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Republic of the Philippines

Department of Education

PUBLIC TECHNICAL-VOCATIONAL

HIGH SCHOOLS

PUBLIC TECHNICAL-VOCATIONAL

HIGH SCHOOLS

Unit of Competency: CHECK IGNITION SYSTEM

Module No.: 3 Module Title: Checking Ignition System

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TABLE OF CONTENTS

Page

How to Use this Module ………………………………………….. i

Introduction……………………………………………………………. ii

Technical Terms …………………………………………………….. iii

Learning Outcome 1 ………………………………………………… 1

Learning Experiences/ Activities ……………………….. 1

Information Sheet 1 ……………………………………….. 3

Self Check ……..……………………………………………. 10

Learning Outcome 2….……………………………………………… 11

Learning Activity ……………………………………………. 12

Operation Sheet 1... ……………………………………….. 12

Operation Sheet 2... ……………………………………….. 14

Assessment Performance ………………………………… 19

Learning Outcome 3….……………………………………………… 20

Learning Experiences/ Activities ……………………….. 21

Information Sheet 1 ………………………………………. 21

Self Check 1.1 ………………………………………………. 23

Operation Sheet 1... ……………………………………….. 24

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Assessment Performance ………………………………… 27

Learning Outcome 4….……………………………………………… 28

Learning Experiences/ Activities ……………………….. 28

Operation Sheet 1... ……………………………………….. 25

Assessment Performance ………………………………… 31

Learning Outcome 5….……………………………………………… 32

Learning Experiences/ Activities ……………………….. 32

Operation Sheet 1 ……………………………………...….. 33

Operation Sheet 2 ……………………………………...….. 34

Assessment Performance ………………………………… 37

Learning Outcome 6….……………………………………………… 38

Learning Experiences/ Activities ……………………….. 39

Operation Sheet 1 ……………………………………...….. 40

Operation Sheet 2 ……………………………………...….. 43

Operation Sheet 3 ……………………………………...….. 45

Assessment Performance ………………………………… 47

Learning Outcome 7 ………………………………………………… 48

Learning Experiences/ Activities ……………………….. 49

Operation Sheet 1 ……………………………………...….. 49

Operation Sheet 2 ……………………………………...….. 51

Assessment Performance ………………………………… 54

Learning Outcome 8 ………………………………………………… 55

Learning Experiences/ Activities ……………………….. 56

Operation Sheet 1 ……………………………………...….. 56

Assessment Performance ………………………………… 70

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HOW TO USE THIS COMPETENCY BASED LEARNING MATERIAL.

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 1 (NC1).

You are required t 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 and operation sheets. Use 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 and for the operations master the
procedure.

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 teacher.

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 teacher that you are competent in a particular skill or skills, talk
to your teacher 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
teacher. If the skills you acquired are still current and relevant to their
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 teacher.

After completing this module ask your teacher 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.

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Course Title : AUTOMOTIVE SERVICING

Unit of Competency: Service ignition system

Module Title: Servicing ignition system

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

INTRODUCTION:

This module involves (9) nine Learning outcomes (2) information

sheets and (10) ten essential operation sheets. The information sheets are
composed of the following; servicing ignition timing, Checking ignition coil
resistance. While the operation sheets of this module will be operated by the
teacher concern are the following; Procedures in spark testing of the spark
plugs while cranking the engine. Procedure in spark testing while running
the engine. Procedure in performing triggering test while engine not
cranking or running. Procedures in checking ignition coil resistance.
Procedures in checking ballast resistor of ignition coil. Procedures in
adjusting contact point when the distributor assembly is installed to engine.
Procedures in adjusting contact point when distributor assembly removed
from engine. Procedures in checking ignition system components with the
use of ohmmeter. Procedures in checking ignition system components with
the use of voltmeter. Procedures in performing the wiring installation of
ignition system. Procedures in performing the initial ignition timing.
Procedures in performing the setting base ignition timing. Procedures in
maintaining, servicing, and repairing the ignition system components.

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TECHNICAL TERMS

1. Ohm unit of measure for resistance. One ohm is the resistance of

the conductor such that a constant current of one ampere in it
produces a voltage of one volt between its ends.

2. Ohmmeter a test meter used to measure resistance and

continuity in a circuit.

3. Ground the common negative connection of the vertical system

that is the point of the lowest voltage.

4. Ground circuit an electrical defect that allows current to return to

ground before it has reached the intended load component.

5. Ground side the portion of the circuit that is from the load
component to the negative side of the source.

6. Ignition the action of the spark in staring the burning of the

compressed air-fuel mixture in the combustion chamber.

7. Ignition advance the moving forward, in time, of the ignition

spark relative to the piston position. TDC or one degree ATDC is
considered advanced as compared with 2 degrees ATDC.

8. Ignition timing the delivery of the spark from the coil to the spark
plug at the proper time for the power stroke, relative to the piston
position.

9. Centrifugal advance a rotating weight mechanisms in the

distributor that advances and retard ignition timing through the
centrifugal force resulting from changes in the rotational speed of
the engine distributor.

10. Condenser in the ignition system, a device that is also called a

capacitor, connected across the contact points to reduce arcing
by providing a storage place for electricity (electrons) as the
contact points open.

11. Dwell meter a precision electrical instrument used to measure

the cam angle, or dwell or number of degrees the distributor
points are closed while the engine is running.

12. Timing in an engine delivery of the ignition spark or operation of

the valves (in relation to the piston position) for the power stroke.

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13. Timing light a light that can be connected to the ignition system
to flash each time the no.1 spark plug fires. Used for adjusting
the timing of the ignition spark.

14. Vacuum advance the advancing (or retarding) of ignition timing

by changes in intake-manifold vacuum. Reflecting throttle
opening and engine load. Also, a mechanism on the ignition
distributor that uses intake-manifold vacuum to advance the
timing of the spark to the spark plugs.

15. Arcing name given to the spark that jumps the air gap between
two electric conductors.

16. Dwell in a contact – point distributor, the number of degrees of

distributor – cam rotation that the points stay closed before they
open again. The length of time the points are closed and current
flows through the primary winding of the coil.

17. Ignition resistor a resistance connected into the ignition primary

circuit to reduce battery voltage to the coil during engine
operation.

18. Magnetic line of force the imaginary lines by which a magnetic

field maybe visualized.

19. Retard to delay the occurrence of the spark in the combustion

chamber.

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Program/Course: Automotive Servicing NC I

Unit of Competency: SERVICE IGNITION SYSTEM

Module Title: Servicing Ignition System

Learning Outcome 1. Check Ignition System

ASSESSMENT CRITERIA:

1. Spark plug is checked and inspected in accordance with standard

testing procedure.
2. Ignition distributor and associated parts are checked/evaluated
according to standard procedure.
3. Ignition system harness is checked and inspected.

Resources

 Automotive Mechanics, 10th edition

By: Crouse/ Anglin
 Modern Automotive Technology
By: James E. Duffy
 Manufacturer’s Manual
Toyota Corporation

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Learning Outcome 1: Check ignition system

Learning Activities Special Instructions

1. Read and understand the information  See from topic 1 up to 7.

sheet carefully.
2. Familiarize the types of ignition system.  See only topic 2 of LO1.
3. Identify the parts and functions of the ignition system.
4. Classify the two interconnected electrical  See only topic 3 of LO1.
ignition system /circuits.
5. Analyze the operating principles of the  See only topic 4 of LO1.
ignition system.
6. Follow the safety measures in checking ignition system.  Read the topic 5 of LO1.
7. Perform the servicing ignition system
components.  Read the topic 6 of LO1.

 Read the topic 7 of LO1.

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INFORMATION SHEET No.1

LO 1. SERVICE IGNITION SYSTEM

TITLE: Servicing Ignition System

Topic 1. FUNCTIONS OF THE IGNITION SYSTEM

The ignition system feeds high voltage surge to the spark plugs at
proper time. The three major functions are:

1. It must supply an electric spark with sufficient heat in order to

ignite the air fuel mixture in the combustion chamber of the
engine.
2. It must maintain the spark long enough to permit the combustion
of all fuel charges in the cylinder of the engine.
3. It must draw the spark to each cylinder combustion can begin at
specific time during the stroke of compression for every cylinder
engine.

