Check Ignition System

COMPETENCY BASED LEARNING MATERIAL

Sector:AUTOMOTIVE and LAND TRANSPORT

Distinctive Area of Competence and Qualifications:Automotive Servicing NC I

Unit of Competency:Check Ignition System

Module Title:

Servicing and Repairing Ignition System

Technical Education and Skills Development Authority

East Service Road, South Superhighway, Taguig, Metro Manila

AUTOMOTIVE and LAND TRANSPORTINDUSTRY SECTOR

NATIONAL CERTIFICATE LEVEL 1QUALIFICATION LEVEL

COMPETENCY-BASED LEARNING MATERIALS

No. Basic Competencies Module Title Code1. Receive and Respond to

Workplace CommunicationReceiving and Responding to Workplace Communication

500311101

2. Work with Others Working with Others 5003111023. Demonstrate Work Values Demonstrating Work Values 500311103

4. Practice Housekeeping Procedures

Practicing Housekeeping Procedures

500311104

No. Common Competencies Module Title Code1. Apply Appropriate

Sealant/AdhesiveApplying Appropriate Sealant/Adhesive

ALT723201

2. Move and Position Vehicle Moving and Positioning Vehicle ALT7232023. Perform Housekeeping Performing Housekeeping ALT311201

4. Perform Mensuration and Calculation

Performing Mensuration and Calculation

ALT311202

5. Perform Safety Practices Performing Safety Practices ALT311203

6 Read, Interpret and Apply Specifications and Manual

Reading, Interpreting and Applying Specifications and Manual

ALT723203

7. Use and Apply Lubricant/Coolant Using and Applying Lubricants/ Coolants

ALT723204

8. Perform Shop Maintenance Perform Shop Maintenance ALT723205

No. Core Competencies Module Title Code1. Performing Diesel Engine Tune-

up1. Performing Diesel Engine

Tune-upALT723301

2. Perform Gas Engine Tune-up 2. Performing Gas Engine Tune-up

ALT723302

3. Service Automotive Battery 3. Servicing Automotive Battery ALT7233034. Service Ignition System 4. Servicing Ignition

SystemALT723304

5. Test and Repair Wiring/ Lighting System

5. Installing Automotive Wiring/Lighting System

ALT723305

6. Perform Underchassis Preventive Maintenance

6. Performing Underchassis Preventive Maintenance

ALT723306

HOW TO USE THIS COMPETENCY BASED LEARNING MATERIAL

Welcome to the Module “Servicing and Repairing Ignition System”. This module contains training materials and activities for you to complete.

The unit of competency “Check Ignition System” contains the knowledge, skills and attitudes required for an Automotive Servicing course. This is one of the common modules for National Certificate level I (NC I).

You are required to go through a series of learning activities in order to complete each of the learning outcomes of the module. In each learning outcome there are Information Sheets, Operation Sheets and job Sheets (Reference Materials for further reading to help you better understand the required activities. Follow these activities on your own and answer the self-check at the end of each learning activity.

If you have questions, don’t hesitate to ask your facilitator for assistance.

Recognition of Prior Learning (RPL)

You may already have some or most of the knowledge and skills covered in this module because you have:

been working for some time already completed training in this area.

If you can demonstrate to your trainer that you are competent in a particular skill or skills, talk to him/her about having them formally recognized so you don’t have to do the same training again. If you have a qualification or Certificate of Competency from previous trainings show it to your trainer. If the skills you acquired are still current and relevant to this module, they may become part of the evidence you can present for RPL. If you are not sure about the currency of your skills, discuss this with your trainer.

After completing this module ask your trainer to assess your competency. Result of your assessment will be recorded in your competency profile. All the learning activities are designed for you to complete at your own pace.

Inside this module you will find the activities for you to complete and at the back are the relevant information sheets for each learning outcome. Each learning outcome may have more than one learning activities.

At the end of this module is a Learner Diary. Use this diary to record important dates, jobs undertaken and other workplace events that will assist you in providing further details to your trainer or an assessor. A Record of Achievement is provided for you by your trainer to accomplish once you complete the module.

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Servicing and Repairing Ignition SystemDate: Developed Date: Revised Page #Aug. 15, 2003 1

This module is prepared to help you achieve the required competency, servicing and repairing ignition system. This will be the source of information that will enable you to acquire the knowledge and skills in this particular trade independently at your own pace or with minimum supervision or help from your instructor.

