Automotive Servicing NC 1 Service Automotive Battery Servicing Automotive Battery

Program / Course: Automotive Servicing NC 1
Unit of Competency Service Automotive Battery

Module Title Servicing Automotive Battery
INTRODUCTION
This module contains information and suggested learning activities on

Servicing Automotive Batteries. It includes instructions and procedure on
how to test automotive battery, remove and replace batteries, service and
charge batteries and jump start vehicle.
Completion of this module will help you understand the succeeding

module on Test and Repair Wiring/Lighting System.
This module consists of four (4) learning outcomes. Each learning

outcome contains learning activities with instruction sheets. Before you
follow the instruction, read the information sheets and answer the self-check
and activities provided to assess your competence by your teacher. He/she
will check if you have acquired the knowledge necessary to perform the skill
portion of the particular learning outcome.
SUMMARY OF LEARNING OUTCOMES
Upon completion of the module, you should be able to:
LO1. Test Automotive Battery;

LO2. Remove and Replace Batteries;
LO3. Service and Charge Batteries; and
LO4. Jump Start Vehicle
[Type text] SERVICING AUTOMOTIVE BATTERY Page 1

Pre-Test
LO 1. TEST AUTOMOTIVE BATTERY
Directions: Select the correct answer to each question and write the letter
on the blank provided for.
1. The battery in an electro chemical device, this means the battery

a. makes chemicals by electronic means
b. uses chemicals to provide electricity
c. has non-chemical plates
d. does not use an electrolyte
2. The battery performs the following EXCEPT

a. supplies current to crank the engine
b. supplies current when the charging system cannot handle the
lead
c. supplies current to the ignition system with the engine is off.
d. supplies current to the ECM while the engine is off
3. When working around the battery be sure to;

a. Disconnect the negative first
b. Disconnect the positive first
c. Never disconnect the terminals
d. A and B
4. A type of battery which do not have removable caps.

a. maintenance free battery
b. battery with caps
c. 3A battery
d. B and C
5. This type of hydrometer which is similar to ball type coolant
hydrometer.
a.) ball hydrometer
b.) flat hydrometer
c.) barometer
d.) A and B
6. A type of hydrometer which the state of charge marks on the float stem to
show electrolyte specific gravity.
a.) ball type hydrometer
b.) float hydrometer
c.) A and B
d.) None of the above
7. The indication if the battery is in full charge in using ball hydrometer.

a.) all balls float
b.) no balls float
c.) A and B
[Type the company

TEST AND REPAIR WIRING/LIGHTING SYSTEM-name] SERVICING
systemAUTOMOTIVE
| Servicing
Test electrical Automotive BATTERY
Battery
of open and short 2
circuit to
determine faults.
8. The more fully charge the battery is, the higher the float is indicating the
state of charge of.
a.) float hydrometer
b.) ball hydrometer
c.) A and B
d.) All of the above
9. The more balls float, the higher the state of charge is.
a.) ball hydrometer
b.) float hydrometer
c.) A and B
10. In disconnecting the battery the correct tools used are______.

a.) box wrench (12x13)
b.) open wrench
c.) battery pliers
d.) A and C
[Type the company

TEST AND REPAIR WIRING/LIGHTING SYSTEM-name] | Servicing
Test electrical Automotive
systemAUTOMOTIVE
SERVICING Battery
of open and short
BATTERY 3
circuit to
determine faults.
Program/Course: Automotive Servicing
Unit of Competency: Service Automotive Battery
Module Title: Servicing Automotive Battery
Learning Outcome 1: Test Automotive Battery
Introduction:
An automotive battery is a type of rechargeable battery that supplies

electric energy to an automobile. Usually this refers to an SLI battery
(starting, lighting, ignition) to power the starter motor, the lights, and the
ignition system of a vehicle’s engine. An automotive battery may also be a
traction battery used for the main power source of an electric vehicle
therefore; preventive maintenance procedures must be performed frequently
to avoid automobile malfunctions.
Assessment Criteria
1.Battery is tested to avoid damage to any workplace property or vehicle.
2. Battery is tested to avoid damage to any workplace property or vehicle.
3. Appropriate test equipment and instrument are selected.
4. Test Results are analyzed and interpreted.
5. Findings are reported to immediate supervisor/automotive instructor.
Definition of Terms
BATTERY CELL - the active unit of the battery
BATTERY HOLD DOWNS - brackets that secure the battery to the chassis of
the vehicle.
BATTERY LEAKAGE TEST - test used to determine if current is discharging

across the top of the battery fuse.
BATTERY TERMINAL TEST - test that checks for poor electrical

connections between the battery cables and terminals.
BATTERY TERMINALS - terminals at the battery to which the positive and

the negative battery cables are connected. The terminals maybe posts or
threaded insert.
BATTERY CHARGER - an equipment that is use to charge battery capacity

given in ampere hours.
ELECTROLYTE - Any solution that conducts an electric current. In a car

battery, (40% sulfuric acid and (60%) distilled water is the electrolyte. It
reacts with the battery's lead plates to produce voltage and current.
TEST AND REPAIR WIRING/LIGHTING SERVICING

[Type the company AUTOMOTIVE
SYSTEM-name] BATTERY-
| Servicing
Test electrical Test Automotive
systemAutomotive
of open Battery
Battery
and short 4
circuit to
determine faults.
INFORMATION SHEET No.1
TITLE: BATTERY CONSTRUCTION AND PRINCIPLE OF OPERATION
An automotive battery is a type of rechargeable battery that supplies

electric energy to an automobile. Usually this refers to an SLI battery
(starting, lighting, ignition) to power the starter motor, the lights, and the
ignition system of a vehicle’s engine. An automotive battery may also be a
traction battery used for the main power source of an electric vehicle.
Automotive SLI batteries are usually lead-acid type, and are made of
six galvanic cells in series to provide a 12 volt system. Each cell provides 2.1
volts for a total of 12.6 volt at full charge. Heavy vehicles such as highway
trucks or tractors, often equipped with Diesel engines, may have two
batteries in series for a 24 volt system, or may have parallel strings of
batteries.
Lead-acid batteries are made up of plates of lead and separate plates

of lead dioxide, which are submerged into an electrolyte solution of about
35% sulfuric acid and 65% water. This causes a chemical reaction that
releases electrons, allowing them to flow through conductors to produce
electricity. As the battery discharges, the acid of the electrolyte reacts with
the materials of the plates, changing their surface to lead sulfate. When the
battery is recharged, the chemical reaction is reversed: the lead sulfate
reforms into lead oxide and lead. With the plates restored to their original
condition, the process may now be repeated.
Battery recycling of automotive batteries reduces resources required

for manufacture of new batteries and diverts toxic lead from landfills or
improper disposal.
TYPES OF BATTERY
Below are two types of automotive batteries. On the left, caps can be
removed to check the battery state of charge and to add water if needed. On
the right, a "Maintenance Free" battery (lead acid or alkaline) is sealed and
do not require topping up with distilled water because the electrolyte level
does not change because they do not produce much gas. The charge
indicator in the top shows the state of change.

| Servicing
Test electrical ofTest Automotive
systemAutomotive
open Battery
Battery
and short 5
circuit to
determine faults.
Fig. 1 Two types of Automotive Battery (left) ordinary wet
battery (right) maintenance free battery.
(Courtesy of www. goggle. com.ph.)
BATTERY CONSTRUCTION
The battery case is molded plastic. The plates are molded to plate
straps to form plate groups. To make a battery cell, a positive plate group fits
into a negative plate group. Porous separators are placed between the plates.
This prevents positive and negative plates from touching while allowing
electrolyte to circulate between the plates. The assembly of plate groups and
separators is an element. The elements fit into compartments in the battery
case to favor cells. Heavy leads connectors attach to the cell terminals and
connect the cells in series. A plastic cover forms the top of the battery.
Some batteries have openings in the cover from which filler plugs or vent
caps are removed to add water. Maintenance free batteries do not have
removable caps.
Fig. 2 Parts of Automotive Battery. (Courtesy of Toyota Motor

Sales, U.S.A. ,Inc.)