Topic 2. TYPES OF IGNITION SYSTEM

The ignition system maybe a breaker point and a breaker less type
known as electronics, which is mostly applied in the ignition system
today. There is also a computerized type of ignition system and the
latest is the distributor less type

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A. BREAKER POINT TYPE

The breaker point type distributor assembly consists of the following

parts: Contact point, condenser, springs, lobes, contact set attaching
screw, breaker plate, dwell-angle adjusting slot, vacuum advance unit
and primary lead.

B. BREAKERLESS TYPE

Breaker less type of distributor assembly is composed of the following

parts: pick-up coil assembly, reluctor, pick-up coil, pole piece, mounting
bracket, permanent magnet, reluctor teeth, cap clip, connector, pick up
coil lead and vacuum advance unit.

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Topic 3. PARTS AND FUNCTIONS OF THE IGNITION SYSTEM

1. Battery supplies current to starter in order to crank the engine for

operation. It also supplies the required electric current to the
ignition system.

2. Ignition Switch the key-operated main power switch

that opens and closes the circuit that supplies
current to the ignition and other electrical system.

3. Ignition Resistor a resistor connected into the ignition

primary circuit to reduce battery voltage to the coil during
engine operation.

4. Ignition Coil the ignition system component that set as

a transformer to step up(increase) the battery voltage
into many thousands of volts.

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5. Distributor any device that distribute. In the ignition

system, the rotary switch that direct high voltage surges
to engine cylinders in the proper sequence.

6. Rotor the rotating parts of the distributor assembly that

distributes high voltage from coil center cable to different
spark plug.

7. Contact Point the point in the distributor that opens & closes
the primary circuit to build-up & collapse the magnet line
of force.

8. Condenser connected across the contact point to prevent

arcing and burning. It also provides the storage
of electricity when breaker point is open.

9. Distributor Cap top cover of distributor assembly that

prevents dirt or any particles from entering the
delicate parts.

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10. High Tension Wires bridges of high voltage to

the spark plugs.

11. Spark Plugs a device in the system that serves

as lighter to produce spark on the gap.

12. Vacuum Advancer provide advancing and

retarding the ignition timing by means of intake
manifold vacuum. It advances the timing just
to maintain the spark at top dead center.

Topic 4. The ignition system are of two interconnected electrical

circuits.

1. Primary ( low voltage )

1 Battery
2 Ignition Switch
3 Ballast Resistor or resistance wire
4 Ignition coil primary winding
5 Condenser
6 Contact Point
7 Ground

2. Secondary (high voltage circuits

1. Ignition coil
2. Secondary winding
3. Distributor cap
4. Rotor
5. Ignition cable or high tension wire
6. Spark plug

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Topic 5. OPERATING PRINCIPLES OF THE IGNITION SYSTEM

When the breaker points are close, electric current flows from the
battery through the primary windings in the ignition coil and through the
points back to the ground. This is called the primary circuit. When a
high lobe of the cam pushes on the pivot arm and opens the points, the
primary circuit is broken. The magnetic field that was built up in the coil
while the primary current was flowing now collapses, including the
voltage in the secondary windings as the collapsing magnetic lines of
force sweep across them. Because there are many more secondary
windings than primary windings, the induced voltage is much higher
than the voltage that drove the primary current. This high voltage is sent
through the center wire of the coil to the center of the distributor cap,
which is always in contact with the rotor. The outer end of the rotor is
timed to arrive at the proper moment at the connection to the sparkplug
where a spark is desired. To obtain the correct spark, the distance
between the two electrodes of the spark plug must be “gapped” correctly.
The gap is shown exaggerated for clarity. Cars today use electronic
means rather than mechanical breaker points to bring about the “make
and break” effect.

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Topic 6. SAFETY MEASURES IN CHECKING IGNITION SYSTEM

1. Do not used ordinary pliers for checking the spark plug lead
shorting to ground (earth) in order to sparking. Instead used
non-conductive pliers the appropriate one.
2. Disconnect first the negative cable of the battery when checking
resistance of coil, cut all wires connected from it to ensure the
correct reading of ohms. Note: Individual checking of ignition
parts are properly illustrated in LO.8
3. Does not used jumper wire in checking the ignition system for
continuity, Instead use appropriate instrument for testing with
VOM or multi-tester.
4. Be sure to wear proper working shoes and laboratory uniform in
order to avoid heated loose ground or live wires.
5. Avoid using spark test on common lead wire to earth when there
is leak gasoline to any part of fuel line that will lead for
explosion.
6. Avoid replacement of local parts, other brand and different
character rated for quality reason.
7. Make sure the parts and wires, is correctly connected to their
own designated point of contact.

Topic 7. SERVICING IGNITION SYSTEM COMPONENTS

Pointers to be followed by the technician before proceeded to the

servicing procedures

1. Gather information, regarding the problem to be serviced. If

possible ask the driver or the owner of the vehicle.
2. Apply visual view to inspect thoroughly the troubles.
3. List all parts or items that has been checked and detected by the
used of the appropriate instrument for diagnosing the troubles. If
possible used service repair manual being your guide for the
maintenance and servicing of contact point type of ignition system.

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SELF-CHECK

Direction: Identify and fill-in the blanks with the correct answer. Write your
answers on a separate sheet.

_______________1. It is the point in the distributor assembly that

distributes high voltage from coil center cable to different
spark plug.
_______________2. It is a type of distributor assembly that consist of the
following parts; contact point, condenser, springs, lobes,
contact set attaching screw, breaker plate, dwell-angle
adjusting slot, vacuum advance unit and primary lead.
_______________3. The rotating parts of the distributor assembly that
distributes high voltage from coil center cable to different
spark plug.
_______________4. It is a key-operated main power switch that opens and
closes the circuit that supplies current to the ignition and
other electrical system.
_______________5. It is device connected into the ignition primary circuit to
reduce battery voltage to the coil during engine operation.
_______________6. A device that distributes in the ignition system, the rotary
switch that directs high voltage surges to engine cylinders
in the proper sequence.
_______________7. A type of distributor assembly composed of the following
parts: pick-up coil assembly, reluctor, pick-up coil, pole
piece, mounting bracket, permanent magnet, reluctor
teeth, cap clip, connector, pick up coil lead and vacuum
advance unit.
__ ____________8. It is the ignition system component that sets as a
transformer to step-up( increase) the battery voltage into
many thousand of volts.
___ ___________9. It is connected across the contact point to prevent arcing
and burning. It also provides the storage of electricity
when breaker point opens.
______________10. It is a device in the system that serves as lighter to
produce spark on the gap.

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Program/Course: Automotive Servicing NC I

Unit of Competency: SERVICE IGNITION SYSTEM

Module Title: Servicing Ignition System

Learning Outcome 2. Perform Spark Test

ASSESSMENT CRITERIA:

1. Engine is started as per standard operating procedures.

2. Spark test is conducted in accordance with standard testing
procedures.
3. Safety measures are applied in accordance with standard testing
procedure.

Resources

 Automotive Mechanics, 10th edition

By: Crouse/ Anglin
 Modern Automotive Technology
By: James E. Duffy
 Manufacturer’s Manual
Toyota Corporation

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Learning Outcome 2: Perform spark test

Learning Activities Special Instructions

1. Familiarize the supplies, materials,  See operation sheet no.1.

tools, and equipment needed.
2. Perform spark testing by running the  Read operation sheet no.2 under
engine. LO2.
3. Perform spark testing by cranking the  See operation sheet no.2 under
engine. LO2.
4. Perform triggering test.
5. Follow the safety measures in spark  See operation sheet no.2 under
test and triggering test. LO2.
 See operation sheet no.2 under
LO2.

OPERATION SHEET No. 1

LO 2. PERFORM SPARK TEST

TITLE: Performing Spark Test

Conditions:

Supplies and materials

 Rug cloth
 Sand paper

Tools

 Screw Driver
 Insulated Pliers (special tool)
 Spark Plug wrench
 Feeler Gauge

Equipment

 Engine
 Battery Charger
 Mock – up

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Procedure:

1. Prepare the supplies, materials, tools and equipment needed.

2. Connect battery both positive and negative terminal post, then,

switch on ignition switch.
Note: charge the battery if needed

3. Remove the spark plugs from the Engine by the use of spark plug
Wrench.
Note: Before spark testing clean the tip of the spark plugs with fine
nylon brush.