- Talk to your trainer and agree on how you will both organize the training of this unit.

Read through the learning guide carefully. It is divided into sections which cover all the skills and knowledge you need to successfully complete this module.

- Work through all the information and complete the activities in each section and complete the self-check. Suggested references are included to supplement the materials provided in this module.

- Most probably your trainer will also be your supervisor or manager. He/she is there to support you and show you the correct way to do things. Ask for help.

- Your trainer will tell you about the important things you need to consider when you are completing activities and it is important that you listen and take notes.

- Talk to more experienced work mates and ask for their guidance.

- Use the self-check questions at the end of each section to test your own progress.

- When you are ready, ask your trainer to watch you perform the activities outlined in the learning guide.

- As you work through the activities, ask for written feedback of your progress from your trainer. After completing each element, ask your trainer to mark on the report that you are ready for assessment.

- When you have completed this module (or several modules) and feel confident that you have had sufficient practice your trainer will arrange an appointment with you to asses you. The result of your assessment will be recorded in your Competency Achievement Record.

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QUALIFICATION : AUTOMOTIVE SERVICING NC IUNIT OF COMPETENCY : CHECK IGNITION SYSTEMMODULE TITLE : CHECKING IGNITION SYSTEM

INTRODUCTION:

This module contains information and practices involved in checking the ignition system of a vehicle. It includes instructions on how to check up an ignition system prior to trouble shooting.

You need to complete this module before you can actually start the engine, since this part is the primary system that lets the engine run.

LEARNING OUTCOMES:

At the end of this module you will be able to:

1. Identify and explain the function of the ignition system components2. Check ignition coil, ballast resistor, high tension cable resistance3. Check distributor assembly

ASSESSMENT CRITERIA:

1. Ignition system components are identified2. Functions of ignition system are understood3. Standard clearance and resistance of ignition system components are determined4. Operating principle of the ignition system is explained5. VOM is properly used6. Specified resistance value is obtained from service manual7. Procedure in checking resistance is observed in accordance with the manual of

instructions8. Distributor terminal and rotor tips are cleaned and lubricated9. Rotor and distributor cap are checked for cracks / current leakage10.Condenser is tested by charged and discharged process11.Dwell angle is adjusted / set in accordance with the manual of specifications and

instructions12.Cam lube is checked for wear13.Rotor rotation is determined14.Advance mechanism operation is checked in accordance with the manual of

instructions

PRE-REQUISITE: NONE

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Program /Course Automotive Servicing NC IUnit of Competency CHECK IGNITION SYSTEMModule CHECKING IGNITION SYSTEM

LEARNING OUTCOME #1

Identify and explain the function of ignition system components.

ASSESSMENT CRITERIA

1. Ignition system components are identified.

2. Functions of the ignition system are understood.

3. Standard clearance and resistance of ignition system components are determined.

4. Operating principle of the ignition system is explained.

RESOURCES

CDX Industrial Light Vehicle: under Ignition System contact point (CO) VCD

Automotive Mechanics 10th Edition by Cruise and Anglin (Textbook)

Internal Combustion Engine (ICE)

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LEARNING EXPERIENCES

Learning Outcome 1 : Identify and explain the functions of ignition system components

LEARNING ACTIVITIES SPECIAL INSTRUCTIONS

What types of ignition systems have you worked?

1. Defining ignition system 1.1 Read Information sheet #1 “Contact Point Ignition

System”a) Purpose of the ignition systemb) Producing the sparkc) Determining heat range & reach

After reading a, b and c answer the Self-Check.

What science principles can help us understand more about ignition inside confined containers & cylinders

2. Identifying parts & components of the ignition system2.1 Read a) Components of ignition system

3. Describing all functions of the different ignition components3.1 Identify a) Ignition switch

b) Ignition coil c) high tension wire d) spark plug e) distributor assembly f) condenser g) fusible link h) ballast resistor

4. Discuss safety procedures in handling high voltage current4.1 Outline procedures paragraph

a) refer to special instructions

5. Measuring clearance a) contact points

5.1 measuring resistance a ) primary b ) secondary c ) high tension wire d ) ballast resistor6. Experiment on Electro-magnetism Read a) primary b) secondary

For more information view CDX industrial light vehicle

under ignition Refer to Information Sheet #1

(Contact Point Ignition System.)