[Type the company
SYSTEM-name]AUTOMOTIVE
Test BATTERY-
| Servicing
electrical Test Automotive
systemAutomotive
of open Battery
Battery
and short 6
circuit to
determine faults.
WORKING SAFELY AROUND BATTERIES
Follow the safety cautions listed below when working with batteries,
testing, or charging battery.
1. The sulfuric acid in the electrolyte is very corrosive. It will make

holes in cloth. It can cause serious burns if it sets on your skin.
It can make you blind if it gets into your eyes. Wear eye protector
when working with testing or charging a battery. If you get battery
acid on your skin, flush it off at once with water. If you get battery
acid (electrolyte) into your eyes, flush them with water at once
then go to the school nurse, doctor or hospital emergency room.
2. When disconnecting a battery, always disconnect the negative or

ground cable first.
3. If the battery has vent caps, make sure the vent holes are open
before charging. Cover the caps with a damp cloth. Discard the
cloth after the battery is charged.
4. Never lean over a changing battery.
5. Do not charge a frozen battery for maintenance-free battery

because when the charge indicator dot shows light yellow or clear
the battery could explode.
SERVICING
[Type the company
TEST AND REPAIR WIRING/LIGHTING AUTOMOTIVE
| Servicing
Test electrical of Test
openAutomotive
systemAutomotive Battery
Battery
and short 7
circuit to
determine faults.
SELF – CHECK No.1
Directions: Select the correct answer to each question and write the letter
on the blank provided for.
________1. The battery in an electro chemical device, this means the battery
e. makes chemicals by electronic means
f. uses chemicals to provide electricity
g. has non-chemical plates
h. does not use an electrolyte
________2. The battery performs the following EXCEPT

e. supplies current to crank the engine
f. supplies current when the charging system cannot handle the
lead
g. supplies current to the ignition system with the engine is off.
h. supplies current to the ECM while the engine is off
________3. When working around the battery be sure to;

a. Disconnect the negative first
b. Disconnect the positive first
c. Never disconnect the terminals
d. A and B
________4. A type of battery which do not have removable caps.

e. maintenance free battery
f. battery with caps
g. 3A battery
h. B and C
Resources
 Auto. Mechanics 10th Edition by Crouse/Anglin, Glencoe Division of
Macmillian/Mc Graw-Hill School Publishing Company, USA 1993

 Automotive Electricity, Electronics and Computer Controls By: Barry
Hollembeak, Delmar Cengage Learning, USA 1998
 http://www.google.com.ph
 http://www.autoshop101.com
 http://www.wikihow.com.
 http://auto.howstuffworks.com
[Type the company

TEST AND REPAIR WIRING/LIGHTING SYSTEM-name]
SERVICING Test | Servicing
electrical
AUTOMOTIVE systemAutomotive
of open
BATTERY- Battery
and short
Test Automotive Battery 8
circuit to
determine faults.
INFORMATION SHEET No. 2
TITLE: TESTING THE BATTERY
TOPIC: TWO WAYS OF TESTING THE BATTERY
Batteries are tested in two ways, for state of charge and for
performance. The state of change of a vent – cap battery is determined with
the hydrometer. The built-in battery provides this information. The battery
load test indicates if the battery is capable of performing its job.
HYDROMETER TEST
Two types of Hydrometer:
1. Ball Hydrometer
2. Float Hydrometer
Ball hydrometer is similar to the ball type coolant hydrometer. Put

the rubber tube into the electrolyte, then squeeze and release the bulb.
Electrolyte will be drawn into the tube. If all balls float, the battery is fully
charged. If none, the battery is discharged. The more balls that floats, the
higher the battery state of charge.
The float hydrometer is used in the same way it will float in the
electrolyte drawn in. Marks on the float stem show the electrolyte specific
gravity. This indicates the state of charge, the more fully-charged the
battery, the higher the float.
PRECAUTION: Do not drip electrolyte on the car or on yourself.

Electrolyte will damage the paint and your clothes.
SPECIFIC GRAVITY
STAGE OF CHARGE
1.265 -1.299 Fully charged battery

1.235 -1.265 Three – fourths charged
1.205 -1.235 One-half charged
1.170 -1.205 One-fourth charged
1.140-1.170 Barely Operative
1.110-1.140 Completely discharged
Relationship between specific gravity and state of charge.

| Servicing
systemAutomotive
of open Battery
Battery
and short 9
circuit to
determine faults.
SPECIFIC GRAVITY STAGE OF CHARGE
1.100 18 [-8.2]
1.160 1 [-7.2]
1.200 -17 [-27.3]
1.220 -31 [-35]
1.260 -75 [-59.4]
1.300 -95 [-70.5]
Specific gravities and freezing temperatures for battery electrolyte.

| Servicing
systemAutomotive
of open Battery
Battery
and short 10
circuit to
determine faults.
SELF- CHECK No. 2
Directions: On the blank provided for, write the correct letter of your
choice.
_________1. This type of hydrometer which is similar to ball type coolant

hydrometer.
a.) ball hydrometer
b.) flat hydrometer
c.) barometer
d.) A and B
_________2. A type of hydrometer which the state of charge marks on the
float stem to show electrolyte specific gravity.
e.) ball type hydrometer
f.) float hydrometer
g.) A and B
h.) None of the above
_________3. The indication if the battery is in full charge in using ball
hydrometer.
e.) all balls float
f.) no balls float
g.) A and B
_________4. The more fully charge the battery is, the higher the float is
indicating the state of charge of.
e.) float hydrometer
f.) ball hydrometer
g.) A and B
h.) All of the above
_________5. The more balls float, the higher the state of charge is.
e.) ball hydrometer
f.) float hydrometer
g.) A and B
Resources


[Type the company
SYSTEM-name]AUTOMOTIVE BATTERY-
| Servicing
systemAutomotive
of open Battery
Battery
and short 11
circuit to
determine faults.
OPERATION SHEET No. 1
TITLE: TESTING AUTOMOTIVE BATTERY USING

HYDROMETER
Procedure:
Your teacher will discuss the procedure with you with the aid of
pictures and actual battery.
1. Remove all battery vent caps.

2. Check the electrolyte level, it must be high enough to withdraw the
correct amount of solution into the hydrometer.
3. Squeeze the bulb and place the pick-up tube into the electrolyte of
a cell.
4. Slowly release the bulb. Draw in enough solution until the float is
freely suspended in the barrel. Hold the hydrometer in vertical
position.
5. Read the electrolyte level on eye level as shown in the figure below.
6. List the test result.

[Type the company
SYSTEM-name]AUTOMOTIVE
Test BATTERY-
| Servicing
electrical Test Automotive
systemAutomotive
of open Battery
Battery
and short 12
circuit to
determine faults.
Fig. 3 Checking specific gravity of electrolyte using float
hydrometer. (Courtesy of Toyota Motor Sales, U.S.A. ,Inc.
and www. goggle)
[Type the company

electrical
of open
BATTERY- Battery
and short
circuit to
determine faults.
ASSESSMENT PERFORMANCE
LO 2. Test Automotive battery
Workmanship/Performance Points
A. Quality of Work with Application of Safety Measures
35 - Exemplary
25 - Adequate
10 – Needs improvement
B. Accuracy of Performance under specified time limit
30 – All work is complete and correct
20 – Minor mistake or error
10 – Some of the work maybe incomplete/misdirected
C. Proper use of tools/equipment with safety measures
35 – Select/use properly of tools/equipment
25 – Wrong handling of tools
10 – Tools are not suitable for the job

TOTAL SCORES
Resources

[Type the company

SERVICING | Servicing
Test electrical
of open
BATTERY- Battery
and short
circuit to
determine faults.
Learning Outcome 2: Remove and Replace Batteries
Introduction:
Automobile battery’s service life ranges from two years to five years
depending on the type and the usage of the battery. During battery
replacement, correct procedures must be observed to avoid damage to the
electronics components of the automobile.
Assessment Criteria
1. Battery is removed and replaced to avoid damage to any work place property or
vehicle.
2. Appropriate tools and equipment are selected.
3. Actions are taken to prevent loss of vehicles if electronic memory is applicable
Definition of Terms
the vehicle.



threaded insert.


