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NCII
Checking Ignition System
HOW TO USE THIS COMPETENCY BASED LEARNING
MATERIAL
Welcome to the Module on Checking Ignition System. This module contains training
materials and activities for you to complete.
The unit of competency Checking Ignition System contains the knowledge, skills and
attitudes required for Automotive Servicing. This is one of the common modules for National
Certificate level II (NC II). You are required to go through a series of learning activities in
order to complete each learning outcome of the module. In each learning outcome there are
Information Sheets and Resource Sheets and Reference Materials for further reading to help
you better understand the required activities. Follow these activities and answer the self-
check at the end of each learning outcome. You may tear a blank answer sheet at the end of
each module to reflect your answers for each self-check. If you have questions, please dont
hesitate to ask your teacher for assistance.
Your facilitator will always be available to assist you during the training.
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 dont 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 Learners 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.
Automotive Servicing NC II
LIST OF COMPETENCIES
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.
triggering test while engine not cranking or running. Procedures in checking ignition
coil resistance.
adjusting contact point when distributor assembly removed from engine. Procedures
initial ignition timing. Procedures in performing the setting base ignition timing.
1. Ohm unit of measure for resistance. One ohm is the resistance of the
circuit.
3. Ground the common negative connection of the vertical system that is the
5. Ground side the portion of the circuit that is from the load component to the
6. Ignition the action of the spark in staring the burning of the compressed air-
7. Ignition advance the moving forward, in time, of the ignition spark relative
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.
advances and retard ignition timing through the centrifugal force resulting from
10. Condenser in the ignition system, a device that is also called a apacitor,
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
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
15. Arcing name given to the spark that jumps the air gap between two electric
conductors.
cam rotation that the points stay closed before they open again. The length of
17. Ignition resistor a resistance connected into the ignition primary circuit to
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.
Program/Course : Automotive Servicing NC II
ASSESSMENT CRITERIA:
procedure.
standard procedure.
Resources
Manufacturers Manual
Toyota Corporation
LEARNING ACTIVITIES:
components.
INFORMATION SHEET 1
The ignition system feeds high voltage surge to the spark plugs at proper
1. It must supply an electric spark with sufficient heat in order to ignite the air
2. It must maintain the spark long enough to permit the combustion of all fuel
3. It must draw the spark to each cylinder combustion can begin at specific time
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.
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
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
1. Battery supplies current to starter in order to crank the engine for operation.
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.
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
7. Contact Point the point in the distributor that opens & closes the primary
parts.
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.
circuits.
1 Battery
2 Ignition Switch
5 Condenser
6 Contact Point
7 Ground
1. Ignition coil
2. Secondary winding
3. Distributor cap
4. Rotor
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.
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.
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
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.
SELF-CHECK
Direction: Identify and fill-in the blanks with the correct answer. Write
your answers on a separate sheet.
ASSESSMENT CRITERIA:
Resources
Manufacturers Manual
Toyota Corporation
LEARNING ACTIVITIES
LO2.
OPERATION SHEET 1
Conditions:
Rug cloth
Sand paper
Tools
Screw Driver
Feeler Gauge
Equipment
Engine
Battery Charger
Mock up
Procedure:
Conditions:
Rug cloth
Sandpaper
Functional battery
Tools:
Equipment
Functional vehicle
Battery charger
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.
Conditions:
Rug cloth
Sandpaper
Functional battery
Tools
Insulated/nonconductive pliers
Equipment
Functional vehicle
Battery charger
5. If spark does not occur, check contact point, condenser, ignition coil,
and insulator in the primary lead.
SAFETY MEASURES IN SPARK TEST/TRIGGERING TEST.
The patterns show different troubles that occur in the ignition system.
The pattern of any cylinders 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 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
Program/Course : Automotive Servicing NC I
ASSESSMENT CRITERIA:
Resources
Manufacturers Manual
Toyota Corporation
Topic 1. FUNCTIONS OF IGNITION COIL
1. Soft iron core is the center of the Ignition coil, a laminated soft iron or
steel.
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).