Automotive Mechanics 10th edition by Crouse & Anglin (textbook)

Internal combustion engines Automotive mechanics 10th

edition by Crouse & Anglin (textbook)

CDX Industrial Light vehicle (CD) ASE

From the ignition system mock-up provided, pinpoint the components on the left.

OHS (Occupational Health & Safety

Take actual resistance of the following components & circuits

Refer to service manual

See Electricity master experiment manual

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INFORMATION SHEET #1

CONTACT POINT IGNITION SYSTEM

PURPOSE OF IGNITION SYSTEM

The purpose of the ignition system is to ignite the compressed alt-fuel mixture in the engine combustion chambers. This should occur at the proper time for combustion to begin. To start combustion, the ignition system delivers an electric spark that jumps a gap at the combustion-chamber ends of the spark plugs. The heat from this arc ignites the compressed air-fuel mixture. The mixture burns, creating pressure that pushes the pistons down the cylinders so the engine runs. The ignition system may be either a contact-point ignition system or an electronic ignition system. This chapter describes the contact-point ignition system.

COMPONENTS IN CONTACT-POINT IGNITION SYSTEM

The ignition system (Fig. 1) includes the battery, ignition switch, ignition coil, ignition distributor (with contact points and condenser), secondary wiring, and spark plugs.

Fig. 1 Components in the contact-point ignition system (Ford Motors Company)

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1. IGNITION SWITCH The ignition switch connects the ignition coil to the battery when the ignition key is ON. When the key is turned to START, the starting motor cranks the engine for starting.

2. IGNITION COIL The ignition coil (Fig. 2) is a step-up transformer that raises the battery voltage to a high voltage that may reach 25,000 volts. In some electronic ignition systems, the voltage may go up to 47,000 volts or higher. The high voltage causes sparks to jump the gap at the spark plugs.

Fig.2 Ignition coil, cutaway to show the windings. (Delco-Remy Division of General Motors Corporation)

3. IGNITION DISTRIBUTOR The ignition distributor does two jobs. First, it has a set of contact points or breaker points, (lower right) that work as a fact-acting switch. When the points close, current flows through the coil, When the points open, current flow stops and the coil produces a high-voltage surge. A condenser connects across the points. It aids in the collapse of the magnetic field and helps reduce arcing that burns away the points.

Fig. 3 Ignition distributor with vacuum-advance unit and cap (Delco-Remy Division of General Motors Corporation)

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Second, the distributor distributes the high-voltage surges to the spark plugs in the correct firing order. A coil wire delivers the high-voltage from the coil to the center terminal of the distributor cap. Inside the cap, a rotor (Fig. 4) is on top of the distributor shaft.

Fig. 4 Cutaway ignition distributor and vacuum-advance unit, with rotor and cap in place.

In most contact-point distributors, the distributor shaft is driven from the engine camshaft by a pair of spiral gears (Fig. 5). The rotor has a metal blade. One end of the blade contacts the center terminal of the distributor cap (Fig. 5).When the rotor turns, the other end passes close to the outer terminals in the distributor cap. These are connected by spark-plug wires to the spark plugs. The high-voltage surge jumps the small gap from the rotor blade to the terminal. The spark-plug wires carry the high-voltage surge to the spark plug in the cylinder that is ready to fire.

Fig. 5 Simplified secondary circuit, The coil secondary winding is connected through the distributor cap, rotor, and wiring to the spark plugs.

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4. SECONDARY IGNITION CABLES The second ignition cables or wiring include the coil wire and the spark-plug wires. These cables connect between the center of the ignition coil and the distributor cap, and between the distributor cap and the spark plugs. Figure 6 compares the construction of an older, spark-plug wire with the resistance cable now used on all cars. Secondary cables for contact-point ignition systems have a 7mm (0.276 inch) diameter. Many electronic ignition systems require 8mm (0.315 inch) cables. The use of a silicone insulating jacket makes these cables larger.

Fig. 6 Silicone resistance cable or spark-plug wire (left) now used on all vehicles compared with

older solid-conductor (right) spark-plug wire, (AC-Delco Division of General Motors Corporation)

5. SPARK PLUGS The spark plug has two solid-metal conductors called electrodes positioned to form a gap. The gap is between the insulated center electrode and the ground electrode. The spark jumps the gap to ignite the compressed air-fuel mixture in the engine cylinders.