4. Connect the spark plug no. 1 to high tension. wire no. 1 then,
attach ground electrode of the spark plug to the engine ground.
Note: Do not interchange the cable wires.

5. Switch on key to crank the engine and watch the sparking across
the gap. Hold the plug no. 1 with insulated pliers.
Note: Use a fully charge battery with a good cranking motor
capacity.
6. Proceed to spark plug no. 2, 3, & 4 by performing the same step as
step no. 5.

7. Replace if defective, follow the required gap as specified in the

manual of the car model

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OPERATION SHEET No. 2

LO 2. PERFORM SPARK TEST

TITLE: Performing Spark Test

Conditions:

Supplies and materials:

 Rug cloth
 Sandpaper
 Soft brush nylon
 Functional battery
 Functional starter motor

Tools:

 Set of box wrench

 Spark plug wrench fitted.
 Insulated/non conductive pliers

Equipment

 Functional vehicle
 Functional engine mock –up
 Battery charger

Procedure in spark testing while engine is running:

1. Prepare the supplies, materials, tools and equipment needed.

2. Before operating the engine turn it to correct direction of rotation

by hand with socket wrench and handle.

3. Disconnect the spark-plug cable from the spark plug one by one
while the engine is running.

4. Used non-conductive pliers /insulated pliers hold the extender

about 3/8 inch (10mm) the distance allowed directly to ground in
the black head engine.

5. While the engine is running , observe the sparking across the gap.
Bluish spark from no.1-4 end of cables shows that the ignition
system is at normal condition.
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6. If there’s no spark, proceed to the triggering test of the primary

circuit to determine if there will be the opening and closing
operation in the circuit. (note: if spark show but the engine does
not continuously operating, maybe failure is in the other systems.

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OPERATION SHEET No. 3

LO 2. PERFORM SPARK TEST

TITLE: Performing Spark Test

Conditions:

Supplies and materials

 Rug cloth
 Sandpaper
 Soft brush nylon
 Functional battery
 Functional starter motor

Tools

 Set of box wrench

 Spark plug wrench fitted.
 Insulated/non conductive pliers

Equipment

 Functional vehicle
 Functional engine mock –up
 Battery charger

Procedure in performing triggering test while engine not cranking or

running

1. Prepare the supplies, materials, tools and equipment needed.

2. Turn the crankshaft to correct direction of rotation in order to set

piston no.1 at compression stroke, both values closed.

3. Mark cut on crankshaft pulley align to the specified degrees of

spark. Example if 8º ignition timing required it must be aligned to
it.

4. Loosen the distributor assembly fixing adjusting bolt. Ignition

switch turn on, turn the distributor assembly go against rotor
rotation, see to it that gap adjusted correctly, then, turn the
assembly, by setting contact point gap about to open. Spark
occurred on gap, then, the common cable lead 3/8” gap directly
pointing to ground at the same time spark occurred in the contact
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the finding of the primary circuit and parts are in good service
condition.

5. If spark does not occur, check contact point, condenser, ignition

coil, and insulator in the primary lead.

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SAFETY MEASURES IN SPARK TEST/TRIGGERING TEST.

1. Do not use conductive pliers with only insulated handle. In high-

energy ignition system the spark will jump even more than one
inch or (25.4mm).

2. It will jump around or through the insulation and give a dangerous

shock that might kill a person with heart failure.

3. See to it that there is no fuel or fuel vapor near where the spark
will occur. The spark will ignite the fuel causing a fire or explosion.

4. Do not allow spark to short onto dipstick, cam/rocker cover or

battery as this can cause an explosion of oil or hydrogen fumes.

DETERMINING AND ANALYZING ELECTRIC SPARK.

A waveform, or trace, showing one complete spark-plug firing cycle.

Note that the “dwell section” is the period during which the points are
closed or the electronic control unit is maintaining a complete circuit
between the battery and ignition coil.

1. Reading the Patterns

The patterns show different troubles that occur in the ignition

system. The pattern of any cylinder’s ignition-circuit voltage
shows what voltages are occurring in that circuit. The way that
the voltage varies from normal shows you where the electrical
problem exists. For example, the scope can detect wide or narrow
spark-plug gaps, open spark-plug wires, shorted coils or

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condensers, arcing contact points improper contact-point dwell,

and so on. Many abnormal engine conditions change the voltage
needed to fire the plug. This, too, shows up on the scope. When
you work in a shop that has an oscilloscope, you will have
instructions on how to use it.

ASSESSMENT PERFORMANCE

LO 2. Perform spark test

Workmanship/Performance Points

A. Spark tested when cranking the engine safely.

100

 With 95-100% standard of specifications. All

spark plugs are spark tested correctly

 90-94% standard of specifications. Three spark

plugs are spark tested correctly
 85-89% standard of specifications. Two spark
plugs are spark tested correctly
 80-84% standard of specifications. One spark
plug is spark tested correctly
 75-79% standard of specifications. None

 B. Spark tested safely when running engine. 100

 With 95-100% standard of specifications. All

high tension wires are spark tested properly
 90-94% standard of specifications. Three high
tension wires are spark tested properly
 85-89% standard of specifications. Two high
tension wires are spark tested properly
 80-84% standard of specifications. One high
tension wires is spark tested properly
 75-79% standard of specifications. None

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 Spark triggering tested safety while engine not

cranking or running
 With 95-100% standard of specifications. 100
Within1 to 3 minutes.
 90-94% standard of specifications. Within 3 to 6
minutes.
 85-89% standard of specifications. Within 6 to 9
minutes.
 80-84% standard of specifications. Within 9 to 12
minutes.
 75-79% standard of specifications. Within 12 to
15 minutes.

Program/Course: Automotive Servicing NC I

Unit of Competency: SERVICE IGNITION SYSTEM

Module Title: Servicing Ignition System

Learning Outcome 3. Check Ignition Coil Resistance

ASSESSMENT CRITERIA:

1. Coil terminal of ignition coil is disconnected

2. Ignition coil resistance is checked

Resources

 Automotive Mechanics, 10th edition

By: Crouse/ Anglin
 Modern Automotive Technology
By: James E. Duffy
 Manufacturer’s Manual
Toyota Corporation

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Learning Outcome 3: Check ignition coil resistance

Learning Activities Special Instructions

1. Read and understand the functions  Look at the topic 1 of LO3.

of ignition coil.
2. Identify the parts and function of  Look at the topic 2 of LO3.
ignition.
3. Interpret the primary and  See topic 3 of LO3.
secondary circuit.
4. Perform to check and test the  See information sheet 4 under
ignition coil resistance. LO3.

INFORMATION SHEET No. 1

LO 3. CHECK IGNITION COIL RESISTANCE

TITLE: Checking Ignition Coil Resistance

Topic 1. FUNCTIONS OF IGNITION COIL

Ignition coil is considered as the heart of the Ignition System. It

works in the same of the pulse transformer to step up the low voltage
of 12.6 volts to a voltage high enough to ionize (electrically charge) the
spark plug gap and ignite the fuel charges. The coil has the capacity
to produce approximately 30,000 to 60,000 volts. However, the
amount of voltage produced is dependent on many factors. The coil
will produce current depending on many factors. The coil will produce
only sufficient voltage required to overcome these factors; plug gap,
air/fuel ratio, plugs wire resistance, engine speed, compression ratio,
and so forth. The margin of voltage which can be produced above that
which is required to fire the spark plug represents the electrical
reserve built into the ignition system. As plugs wear and other
resistances in the system increase, the ignition system is capable of
compensating for this through the electrical reserve.

