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1. Low beam filament screen. 2. Thread low beam. 3. High beam thread. 4. Mounting tabs. 5. Lamp flange. 6. Lamp base. 7. Plug thread dipped beam. 8. High beam filament plug. 9. Dust deflector. 10. Plug block. 11. Outer bezel. 12. Reflector. 13. Slots for mounting brackets of the optical element. 14. Diffuser. 15. Screw for horizontal headlight adjustment. 16. Headlight mounting hole. 17. Nut holder. 18. Screw for vertical headlight adjustment. 19. Nut. 20. Headlight housing. 21. Screen. 22. Lamp A12-45+40. 23. Wire seal. 24. Spring. 25. Inner rim. 26. Screws for fastening the outer rim to the inner one. 27. Headlights. 28. Battery. 29. Generator. 30. Fuse block. 31. Switch for direction indicators and headlights. 32. Ignition switch. 33. Block of switches. 34. Instrument cluster. 35. Control lamp for switching on high beam headlights. 36. Outdoor lighting switch. 37. Speedometer. 38. Relay for switching on high beam headlights.
Headlights are designed to illuminate the road in front of the car at night.
Two identical headlights of the FG-140 type are installed on VAZ-2101 and VAZ-2102 cars. Four headlights are installed on the VAZ-2103 car: two external type FG-145 and two internal ones - FG-146. The optics and lamps' of the headlights provide an asymmetric low-beam beam and comply with the requirements of international standards. Each FG-140 headlight is attached to the front of the body with four screws, three of which are screwed into special steel spring clips, and the fourth, connecting the black wire of the headlight to ground, is directly into the front of the body. A shock-absorbing plastic gasket is installed under the headlight.
Headlights FG-145 and FG-146 are each fixed with three screws. Two screws are screwed into plastic plates, and the third - directly into the front of the body. The role of the shock-absorbing element is performed by plastic plates. Therefore, gaskets are not placed under these headlights. Staples and plates are put on the edges of the hole for the headlight. Outside, the headlights are covered with chrome-plated steel facing rims.
On VAZ-2101 and VAZ-2102 vehicles, the dipped and main beams of the headlights are switched on by switch 31 located on the steering column, when the external lighting switch in block 33 is turned on. In addition, by pulling the long lever of switch 31 towards you, you can get a short-term inclusion of high beam headlights (for cars manufactured before January 1973, the dipped beam is switched on) both when the outdoor light switch is on and off. This is ensured by the fact that the voltage to the light signaling contacts of switch 31 is supplied directly from the plug «INT» ignition switch 32, bypassing the outdoor lighting switch in block 33.
On a VAZ-2103 car, the headlights are also turned on using the outdoor lighting switch 36 and switch 31. When the high beam is turned on, all four headlights are on, providing good and uniform illumination of the road in front of the car, and when the dipped beam is turned on, only two external headlights are on. When the high beam is turned on, four headlights consume a current of 15-16 A. Such a current can damage the switch contacts 31, designed for a current of 8 A. Therefore, the main beam of the headlights is turned on through an additional relay 38 of the RS-527 type, the contacts of which are capable of withstanding a current of 20 A, and only the supply current of the relay winding flows through the contacts of switch 31, not exceeding 0.3 A.
Headlights are produced by several companies and therefore have slight differences in the design of some elements. These differences relate mainly to the method of attaching the lamp to the optical element. In addition, the headlights can be with or without screen 21.
The FG-140 headlight has a painted steel body 20, in which an inner rim 25 is fixed with a spring 24 and two screws 15 and 18. This rim has three sockets 13, which include the mounting brackets of the optical element. The sockets in the rim and the brackets of the optical element corresponding to them are located asymmetrically with respect to the axis of the headlight. Therefore, the optical element can only be inserted into the bezel 25 in one specific position. The optical element is pressed against the inner rim 25 by the outer chrome-plated steel rim 11, which is attached to the inner rim with three screws 26.