SERVICING
[Type the
TEST AND REPAIR WIRING/LIGHTINGcompany AUTOMOTIVE
SYSTEM- name] BATTERY-
| Servicing
Test electrical Remove
system andand
Automotive
of open Replace Batteries
Battery
short 15
circuit to
determine faults.
TITLE: CORRECT PROCEDURES IN CONNECTING/DISCONNECTING A

BATTERY.
TOPIC 1:
Connect a memory holder (a 9-volt battery and adaptor) to the
cigarette lighter to keep the volatile memories alive while the battery is
disconnected from the vehicle. Follow the manufacturer’s instruction to
avoid overloading the 9-volt battery.
Disconnect the ground cable clamp; use a box wrench or battery

pliers. Loosen the clamp ball then pull the clamp from the terminal. Do not
use other pliers or an open-end wrench. If the clamp sticks, use a battery
clamp puller, do not pry the clamp off with screw driver or pry bar. You
might break the cover. Next, disconnect the insulated cable from the battery.
Clean the terminals and cables clamp. Detach the spring ring cable clamp
squeeze a part the ends of the rings with pliers. Next, disconnect the
insulated cable from the battery. Clean the terminals and cable clamps.
Loosen the hold-down clamps and remove the battery. Clean the battery tray
and hold-down clamps if the parts are metal, clean them with stiff brush in
a solution of baking soda and water. Open the water drain holes in the
bottom of the tray, after rinsing and drying, paint the tray and other metal
parts with acid resistant paint.
When installing the battery, do not reverse the terminal connections.

Reconnect the insulated cable first then the ground cable – tighten the hold
down clamps, do not over-tighten.
BE CAREFUL: Never install a battery backward. The reversed

polarity may cause high current flow which will damage electrical
components.
Fig. 4 Loosen the clamp bolt using open end wrench

(Courtesy of http://www.google.com.ph.)
[Type the
TEST AND REPAIR WIRING/LIGHTINGcompany
SYSTEM-
SERVICING name]
AUTOMOTIVE | Servicing
Test electrical system
BATTERY- Automotive
of open
Remove and and Battery
short
Replace Batteries 16
circuit to
determine faults.
SELF - CHECK No. 1
TITLE : REMOVING AND REPLACING BATTERY
Directions: On the blank provided for write the correct letter of your choice.
______1. In disconnecting the battery the correct tools used are______.

e.) box wrench (12x13)
f.) open wrench
g.) battery pliers
h.) A and C
______2. The tool to be used to clamp the battery is _______.

a.) battery clamp puller
b.) screw driver
c.) pry bar
d.) B and C
______3. In cleaning the corrosion and foreign materials on the battery tray
you must clean with___________.
a.) brush with soda and water
b.) oil
c.) gasoline
d.) none of the above
______4. To disconnect the battery first ________.

a.) remove the vent plug
b.) disconnect the insulated cable from the battery
c.) disconnect the ground cable from the battery
d.) put the transmission in park or reverse
Resources

SERVICING
[Type the
| Servicing
system andand
Replace
Automotive
of open Batteries
Battery
short 17
circuit to
determine faults.
OPERATION SHEET No.1
TITLE: REMOVING AND REPLACING BATTERY
Conditions
Supplies and materials
 Apron
 Safety goggles
 Gloves
 Soda solution
 Battery lithium grease
Tools
 Box wrench(12x13)
 Screw drivers
 Lifting clamp
 Wire brush
Equipment
 Engine mock-up
 Vehicle
 New battery
PROCEDURE:
1. Make sure the battery needs to be replaced. You don't want to spend
time and money installing a new battery if the problem is not with the
battery itself. Look for sulfate build-up in the form of a whitish or blue
residue around the terminal--removing this can sometimes solve
issues with a faulty battery. DO NOT TOUCH THIS POWDER WITH
YOUR BARE HANDS, as it can often contain dried out sulfuric acid
which will begin to corrode your skin. Also verify that the battery has
been given the chance to recharge properly by driving constantly for
30 minutes (with minimal electrical usage, including the air
conditioner). Finally, check the alternator. Some cars also have a
battery meter, with the engine running, the alternator usually
maintains a charge close to 13.8-14.2 volts in a properly functioning
charging system. The battery should have 12.4-12.8 volts with the
engine off, and with no accessory load. If you've determined that your
SERVICING
[Type the
| Servicing
system andand
Automotive
Battery
short 18
circuit to
determine faults.
battery problems can't be attributed to any of the above, or if you see
cracks or oozing liquid on the top of the battery, it's probably safe to
proceed with replacement.
2. Buy the correct replacement battery. Find out what kind of battery
you're replacing (Or the dimensions of your battery) and bring this,
your cars make model, and engine size information to a local auto
parts store. This is important because automotive batteries vary in
size, and electrical capacity and you will want to purchase a battery
which matches the size of the battery tray/support in your vehicle.
3. Set up a secure working environment - Park on a flat, level surface at

a safe distance from traffic sparks or open flames. Put on the parking
brake. Don't smoke, and make sure any smokers in proximity to the
working area know not to smoke as well. Remember that electricity is
not the only danger; batteries contain a sulfuric acid electrolyte
solution, which is highly corrosive (i.e. can burn your skin) and
produces a flammable gas. Put on gloves and safety goggles.
Fig. 5: Vehicle park on a flat, level surface at a safe distance from

traffic sparks or open flames. (Courtesy of
http://www.wikihow.com/Change-a-Car-Battery)
4. Remove the cigarette lighter and plug the memory keeper into the
lighter socket. A Complementary metal–oxide–semiconductor (CMOS)
will keep the PIN codes and settings for radios and navigation systems
from getting erased when you disconnect the battery. If you don't have
a memory keeper make sure you have all the PINs for your electronic
equipment before you start. You may wish to check your car manual
to see what devices may be affected.
SERVICING
[Type the
TEST AND REPAIR WIRING/LIGHTINGcompanyAUTOMOTIVE
| Servicing
system and and
Replace
Automotive
of open Batteries
Battery
short 19
circuit to
determine faults.
5. Open the hood - After opening your hood, use the prop rod to keep
your hood open (Most newer cars have hoods that hold themselves up.
Fig. 6: Opening the hood of the vehicle. (Courtesy of

6. Locate the battery - The battery should be located in an accessible

part on either side of the car's frame. The battery is a rectangular box
with two cables attached to it. Some European cars (BMW's, new
Benz-Chrystler's) have the battery under the metting in the trunk, or
inside the fender of the wheel well (The latter is often very difficult to
remove).
Fig.7: Location of battery in a vehicle. (Courtesy of

7. Identify battery terminals - Locate the positive and the negative

terminals of the old car battery. The positive terminal will have a plus
sign and the negative terminal will have a minus sign.
[Type the
SYSTEM-
SERVICING name]
BATTERY- Automotive
of open
short
circuit to
determine faults.
8. Disconnect the negative terminal - Loosen the negative cable clamp
with a wrench (Usually 8mm or 10mm) and slide it off of the terminal.
If the cables are unmarked, label them so that they don't get mixed up
(otherwise you may ruin your car's electric system later on). It is also
important that you disconnect the negative terminal socket before the
positive terminal socket. Otherwise, you may short circuit the positive
terminal to a grounded part of the car.
Fig.8: Disconnect the negative terminal first. (Courtesy of

9. Disconnect the positive terminal.
10. Remove the car battery - Unfasten the battery holder and remove
any screws, clamps or bars holding the battery in place. Carefully lift
the battery out of the car. Remember that a battery can weigh 30 to
60 pounds, or 13.5 to 27 kilos, so if you have any back problems, get
a helping hand.
Fig. 9: Removing the car battery. (Courtesy of

SERVICING AUTOMOTIVE BATTERY- Remove and Replace Batteries
[Type the company

TEST AND REPAIR WIRING/LIGHTING SYSTEM-name] | Servicing
Test electrical systemAutomotive Battery
of open and short 21
circuit to
determine faults.
11. Clean the terminal clamps and the battery tray. You can use a
baking soda solution and a wire brush. If there's any severe corrosion,
consider replacement by a mechanic. Otherwise, let the area dry
before moving onto the next step.
12. Replace the battery - Place the new battery where you just took the
old battery out, with the positive and negative terminals on the correct
sides. Connect all the screws, clamps or bars that may hold the
battery in place.
Fig. 10: Replacing the battery. (Courtesy of