Topic 2. PARTS OF IGNITION COIL

1. Soft iron core is the center of the Ignition coil, a laminated soft
iron or steel.

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2. Primary coil winding These are several hundred turns of heavy

wire, wrapped around or near the secondary.(approximately 200
turns of gauge wire)
3. Secondary coil windings These are several thousand turns of very
fine wire located inside or near the primary
windings.(approximately 22,000 turns of very fine wire)
4. Oil in the coil that prevents heat and help cool the coil.
Note: E-coil – this type of core does not use oil. It uses an air-
cooled, epoxy-sealed
5. Positive terminal where wire connected from ignition terminal of
switch to the + sign or the ballast resistor + sign side of it.
6. Negative terminal It is wire connected from the distributor
assembly lead wire with insulated terminal to the negative sign of
coil.
7. Center pole negative this is the plug polarity, negative plug
polarity requires less voltage to ionize the plug than does positive
polarity. This is because of the relative temperature between the
center electrode (hot) and the ground electrode (cold).

Topic 3. INTERPRETING SECONDARY AND PRIMARY CIRCUIT

1. Operation of the Primary Circuit When the Ignition switch on or

it is in the run position, current from the battery flows through the
ignition switch and primary circuit resistor to the primary winding
of the ignition coil. From there, it passes through some type of
switching device that can be mechanically or electronically
controlled by a triggering device. The current flow in the Ignition
Coil primary winding creates a magnetic field. The switching
device or control module interrupts this current flow at
predetermined times, when it does, the magnetic field in the
primary winding collapses, this collapse generates a high-voltage
surge in the secondary winding of the ignition coil. The secondary
circuit of the system begins at this point.

Schematic of the primary circuit in the contact point ignition system

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2. Operation of Secondary Circuit The secondary circuit carries

high voltage to the spark plugs. The exact manner in which the
secondary circuit delivers these high-voltages surges depends on
the system design. Until 1984 all ignition systems used some type
of distributor to accomplish this job. However, in an effort to
reduce emissions, improve fuel economy, and boost component
reliability, most auto manufacturers are now using distributor less
or electronic ignition (EI) system.

Simplified secondary circuit means that

coil secondary winding is connected through
the distributor cap, rotor, and wiring to
the spark plugs.

Self-check

Direction: Identify the following.

1. _________ It is a wire connected from the distributor assembly lead wire

with insulated terminal to the negative sign of coil.

2. __________It prevents heat and help to cool the coil.

3. __________It is the center of the ignition coil, a laminated soft iron or steel.

4. __________This winding is surrounded the secondary coil windings which

is approximately 200 turn of 20-gauge wire.

5. __________It is winded in the core approximately 22,000 turns of very fine

wire.

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OPERATION SHEET No. 3

LO 3. CHECK IGNITION COIL RESISTANCE

TITLE: Checking Ignition Coil Resistance

Conditions:

Supplies and materials

 Ball pen/pencil
 Bond paper

Tools
 Pliers
 VOM
 Multi tester

Equipment

 Engine mock-up

Procedure in checking ignition coil resistance:

1. Prepare the supplies, materials, tools and equipment needed.

2. Inspect the Ignition coil

a. Clean the coil and inspect it

for carbon paths around the
terminals and check the
outside body for cracks.

b. Inspect the high tension

cord insertion hole for
carbon deposit or corrosion.

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3. Inspect / Check / Test the Primary Coil Resistance

a. Measure the following resistance

With out the used of resistor the

reading must be 2.6 – 4.0 ohm. This is
the primary coil resistance (reference
only)
Note: If the reading is not within
the specified resistance replace the
coil.

Causes: If the readings show the

specified ohms or very high
resistance the condition of the
primary coil is burn. But if it is
low, the condition will be weak,
but if the hand, remains at infinity
(∞) the condition of primary winding is
b. With theopen.
used of resistor
The reading must be 1.3 – 1.6
ohms this is the primary coil resistance
(reference only)
Note: If the reading is not within
the specified resistance replace the
coil.

Causes: If the reading appear

higher than the required ohms or
higher resistance, the condition of
primary coil is burn out, but if it is
low than specified ohms the
condition is weak, but if the hand
of ohmmeter remain at infinity ∞
the condition of primary coil
maybe open.

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4. Inspect/check/ test the secondary coil resistance.

c. Measure the following resistance

With out the used of resistor the
reading must be 6.0 – 9.0 k ohms, the
secondary coil resistance (references
only)
Note: If the reading does not meet
within the range of minimum and
maximum in the secondary coil
resistance that will be
recommended for replacement.
Cause: If the reading of
ohmmeter show more than the
specified ohms the condition will
be burn out winding, but if it is
lower reading, the coil is weak, but
if remain at infinity (∞) the
condition of secondary coil maybe
opened.

b. With the used of resistor

The reading must be 9.5 – 14.5 k
ohms, the secondary coil resistance
(references only)
Note: If the reading does not meet
the minimum and maximum of
secondary coil resistance that will
be recommended for replacement.
Cause: If the reading of
ohmmeter show more than the
specified ohms the condition is
burn out, if lower reading the coil
is weak, but if remain at infinity
(∞) the condition of secondary coil
maybe opened.

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ASSESSMENT PERFORMANCE

LO 3. Check ignition coil resistance

Workmanship/Performance Points

50

A. Checked ignition coil safety when disconnected

from the circuit.

 With 45-50% standard of specifications. Within

1 to 3 minutes including the test results and
conditions of coil.

 39-44% standard of specifications. Within 3 to

16 minutes including the test results and
condition of coil

 33-38% standard of specifications Within 6 to 9

minutes including the test results and the
condition of coil
 27-32% standard of specifications. Within 9 to
12 minutes including the test results and the
condition coil.

 21-26% standard of specifications. Within 12 to

15 minutes including the test results and the
condition coil.

B. Checked the ignition coil safely, when connected 50

in the circuit, while engine is functioning

 With 45-50% standard of specifications. It was

checked properly with the correct instrument

 38-44% standard of specifications. It was not

checked correctly with the instrument.
 32-37% standard of specifications. It was not
checked correctly without instrument.
Total=100

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Program/Course: Automotive Servicing NC I

Unit of Competency: SERVICE IGNITION SYSTEM

Module Title: Servicing Ignition System

Learning Outcome 4. Check Ballast Resistor

ASSESSMENT CRITERIA:

1. Ballast resistor is checked as per requirement

Resources

 Automotive Mechanics, 10th edition

By: Crouse/ Anglin
 Modern Automotive Technology
By: James E. Duffy
 Manufacturer’s Manual
Toyota Corporation

Learning Outcome 4: Check ballast resistor

Learning Activities Special Instructions

1. Check and test the resistance of  See the operation sheet no.5.
ballast resistor.

 See the operation sheet no.5. under

2. Analyze the resistance test results LO 4.
of ballast resistor.

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OPERATION SHEET No. 4

LO 4. CHECK BALLAST RESISTOR

TITLE: CHECKING BALLAST RESISTOR

Conditions:

Supplies and materials:

 Ball-pen/pencil
 Bond paper
Tools:
 Box wrench
 Screw driver
 VOM tester
 Multi-tester
 Screw drive
Equipment:
 Ignition mock-up
 Engine mock-up

A. PROCEDURES IN CHECKING BALLAST OF IGNITION COIL.

1. Prepare the supplies, materials, tools and equipment needed.
2. Disconnect wires connected from the ballast resistor
3. Check and test ballast resistor of ignition coil.

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4. Turn the selector switch to R X 1 of the ohmmeter.

5. Both test prods of the ohmmeter will be injected to both ends of the
ballast resistor.

6. If the readings show 0.8 – 1.2 ohms the ballast resistance is normal.

7. But if the readings show infinity or does not move the hand of the
tester, the condition is open

8. If the reading is not within the specified resistance replace the resistor.

B. ANALYSIS OF RESISTANCE TEST RESULTS

Appropriate instrument used for testing and checking the resistance

express in ohms is no other than ohmmeter tester. If the resistance varies
from .08 to 1.2 ohms meaning the hand of the tester will move and stop
with in the range, to be sure in the measurement, possible see the manual
of the Ballast resistor specifying the resistance of the ignition resistor.
When you turn the selector to RX1, the hand will move from (∞) infinity to
the correct range given from manual, the condition will be normal, but if
the hand will move from (∞) infinity to (0) zero the condition is weak or
leak but then, the hand remain at (∞) infinity the condition maybe open.

