storage

. Charge the battery fully before storage as it reduces sulfation during storage

. Make sure that the case is clean

. Check the battery once per month

 . Store the battery in a dry area

. Precautions

. While servicing batteries, protective clothing and a face shield must be worn

. It contains sulfuric acid which can cause severe burns

. Keep sparks and open flames away

. Never smoke while servicing batteries

. Never use the battery as a work surface

. Battery Replacement

. Always disconnect the negative battery cable first

. When installing, always connect positive battery cable first

. Jump-Starting Cautions

. Connect a positive jumper cable to the positive battery terminal post (Disabled)

. Connect the other positive jumper cable to positive battery post (Good Vehicle)

. Connect a negative jumper cable to the negative battery post (Good Vehicle)

. Connect the other negative jumper cable to a suitable ground. Do not connect the
negative jumper cable to the negative battery post of the disabled vehicle; instead, connect it to a metal
engine bracket away from the battery

40. Electricity

. It is the flow of electrons through atoms.

. Atoms are the smallest particles of matter

. Electrons having negative charge

. Protons having positive charge

. Neutrons having no charge

. Balanced Atoms have the same number of protons and electrons. As long as atoms are
balanced, there can be no electricity because electricity occurs only when electrons can move from one
atom to another

. Unbalanced Atoms do not have the same number of protons and electrons

. To get an electron leave an atom

. Add Heat

. Add Light
 . Friction

. Magnetic Reaction

. Chemical Reaction

. Potential Difference is difference in charge

. Electrons flow only when three conditions are met

. Difference in charges

. Free electrons to travel from atom to atom

. Complete path for the electrons to flow

. Voltage is a measure of the force that pushes electron. It is also known as "electromotive
force"

. Circuits include

. Power Source

. Wires

. Load (device performing the work)

. Switch

. Ground

. Current flows only when there is voltage present and a complete circuit/path

. Types

. Direct Current such as batteries

. Alternating Current such as alternators

. Resistence

. Infinite Resistance is caused by an open in a circuit caused by an open switch or broken

wire

. Unwanted resistance is caused by unintentional sources developed in a circuit such as

corrosion or loose connection

. Wattage is a measure of the amount of electrical power that a component needs to operate
properly

. Conductors are mat'ls that allow electricity/current to flow easily.

. Copper

. Iron
 . Aluminum

. Resistance of conductor increases when

. Temperature increases

. Diameter decreases

. Length increases

. Insulators are materials that prevent electricity from flowing easily. It is Useful for protecting
wires and electrical devices

. Semi-Conductors are neither good conductors nor good insulators. Examples: Diodes and
Transistors

. Magnetism and Electricity

. Conductors carrying a current create a magnetic field

. Alternator

. Relay

. A wire carrying current flow produces a magnetic field. if that sime wire is wrapped
around an iron bar, the field is strengthened creating an electromagnet

. Types of Magnets

. Permanent Magnet is made from materials such as hardened steel

. Temporary Magnet is made from materials such as soft iron and remains
magnetic as long as the outside magnetizing force is present

. Electromagnets present in automobiles

. Relay uses a temporary amgnet to open/close a switch in a circuit

. Solenoid is a device that converts voltage into mechanical movement

. Induction is making use of magnetic field used to create current flow

. The amount of current induced depends on

. Number of windings in the coil

. Strength of Magnetic Field

. Speed at which the wire passes through the magnetic field

41. Circuits Overview

. It is a path, simple, and an unbroken loop through which current can flow.