PRODUCING THE SPARK

The ignition system consists of two separate but related circuits: the low-voltage primary circuit and the high-voltage secondary circuit. The ignition coil (Fig. 1) has two windings. The primary winding of a few hundred turns of heavy wire is part of the primary circuit. The secondary winding at many thousand turns of fine wire is part of the secondary circuit, When the ignition key is ON and the contact points closed, current flows through the primary winding (Fig. 7). This produces a magnetic field around the primary windings in the coil.

Fig 7. Schematic of the primary circuit in the contact-point ignition system (ATW).

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When the contact points open, current flow steps and the magnetic field collapses. As it collapses, it cuts across the thousands of turns of wire in the coil secondary winding.This produces a voltage in each turn. These add together to produce the high voltage delivered through the secondary circuit to the spark plug (Fig. 5).

CONTACT POINTS

The contact-point set mounts on the breaker plate in the distributor (Fig. 7). The points are operated by a breaker cam on top of the distributor shaft. The cam has the same number of lobes as there are cylinders in the engine. As the cam revolves and the points close and open, they act as mechanical switch to make and break the primary circuit.

One contact point mounts on the grounded breaker plate and is stationary. The other point mounts on the end of an insulated movable arm. The arm swings back and forth on a pivot as the cam lobes push on the rubbing block to open the points. A spring attached to the movable-point arm closes the points.

When the points close, this connects the coil primary winding to the battery. A magnetic field builds up in the coil. As the breaker cam rotates, the next lobe pushes the movable arm away from the stationary contact point. This opens the points and stops the current flow. The magnetic field collapses and a high-voltage surge results. The length of time in degrees of distributor-shaft rotation that the contact points remained closed in the dwell. The distance that separates the points when they are fully open is the gap. Points are normally adjusted by dwell or gap measurements.

The distributor shaft and cam are driven by the engine camshaft which turns at one-half crankshaft speed. It takes two complete revolutions of the crankshaft to rotate the distributor shaft one complete revolution.

Fig. 8. Top view of a contact-point ignition distributor with the cap and rotor removed. Note that the cam has

six lobes (for a six cylinder engine). The drawings at the top show the cam action. When a lobe moves

under the rubbing block, the contact arm is moved, separating the points. (Delco-Remy Division of

General Motors Corp).

The relationship between piston position and spark plug firing is ignition timing.

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PRIMARY RESISTANCE

Excessive current flow in the primary circuit causes arcing and burning of the contact points. To prevent this, a resistance is placed between the ignition switch and the coil primary winding. The resistance may be a separate resistor or a special resistance wire. For easier starting, the resistance is bypassed and full battery voltage reaches the coil during cranking. After the engine starts, the resistance reduces coil voltage to 5 to 8 volts.

SECONDARY VOLTAGE

The high voltages and high rate of charge prevent many voltmeters from measuring secondary voltage. Figure 9 shows a computerized engine analyzer that includes two cathode-ray tubes (CRTs). The CRT on the left is a oscilloscope or scope. It can display the primary and secondary voltage patterns and the length of time this occur.

Figure 10 shows the basic pattern for on spark plug firing cycle in the secondary circuit. At the left, the points open. This stops the current flow through the coil primary winding. The magnetic field then collapses, causing a sudden high voltage (A to B) in the secondary winding. This is the firing voltage that starts the spark jumping the gap at the spark plug. The volts quickly drops from B to C because it takes less voltage to sustain the spark than it does to start it. The spark continues from C to D, where it stops.

Figure 9. Computerized Engine Analyzer.

This is the spark line burn time. It lasts for about 20 degrees of crankshaft rotation, or 1 to 2 milliseconds (thousands of a second). The remaining energy causes voltage ripples or oscillations from D to E in Fig. 10. However, the voltage is not great enough to restart the spark. At E, the points close and current starts flowing through the coil primary winding. The expanding magnetic lines of force pass through the primary winding, creating a slight alternating voltage in it. This is shown by the dip and small ripples to the right of E in Fig. 10.

From E to F is the dwell section.

Figure10. Oscilloscope waveform or trace, showing one complete spark-plug firing cycle in the secondary circuit. The

dwell section is the time period during which current flows through the primary circuit.

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Dwell is the length of time the points are closed and current flows through the primary winding of the coil. Then at F, the points open and the cycle begins again at A as the spark occurs at the spark plug. The whole procedure repeats continuously as long as the engine runs.