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ASSESSMENT PERFORMANCE

LO 4. Check ballast resistor

Workmanship/Performance Points

A. Checked safely the ballast resistor, when it is not

connected from the coil as per requirements. 50

 With 45 to 50% standard of specification.

Within 2 to 5 minutes including the test results
and conditions.

 39 to 44% standard of specification. Within 6

to 10 minutes including the test results and
conditions.

 33 to 38% standard of specification. Within 10

minutes or more including the test results and
the condition.
B. Checked safely the ballast resistor when it is
connected in the coil, while engine is running.
50

 With 40 to 50% standard specifications. Within

5 to 10 minutes. The ballast resistor was tested
properly while the engine is running

 29 to 39% standard specifications. Within 10 to

15 minutes. The ballast resistor was tested
improperly while the engine is functioning
Total=100

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Program/Course: Automotive Servicing NC I

Unit of Competency: SERVICE IGNITION SYSTEM

Module Title: Servicing Ignition System

Learning Outcome 5. Adjust Contact Point Clearance

ASSESSMENT CRITERIA:

1. Contact point is adjusted per service manual specification

2. Contact point adjustment is analyzed and interpreted

Resources

 Automotive Mechanics, 10th edition

By: Crouse/ Anglin
 Modern Automotive Technology
By: James E. Duffy
 Manufacturer’s Manual
Toyota Corporation

Learning Outcome 5: Adjust contact point clearance

Learning Activities Special Instructions

1. Perform the adjusting contact point  See the operation sheet no.6.
when the distributor assembly is
installed to engine
 See the operation sheet no.7. under
2. Perform the adjusting contact point LO 5
when the distributor assembly
remove from the engine.

3. Follow the safety measures in  Read the operation sheet [Link]

adjusting contact point. LO 5

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OPERATION SHEET No. 1

LO 5. ADJUST CONTACT POINT CLEARANCE

TITLE: ADJUSTING CONTACT POINT CLEARANCE

Conditions:

Supplies and materials:

 Sand paper
 Rags
 Grease

Tools

 Set of screw driver

 Feeler gauge
 Set of wrench

Equipment

 Ignition mock-up

Procedures adjusting contact point when the distributor assembly

is install to engine.

1. Prepare the supplies, materials, tools and equipment needed.

2. Turn the engine to correct direction of rotation by the use of correct

size box or socket wrench that fit to crankshaft pulley fixing bolt.

3. Position the contact point to be set in highest portion of the cam

lobe in distributor shaft.

4. Use proper type, and size of screw driver prior to the screw head
kind.

5. Loosen the slightly lock and adjusting screw then, insert the feller
gauge with correct size of clearance, follow what is in the manual.

6. Tighten first the adjusting screw with two working screw drivers for
it to locks then, lastly tighten the lock screw. If possible check it
thoroughly again by retightening the adjuster and locker screws.

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7. Test run then, proceed to next operation sheet.

Fig.1: Adjusting the breaker point gap

OPERATION SHEET No. 2

LO 5. ADJUST CONTACT POINT CLEARANCE

TITLE: ADJUSTING CONTACT POINT CLEARANCE

Conditions:

Supplies and materials:

 Sand paper
 Rags
 Grease

Tools

 Set of screw driver

 Feeler gauge
 Set of wrench

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Equipment

 Ignition mock-up

Procedure in adjusting contact point when distributor assembly

remove from engine.

1. Prepare the supplies, materials, tools and equipment needed.

2. Position correctly and firmly the distributor assembly in the Bench

vise.

3. Position the contact point to be set on the highest part camlobe in

distributor shaft.

4. Used proper type, and size of screw driver prior to the screw head
kind.

5. Loosen slightly lock and adjusting screw then, insert the feller
gauge with correct size of clearance, follow what state in the
manual.

6. Tighten first the adjusting screw with two working screw drivers for
it, to locks then, lastly tighten the lock screw. If possible check it
thoroughly again by retightening the adjuster and locker screws.

7. Set engine correctly then install the distributor assembly, time it

properly, see the steps of initial ignition timing.

8. Test run, then check if dwell angles is within the specified value, by
the used of the dwell meter, follow the dwell of 4 cylinders is 51⁰
(50⁰ - 52⁰)

POINT GAP ADJUSTMENT (W/O IGNITER)

1. If the points are excessively burnt or fitted, replace
the breaker points.

2. Adjust point gap.

Point gap 0.45 mm (0.18 in)

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IF dwell angle below specified degrees point gap is too big. But if the
dwell angle above specified degrees point gap is too small, readjust the point
clearance to make it with the correct dwell angle, by the used of dwell meter
for dwell angle while for the R.P.M used tachometer for setting the correct
idling of engine.

B. SAFETY MEASURES IN ADJUSTING CONTACT POINT.

1. When testing a vehicle, never short plug lead to the dipstick,

cam/rocker arm cover, battery or other components, which may
not be directly earthed. This can cause an explosion of oil fumes or
hydrogen.

2. Beware of the danger from rotating components of ignition system.

3. Never bend movable point arm with your hand.

4. Do not use the car, if the contact breaker point is not exactly
adjusted to the manufacturer specifications.

5. Do not install local contact point to the car of your customers and
replacement of part be checked thoroughly, to avoid any trouble?

6. Use the proper screw driver for right head of bolt screw.

7. In replacing contact points do the same with the condenser or

capacitor used the required capacitance or farad.

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ASSESSMENT PERFORMANCE

LO 5. Adjust contact point clearance

Workmanship/Performance Points

A. Adjusted contact point safely as per service 50

manual specification when distributor assembly
is installed to engine.

 With 45 to 50% standard of specification. 5

to 10 minutes.

 39 to 44% standard of specification. 11 to 15

minutes.

 33 to 38% standard of specification. 16 to up

minutes.
B. Adjusted contact point safely as per service
manual specification when distributor assembly
50
not installed to engine.

 With 45 to 50% standard of specification. 15

to 30 minutes.

 39 to 44% standard of specification. 30

minutes to 1 hour.

 33 to 38% standard of specification. 1 hour

and more.
Total=100

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Program/Course: Automotive Servicing NC I

Unit of Competency: SERVICE IGNITION SYSTEM

Module Title: Servicing Ignition System

Learning Outcome 6. Perform Ignition Wiring Installation

ASSESSMENT CRITERIA:

1. Tools and ignition wiring materials are checked and evaluated per standard
specifications.
2. Ignition wirings are installed based on a required diagram.
3. Safety measures are applied in installing wirings of the ignition system in
accordance with OHS policy.

Resources

 Automotive Mechanics, 10th edition

By: Crouse/ Anglin
 Modern Automotive Technology
By: James E. Duffy
 Manufacturer’s Manual
Toyota Corporation

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Learning Outcome 6: Perform Ignition Wiring Installation

Learning Activities Special Instructions

1. Perform the checking of ignition  See the operation sheet no. 8

circuit system components with the under LO6.
use of ohm meter.
 See the operation sheet no.9
2. Perform the checking Ignition under LO9.
components with the use of volt
meter.  See the operation sheet no.9
under LO10.
3. Perform the wiring circuit
installation of ignition system.  See the operation sheet no.9
under LO10.
4. Follow the safety measures in
wiring installation of ignition circuit
system.

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OPERATION SHEET No. 1

LO 6. PERFORM IGNITION WIRING INSTALLATION

TITLE: PERFORMING IGNITION WIRING INSTALLATION

Conditions

Supplies and materials:

 Soldering leads
 Automotive wires
 Wire terminals
 Electrical tape

Tools:
 Electrical pliers
 Set of screwdriver
 Wire stripper
 Soldering iron
Equipment:
 Engine mock-up
 Vehicle

PROCEDURES IN CHECKING IGNITION COMPONENTS WITH THE USE

OF OHMETER:

1. Prepare the supplies, materials, tools and equipment needed.

2. Disconnect negative terminal of battery.

3. Check Ignition switch by the use of ohmmeter, RX1 one prod to AM

while other prod to Ignition. Hand will move from infinity to zero in
two pull position of ignition key – it’s okay.

