Repair and Install lighting and windshield

wiper system

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 Unit one
Overview of lighting system and windshield
wiper and washer system

This unit covers

 Introduction to lighting and windshield wiper system

 Lamps

 Installation and testing procedures

 Identifying materials, tools and equipment

 Safety requirements
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Purpose of lighting and windshield wiper system
 maintaining optimal visibility both in and out of the
vehicle
 provides nighttime visibility, signals and alerts other
drivers of your intentions
 supplies light for viewing instruments and the vehicle’s
interior.
 The wiper system keeps excessive dirt, water, or snow
from building up on the windshield
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Lamps or Light Bulbs
 A lamp generates light as current flows through the
filament
Types of lamps
There are several lamp types available
 standard incandescent lamps,

 halogen lamps,

 vacuum tube fluorescent (VTF) lighting,

 HID xenon gas systems,

 LEDs, and more.

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1. Incandescent lamp
 consist of one or more tungsten filaments.
 The filaments heat up to approximately 5000°F
(2760°C) and glow white-hot
 The fi lament material does not burn because there is no
oxygen in the bulb.

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2. Halogen lamps
 are another type of incandescent lamp.
 They are filled with a halogen gas such as bromine or iodine
 These lamps have a much longer life and are generally
brighter than standard incandescent bulbs.

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3. Vacuum tube fluorescent (VTF)
 Is also called a vacuum fluorescent display(VFD).
 They are used for instrumentation displays on instrument
panel clusters.
They can display various colors VTFs usually
 display bar graphs,
 seven-segment numerals,
 multi-segment alphanumeric characters,

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4. High-Intensity Discharge
 High-intensity discharge (HID) headlamps produce light
with an electric arc.
 This is instead of a glowing filament.
 The high intensity of the arc comes from metallic salts that
are vaporized within an arc chamber

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5. Light-emitting diodes (LEDs)
 LEDS are not new in automotive applications.
 Examples include warning indicators and alphanumeric
displays.
 It is now possible to get LEDs that emit bright red, green,
blue, yellow, and clear or white light.
 For example, LEDs are now often used for stop lights, turn
signals, and interior lighting

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There are many reasons for using LEDs in headlights
 LEDs do not require a vacuum bulb or high voltage to work.
 LED-based lighting sources require less power (up to 40% )
 LEDs provide a whiter light than xenon.
 LEDs environmentally friendly
 operating life of an LED is twice that of the vehicle itself.
 LEDs are resistant to shock and vibration.
Disadvantages of LED:
 LEDs are more expensive.
 LEDs need temperature controls and must be mounted to
heat retarding materials.
 LEDs also require precise current control, which requires
complicated electronic circuitry.

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Design of lamps bulbs
 Lamps/light bulbs come in a variety of configurations to fit
the various applications within a vehicle
I. Based on number of filaments the bulb has:
A. Single-filament
 bulbs are common for use as courtesy lights, dash lights,
and warning lights, stop light, and the turn signal.

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B. Dual-filament
 bulbs have two filaments of different wattage One filament
emits a small amount of light.
 The second filament emits more light.
 For example taillight (emits less light) and brake light (emits
more light).
 Headlights (high beam and low beam) can also be dual-
filament bulbs.

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II. Based on the type of base on the lamp
A. Bayonet-style bulbs
 They get their name from the two retaining pins on the side
of the base.
 The pins are retained in the pocket by the spring-loaded
base in the bottom of the socket.
 This design resists vibration very well.

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B. wedge base
 use either made from the glass bulb itself or with a built-
in plastic base the bulbs are pushed straight into the
socket, and tension from the socket retains the bulb

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C. festoon lights
 which have a base on each end of a cylindrical light
bulb Each end of the filament is connected to one of
the bases.

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Identifying materials, tools and equipment
Multi-meter
 Used to measure DC volts, AC volts, Ohms, DC Amperes,
AC Amperes
Crimping tools
 Crimpers are tools used to make cold weld joints between
two wires or a wire and a connector, such as lugs
Electric soldering gun
 An electric soldering gun used to make electrical repairs.
wires and cable
 A wire in a wiring harness is made up of a conductor and
an insulator Solid wires (single-strand, multi strand and
Printed circuitry
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Terminals and connectors
 To perform the function of connecting the wires from the
voltage source to the load component reliably, terminal
connections are used.
 Today’s vehicles can have as many as 500 separate circuit
connections.

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 Electrical tape
 Electrical tape (or insulating tape) is a type of
pressure-sensitive tape used to insulate electrical wires and
other materials that conduct electricity.

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 Unit two
lighting wiring system
1. Exterior Lights
Headlights are mounted on the front of a vehicle to light
the road ahead during darkness or other times when
normal visibility is poor.

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Semi sealed beam headlight
 The difference between the sealed beam and semi-sealed
beam headlight is its design, which allows bulb
replacement.

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Headlight Switches
Combination switch
 Headlight switches are either mounted to the instrument
panel or are part of the multifunction switch on the
steering column.
 The head light switch controls most of the exterior lighting
for the vehicle.
 Most switches have three positions: off, park, and head
light

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Dimmer Switches
 The dimmer switch provides a way for the driver to switch
between high and low beams.
 A dimmer switch is connected in series with the headlight
circuit and controls the current path to the headlights.

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Adaptive Headlights
 Adaptive headlight systems are electronically controlled
through inputs from the steering system and vehicle speed.
 They aim the lights in the direction the vehicle is turning
 Currently there are two basic system designs for adaptive
lighting.
 Both are controlled by the vehicle’s body control module
(BCM).
 The systems respond in real time by responding to the
vehicle’s current steering angle and road speed.
 Adaptive headlights can also be controlled by GPS
navigation and digital road maps.