The optical element is non-separable, consists of a reflector 12 and a diffuser 14 glued to it. The reflector is steel, has the shape of a paraboloid, which concentrates the reflected rays of light into a beam, directing them along its axis if the lamp filament is in its focus. To create a mirror surface, the reflective surface of the reflector is coated with varnish and then with a thin layer of aluminum.
The outer surface of diffuser 14 is smooth, and on the inner surface there is a complex system of prisms that scatter light more strongly in the horizontal direction than in the vertical one. Therefore, if you direct a high-beam beam at the wall, then the spot of light will have the shape of an ellipse. This dispersion of light provides better illumination of the road in front of the car and at the curb.
From the back, a lamp 22 of type A12-45+40 is inserted into the optical element. The lamp is hollow, i.e., air has been evacuated from its flask. It has two tungsten filaments: one (40 W) for low beam and other (45 W) for far. The main beam thread 3 is at the focus of the reflector, and therefore the high beam beams are concentrated into a narrow beam directed almost parallel to the road and well illuminating it at the maximum distance from the car. The thread 2 of the low beam is brought forward from the focus of the reflector and is closed from below by a special metal screen 1. This is done in order to limit the spread of light upwards. If you direct a beam of low beam at the wall, then the spot of light will have the shape of an ellipse with a cut off upper half. The upper boundary of the illuminated area in the left part of the spot will pass exactly along the horizontal axis of the ellipse, and in the right part - along the line extending upward from the center of the ellipse at an angle of 15°to its horizontal axis. This shape of the beam of light provides good illumination of the road in front of the car (especially her right side and curb) and reduces the possibility of dazzling oncoming drivers.
At a part of the headlights, a screen 21 is installed in the optical element in front of the lamp. It delays the direct light coming from the lamp filaments and provides a clearer upper boundary of the dipped beam.
The lamp has a steel stepped flange 5. With a larger diameter step, it is inserted into the FG-140 headlight reflector, and with a smaller diameter step it is inserted into the VAZ-2103 headlight reflectors, which are smaller. On both steps of the flange there are protrusions 4, which are included in the corresponding groove of the reflector. Therefore, the lamp is installed in the optical element in a strictly defined position and there is no need to adjust the position of the lamp in the focus of the reflector. Outside, the lamp is closed with a plastic dust deflector 9.
On the base of the lamp there are three plugs for supplying voltage: one for the filament of the low beam, the other for the high beam, and the third - common - is connected to the ground. A plastic block 10 with wires is put on the plugs. Two wires through the rubber seal 23 are removed from the headlight housing, and the tip of the third (black) the wires are rolled in the housing to the headlight mounting hole and connected to the vehicle ground through the headlight mounting screw.
Screws 15 and 18 serve not only to fasten the inner rim 25, but also to regulate the direction of the headlight beam. When screwing in or out, for example, screw 18, it attracts or moves away from the headlamp housing the upper edge of the rim 25 and the optical element pressed against it rotates about the horizontal axis. When screwing in or out of the screw 15, the optical element rotates about the vertical axis. The screws are screwed into plastic nuts 19, which prevent self-unscrewing of the screws. Holders of 17 nuts are attached to the headlight housing.
Headlights FG-145 and FG-146 of the VAZ-2103 car have the same device as the headlights FG-140 of the VAZ-2101 car, but differ in smaller sizes, body shape and characteristics of optical elements. The lamps in these headlights are also installed of the A12-45 + 40 type, but the filament of the low beam of the lamps is not used for the internal headlights.
Internal FG-146 and external FG-145 headlights differ in the system of diffuser prisms, since the internal headlights work only when the high beam is turned on, and the outer ones work both when the high and low beams are turned on. In addition, the screen 21 is missing in the inner headlights. The sockets 13 for installing the optical element of the inner and outer headlights have different coordinates so that the optical element of the inner headlight cannot be placed in the outer headlight and vice versa.
Both internal and external headlights are divided into right and left (an index is added to the designation of the headlight type «P» or «L»).