4. Test auto wire from Ignition of switch to positive terminal of coil,

RX1, hand move to infinity to near zero – then it’s in proper.

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5. Test auto wire from negative terminal of coil to ground part of

distributor assembly open the cap see the position of contact point,
RX1, if the contact point open the hand remain infinity – then it’s
proper if hand will move to zero the condition is grounded contact
point. If breaker points close the hand will move near to zero – then
it’s proper.

6 Test/check condenser, used ohmmeter, RX1, connect one prod to

the eye tail of condenser, and the other prod to the body ground
parts, the hand of meter will move little bit abrupt to zero side then,
back to infinity side of tester it’s proper – if does not move or remain
at infinity it is defective, condenser is to be replaced

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7 Test/check high tension wire individually used ohmmeter RX 25Ω.

Both prods of the meter will be connected at both ends. See the
reading must be on the specified ohms at all cords.

8 Check the adjustment of spark plug gap by the used of feeler gauge
follow the gap specification in the manual.

GAP ADJUSTMENT
Check the plug gap with plug gap gauge. If not
to specified value, adjust by bending
the ground (outer) electrode.
Plug gap 0.8 mm (0.031 in)

1.0 mm (0.039 in for USA

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OPERATION SHEET No. 2

LO 6. PERFORM IGNITION WIRING INSTALLATION

TITLE: PERFORMING IGNITION WIRING INSTALLATION

Conditions

Supplies and materials:

 Soldering leads
 Automotive wires
 Wire terminals
 Electrical tape
Tools:
 Electrical pliers
 Set of screwdriver
 Wire stripper
 Soldering iron
Equipment:
 Engine mock-up

Procedure in checking ignition system components with the use of

voltmeter:

1. Prepare the supplies, materials, tools and equipment needed.

2. Connect the voltmeter positive lead to the positive terminal of the ignition
coil. Connect the negative lead to engine ground.

3. Set the voltmeter to a scale that will read 12 volts accuracy.

4. Turn the ignition switch to the “start” position while observing the
voltmeter reading. Check manufacturer’s specification for proper voltage
reading (usually bout 9.5 volts).

5. If the voltage is too low than there is a resistance in the supply circuit to
the coil. This could be caused by any of the following.

a. Battery condition.
b. Excessive starter draw.
c. Excessive resistance in the ballast by pass circuit.
d. Excessive resistance in the ignition switches start
circuit.
e. Excessive resistance in the starter relay to the pass
circuit.

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6. With the voltmeter still connected as in step one, turn the ignition switch
to the “run” position. The voltmeter reading should now be about7.5
volts (or factor specifications).

7. If the reading is below specification it could be due to

a. Battery condition
b. Ignition switch resistance
c. Excessive resistance in the ballast resistor circuit.

If the results of this test show that the coil supply

circuit is operating properly then the coil should be
tested.

Note: In this ignition circuit the teacher

will demonstrate using voltmeter

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OPERATION SHEET No. 3

LO 6. PERFORM IGNITION WIRING INSTALLATION

TITLE: PERFORMING IGNITION WIRING INSTALLATION

Conditions:

Supplies and materials

 Soldering lead 40/60

 Auto wires size no. 12 & 14
 Eye terminals
 Electrical tape
 Fuse/ fuse box
 Wire harness flexible hose
 Battery clamp / cables
 Battery log
Tools
 Cutter pliers
 Wire’s stripper
 Soldering rod / Iron
 Set of insulated pliers
 Set of screw drivers

Equipment

 Functional Engine mock –up for ignition wiring
circuit.
Procedure:
1. Prepare the supplies, materials, tools and equipment needed.

2. Connect newly battery cables to earthly ground, from negative post

and battery cable live from positive post to battery solenoid
terminal.

3. Auto wire size no. 12 will be converted from battery terminal

solenoid to the positive side of ammeter and from negative side to
Bat/AM terminal of Ignition switch.

4. Auto wire size no. 14 will be connected from ignition terminal of

ignition switch to ballast resistor, from then, to positive terminal of
coil.
Note: But in order to complete the circuit to crank the engine for
starting, connect auto wire size no. 14 from ST terminal of
switch to ST terminal of the solenoid starter switch.

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5. Used auto wire size no. 14 from negative terminal of coil to insulated
lead terminal in the distributor assembly.
Note: See to it that engine and distributor assembly are set
properly and contact point adjusted to specified gap.

6. Proceed to the proper connection of high tension wires from center

lead of coil to center terminal of cap. If rotor pointing no.1 terminal
cap it could be the no.1 spark plug then followed prior to the firing
order given.

7. All end wires in provided with eye terminals and solenoid the wires
with the eye to ensure proper contact.

8. Crank the engine and run it, for further trouble shooting

SAFETY MEASURES IN WIRING INSTALLATION

1. Do not use ohmmeter, in the testing resistance into the ignition

circuit, if battery connected, other wise the meter will be damaged.

2. Always connect the battery to ground if negative white to live wire if

positive, do not invert the connection. Otherwise the harness will be
burnt or affected.

3. Always shield the ignition circuit harness with electrical tape or

flexible hose wires if required.

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4. Provide fuse for the ignition circuit.

5. Eye terminal of every end wires, must be soldered properly in order

to ensure the contact between terminal points is good.

6. Avoid open wires, unshielded wires and overloaded terminals within

the circuit.

7. Avoid using jumper wire or short circuiting of parts, otherwise those

components will be busted.

ASSESSMENT PERFORMANCE

LO 6. Perform ignition wiring installation

Workmanship/Performance Points

A. Checked ignition system components safely with 100

the use of ohmmeter.

 With 95-100% standard of specifications.

 75% standard of specifications.

 50% below.

B. Checked ignition system safely with the used of

voltmeter.
 With 95-100% standard of specifications.

 75% standard of specifications.

 50% below.

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C. Performed wiring installation of ignition

circuit/system safely.

 With 95-100% standard of specifications.

 75% standard of specifications.

 50% below.

Total=100

Program/Course: Automotive Servicing NC I

Unit of Competency: SERVICE IGNITION SYSTEM

Module Title: Servicing Ignition System

Learning Outcome 7. Perform Ignition Timing

ASSESSMENT CRITERIA:

1. Ignition Timing procedure is applied per engine requirement

2. Ignition timing is checked per ignition specifications
3. Safety measures are applied

Resources

 Automotive Mechanics, 10th edition

By: Crouse/ Anglin
 Modern Automotive Technology
By: James E. Duffy
 Manufacturer’s Manual
Toyota Corporation

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Learning Outcome 7: Perform ignition timing

Learning Activities Special Instructions

 Read the operation sheet no.11

1. Interpret the ignition timing. under LO7.

 See the operation sheet no.12under

2. Perform the initial ignition timing. LO7.

 See the operation sheet no.12 under

3. Perform the process of setting the
LO7.
base of the ignition timing.

 See the operation sheet no.12 under

4. Follow the safety measures in LO7.
performing ignition timing.

OPERATION SHEET No. 1

LO 7. PERFORM IGNITION TIMING

TITLE: PERFORM IGNITION TIMING

CONDITION:

Supplies and Materials

 Rags
 White chalk

Tools

 Box wrenches
 Set of screw drivers

Equipment

 Engine mock-up

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 Vehicle
 Ignition timing light
 Dwell meter
 Tachometer

Procedure in performing the initial ignition timing

1. Prepare the supplies, materials, tools and equipment

needed.
2. Piston no. 1 TDC the compression stroke, timing mark
coincide, aligned.
Note: Before installing distributor to the engine adjust the
contact point to the correct specified contact point
gap or set point to specification.
3. Set the contact point ready to open or just beginning to
open.
4. Install rotor and cap arrange high-tension wire in cap
according to the firing order.
5. Run engine and check timing with power timing light at
idling speed.
Note: To determine the contact point it is about to
open
a) Spark test method b) Ignition timing light

Dwell angle or Cam angle

The time in degrees by which contact point remain
closed for the magnetic built up of ignition coil.

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Ignition Timing: Type initial setting in order the spark will reach
spark gap at the right time.