13. Reconnect the positive terminal - Tighten the clamps using a

wrench.
Fig. 11: Reconnecting the positive terminal first. (Courtesy of

[Type the
SYSTEM-
SERVICING name]
BATTERY- Automotive
of open
Remove andand Battery
short
circuit to
determine faults.
14. Reconnect the negative terminal - Tighten the clamp with the
wrench.
15. Apply battery lithium grease - Spray the terminals with lithium
grease to prevent corrosion.
Fig. 12: Applying battery lithium grease to prevent corrosion. (Courtesy of

16. Close the hood - Shut the hood of your car firmly and start
your car. Check that all the electronic devices are working properly.
Fig. 13 Close the hood of the vehicle. (Courtesy of

SERVICING
[Type the
| Servicing
system andand
Automotive
Battery
short 23
circuit to
determine faults.
17. Dispose of the used battery at service garages, auto supply
stores, and recycling centers. There may be a small fee for the
service, but throwing the battery away as normal garbage is not an
option.
In the US, most battery retailers charge a deposit on the battery; this
will be refunded with the return of an old battery.
PRECAUTIONS: Wear protective clothing or gloves to prevent acid

spills onto your hands.
[Type the
SYSTEM-
SERVICING name]
BATTERY- Automotive
of open
short
circuit to
determine faults.
LO 4. Jump start vehicle
35 - Exemplary
25 - Adequate
TOTAL SCORES
Resources

[Type the
SYSTEM-
SERVICING name]
BATTERY- Automotive
of open
short
circuit to
determine faults.
Unit of Competency Service Automotive Battery
Module Title Servicing Automotive Battery
Learning Outcome 3: Service and Charge Battery
Introduction:
To prolong the service life of the battery and to make sure that the
battery is always in good working condition, battery servicing must be
performed.
Assessment Criteria
1. Battery is charged using the appropriate battery charger.
2. Electrolyte level is checked and tapped.
3. Battery and its terminals are cleaned
Definition of Terms
the vehicle.



threaded insert.


[TypeSERVICING
the company
TEST AND REPAIR WIRING/LIGHTING SYSTEM- name] | Servicing
Test electrical
AUTOMOTIVE BATTERY- Service
system and Charge
Automotive
of open Battery
Battery
and short 26
circuit to
determine faults.
TITLE: CHARGING BATTERIES
TOPIC 1. METHODS OF BATTERY CHARGING:
A battery in good condition may occasionally fail to crank the engine

fast enough to make it start. In such cases, the battery may require charging.
All battery chargers operate on the battery to reverse the chemical action in
the cells. Never connect or disconnect leads with the charger turned ON.
Follow the battery charger manufacturer’s instruction. And, do not attempt
to charge a battery with frozen electrolyte.
When using a battery charger, always disconnect the battery ground
cable first. This will minimize the possibility of damage to the alternator or to
electronic components. Otherwise, use a charger with polarity protection
that prevents reverse charging.
The battery can be considered fully charged when all cells are gassing
freely and when there is no change in specific gravity readings for more than
one hour.
Fig. 14: A battery being charge (Courtesy of Toyota Motor Sales, U.S.A.,Inc.)
A. Fast Charging: Fast charging is used to charge the battery for a short
period of time with a high rate of current. Fast charging may shorten
battery life. If time allows, slow charging is preferred. Some low
maintenance batteries be fast charged.
[TypeSERVICING
the company
Test electrical
system and Charge
Automotive
of open Battery
Battery
and short 27
circuit to
determine faults.
1. Preparation for charging.
o Clean dirt, dust, or corrosion of the battery; if necessary, clean
the terminals.
o Check the electrolyte level and add distilled water if needed.
o If the battery is to be charged while on the vehicle, be sure to
disconnect both (-) (+) terminals.
2. Determine the charging current and time for fast charging.

o Some chargers have a test device for determining the charging
current and required time.
o If charger does not have a test device, refer to the chart below
to determine current and time(Table 1).
3. Using the charger:

o Make sure that the main switch and timer switch are OFF and
the current adjust switch is at the minimum position.
o Connect the positive lead of the charger to the battery positive
terminal (+) and the negative lead of the charger to the negative
terminal (-).
o Connect the charger’s power cable to the electric outlet.
o Set the voltage switch to the correct battery voltage.
o Set the main switch at ON.
o Set the timer to the desired time and adjust the charging
current to the predetermined amperage.
4. After the timer is “off”, check the charged condition using a

voltmeter.
o Correct voltage: 12.6 volts or higher.
o If the voltage does not increase, or if gas is not emitted no
matter how long the battery is charged, there may be a problem
with the battery, such as an internal short.
5. When the voltage reaches the proper reading:

o Set the current adjust switch to minimum.
o Turn off the main switch of the charger.
o Disconnect the charger cables from the battery terminals.
o Wash the battery case to clean off the acid emitted.
Table 1. Showing typical charging rates for fully discharged batteries.
[TypeSERVICING
the company
Test electrical
system and Charge
Automotive
of open Battery
Battery
and short 28
circuit to
determine faults.
B. Slow Charging: High charging rates are not good for completely
charging a battery. To completely charge a battery, slow charging with a
low current is required. Slow charging procedures are the same as those
for fast charging, except for the following:
1. The maximum charging current should be less than 1 1/10th of the

battery capacity. For instance, a 40AH battery should be slow charged
at 4 amperes or less.
2. Set the charger switch to slow position (if provided).
3. Readjust the current control switch from time to time while charging.
4. As the battery gets near full charge, hydrogen gas is emitted. When
there is no further rise in battery voltage for more than one hour, the
battery is completely charge.
o Battery Voltage: 12.6 volts or higher
FACTORS AFFECTING CHARGING
Five factors affect charging by increasing its internal resistance and

CEMF (counter-electromotive force produced by the electrochemical reaction);
1. Temperature. As the temperature decreases the electrolyte resist

charging. A cold battery will take more time to charge; a warm battery,
less time. Never attempt to charge a frozen battery.
2. State of charge. The condition of the battery’s active materials will

affect charging. A battery that is severely discharge will have hard
sulfate crystals on its plates. The vehicle’s charging system may
charge at too high of a rate to remove such sulfates.
3. Plate area. Small plates are charged faster than large plates. When
sulfation covers most of the plate area, the charging system may not
be able to restore the battery.
4. Impurities. Dirt and other impurities in the electrolyte increase

charging difficulty.
5. Gassing. Hydrogen and oxygen bubbles form at the plates during

charging. As these bubble out, they wash away active material, cause
water loss, and increase charging difficulty.
[TypeSERVICING
the company
Test electrical
system and Charge
Automotive
of open Battery
Battery
and short 29
circuit to
determine faults.
Fig.15: Factors Affecting Charging(Courtesy of Toyota Motor Sales,
U.S.A.,Inc.)
[TypeSERVICING
the company
Test electrical
AUTOMOTIVE BATTERY-systemAutomotive
Service and Charge
of open Battery
Battery
and short 30
circuit to
determine faults.
SELF- CHECK No. 1
LO 3. SERVICE AND CHARGE BATTERY
Directions: On the blank before each number write the correct letter of
your choice.
________1 A method of charging the battery using low current for several
hours.
a.) slow charge
b.) fast charge
c.) A and B
________2.The presence of hydrogen and oxygen bubbles at the plate during
charging.
a.) gassing
b.) sulfation
c.) impurities
d.) A and B
________3. A method of battery charging for a short period of time with a high
rate of current.
a.) quick or fast charge
b.) slow charge
c.) A and B
________4.When charging the battery in a vehicle, first
a.) disconnect the ground cable
b.) disconnect the positive cable
c.) A and B
________5. The voltage for a completely charge battery is ______
a.) 10.2 volts
b.) 12.6 volts
c.) 20 volts
d.) All of these
Resources

[TypeSERVICING
the company
Test electrical
system and Charge
Automotive
of open Battery
Battery
and short 31
circuit to
determine faults.
Learning Outcome 4: Jump Start Vehicle
Introduction:
Jump starting is a process of starting the vehicle with a dead battery.