Self-check
Conditions:
Ball pen/pencil
Bond paper
Tools
Pliers
VOM
Multi tester
Equipment
Engine mock-up
ASSESSMENT CRITERIA:
Resources
Manufacturers Manual
Toyota Corporation
OPERATION SHEET No. 4
Conditions:
Bond paper
Tools:
Box wrench
Screw driver
VOM tester
Multi-tester
Screw drive
Equipment:
Ignition mock-up
Engine mock-up
ASSESSMENT CRITERIA:
Resources
Manufacturers Manual
Toyota Corporation
OPERATION SHEET No. 1
Conditions:
Sand paper
Rags
Grease
Tools
Equipment
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.
7. Test run then, proceed to next operation sheet.
Conditions:
Sand paper
Rags
Grease
Tools
Equipment
Ignition mock-up
Procedure in adjusting contact point when distributor assembly
remove from engine.
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.
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)
4. Do not use the car, if the contact breaker point is not exactly
6. Use the proper screw driver for right head of bolt screw.
ASSESSMENT CRITERIA:
1. Tools and ignition wiring materials are checked and evaluated per
standard specifications.
Resources
Manufacturers Manual
Toyota Corporation
OPERATION SHEET 1
Conditions
Soldering leads
Automotive wires
Wire terminals
Electrical tape
Tools:
Electrical pliers
Set of screwdriver
Wire stripper
Soldering iron
Equipment:
Engine mock-up
Vehicle
4. Test auto wire from Ignition of switch to positive terminal of coil, RX1,
hand move to infinity to near zero then its in proper.
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 its 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 its proper.
Conditions
Soldering leads
Automotive wires
Wire terminals
Electrical tape
Tools:
Electrical pliers
Set of screwdriver
Wire stripper
Soldering iron
Equipment:
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.
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).
If the results of this test show that the coil supply circuit is
operating properly then the coil should be tested.
OPERATION SHEET No. 3
Conditions:
Tools
Cutter pliers
Wires stripper
Soldering rod / Iron
Set of insulated pliers
Set of screw drivers
Equipment
Procedure:
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.
Note: See to it that engine and distributor assembly are set properly and
contact point adjusted to specified gap.
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.
3. Always shield the ignition circuit harness with electrical tape or flexible
hose wires if required.
ASSESSMENT CRITERIA:
Resources
Toyota Corporation
OPERATION SHEET No. 1
CONDITION:
Rags
White chalk
Tools
Box wrenches
Set of screw drivers
Equipment
Engine mock-up
Vehicle
Dwell meter
Tachometer
Note: Before installing distributor to the engine adjust the contact point
to the correct specified contact point gap or set point to specification.
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.
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.
Ignition Timing: Type initial setting in order the spark will reach spark
gap at the right time.
CONDITION:
Rags
White chalk
Tools
Box wrenches
Set of screw drivers
Equipment
Engine mock-up
Vehicle
Ignition timing light
Dwell meter
Tachometer
NOTE: Use a stroboscopic timing light to check the timing. Follow these
steps for ignition timing adjustment.
4. Aim the timing light marks at the timing indicator, and observe the
timing marks. Compare this reading to the manufacturers 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.
7. Connect the vacuum advance hose and any other connectors, hoses,
or components that were disconnected for the timing procedure.
9.
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 inperforming
the test.
5. See to it that the test probes of timing light and other connections are
tight, set and connected correctly.
Learning Outcome 8.
Repair Non-electronic Ignition System and/or Component
ASSESSMENT CRITERIA:
Resources
Automotive Mechanics, 10th edition
By: Crouse/ Anglin
Manufacturers Manual
Toyota Corporation
OPERATION SHEET No. 1
COMPONENT
CONDITION
Rags
Paint brush
Soldering lead
Wire
Fine sand paper
Tools
Equipment
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 d.cam 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.
TESTING CONDENSER
Distributor Cap
Distributor Rotor
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.
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.
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.
LO1
1. contact point
3. rotor
4. ignition switch
5. ignition resistor
6. distributor
8. ignition coil
9. condenser
LO3
1. negative terminal