Interpreting ignition timing – is the delivery of spark from the coil to the
spark plug at the proper time for the power stroke relative to the piston
position. Usually expressed in crankshaft degrees before or after top dead
center (TDC) at the end of the compression stroke.

OPERATION SHEET No. 2

LO 7. PERFORM IGNITION TIMING

TITLE: PERFORM IGNITION TIMING

CONDITION:

Supplies and Materials

 Rags
 White chalk

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Tools

 Box wrenches
 Set of screw drivers

Equipment

 Engine mock-up
 Vehicle
 Ignition timing light
 Dwell meter
 Tachometer

Procedure in performing the setting base ignition timing.

1. Prepare the supplies, materials, tools and equipment needed.

NOTE: Use a stroboscopic timing light to check the timing.

Follow these steps for ignition timing adjustment.]

2. Connect the timing light, and start the engine.

3. The engine must be idling at the manufacturer’s recommended rpm

end all other timing procedures must be followed.

4. Aim the timing light marks at the timing indicator, and observe the
timing marks. Compare this reading to the manufacturer’s
specifications. For example if the specification reads 10 degrees
before top dead center and the reading found is 3 degrees before
top dead center, the timing is retarded or off by 7 degrees.

5. If the timing mark is not at the specified location, rotate the

distributor until the mark is at the specified location.

6. Tighten the distributor hold-down bolt to the specified torque, and

recheck the timing mark position.

7. Connect the vacuum advance hose and any other connectors,

hoses, or components that were disconnected for the timing
procedure.

8. Road testing in the highways.

9.
a) Timing marks illuminated by a timing light and
showing 10 degrees BTDC.

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b) Timing marks at 3 degrees BTDC.

c) The timing light flashes every time the number 1

spark plug fires.

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SAFETY MEASURES IN PERFORMING IGNITION TIMING

1. Do not puncture cables or nipples with test probes. This will ruin
the cables of ignition timing light.
2. Do not point laser flashes of stroboscopic light to any body due to
the strong ultraviolet rays, especially to eyes.
3. Keep off your hands to the rotating parts of the engine in
performing the test.
4. Remove necklace, rings, and watches or wear suitable working
uniform in conducting the ignition timing with stroboscopic light.
5. See to it that the test probes of timing light and other connections
are tight, set and connected correctly.
6. Always use the manual as your guide for the adjustment.
7. Be sure your concentration is given fully to the job in performing
gasoline ignition timing.
ASSESSMENT PERFORMANCE

LO 7. Perform ignition timing

Workmanship/Performance Points

B. Performed initial ignition timing safely using only a 100

pair of tools.

 95-100% of all the steps.

 75% only of the steps.

 50% only of the steps.

Total=100

C. Performed setting base ignition timing safely with

the used of stroboscopic timing light, dwell meter, 100
and tachometer.

 95-100% of all the steps

 75% only of the steps

 50% only of the steps

Total=100

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Program/Course: Automotive Servicing NC I

Unit of Competency: SERVICE IGNITION SYSTEM

Module Title: Servicing Ignition System

Learning Outcome 8. Repair Non-electronic Ignition System and/or

Component

ASSESSMENT CRITERIA:

1. Parts and components of non-electronic ignition system are identified

and located.
2. Ignition system/components are repaired without causing any damage
on them.

Resources

 Automotive Mechanics, 10th edition

By: Crouse/ Anglin

 Modern Automotive Technology

By: James E. Duffy

 Manufacturer’s Manual
Toyota Corporation

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Learning Outcome 8: Repair non-electronic ignition system and or

component

Learning Activities Special Instructions

1. Perform the maintenance,  See the operation sheet no.13 under

servicing, and repairing of the LO8.
ignition system components.
2. Perform electrical testing and  See the operation sheet no.13 under
checking. LO8.
3. Perform mechanical inspection,  See the operation sheet no.13 under
maintenance and repair. LO8.
4. Perform the installation and  See the operation sheet no.13 under
adjustment of distributor LO8.
assembly.
5. Diagnosing non-electronic ignition  See the operation sheet no.13 under
system. LO8.
6. Follow safety measures in
maintaining and repairing the non-  See the operation sheet no.13 under
electronic ignition system. LO8.

OPERATION SHEET No. 1

LO 8. REPAIR NON-ELECTRONIC IGNITION SYSTEM AND/OR

COMPONENT

TITLE: Repairing non-electronic ignition system and/or

Component

CONDITION

Supplies and Materials

 Rags
 Paint brush
 Soldering lead

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 Wire
 Fine sand paper

Tools

 Set of box wrenches

 Set of screw drivers
 Pliers
 Volt meter
 Soldering iron/gun

Equipment

 Ignition system mock-up

 Running engine with complete ignition system
 Vehicle

Procedure in maintaining, servicing, and repairing for ignition system

components.

1. Prepare the supplies, materials, tools and equipment needed.

2. Repair wiring harness if needed; for burn, loose, cut wires and
wires not shielded with electrical tape. Rewire if necessary the
circuit with a wire flexible hose.
3. Inspect and repair the spare parts such as; ignition switch, ballast
resistor, ignition coil, distributor component assembly; a. contact
point b. condenser c. spring [Link] lobe e. rotor distributor cap
and g. distributor insulated terminal. High tension wires and spark
plugs.
4. Check, inspect mechanical parts and check, Test Electrical parts
using ohmmeter tester.

IGNITION SYSTEM COMPONENT

a. Electrical Testing Procedures:

TESTING IGNITION SWITCH

Ohmmeter tester selector switch to RX1, the

hand will move from infinity to zero, on
ignition switch to Position click two.
AM

ACC
ST

IGN

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RX1
TESTING BALAST RESISTOR

Ohmmeter tester switch to RX1 test prod as

shown

external resistor resistance

1.3 – 1.7 Ω (Reference only)

see manual.

TESTING COIL RESISTANCE

Ohmmeter Tester Switch to R X 10k test

prod as shown

w/o resistor type 6.0 – 9.0 k Ω

w/ resistor type 9.5 – 14.5 k Ω (Reference Only)

see manual.

TESTING PRIMARY COIL RESITANCE

Ohmmeter Tester Switch to RX1 test prod as

shown

w/o resistor type 2.6 – 4.0 Ω

(Reference Only)
w/ resistor type 1.3 – 1.6 Ω

To be sure see manual.

Note: If the reading is not within the specified

résistance, replace coil.

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TESTING INSULATION RESISTANCE

VOM Tester switch to RX10M Ω at 500V –

Test Prod as shown

Insulation resistance over 10M Ω at 500V.

TESTING HIGH TENSION WIRES

Ohmmeter tester switch to RX100K Ω

Resistance less than 25K Ω

To be sure see manual

Note: If the reading exceeds the limit replace the

cord.

TESTING CONDENSER

VOM tester switch to RX1 Ω

Test prod as shown

The hand of the meter will move abrupt then back

to infinity.(∞)

Note: If hand does not move replace the condenser.

RX1

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TESTING DISTRIBUTOR TERMINAL INSULATION

Ohmmeter Tester Switch to RX1. Test Prod

connection as shown.

If contact point opens hand of the meter remain

infinity. ∞

Note: If hand move to zero O the insulation of the

terminal is broken.
RX1

Ohmmeter Tester Switch to RX1 Test Prod

connection as shown.

If contact point close. Hand of the meter will move

from infinity ∞ to zero O.

Note: The condition is normal.

RX1

b. Mechanical Inspection and repair procedures

Distributor Cap

Inspect for cracks, carbon tracks, burnt or corroded

terminals, and check center contact for wear.

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Distributor Rotor

Inspect for cracks, carbon tracks, burnt or corroded

terminals.

Breaker Plate

Check breaker plate for smooth rotation.

Governor weights and pin

Check the fitting portions of governor weights with

support pins for binding.

Vacuum Advancer Diaphragm

Suck the tube with mouth. The diaphragm should

move.

Note: If it does not move, replace the diaphram.

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Cam and Shaft

Inspect cam for wear, damage, and fit between cam

and shaft.

Governor Shaft and Housing

1. Check shaft thrust clearance.

Thrust clearance 0.15-0.5mm
(0.006-0.020in)

2. Remove Gear and Pin

Grind off the pin end, then remove the pin

and gear.