This is performed in a car instead of replacing with a new battery to have a
quick starting of the engine. This is much easier to do than to replace the
dead battery with a new unit or to recharge the battery that takes at least 2
hours to replace the used current from the dead battery. However, extra care
must be observed to avoid damaged to automobiles electronic and electrical
components.
Assessment Criteria
1. Vehicle is jump started to avoid damage to any workplace property or
vehicle.
2. Jumper leads are selected and used to ensure spark protection which is
employed when necessary.
3. Leads are connected /disconnected correctly according to sequence and
polarity.
Definition of Terms


threaded insert.


[Type the company

electrical
AUTOMOTIVE system Jump
Automotive
of open
BATTERY- Start
and Vehicle
Battery
short 32
circuit to
determine faults.
TITLE: JUMP STARTING A VEHICLE SAFELY
Conditions:
Supplies and Materials
 Correct size of cable wires
Tools
 Wrenches
 Pliers
Equipment
 Fully charge battery

 Vehicle
PROCEDURE
1. Verify that everything is off in the vehicle with the dead battery, i.e.
lights, ignition.
2. Use a vehicle with a good battery to power (or start) a vehicle with the
bad battery. Make sure the vehicles are not touching, but close
enough for the jumper cables to reach both batteries.
3. Identify the red positive terminals and black negative terminals on
both the batteries.
4. Make sure the vehicle with the good battery is running, then in the
following sequence, connect the jumper cables
5. Connect one of the red clips on the cables to the red positive terminal
on the dead battery.
6. Connect the other red clip on the jumper cables to the red positive
terminal of the good battery.
7. Connect the black clip to the black negative terminal on the good
battery.
8. Find a solid piece of metal underneath the hood of the dead vehicle to
act as a ground. Do not connect the last black clip to the black
negative terminal on the dead battery. A bracket or bolt can act as a
solid ground for the dead vehicle. You most likely will see a small
spark when this connection is made, do not be alarmed, this is
completion of the circuit.
[Type the company

electrical
of open
BATTERY- Jumpand Battery
short
Start Vehicle 33
circuit to
determine faults.
Figure: 16: showing steps and connection in jumpstarting a vehicle.
(Autoshop 101.com)
NOTE: Do not connect the negative jumper cable end to the

battery negative terminal. Doing so may create a spark that
will cause the battery to explode.
9. Wait a minute or two to give the dead battery a chance to charge. A

good way to check that this is working is to turn on the interior lights
of the dead vehicle.
10. Attempt to start the car with the dead battery. If it doesn’t start, try
two or three more times. If it still will not start, do not keep trying,
because you could burn out the ignition.
[Type the company

electrical
of open
short
Start Vehicle 34
circuit to
determine faults.
11. Remove all the cables the opposite way they were connected: black
clip off ground of dead car, black clip off the negative terminal of the
good battery, red clip off of positive terminal of dead battery, and red
clip off of positive terminal of good battery.
12. Let the car that had the dead battery run for a few minutes, and then
it is safe to drive.
CAUTION: Do not use more than 16 volts to jump start a vehicle

that is equipped with an engine control module (EICM). The excess
voltage may damage the electronic components of the vehicle.
[Type the company

electrical
of open
short
Start Vehicle 35
circuit to
determine faults.
35 – Exemplary
25 – Adequate
TOTAL SCORES
Resources

[Type the company

electrical
AUTOMOTIVE system Jump
Automotive
of open
BATTERY- Start
and Vehicle
Battery
short 36
circuit to
determine faults.
Program/Course: Automotive Servicing NC 1
Unit of Competency: Test and Repair Wiring/Lighting System
Module Title: Testing and Repairing Wiring/Lighting System
INTRODUCTION:
This module contains information and suggested learning activities on

testing and repairing electrical system. It includes instructions and
procedure on how to use hand tools and electrical instruments in
accordance to the manual instructions and specifications.
Completion of this module will help you understand the succeeding

module on Test and Repair Wiring/Lighting System.
This module consists of three (3) learning outcomes. That contains

learning activities with instruction sheets. Before you follow the instruction,
read the information sheets and answer the self-check and activities
provided to assess your competence by your teacher. He/she will check if
you have acquired the knowledge necessary to perform the skill portion of
the particular learning outcome.
Upon completing this module, report to your teacher for assessment. If

you pass the assessment, you will be given a certificate of completion.
SUMMARY OF LEARNING OUTCOMES
Upon completion of the module, you should be able to:
LO1. test electrical system for open and short circuits to determine faults;
LO2. repair electrical system; and
LO3. test and repair starting system.
TEST[Type the company

AND REPAIR name] | Testing
WIRING/LIGHTING SYSTEM- and
TEST Repairing
Test
ANDelectrical Wiring/Lighting
REPAIRsystem System
of open and short
WIRING/LIGHTING SYSTEM 37
circuit to
determine faults.
Pre Test
Directions: On your answer sheet, write the letter of your answer
1. The exterior lights consist of several components except one

a. signal light c. parking light
b. stop light d. dome light
2. The type of switch that controls the high and low head lamp beam
function.
a. signal switch c. dimmer switch
b. hazard switch d. stop light switch
3. The components of exterior light which are mounted on the the brake
pedal
a. back-up light c. emergency light
b. stoplight d. signal light
4. The back-up light switch is mounted on the side of the..
a. transmission c. differential
b. engine d. brake pedal
5. Type of lighting system that permits the driver to turn the vehicle to the
left or to the right.
a. stop light system c. back-up light system
b. signal light system d. head lamp system
6. Before performing any lighting system repairs or tests check the following
except one.
a.) battery b.) tire
c.) cable connection d.) wires for damage
7. The circuits in the vehicle include all except.
a.) protectors b.) switches
c.) lamps d.) battery
8. The lighting systems of the vehicle should be checked to avoid.
a.) danger to the driver and other people
b.) improper functioning of the lighting circuits
c.) prevent injury and damaged to property
d.) all of the above.
9. In repairing the lighting system of the vehicle the following must be
observed.
a.) be sure to use the correct lamp types
b.) size of the wire to be used
c.) assure safety at all times
d.) all of the above
10. The number of light bulbs and length of wiring in the lighting circuits.
a.) 10 bulbs and 2 feet of wire
b.) 15 bulbs and 3 feet of wire
c.) 50 bulbs and hundreds of feet of wiring
d.) 20 bulbs and 5 feet of wires

WIRING/LIGHTING SYSTEM- and
TEST Repairing
Test
ANDelectrical Wiring/Lighting
REPAIRsystem System
of open and short
WIRING/LIGHTING SYSTEM 38
circuit to
determine faults.
Learning Outcome 1: Test electrical system of open and short circuit to

determine faults.
Introduction:
To determine the electrical faults, electrical components must be
tested and evaluated. Correct information must be interpreted based on the
manufacturer’s specification to prevent serious damage to the components.
Assessment Criteria
1. Correct information is assessed and interpreted from appropriate
manufacturer’s specifications.
2. Tests are to determine faults using appropriate tools and
techniques.
3. Faults are administered, interpreted and applied
4. Tests are completed without causing damage to the workplace
property or vehicle.
Definition of Terms:
AMMETER - An instrument which measures the amount of amperes of

current flowing through an electrical circuit. Also known as an amp. gauge.
CONTINUITY refers to the circuit being continuous with no open.
FUSE - a device that contains a small piece of wire that melts or "blows" if
excessive current flows through it. Designed to prevent the circuit from being
overloaded.
OHMMETER a test meter resistance and continuity in a circuit.
OPEN CIRCUIT a term used to indicate that current flow is stopped. By

opening the circuit, the path for electron flow is broken.
RESISTANCE - opposition to current flow.
SHORT CIRCUIT - a defective electrical circuit where the current in a wire

or device takes an alternate (typically shorter) path to ground. Usually the
result of melted, burned or broken wire(s) or damaged electrical part.
Usually referred to as just short.
WIRING HARNESS - an arrangement of bundled color-coded wires which is

routed through a vehicle and carries electric current to the engine and all
electrical parts of the automobile. An automobile's equivalent of a circulatory
system.