ADVANCING THE SPARK

When the engine is idling, the spark is timed to reach the spark plug just before the piston reaches TDC on the compression stroke. At higher speeds, the spark must occur earlier. If it does not, the piston will be past TDC and moving down on the power stroke before combustion pressure reaches its maximum. The piston is ahead of the pressure rise which results in a weak power stroke. This wastes much o the energy in the fuel.

To better use the energy in the fuel, the spark takes place earlier as engine speed increases. This spark advance causes the mixture to burn producing maximum pressure just as the piston moves through TDC. Most contact-point distributors have two mechanisms to control spark advance. A centrifugal-advance mechanism adjusts the spark based on the engine speed. A vacuum advance mechanism adjusts the spark based on engine load. On the engine, both work together to provide the proper spark advance for the engine operating conditions.

CENTRIFUGAL ADVANCE

The centrifugal-advance mechanism advances the spark by pushing the breaker cam ahead as the engine speed increases. Two advance weights, two weight springs, and a cam assembly provide this action. The cam assembly includes the breaker cam and an oval-shaped advance cam (Fig. 11). At low speed, the springs hold the weights in. As engine speed increases, centrifugal force causes the weights to overcome the spring force and pivot outward (Fig. 12). This pushes the cam assembly ahead. The contact points open and close earlier, advancing the spark.

Figure 11. Parts of a centrifugal-advance mechanism for a contact-point distributor.

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VACUUM ADVANCE

When the throttle valve is only partly open, a partial vacuum develops in the intake manifold. Less air-fuel mixture gets into the engine cylinders. Then the fuel burns slower after it is ignited. The spark must be advanced at part throttle to give the mixture more time to burn.

Figure 12. Centrifugal-advance mechanism in no-advance and full-advance positions. In the example shown, the ignition is timed at 8 degrees before TDC on idle. There is no centrifugal advance at 1,000 engine rpm. At 4,000 engine rpm, there is a total of 28 degrees advance (8 degrees original timing plus 20 degrees centrifugal advance).

The vacuum-advance mechanism Fig. 8 and 13) advances spark timing by shifting the position of the breaker plate. The vacuum-advance passage connects the diaphragm to a port just above the closed throttle valve. When the throttle valve moves past the vacuum port, the intake manifold pulls on the diaphragm. This rotates the breaker plate so the contact points open and close earlier (Fig. 14). Any vacuum port above the throttle valve provides ported vacuum.

Figure 13. When the throttle valve is closed, there is no vacuum advance. The ported vacuum passage is above the closed throttle

valve.

Figure 14. Operation of the vacuum-advance unit. When the throttle valve moves past the port, intake-manifold vacuum is admitted to

the vacuum-advance unit on the distributor. The breaker plate then rotates to advance the spark.

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COMBINED CENTRIFUGAL AND VACUUM ADVANCE

At any speed above idle, there is some centrifugal advance. Depending on intake-manifold vacuum, there may also be some vacuum advance. The total advance curve in Fig. 15 shows how the centrifugal and vacuum advance combine. At 40 miles per hour (64 km/h), there are 15 degrees of centrifugal advance. The vacuum advance can produce up to 15 degrees of additional advance at part throttle. The advances shown in Fig. 15 combine to produce a maximum advance of 30(15 + 15) degrees.

When the engine runs at wide-open throttle, intake manifold vacuum drops to zero. There is no vacuum advance. Normally, the total advance varies between the straight line (centrifugal advance) and the curved line (centrifugal plus vacuum advance) in Fig.15.

Figure 15. Centrifugal and vacuum advance curves for one engine.

SPARK PLUGS

The spark plug has a metal outer shell enclosing a ceramic insulator. Centered in the insulator is the center electrode which carries the high-voltage current from the ignition coil. A ground electrode attaches to the metal shell and is bent inward to produce the proper spark gap. The gap varies from 0.035 inch (0.9 mm) for contact-point ignition systems to 0.080 inch (2.03 mm) for some electronic ignition systems. The spark jumps from the center electrode to the ground electrode. The wider the gap, the higher the voltage required to jump it.

Spark plugs may have a suppressor or resistance built into the center electrode (Fig. 16). It reduces television and radio interference (static) caused by the ignition system. Spark plugs may require gaskets when installed to assure a leakproof seal. Many engines use spark plugs with tapered seats which seal without a gasket. Spme spark-plug threads are coated with an antiseize compound. This makes plug removal easier, especially from aluminum cylinder heads.

