939003542 - 5540 EXTERIOR LIGHTING

COMPOSITION

The vehicle exterior lighting system has been designed and produced with two objectives in mind:- guaranteeing maximum efficiency with regard to the international regulations that define the lighting technology specifications for the various components;- being integrated with the design of the vehicle so that the various components enhance the image.

Location of components on vehicle

The vehicle components and their location are illustrated below.

1 - Right front light cluster2 - Left front light cluster3 - Left front direction indicator4 - Right front direction indicator5 - Right rear light cluster (fixed part)6 - Right rear light cluster (moving part on boot)7 - Left rear light cluster (fixed part)8 - Left rear light cluster (moving part on boot)9 - Third brake light10 - Number plate lights

Front light cluster (halogen version)

The unit consists of:

1 - Cover for main beam headlamp2 - Cover for direction indicators and side lights3 - Cover secured by catch and seal for dipped headlamp4 - 14-way connector for lamp power supply5 - Bevel pinion / adjustment screw for lamp horizontal axis6 - Bevel pinion / adjustment screw for lamp vertical axisWiring diagram and connector

PIN OUT:2- Dipped headlamps control3 - Main beam headlamps control4 - Side lights control5 - Direction indicators control6 - Power supply for headlamp alignment corrector7 - Headlamp alignment correction signal8 - Earth connection for headlamp alignment corrector14 - Bulb earth connection

Electrically controlled headlamp alignment corrector

The headlamp alignment device is designed to adjust dipped light beam correctly in a vertical direction irrespective of the load on the axles.With the dipped headlamps on, using the wheel in the contol panel on the left side of the driver, it is possible to alter the angle/direction of the light cluster in 4 standard positions: the following loads correspond to the four positions:0 - 1 person (driver), 2 persons (in the front seats)1 - 5 persons, 2 persons (in the front seats), 3 persons (in the rear seats)2 - 5 persons plus maximum load3 - 1 person (driver) plus maximum permitted load in luggage compartment without rear seat folded downThe maximum load refers to: the maximum permitted load on the rear axle or: the total permitted load for the vehicle.The weight of a person is taken as 75 kg.

Front light culster (gas discharge - xenon version)

The need to improve the performance of current systems based on halogen bulbs in terms of the light energy emitted and the spectral distibution and life of the bulb has led to the development of gas discharge headlamps technology and the devices that allows its operation on the vehicle.There are basically three types of advantage from the development of this technology:- the increased light efficiency allows a reduction in the absorption of electrical energy;- the high light flow emission makes it possible to reduce the dimensions of the light cluster (in particular the height) with greater freedom in the design of the front section;- the bulb lasts, on average, twice as long as a halogen bulb.The technology of gas discharge headlamps has led to the development of a series of devices that include:- xenon bulbs;- optics (reflective surface of the headlamp);- electronic control (ballast);- automatic light beam alignment correction.Traditional lamp light beam (isolux curve).

Discharge lamp light beam (isolux curve).

Every light cluster includes the components necessary for the operation of the discharge bulb (bulb, igniter, control unit, control motor): the traditional components are also present (side lights, direction indicators, main beam).The unit consists of:

The spot main beam only comes on through the flasher control with the main beams switched off, whilst it is turned on together with the xenon bulb with the lights are switched from dipped to main beam.

The front light cluster is a lamp made using a special lens reflection technology.There are three separate functions in the form of chrome covers incorporated in a single casing.The casing is made from polypropylene and has three points fitted with metal inserts for ensuring the torque tightening on the metal crossmember.It includes a cover securing the lens, the housings for the electrical corrector, the adjustment screws and the bulb access covers.The reflector is made from a thermal hardening material and includes the seats for the elliptical module (dipped/main beam headlamps) whilst the side light, direction indicator and main beam headlamp functions are produced through calculated surface areas. It is painted, metalized and protected.The lens is made from polycarbonate and incorporates the housings for fastening the chrome frames and the (black) outer surround treated with scratch-resistant paint.The switching between the dipped and main beam functions for xenon bulbs takes place by means of a suitably shaped metal screen that is lowered for dipped operation and raised for main beam operation.Bulbs present:- D1S xenon bulb for dipped headlamps function- All glass W5W bulb for side lights function -12V-5W- All glass PY21W bulb for direction indicators function - 12V-21W- H1 halogen bulb for main beam headlights spot function 12V-55W.One of the two lamps carries out the MASTER function (left): the sensors, that detect the vehicle geometry are connected to it whilst the other (right) lamp has a SLAVE function and is connected to the MASTER lamp by a special serial line:Xenon bulbXenon bulbs consist of a bulb containing two electrodes spaced a few millimetres apart and filled with low pressure xenon gas.The emission of light is produced by an arc between the two electrodes which is maintained during the operation of the bulb; this process is similar to what takes place in neon lights.Unlike the latter however, in automotive applications, it is unthinkable to have to wait for a few minutes before the process stabilizes, therefore the light cluster has an electronic control device (control unit) that allows operation, as far as the warming up times are concerned, comparable to traditional headlamps.