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Smart headlights
 Smart headlights dim when passing cars to prevent
dazzling other drivers.
 Headlight illuminates the road without blinding other
drivers.
 Lights improve driver visibility during poor weather such
as snowstorms.

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Clearance lights and Tail Lights
 These are low-intensity lights to indicate the presence and
width of a vehicle at night or in tunnel to other vehicles in the
front or behind.
 Those in the front are called clearance-lights and those in the
back are called taillights.
 The power rating of these lights is 5 watts

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License plate lights
 These lights illuminate the rear license plate.
 The license plate lights go on when the taillights go on.

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Signal Light Systems/ Cornering Lights
 Cornering lights are lamps that illuminate when the turn
signals are activated.
 They burn steady when the turn signal switch is in a turn
position to provide additional illumination of the road in the
direction of the turn.

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Hazard Warning Lights
 The event of an emergency, such as a roadside breakdown, all
the lamps should be capable of working simultaneously, when
they are called "hazard warning lights".
 The hazard warning lights indicate the existence of the vehicle
to the front, rear and both sides during emergency stopping or
parking.

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Brake Lights
 The brake (stop) lights are usually controlled by a stop light
switch that is normally mounted on the brake pedal arm.
 Some cars are equipped with a brake or stop switch mounted
on the master cylinder, which closes when hydraulic pressure
increases as the brake pedal is depressed.

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Backup Lights
 When the transmission is placed in reverse gear, backup lights
are turned on to illuminate the area behind the vehicle and to
let drivers know that the vehicle is in reverse.
 When the transmission is shifted to reverse, the backup lights s
witch closes and power flows to the backup lights.

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Fog light
 Fog lights are designed to be used when visibility is
severely restricted, chiefly by fog, but also in other poor
visibility conditions such as snow or heavy rain.
 Turn the headlight switch on to the low-beam position.
Press the fog light switch (pilot indicator is on).

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Interior Light Assemblies
 Modern automotive lighting is used for both functional and
decorative purposes.
 Interior lighting is used to illuminate driver controls and to
provide style and decoration inside the vehicle.

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Horn
 The horn is an electromagnetic vibrating device, which is
operated by the driver to produce an audible warning
signal.
 It provides a warning sound to other road users.
Automotive horns are usually wired directly to battery
voltage from the fuse panel.
 Horns are manufactured in several different tones or
frequencies ranging between 1800 and 3550 Hz.
 Car manufacturers can select various horn tones for a
particular car sound.
 When two horns are used, each

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All circuits require the same basic components

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Head Light Aiming
 Headlight aiming is a critical service item on cars, the
headlights must be aimed correctly, aim of headlights that are
properly adjusted cover the correct range and afford the driver
the proper night time view
 If they are aimed too high or to the left, they might blind an
oncoming driver and cause a serious accident.
 Incorrect aiming can also reduce the driver’s ability to see the
road properly

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Headlight aim should be checked and adjusted:
 every 12 months,
 when a headlamp bulb is replaced,
 when there are special situations of vehicle rear loading, or
 when front end sheet metal is repaired or adjusted.

Headlight dazzling
 Glare or dazzle occurs when visual field brightness is greater than
the luminance to which the eyes are adapted.
 Too much light or improper lighting may result in glare (dazzle),
which causes visual discomfort
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 Unit three
Windshield wiper and washer system
This Unit Covers
 Determine Windshield wiper
and wiring system
 Test and Repair of Windshield
wiper

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 The windscreen must be clean enough to provide suitable
visibility at all times.
 To do this, the wiper system must meet the following
requirements.
 Efficient removal of water and snow.

 Efficient removal of dirt.

 Operate at temperatures from _30 to 80 ° C.

 Pass the stall and snow load test.

 Service life in the region of 1500 000 wipe cycles.

 Resistant to corrosion from

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acid, alkali and ozone
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Functional requirements
 Wipers ensure the visibility of the driver by wiping the
rain or dirt from the front or rear windshield.
 Recently, a wiper is often installed also on the rear
window to improve rear visibility.
 The wipers usually have a number of speeds and
intermittent operation for varying rainfall conditions.

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wiper system component
Wiper Switch
 Turns the wipers ON/OFF and changes their speeds.
Wiper Motor
 This motor produces the power to operate the
wipers.
Wiper Linkage
Changes the rotational movement of the wiper motor
into a reciprocal movement and operates both right
and left wipers in unison
Wiper Arm
 Applies a constant pressure to the wiper blade against the
windshield surface, in addition to transmitting the movement
to the wiper blade
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Wiper Blade
 Is the portion that wipes the windshield glass.
 The rubber insert of the wiper blade must be replaced
periodically
washer system
 The washer system provides a cleaning spray.
 A windshield washer sprays washer fluid to remove dirt or oil
that cannot be removed by the wipers alone.

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The windshield washer system consists of a
 washer fluid reservoir - Stores washer fluid
 washer motor - pump washer fluid
 Hose - Transports fluid from reservoir to the nozzles
 washer nozzle - spout that sprays washer fluid
 washer fluid - fluid that removes dirt from the
windshield glass

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Symptom Possible fault
Wipers not working or  Loose or broken wiring/connections/fuse.
 Corrosion in wiper connections.
poor operation
 Switch not making contact.
 High resistance contact on switch or wiring.
 Relay/timer not working.
 Motor brushes or slip ring connections worn.
 Limit switch contacts open circuit or high
resistance.
 Blades and/or arm springs in poor condition
Washers not working or  Loose or broken wiring/connections/fuse.
 Corrosion in washer motor connections.
poor operation
 Switch not making contact.
 Pump motor poor or not working.
 Blocked pipes or jets.
 Incorrect fluid additive used.

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