Figure 16. Cutaway resistor-type spark plug. The center electrode is insulated. The side electrode is grounded

through the engine. (AC Spark Plug Division of General Motors Corporation)

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Some engines have two spark plugs in each combustion chamber. Both plugs may fire together or one slightly ahead of the other. The additional plugs help reduce exhaust emissions and increase engine power.

Most spark plugs have electrodes made of nickel and chrome alloys that resist corrosion. Some ground and lower center electrodes have a copper core. Other also have a thin-wire platinum tip. These foul and misfire less often, last longer, and have a greater heat range than other plugs.

Figure 17. Spark plugs with center electrodes that have a (A) copper core and a (B) platinum tip. (Robert Bosch

Corporation)

SPARK PLUG HEAT RANGE AND REACH

Spark plugs are made in different heat ranges (Fig 18). The heat range indicates how fast the plug transfers heat from the combustion chamber to the cylinder head. This is primarily determined by the length of the lower insulator. The longer the head path, the hotter the plug will run. A short path transfers the heat faster so the plug runs cooler.

Sooty deposits accumulate on the firing end of the spark plug if it runs too cold. The end does not get hot enough to burn away the deposits. Then the high-voltage surges short across the deposits instead of jumping the spark-plug gap. A plug that runs too hot burns away the electrodes more rapidly. This can widen the gap so much that the spark cannot jump it and miss occurs.

Spark plug reach is the distance from the shell gasket seat (or top of the tapered seat to the end of the threads. If the reach is too long, the plug electrodes too far into the combustion chamber The plug could interfere with moisture turbulence or be struck by valve or piston. A plug that does not reach far enough fail to will fail to ignite the mixture properly. The recommended spark plugs for an engine have the correct reach.

Figure 18. Heat range and reach of spark plugs. The longer the heat path, as indicated by arrows, the hotter

the plug runs. (AC Spark plug Division of General Motors Corporation)

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IGNITION SWITCH

The ignition switch does several jobs. It turns the ignition system on and off. It has a START position for operating the starting motor. It operates the steering-wheel lock, an audible or light signal if the ignition key is in the ignition lock when a door opens or if seat belts are not buckled. On many vehicles, the electric fuel pump connects to the battery through the ignition switch. Other accessories such as radio and heater blower motor also receive current through the ignition switch.

Figure 19. Combination ignition-switch and steering-wheel lock, showing the opening mechanism inside the steering column.

(General Motors Corporation)

In most cars, the ignition key is placed in the ignition lock or lock cylinder in the steering column (Fig. 19). The ignition switch may attach to the lock, or go further down the steering column Turning the ignition key moves an actuator rod that operates the ignition switch.

The five positions of the ignition lock are ACCESSORY, LOCK, OFF, RUN, and START. Figure 19 shows how the ignition lock operates the steering-wheel lock. The notched disk is splined to the top end of the steering shaft. With the automatic transmission in PARK, the driver turns the key to LOCK. The spring-loaded plunger moves up into a notch in the disk, locking the steering wheel. This also locks the transmission in park.

If the key will not move to LOCK, turn the steering wheel until the plunger and a notch align. Then the spring will force the plunger up and the key will turn to LOCK. Turning the key from LOCK to OFF pulls the plunger out of the notch in the disk. This unlocks the steering wheel and the transmission. Figure 20. Ignition-system oscilloscope pattern.

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SELF CHECK

I. Multiple Choice Test

Instruction: Select the best answer to each question

1. The ignition system performs all the following jobs excepta. controls the compression pressureb. produces the spark that jumps the spark-plug gapc. ignites the compressed air-fuel mixtured. delivers the spark at the proper time

2. The contact-point distributor has two major jobsa. to advance and retard sparkb. to distribute the high voltage surges and switch the current to the coil on

and offc. to distribute the battery voltage and switch the current to the spark plugs

on and offd. to provide centrifugal advance and vacuum advance

3. Technician A says the spark occurs when the contact points open. Technician B says the spark occurs when the coil magnetic field collapses. Who is right?

a. A onlyb. B onlyc. both A and Bd. neither A nor B

4. Cross-firing may be caused by all the following excepta. wet distributor cap or rotorb. defective insulation on secondary cablesc. improper routing of spark-plug cablesd. a fouled spark-plug