3. Inspect governor shaft for wear and

damage.

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4. Inspect housing bushings, and O ring for

wear, deformation, and damage.

5. Assemble washers in order as shown.

6. Assemble washers and gear in order as

shown and check thrust clearance. If it
exceeds specified value, adjust the
clearance with steel washer.

7. Peen both pin ends with a vise Inspect for the

following Items. Clean or replace plugs if
necessary.

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1. Cracks or damages in the threads or

insulator.
2. Damaged or deteriorated gaskets.

3. Wear on the electrodes.

4. Burnt condition of electrode and amount of

carbon deposit.

Check the plug gap with plug gap gauge. If not to

specified value, adjust by bending the ground
(outer) electrode.

Spark plug 0.8 mm (0.031in) for Japan

1.0 mm (0.039in) for USA

Refer Manual

c. Installation and adjustment of distributor assembly components

procedures;

Install governor springs in the direction as shown.

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Install breaker points and adjust the gap.

Point gap 0.45mm (0.018in)

Set the octane selector at standard line.

B. Diagnosing Non-Electronic Ignition Component

1. Causes of Ignition Failures

Ignition failure results from normal wear of the contact points,

sparkplugs, and other components. Ignition failure can be
classified under three headings.

a. Loss of energy in the primary circuit due to defective.

a. Resistance in the primary circuit due to defective leads,

bad connections, burned distributor contact points or
switch, or open coil primary.
b. Points not properly set.
c. Discharged battery or defective alternator.
d. Defective condenser (shorted, low insulation resistance,
high series resistance).
e. Grounded primary circuit in coil, wiring, or distributor.
b. Loss of energy in the secondary circuit.

a. Plugs fouled, broken, or out of adjustment.

b. Defective high-voltage wiring, which allows high voltage
leaks.

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c. High-voltage leakage across coil head, distributor cap, or

rotor.
d. Defective connections in high-voltage circuits.
e. Defective ignition coil
c. Out of time

a. Timing not set properly

b. Distributor bearing or shaft worn, or shaft bent.
c. Vacuum advance defective.
d. Centrifugal advance defective.
e. Pre-ignition, due to plugs of wrong heat range, fouled
plugs. Etc.

2. Quick checks of Ignition System.

a. Engine does not run. If the engine cranks at normal speed but
does not start, the trouble could be in either the ignition or the
fuel system. To check the ignition system, disconnect the lead
from one spark plug (or from the center distributor-cap terminal).
Use insulated pliers to hold it about 3/16 inch [4.76 mm] from the
engine block. Crank the engine. If a good spark occurs, chances
are that the ignition system is in reasonable condition (although
the timing could be off). If no spark occurs, check the ignition
system further.

Connect a test ammeter into the ignition-coil primary circuit,

and watch it while cranking the engine. If there is a small, steady
reading that fluctuates somewhat, the primary circuit is probably
all right. The trouble is probably a defective coil secondary or
secondary leads, a defective condenser, or high-voltage leakage
across the cap, rotor, or coil head.

If the ammeter shows a fairly high a steady reading:

1. The contact points are out of adjustment.

2. The condenser is shorted.
3. The coil primary circuit is grounded.
If there is no ammeter reading, the primary circuit is open.
This could be due to out-of-adjustment contact points, a loose
connection, defective wiring or switch, or an open coil primary
winding.

b. Engine misses. Missing is caused by such defects in the

ignition system as:

a. Worn or out-of-adjustment contact points.

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b. Defective condenser.
c. Centrifugal or vacuum advance malfunctioning.
d. Defective secondary wiring.
e. Defective ignition coil.
f. Poor connections.
g. High-voltage leakage across ignition-coil head, rotor, or
cap.
h. Defective spark plugs.

The wrong ignition coil for the engine, or reversed connection

to the ignition coil, may also cause misfiring. Putting a battery in
backwards can also cause misfiring, because this also reverses the
polarity of the coil.

c. Overheating and Spark. These conditions may be caused by

Improper Ignition Timing.

3. Ignition Troubles Various troubles that will occur mostly to the

NON-ELECTRONIC IGNITION SYSTEM COMPONENT.

a. Burned or oxidized contact points. It is normal for ignition-

distributor contact points gradually to burn away over a long
period of time. Rapid burning or oxidizing of the points may be due
to several conditions.

 Excessive resistance in the condenser circuit caused by

high series resistance in the condenser or by a loose
mounting or connection.
 High voltage produces by a high-voltage-regulator setting.
 Dwell angle is too large (point opening too small). If the
points, are too closed it will burned rapidly.
 Weak spring tension that causes the contact points to
bounce and arc.
 Oil or crankcase vapors entering the distributor housing are
deposited on the pint surfaces, causing them to burn
rapidly. A glance at the breaker plate usually discloses this
condition. It causes a black smudge on the breaker plate
under the points. Clogged engine crankcase PCV valves or
hoses and worn distributor bearings can produce this
trouble.
b. Sooty, burned, or cracked spark-plug insulator. Spark plugs
may fail for a variety of reasons. Spark-plug manufacturers
usually recommend replacement of spark plugs at 10,000 mile
[16,090-km] intervals. This will help prevent failure and maintain
the engine at food operating efficiency. One cause of spark plug

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trouble is the installation of plugs o f the wiring heat caused by

careless installation of the plug or by careless adjustment of the
plug gap.

Spark plug visual check

Condition is good if none of the following

defects are present.

1. Cracks or damages in the threads or

insulator.
2. Wear on the electrodes.
3. Damaged or deteriorated gaskets.
4. Burnt condition of electrode and
undesirable carbon deposit.

C. Safety Measures in Repairing Ignition Component Parts.

1. In pulling out the high tension cord from the

spark plug, grip it properly the end of plug cord
then, pull suddenly the cable.

2. Match 15 mark with stopper, fit on the cam and

tighten with screw.

3. Remove with care the high tension cable by

way of pulling the rubber boat.

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4. Do not bend cords that will cause the

conductor be broken.

5. Used insulated pliers or non-conductive pliers in

conducting spark test for ground.

6. Wires, Cord, Cables, Resistance, Capacitance,

Fuses and switches for shorts, Ground, open
wrenches and continuity as well.

7. Do not use any kind of cleaning solvents

for cleaning the spark plugs. Use only
the recommended spark plug cleaner.

Cleaning

1. Do not use spark plug cleaner longer

than necessary.
2. Blow off cleaning compound and
carbon on the threads thoroughly
with air.
3. Clean off dirt from the outer surface
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ASSESSMENT PERFORMANCE

LO 8. Repair non-electronic ignition system and/ or component

Workmanship/Performance Points

A. Repaired, maintained and serviced safely the 100

ignition system parts and components.

 With 95-100% standard of specifications.

 90-94% standard of specifications.

 85-89% standard of specifications.

 80-84% standard of specifications.

 75-79% standard of specifications.

Total=100

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Answer Key

LO1

1. contact point
2. breaker point type
3. rotor
4. ignition switch
5. ignition resistor
6. distributor
7. breaker less type
8. ignition coil
9. condenser
10. spark plugs

LO3

1. negative terminal
2. oil in the coil
3. soft iron core
4. primary coil winding
5. secondary coil winding

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ACKNOWLEDGMENT

Copyright Department of Education 2008

First Published May 2008

This draft was prepared at the Competency-Based Learning Materials

Development Workshop conducted at the Development of the Philippines on
May 5-10, 2008.

This learning instrument was developed by the following personnel:

Technology Teachers:

TEAM LEADER: GEORGE CALLANTA

Members : ROBERT DOMINGO

JOHN DIEGO

LINO OLIT

ROMEO IBLOGUIN

NELSON SENEDO

ENGLISH : BELEN TADO

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Facilitator: Beatriz Adriano

This work was produced with funding provided by the Department of

Education.

REFERENCES AND FURTHER READING:

Modern Automotive Service and System

James E. Duffy

Basic Automotive Service and System

Jay Webster

Automotive Mechanics
10th Edition

William Crouse and Donald Anglin

Manufacturer’s Manual
Toyota Corporation

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