OperationThe operation of a xenon bulb is divided into four stages.- Ignition: During this stage the ballast produces a voltage capable of causing the engagement of a suitable device located in the igniter. A step-up transformer circuit transfers the suitably amplified excess voltage to the bulb thereby causing a discharge between the electrodes.- Take-over (arc maintenance) during this stage (lasting several seconds) the bulb receives the excess power supply necessary for producing the rapid evaporation of the metallic halides contained in the bulb in order to guarantee that the operating brightness is reached quickly. In these conditions the bulb produces a light flash that is twice the intensity of normal for a period of about 100 microseconds.- Warm up for a period of about two minutes, the ballast regulates the light intensity determining the physical state of the bulb from its impedance properties (closed loop control).- Steady state: the light beam is controlled continuously in closed loop in the steady state.The igniter is located in the base of the actual bulb, whilst the ballast is located in the control unit.Lamp rear view

1 - Cover for main beam headlamp2 - Cover for direction indicators and side lights3 - Cover secured by catch and seal for dipped headlamp4 - 14-way connector for lamp power supply5 - Headlamp horizontal axis adjustment screw6 - Headlamp vertical axis adjustment screw7 - Electronic control unit8 - (6-way) connector for automatic sensor correction (only on MASTER)Wiring diagram and connector(14-way) connector for lamp power supply

PIN OUT:1- Dipped headlamps control3 - Main beam headlamps control4 - Side lights control5 - Direction indicators control9 - Ignition-operated control power supply10 - Speedometer signal (only on MASTER)11 - Diagnostic K line12 - Serial line13 - Control unit earth connection14 - Bulb earth connection

Automatic headlamp alignment correcter

As a result of the brightness of the bulb light beam, the vehicle must be equipped with an automatic headlamp alignment correcter to prevent the drivers of oncoming vehicles being dazzled. The device intervenes in certain conditions:- static type, due to the distribution of the load;- dynamic type, due to acceleration and deceleration.The automatic correcter also guarantees improved driving comfort because the area lit is kept stable and your eyes do not have to constantly adapt to the variations in the lighting.The device consists of:- a stepping actuator for each headlamp.- two load sensors, connected to the front and rear suspension, right side.CorrectionThis is carried out through the load sensor signal which, connected to the suspension, provide a reading on the vehicle load status.The control unit is activated at every Key on and resets the headlamps to the exact distance (calculated depending on the vehicle load) which consists of completely lowering and then positioning the reflector.The load sensor signals are periodically acquired and a suitable average taken in order to readjust the position of the headlamp if necessary (e.g. fuel consumption whilst driving). This adjustment is not immediate, but is filtered over time to avoid undesired corrections (e.g. if there are potholes, uneven road surface, etc.).This correction is also made with the lights off, so that the moment the beam is switched on it is already correctly positioned.Load sensorsThe sensors are fastened to the vehicle bodyshell, whilst a suitable shaped lever follows the movement of the suspension.The sensor receives a power supply from the headlamp control unit and provides a linear output signal proportional to the position of the suspension in relation to the bodyshell.

A - Part fastened to the bodyshellB - Part fastened to the suspension linkagea - Lever angleV - Sensor output signal voltageAdjustment actuatorA stepping actuator inside the light cluster carries out this adjustment. It consists of an electric stepping motor and a worm screw reduction unit which transforms the rotary motion of a hinged push rod into linear motion by means of a ball joint on the reflective surface.Self-diagnosisThe electronics that manage the system have an autodiagnostic function that continuously checks operation.The control unit carries out continuous self-diagnosis of system operation. In particular it detects and stores any faults.The faults memorized in the control unit can be analyzed using the Examiner or other diagnostic equipment.RecoveryThe autodiagnostic management logic also has a recovery function: if errors are detected, the system no longer works properly and therefore the incorrect adjustment of the light beam could be dangerous and dazzle other vehicles.The light beam is therefore positioned downwards in order not to dazzle anyone, but allows sufficient light to drive safely to a service centre.ResettingIf the master control unit (in the left headlamp) is replaced, a self-learning procedure must be carried out, connecting to the diagnostic equipment, which makes it possible to automatically reset the system which should recognize the the position of the headlamp correctly aligned in position 0 from where the various adjustments can be set.

Rear light cluster

The rear light cluster is divided into two parts, one fixed one and one moving one on the boot.The exterior aesthetic appearance is a single polychromatic structure in line with the shape of the vehicle.The following signals are contained in the light cluster on the fixed part:- Red brake lights and side lights (double filament).- White direction indicator and orange reflector.The following are present in the units on the boot:- Red coloured side lights- Red rear fog lamp (driver''s side only)- White reversing light (passenger side only)

- on the fixed section1 - Direction indicator: 12V - 21W2 - Brake light bilux 12V - 21W (P21W-5W)- on the boot3a - Rear fog lamp: bulb 12V- 21W (driver''s side only)3b - Reversing light: bulb 12V- 21W (passenger side only)4 - Side light 12V - 5W

Number plate light

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