II. Identification

1. List the five (5) major components in the contact point ignition system

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Answer Key

I.1. a

2. b

3. c

4. d

II.1. ignition switch

2. ignition coil

3. distributor assembly

4. secondary cable/high tension cables

5. spark plugs

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QUALIFICATION : AUTOMOTIVE SERVICING NC I

UNIT OF COMPETENCY : CHECK IGNITION SYSTEM

MODULE TITLE : CHECKING IGNITION SYSTEM

LEARNING OUTCOME #2: Check Ignition coil, ballast resistor, and high tension cable resistance

ASSESSMENT CRITERIA :

1. VOM is properly used

2. Specified resistance value is obtained from service manual

3. Procedure in checking resistance is observed in accordance with manual instruction

RESOURCES :

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Learning Outcome #2: Check Ignition coil, ballast resistor, & high tension cable

LEARNING ACTIVITIES SPECIAL INSTRUCTIONS

- Differentiate analog from digital testers- Have you tried using VOM testers

The next activity will require you to take actual resistance of the following ignition system components.

1. Conducting ignition system component system testing on:a. ignition coilb. ballast resistorc. high tension cable

- refer to self check on LO2-1 (see back portion for table)

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QUALIFICATION : AUTOMOTIVE SERVICING NC I

UNIT OF COMPETENCY : CHECK IGNITION SYSTEM

MODULE TITLE : CHECKING IGNITION SYSTEM

LEARNING OUTCOME #3: Check Distributor Assembly

ASSESSMENT CRITERIA :

1. Distribution terminals & rotor tip cleaned & lubricated

2. Rotor and distributor cap check for crack / current leakage

3. Condenser is tested by charged and discharged process

4. Dwell angle is adjusted / set in accordance to manual specifications & instructions

5. Cam lube is check for wear

6. Rotor rotation is determined

7. Advance mechanism operation is checked in accordance to manual instructions

RESOURCES :

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Learning Outcome #3 : LO3 CHECK DISTRIBUTOR ASSEMBLY

LEARNING ACTIVITIES SPECIAL INSTRUCTIONS Have you tried removing the distributor from the

engine

1. Servicing the distributor cap & rotor1.1 removing the distributor cap & rotor

1.2 cleaning of terminals & tips

2. Testing the condenser for charging & discharging & leak conditions

2.1 removing the condenser without damaging rebated parts.

2.2 replacing the condenser with the approved replacement

2.3 testing the newly replaced condenser accurately

2.4 adjust dwell angle according to specification

Have you seen the internal parts of the distributor Have you tried disassembling its pats

3. Inspecting Internal parts of the distributor 3.1 Inspect a) cam lobe for wear b) rotor for rotation c) advance mechanism for normal

operation

After disassembling all of the parts under 3.1 you can now going to apply the procedure suggested in the service manual

Note: Inform your trainer after you have completed the assembling procedure.

3.2 Answer self-check after assembling

Refer to manufacturer service manual on distributor servicing

Self-check see LO3-1 (see back for table)

Refer to manufacturer service manual

Refer to manufacturer service manual

Read p. 392 fig. 3-11 of Automotive Mechanic Crouse & Anglin 10th ed.

Read Auto Repair Manual for Toyota Corolla Series by Haynes for general procedures on disassembling & assembling

See self-check LO3-1

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SELF-CHECK

Answer the following test items

1. Enumerate briefly the disassembly-assembly procedures that you have performed

1.1____________________________________________1.2____________________________________________1.3____________________________________________1.4____________________________________________1.5____________________________________________1.6____________________________________________1.7____________________________________________1.8____________________________________________1.9____________________________________________2.0____________________________________________

2. State your inspection results in the table provided below

PARTS RESULT/DESCRIPTION

Cam Lobe

Rotor

Advance Mechanism

Please record your actual data on the space provided under reading

CAPACITOR TEST

TEST READING REMARKS

Charging

Discharging

Leak

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SELF-CHECK

Answer the following test items

I. Enumerate briefly the disassembly-assembly procedures that you have just performed

1.1___________________________________________1.2___________________________________________1.3___________________________________________1.4___________________________________________1.5___________________________________________1.6___________________________________________1.7___________________________________________1.8___________________________________________1.9___________________________________________2.0___________________________________________

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PERFORMANCE TEST

Learner's Name Date

Competency: Check Ignition System

Test Attempt 1st 2nd 3rd

Directions: CALL INSTRUCTOR and ask him/her to assess your performance in the following critical task and performance criteria indicated below

You will be rated based on the overall evaluation outlined on the right side.