WIRING/LIGHTING SYSTEM- and Repairing
Test Wiring/Lighting
electrical system System
circuit to
determine faults.
Automotive Lighting System and Components
The lighting system of an automobile comprises of various lighting and

signaling devices or components fixed to the front, sides and rear of the
vehicle. Automobile lighting system has multiple uses and functions, which
are:
 It provides illumination for the driver of a vehicle to drive safely in

dark.
 Secondly, automobile lights enhance the visibility of an automobile.
 Thirdly, automobile lights act as the warning signals. They showcase
information about the presence, position, size, speed and direction of
an automotive.
Fig. 17. Schematic wiring diagram of automotive lighting system
Exterior Lights
Typically include the headlights, signal lights, stoplights,
parking lights, back up lights and side marker lights.
Interior Lights
Normally include the dome light instrument light, in the dash
board, trunk light.

circuit to
determine faults.
Fig. 18. Components of the lighting system.
Headlights
These lighting devices are affixed to the front side of an automobile,

whose main function is to light the road ahead of you. These lights are really
powerful and have reflectors as well. Its usage is not only restricted during
nights but can also be used in the foggy conditions as well. Headlights are
the intrinsic parts of the vehicle, which are affixed to the header panel
assembly at the front side of your automobile. These lights comprise of three
basic components: reflectors, filament and special lenses that are melded
closely in an airtight unit. Headlights come in variety of shapes, designs,
colors, materials and sizes but round is the common shape as it is easy to
manufacture. They are mostly made of plastic, Headlights usually come in
pairs and are operated electronically.
Fig. 19. Construction of a sealed-beam headlamp (Toyota Corp.)

circuit to
determine faults.
Head Lamp Switch- is an on/off switch and rheostat in the dash panel or
on the steering column.
Fig. 20 Exploded view of headlight switch
Dimmer Switch- controls the high and low head lamp beam function.
This switch may be mounted on the steering column or flow board.
HIGH__________
LOW___________
BATTTERY________
Dimmer Switch
Fig. 21 Dimmer switch
Head Lamp Circuit
The headlight circuit is composed of the headlights, dimmer switch,

fuse, light switch, and storage battery. Although the ammeter properly
belongs to the charging system, it may also be considered as part of the
lighting system if the current used in this system passes through the
ammeter. Note that the headlights have two filaments, one for the bright and
the other for dim lights. Both filaments are connected to a common ground
terminal. However, only one of these filaments lights at a time.
Switching the headlights from bright to dim or from dim to bright is

accomplished by means of the dimmer switch. The fuse, which may be found
in a fuse box, protects the headlights from damage or burning out due to
grounded live wire. The fuse burns out to cut off the flow of excessive current.
The light switch is the main switch of the lighting system. It controls
the flow of current to the headlight circuit, taillights, and instrument panel
lights

circuit to
determine faults.
Fig. 22 Schematic diagram of headlight circuit. Courtesy of
http://www.google.com.ph
Fig. 23 Headlight Circuit without relay.

circuit to
determine faults.
 HEAD LIGHT CIRCUIT WITH SINGLE RELAY
HEAD LIGHT
86 DIMMER SWITCH SWITCH
87
RELAY H L B H P B
HEAD LAMP 85 30
IGNITION
SWITCH
B
FUSE
BATTERY
Fig. 24 Headlight Circuit with single relay.

HEAD LIGHT
HEAD LIGHT CIRCIUT WITH DOUBLE RELAY
RELAY
DIMMER SWITCH HEAD LIGHT
86 87 SWITCH
H L B B
H P
85 30
HEAD LAMP IGNITION
SWITCH
86 87
FUSE BLOCK B
85 30
BATTERY
RELAY
Fig.25 Headlight circuit using two relays.

circuit to
determine faults.
TAIL LIGHTS
Tail Lights are the lamps, usually covered by a red or

translucent body, which are installed at the rear end of an automobile.
Taillights are mounted at the backside of a vehicle and usually come
in pairs.
PARK LIGHTS
Park lights are used for warning or signaling the drivers about
the presence of another vehicle at the time of foggy, rainy or dark
weather. These lights are also used as brake lights.
PARK AND TAIL LIGHT
 PARK AND TAIL LIGHT CIRCUIT WITH OUT RELAY
FRONT FRONT
HEAD LIGHT
SWITCH IGNITION SWITCH
ST
H P B IG B
ACC
PLATE LAMP
FUSE
BATTERY
REAR REAR
Fig. 26 Schematic diagram of Park/Taillights circuit without

relay.

circuit to
determine faults.
PARK AND TAIL LIGHT
 PARK AND TAIL LIGHT CIRCUIT WITH OUT RELAY, GROUND SWITCHING
FRONT FRONT
HEAD/PARK
SWITCH
IGNITION SWITCH
H P B
ACC
ST IG
B
FUSE
REAR REAR battery
Fig. 27 Schematic diagram of Park/Taillights circuit without

relay and using ground switching.
PARK AND TAIL LIGHT

 PARK AND TAIL LIGHT CIRCUIT WITH RELAY
HEAD LIGHT
FRONT FRONT SWITCH
86 87 RELAY
H P B
PLATE LAMP
85 30
ACC
IGNITION
B IG SWITCH
ST
Battery
REAR REAR FUSE
BATTERY
Fig. 28 Schematic diagram of Park/Taillights circuit with relay.

circuit to
determine faults.
Directional Light Circuit
The turn light system basically consists of a fuse, switch, flasher, unit,
turn light bulbs, indicator bulbs, and related wiring. The turn signal light is
used by the driver to indicate his/her intention of driving either to the right
or to the left. A directional signal light switch is used by the driver to operate
the right signal lights if his/her intention is to drive to the drive to the right,
or the left signal lights if his intention is to drive to the left.
Fig. 29 Turn signal light lever on the steering column.

(Courtesy of Chysler Corporation)
Fig. 20 Schematic diagram of turn signal light circuit without relay.
[Type
TEST AND REPAIR WIRING/LIGHTING SYSTEM- Test electrical the
system company
of open name]
and short | 47
circuit to
determine faults.
Fig. 21 Schematic diagram of turn signal light circuit with relay.
Emergency Light System
The emergency light system also named hazard warning system. The
emergency light switch is normally mounted on the steering column. It is
usually a push-pull switch.
[Type
system company
of open name]
and short | 48
circuit to
determine faults.
Fig. 22 Schematic diagram of signal and hazard light circuit without
relay
Fig. 22 Schematic diagram of signal and hazard light circuit with relay.
[Type
system company
of open name]
and short | 49
circuit to
determine faults.
Stoplight Circuit
The stoplight system is commonly made up of a fuse, brake light

switch, two rear lamps, and wiring. The brake light switch is normally
mounted on the brake pedal.
Fig. 23 (a) Off position (b) On position of stoplight switch
Fig. 24 A typical schematic diagram of stoplight circuit
[Type
system company
of open name]
and short | 50
circuit to
determine faults.
Fig. 24 A typical schematic diagram of stoplight circuit with relay.
Back-up Light Circuit
A back-up light circuit typically has a fuse, transmission mounted

switch, two back-up lamps and wiring connections.
The back lamp switch closes the light circuit when the transmission is
shifted into reverse, to illuminate the area behind the car.
Fig. 25 A simple diagram of back-up light circuit
[Type
system company
of open name]
and short | 51
circuit to
determine faults.
Fig. 24 A typical schematic diagram of backup light and backing horn
circuit with relay.
Horn
The horn is an electromechanical device consisting of a switch, wiring

and a buzzer which produces noise when activated. Used to warn or
communicate to other drivers. Large trucks often use air horns which are
louder.
Automobile horns are usually electric, driven by a flat circular steel

diaphragm that has an electromagnet acting upon it and is attached to a
contactor that repeatedly interrupts the current to the electromagnet. This
arrangement works like a buzzer or electric bell and is commonly known as
"sounding" or "honking" one's horn. There is usually a screw to adjust the
distance/tension of the electrical contacts for best operation. A spiral
exponential horn shape (sometimes called the "snail") is cast into the body of
the horn, to better match the acoustical impedance of the diaphragm with
open air, and thus more effectively transfer the sound energy. Sound levels
are approximately 107-109 decibels, and current draw 5-6 amperes.
[Type
system company
of open name]
and short | 52
circuit to
determine faults.
Fig. 25 A typical schematic diagram of horn circuit.
Fig. 26 Pictorial diagram of horn circuit. Courtesy of

http://www.secondchancegarage.com/public/133.cfm)
[Type
system company
of open name]
and short | 53
circuit to
determine faults.
Fig. 27 A schematic diagram of horn circuit without relay.
Fig. 28 A schematic diagram of horn circuit with relay.
[Type
system company
of open name]
and short | 54
circuit to
determine faults.
Fig. 29 A schematic diagram of horn circuit with relay.
(http://www.google.com.ph)
[Type
system company
of open name]
and short | 55
circuit to
determine faults.
Lighting Circuit Repair and Diagnosis
The lighting system of a vehicle is becoming very complex. There may

be over 50 light bulbs and hundreds of feet of wiring in the lighting circuits.
The circuits include circuit protectors, switches, lamps, and connectors. Any
failure requires a systematic approach to diagnose, locate, and correct the
fault in the minimum amount of time.
The importance of a lighting system cannot be overemphasized. The

lighting system should be checked whenever the vehicle is brought to the
shop for repairs. Often a customer may not be aware of a light failure. If a
lighting circuit is not operating properly there is a potential danger to the
driver and other people. When today’s technician performs repairs on the
lighting systems, the repairs must assure vehicle safety and meet all
applicable laws. It is important to use the correct lamp type and size for the
application.
Before performing any lighting system tests:
a. Check first the battery for state of charge.