. Voltage forces the current to flow through the circuit

 . Configurations

. Series circuits provide one path for current to flow

. Parallel circuits provide more than one path for current

. Series-Parallel circuits combine these two types

. Types

. Switch to ground; switch is located between load and the ground

. Load to ground; switch is located between power source and load

. Series Circuit is the simplest type of circuit with the following characteristics

. Provides a single path for the voltage to flow

. Current will not flow if any part of the circuit opens

. Total Resistance = Resistance 1 + Resistance 2 + ... + Resistance "n"

. Total Voltage = Voltage Drop 1 + Voltage Drop 2 + ... + Voltage Drop "n"; Voltage drop
is the difference in voltage on one side of a load compared to the voltage on the other side of the load

. Current is constant

. Parallel Circuit provides more than one path for current to flow

. Resistance = reciprocal of 1/Resistance 1 + 1/Resistance 2 + ... + 1/Resistance "n"

. Total Voltage is constant

. Total Current = Current Flow 1 + Current Flow 2 + ... + Current Flow "n"

. Series-Parallel Circuit combines series and parallel circuits

. Series portion of the circuit has at least one load

. Parallel portion of the circuit also has at least one load

. Switch-To-Ground circuits

. Switch is located between the load and the ground

. Most common type of circuit on Honda and Acura vehicles

. Example: interior light circuit. In this circuit, light will operate when either switch is
closed. The door switches are closed with the doors open

. Load-To-Ground circuit

. Switch is located between the power source and the load

. Disadvantage: when switch closes, there may be a small arc of current that crosses the
switch that shortens its life
42. Basic Circuit Components

. For automotive purposes, current flows from positive terminal to the negative terminal

. Components:

. Power Source provides vehicle's electrical system. It also provides a voltage source to
the vehicle during starting and engine off conditions

. After the engine is running, the alternator provides the vehicle's electrical
system with power

. Alternator: Mechanical Energy -> Electrical Energy using

electromagnetic induction

. Protection Device are intended to protect the circuit components from damage caused
by excessive current flow in the circuit

. Fuses are designed to fail when current exceed a specified value

. Operation: protective element within the fuse case will heat up and
melt when exposed to excessive amperage. It opens the circuit and thus prevents short circuit

. When a fuse melts, it must be replaced. Never substitute a higher

rated fuse since it may not melt even when there is a problem in the circuit

. Fusible Links are designed to protect the circuit by failing before the larger
diameter wire in the rest of the circuit; has a smaller diameter wire with a lower melting point

. Circuit Breakers are used to protect circuits where temporary overloads may
occur. It can be reset unlike fuses

. It contain a strip formed out of two different metals

. Control Devices open and close a circuit

. Mechanical Devices

. Switches control the current flow in a circuit

. Relays are remote, heavy-duty switches that are electronically

controlled by another switch or device

. Control circuit contains electromagnet that is the heart of the

relay

. Power circuit contains the switch that operates the load

. Solid State Devices

. Transistors

. Load uses electricity to perform work

 . Four Basic Operations

. Motion Generating Devices: Door Lock Actuators, Power Window

Motors etc.

. Light Generating Components: Interior and Exterior Lights, LED

Displays

. Heat Generating Devices: Rear Window Defrosters, Seat Heaters

. Sound Generating Devices: Audio Systems, Entertainment Systems

. Common Characteristics

. Create resistance

. Major source of resistance

. Create a significant voltage drop

. Measuring Resistance: Honda recommends using Voltage Drop Method

. Unwanted Resistance decreases current in the circuit

. Path for the electricity consists of conductors that carry the electricity through the
circuit and back to the source

. Wiring

. Grounds

. Connectors and Terminals are palstic housing joining two wire harnesses

. Connectors can be described by

. Number of Cavities

. Shape (Male or Female)

. Wire Size

. Color

. Ground Path carries current flow back to the negative battery terminal

. Most automotive circuits in a vehicle use vehicle body as a ground

43. Circuit Fault Symptoms

. Circuit may

. Not operate at all

. Operate incorrectly

. Component may
 . Operate incorrectly

. Types of Circuit Faults

. High Resistance/ Open Circuit: system may still operate but not function correctly;
caused by corrosion or damage

. Low Resistance/ Short Circuit: occurs when resistance drops too low

. Component Failure: caused by high resistance or low resistance fault

. Circuit Fault Symptoms

. High Resistance Fault: Reduced performance

. Low Resistance Fault: Circuit overload; when short to ground occurs a much higher
level of current flows; short to power occurs when the insulation on two wires running next to each
other fails and the wires are exposed to each other, thus electricity can pass from circuit to another