OVERALL EVALUATION

LevelAchieved PERFORMANCE LEVELS

4 - Can perform this skill without supervision and with initiative and adaptability to problem situations.3 - Can perform this skill satisfactorily without assistance or supervision.2 - Can perform this skill satisfactorily but requires some assistance and/or supervision.1 - Can perform parts of this skill satisfactorily, but requires considerable assistance and/or supervision.

Instructor will initial level achieved.

PERFORMANCE STANDARDSFor acceptable achievement, all items should receive a "Yes" or "N/A" response.

Yes No N/A

Ignition system components are identified Functions of ignition system are understood Standard clearance and resistance of ignition system components are

determined Operating principle of the ignition system is explained VOM is properly used Specified resistance value is obtained from service manual Procedure in checking resistance is observed in accordance with the

manual of instructions Distributor terminal and rotor tips are cleaned and lubricated Rotor and distributor cap are checked for cracks / current leakage Condenser is tested by charged and discharged process Dwell angle is adjusted / set in accordance with the manual of

specifications and instructions Cam lube is checked for wear Rotor rotation is determined Advance mechanism operation is checked in accordance with the

manual of instructions

Code No. ALT723304


Learner’s diary

DIARY NOTES

Record important dates, jobs undertaken and other workplace events that will assist you in providing further details to an Assessor.

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Code No. ALT723304


Record of Achievement

Module: Checking Ignition System

LO#1: Identify and explain the function of the ignition system components.

Performance Criteria:

1. Ignition system components are identified.

2. Functions of ignition system are understood.

3. Standard clearance and resistance of ignition system components are determined.

4. Operating principle of the ignition system is explained.

Comments:

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Learner has satisfied the above performance criteria.Learner’s signature:.......................................................................Trainer’s signature:........................................................................Date:..............................................................................................

Code No. ALT723304




LO#2: Check ignition coil, ballast resistor, high tension cable resistance.


1. VOM is properly used.

2. Specified resistance value is obtained from service manual

3. Procedure in checking resistance is observed in accordance with the manual of instructions

Comments:

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Code No. ALT723304




LO#3: Check distributor assembly.


1. Distributor terminal and rotor tips are cleaned and lubricated2. Rotor and distributor cap are checked for cracks / current leakage3. Condenser is tested by charged and discharged process4. Dwell angle is adjusted / set in accordance with the manual of specifications and

instructions5. Cam lube is checked for wear6. Rotor rotation is determined7. Advance mechanism operation is checked in accordance with the manual of

instructions

Comments:

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Code No. ALT723304



Module: Testing and Servicing Automotive Battery

LO#3: Demonstrate the correct procedure on how to remove and replace batteries.


1. Battery is removed without causing damage to the workplace, property or vehicle.

2. Proper procedure is followed in removing/ replacing battery.

3. Proper procedure is followed to prevent loss of vehicle electronics memory as per manufacturer’s standards (if applicable.)

4. Appropriate tools and equipment are used.

5. Personal safety in removing and replacing battery is observed.

Comments:

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Code No. ALT723304


Terms and Definitions

Battery - an electrochemical device for storing energy in chemical form so that it can be released as electricity for cranking the engine and powering the electrical load.

Battery Acid – the electrolyte used in a battery; a mixture of sulfuric acid and water.

Battery Charger – an equipment used to charge battery capacity given in ampere hours.

Cell tester – a testing device used to measure the voltage of each cell of battery.

Circuit – the complete path of an electric current including current source.

Corrosion – a process of combining one metal with oxygen producing an undesirable product.

Electrolyte - the liquid mixture of about 40% sulfuric acid and 60% water in a fully charged lead-acid storage battery.

Hydrometer – a testing device used to measure the specific gravity of battery electrolyte.

Load tester- an instrument used to measure the capacity or load of a battery.

Multi-tester – a device used to measure two or more instruments.

Plate Strap – a part of a battery which is composed of both negative and positive accessories

Polarity - the quality of an electric component or circuit that determines the direction of current flow.

Side Terminal – the positive or negative terminal found in a maintenance free battery type.

Volt meter – an instrument used to measure the electromotive force or voltage of a battery.

Code No. ALT723304


Documents

Check Ignition System