b. Also be sure that all cable connections are clean and tight.
c. Visually check the wires for damaged insulation, loose
connections, and improper routing.
When troubleshooting the lighting system, if only one bulb is not

operating it is usually faster to replace it with a known good unit first. Check
the connector for signs of corrosion. When testing the circuit with a
voltmeter, or test light, check those components that can be easily accessed
first.
[Type
system company
of open name]
and short | 56
circuit to
determine faults.
AUTO LIGHTING TROUBLE DIAGNOSIS CHART
PROBLEM POSSIBLE CAUSE SOLUTION
One light bulb Burned out bulb Check, repair or
doesn’t light up Faulty or grounded socket replace
Headlight did not Blown fuse Repair, check,
lights on Faulty relay repair or replace
Faulty headlight switch
Faulty dimmer switch
Faulty wiring
High beam of Faulty headlight switch Repair, check,
headlights or Faulty dimmer switch repair or replace
flasher did not Faulty wiring
lights on
Tail light and Blown fuse Repair, check,
parking light did Faulty relay repair or replace
not turn on Faulty switch
Faulty wiring
Stop light did not Blown fuse Repair, check,
turn on Faulty relay repair or replace
Faulty switch
Faulty wiring
Stop light did not Faulty switch Repair, check,
turn off repair or replace
Signal light did Faulty switch Repair, check,
not flash Faulty wiring repair or replace
Signal light did Blown fuse Repair, check,
not turn on Faulty flasher repair or replace
Faulty switch
Faulty wiring
Hazard light did Blown fuse Repair, check,
not operate Faulty flasher repair or replace
Faulty switch
Faulty wiring
Back up light did Blown fuse Repair, check,
not operate Faulty flasher repair or replace
Faulty switch
Faulty wiring
Fig.29 Lighting system trouble-diagnosis chart.
[Type
system company
of open name]
and short | 57
circuit to
determine faults.
SELF - CHECK No. 1
LO 1. TEST ELECTRICAL SYSTEM
Directions: On your answer sheet, write the letter of your answer
_______ 1. The exterior lights consist of several components except

one
a. signal light c. parking light
b. stop light d. dome light
_______ 2. The type of switch that controls the high and low head
lamp beam function.
a. signal switch c. dimmer switch
b. hazard switch d. stop light switch
_______ 3. The components of exterior light which are mounted on the

the brake pedal
a. back-up light c. emergency light
b. stoplight d. signal light
_______ 4. The back-up light switch is mounted on the side of the..

a. transmission c. differential
b. engine d. brake pedal
_______ 5. Type of lighting system that permits the driver to turn

the vehicle to the left or to the right.
a. stop light system c. back-up light system
b. signal light system d. head lamp system
Resources

[Type
system company
of open name]
and short | 58
circuit to
determine faults.
Connecting Back up Light Circuit
CONDITIONS:
 Automotive wires
Tools
 Electrical Pliers
 Long nose plier
 Test light
 Screw Driver
Equipment
 Battery 12 volts
 Electrical mock-up/Vehicle
Plan/Working Drawing
PROCEDURE
1. Prepare the necessary tools and materials/equipment
2. Connect a wire to the lamp specified as the back-up light to the back-
up switch found on the transmission.
3. Connect the other terminal to one terminal of the fuse box.
4. Connect a wire from the fuse box to the ACC terminal of the ignition
switch
.
5. Connect a wire from the fuse box to the AM terminal of the ignition
switch.
6. Connect a wire from AM terminal to the positive terminal of the

ampere, and a wire from negative terminal to the positive terminal of
the battery.
7. Connect the negative terminal of the battery to the ground part of the
vehicle.
[Type
system company
of open name]
and short | 59
circuit to
determine faults.
35 - Exemplary
25 - Adequate
TOTAL SCORES
Resources

[Type
system company
of open name]
and short | 60
circuit to
determine faults.
Learning Outcome 2. Repair Electrical Circuit
Introduction:
Correcting electrical faults are quite tricky and needs more patients.
Correct diagnosis is a must and accurate tools and equipment must be used
to carry out the repair. Extra care must also be observed because it deals
with electric current and working with electric current needs no mistake.
ASSESSMENT CRITERIA:
1. Correct information is assessed and interpreted using appropriate
tools and equipment
2. Necessary repairs are carried out using appropriate tools, techniques
and materials
3. Electrical circuit is repaired without causing damage to the work
place, property or vehicle
Definition of Terms
AMMETER - An instrument which measures the amount of amperes of

current flowing through an electrical circuit. Also known as an amp. gauge.
BACK UP LIGHTS- Light bulbs in the taillight housing that come on when
the shifter is put in the reverse position. Used to illuminate the area behind
the vehicle when backing up.
CONTINUITY refers to the circuit being continuous with no open.
DIMMER SWITCH - a switch and lever system that switches between low
beam and high beam headlights. On modern vehicles the lever is positioned
on the left side of the steering wheel. When the lever is pulled back (and
pushed forward on some vehicles) it controls an electrical switch which
switches current that powers the bright and dim headlight circuits when the
headlights are turned on. Many vehicles have an additional mode which
turns on the lights momentarily when the lever is pulled back -- even if the
lights are not turned on, for purposes of signaling to other drivers.
FUSE - a device that contains a small piece of wire that melts or "blows" if
excessive current flows through it. Designed to prevent the circuit from being
overloaded.
GROWLER - test equipment used to test starter armatures for shorts and
grounds. It produces a very strong magnetic field that is capable of inducing
a current flow and magnetism in a conductor.

AND REPAIR name]
TEST | Testing
WIRING/LIGHTING SYSTEM-
AND REPAIR and Repairing
electrical SYSTEM
WIRING/LIGHTING system of| Repair
open and System
short
Electrical Circuit 61
circuit to
determine faults.
HAZARD LAMPS - flashing lights which can be turned on in emergency
situations or to warn other drivers. Also known as emergency lights.
HEADLIGHTS - high-performance light bulbs mounted on the front of

vehicles to provide illumination at night and in low-visibility conditions. Most
older vehicles use four headlights; two for high-beam (brighter), two for low-
beams. Modern vehicles use composite headlamps that are designed to
complement the aerodynamic shape of a vehicle's front end. These
headlights generally have removable/replaceable bulbs.
HORN - an electromechanical device consisting of a switch, wiring and a

buzzer which produces noise when activated. Used to warn or communicate
to other drivers. Large trucks often use air horns which are louder.
OHMMETER a test meter resistance and continuity in a circuit.
OPEN CIRCUIT a term used to indicate that current flow is stopped. By

opening the circuit, the path for electron flow is broken.
PARKING LIGHTS - lights that mark the front of a parked vehicle and to
mark the front of a vehicle if a headlamp fails.
RELAY- An electromechanical device that when operated opens/closes

another electric circuit; acts as a remote power switch. Relays are used to
engage many accessories from remote switches. The main advantage is
eliminating the need to route high current wires throughout a vehicle to each
switch.
RESISTANCE - opposition to current flow.
SHORT CIRCUIT - a defective electrical circuit where the current in a wire

or device takes an alternate (typically shorter) path to ground. Usually the
result of melted, burned or broken wire(s) or damaged electrical part.
Usually referred to as just short.
SOLENOID CIRCUIT RESISTANCE TEST - diagnostic test used to

determine the electrical condition of the solenoid and the control circuit of
the starting system.
STATOR - the stationary coil of the ac generator in which current is

produced.
TURN SIGNAL LIGHTS - a lights which indicate an intended change in

directions by flashing lights on the side towards which the turn will be made.
TROUBLESHOOTING - the diagnostic procedure of locating and identifying

the cause of the fault. It is a step-by-step process of elimination by use of
cause-and-effect.
WIRING HARNESS - an arrangement of bundled color-coded wires which is

routed through a vehicle and carries electric current to the engine and all
electrical parts of the automobile. An automobile's equivalent of a circulatory
system

AND REPAIR name]
AND |REPAIR
WIRING/LIGHTING
TEST Testing
SYSTEM- and Repairing
electrical system
WIRING/LIGHTING SYSTEM of |open
Repairand System
short
circuit to
determine faults.
Safety Measure’s In Repairing Electrical Circuit
Safety is a basic requirement for the teacher and the students. Most
accidents can be prevented if all students cooperate in eliminating unsafe
conditions and acts. To this end, each individual is responsible for
understanding and applying safety rules, standards, and regulations. In all
activities, safety consciousness will help prevent personal injury and damage
to property.
The lighting system of the vehicle should be checked whenever the

vehicle is brought to the shop for repairs. Often a costumer may not be
aware of a light failure. If a lighting circuit is not operating properly there is
a potential danger to the driver and other people.
The electrical circuit of the vehicle is becoming very complex. There

may be over 50 light bulbs and hundreds of feet of wiring in the lighting
circuits. The circuits include protectors, switches, lamps, and connectors.
Any failure requires a systematic approach to diagnose, locate and

repair or correct the fault immediately. When performing repairs on the
lighting or electrical circuits/systems, the repairs must assure vehicle safety
and should meet all the applicable laws. Be sure to use the correct lamp type
and size for the application.
Before performing any lighting systems test or repair, check the

battery connections. Also be sure that all cable connections are removed.
Visually check the wires for damage and insulation, loose connections, and
improper routing.

AND REPAIR name]
TEST | Testing
electrical SYSTEM
open and System
short
circuit to
determine faults.
SELF-CHECK No. 1
LO. 2. REPAIR ELECTRICAL SYSTEM
DIRECTIONS: On your answer sheet, write the letter of your answer.
__________1. Before performing any lighting system repairs or tests check

the following except one.
a.) battery b.) tire
c.) cable connection d.) wires for damage
_________ 2. The circuits in the vehicle include all except.
a.) protectors b.) switches
c.) lamps d.) battery
______ ___3. The lighting systems of the vehicle should be checked to
avoid.
a.) danger to the driver and other people
b.) improper functioning of the lighting circuits
c.) prevent injury and damaged to property
d.) all of the above.
_________4. In repairing the lighting system of the vehicle the following
must be observed.
e.) be sure to use the correct lamp types
f.) size of the wire to be used
g.) assure safety at all times
h.) all of the above
_________5. The number of light bulbs and length of wiring in the lighting
circuits.
e.) 10 bulbs and 2 feet of wire
f.) 15 bulbs and 3 feet of wire
g.) 50 bulbs and hundreds of feet of wiring
h.) 20 bulbs and 5 feet of wires
Resources


AND REPAIR name]
AND |REPAIR
WIRING/LIGHTING
TEST Testing
SYSTEM- and Repairing
electrical system
WIRING/LIGHTING SYSTEMof |open
Repairand System
short
circuit to
determine faults.
Connecting Back -up Light Circuit
CONDITIONS:
Tools
 Electrical Pliers
 Long nose pliers
 Test light
 Screw Driver
 Multi-tester
Equipment
 Battery 12 volts
Plan/Working Drawing
PROCEDURE
1. Prepare the necessary tools and materials/equipment.
2. Connect a wire to the lamp specified as the back-up light to the back-
up switch found on the transmission.
3. Connect the other terminal to one terminal of the fuse box.
4. Connect a wire from the fuse box to the ACC terminal of the ignition
switch.
5. Connect a wire from the fuse box to the AM terminal of the ignition
switch.
6. Connect a wire from AM terminal to the positive terminal of the

ampere, and a wire from negative terminal to the positive terminal of
the battery.
7. Connect the negative terminal of the battery to the ground a part of

vehicle body.

AND REPAIR name]
TEST | Testing
electrical SYSTEM
open and System
short
circuit to
determine faults.
35 - Exemplary
25 - Adequate
TOTAL SCORES
Resources


AND REPAIR name]
TEST | Testing
electrical system
WIRING/LIGHTING SYSTEM of| open
Repairand System
short
circuit to
determine faults.
OPERATION SHEET NO. 2
Head Light Repair And Replacement
CONDITIONS:
Supplies and Materials:

 Headlamp
 Test lamp
 Soldering iron
 Electrical tapes
 Wire terminal
Tools:
 Philip screw drivers
 Standard screw drivers
 Electrical pliers
 Wrenches(Box and Open)
Equipment:
 Battery (12 volts)
PROCEDURE:
Your teacher will discuss and demonstrate the procedure to you with
the aid of diagram and pictures. Then you will do the procedure yourselves.
1. Place fender covers around the work area
2. This type of replacement usually requires the removal of the

bezel.( The bezel is the retaining trim around a component)
Fig. 30 Remove the light bezel.

3. Remove the retaining ring screws and the retaining trim. Do not turn
the two headlight aiming adjustment screw.
4. Remove the headlight from the shell assembly.

AND REPAIR name]
TEST | Testing
electrical system
Repairand System
short
circuit to
determine faults.
5. Disconnect the wire connector from the back of the lamp.
6. Check the wire connector for corrosion or other foreign materials.

Clean as needed.
Fig. 31 Exploded view of headlight assembly.
7. Coat the connector terminals and the prongs of the new headlight
with the dielectric grease to prevent corrosion.
8. Install the wire connector to the headlight prongs and place the
headlight into the shell assembly. When positioning the headlight, be
sure that the embossed number is at the top.
9. Install the retainer trim and fasteners.
10. Check the operation of the headlight.
11. Check headlight aiming as described.
12. Install the headlight bezel.

AND REPAIR name]
TEST | Testing
electrical SYSTEM
open and System
short
circuit to
determine faults.
35 - Exemplary
25 - Adequate
TOTAL SCORES
Resources


AND REPAIR name]
TEST | Testing
electrical system
Repairand System
short
circuit to
determine faults.
OPERATION SHEET NO. 3
Repair Automotive Wiring
CONDITIONS:
Supplies and Materials:

 Soldering lead
 Safety glasses
 Soldering iron
 Electrical tapes
 Wire terminal
 Wires
Tools:
 Philip screw drivers
 Standard screw drivers
 Wrenches(socket and ratchet)
 Soldering gun
Equipment:
 Battery (12 volts)
PROCEDURE:
Automotive wiring can become damaged and will need to be repaired

over the lifetime of a vehicle. You can repair wiring in multiple ways;
however, automotive industry standards dictate the proper way to repair
damaged wire is to solder the broken pieces together to create a strong bond
that is equal to the strength of new wiring.
1. Put on the safety glasses. Disconnect the positive and negative battery
cables from the vehicle's battery using the socket and ratchet.
2. Place a piece of heat-shrink tubing over either side of the broken wire
and slide as far away from the break as possible.

AND REPAIR name]
TEST | Testing
electrical system
Repairand System
short
circuit to
determine faults.
3. Trim back the remaining protective coating with the wire trimmers
and provide about an inch of bare wire on each end of the break, then
overlap and twist the wire together, creating a strong connection.
4. Heat up the soldering iron and solder over the twisted wire. When
done correctly the heat will cause the solder to wick into the wiring,
creating a strong joint. Allow to cool and provide a gentle tug to the
wire to ensure a good solder.
5. Slide the heat-shrink tubing up and over the bare wire joint and use
the heat gun to shrink the tubing, effectively creating an air-tight seal.

AND REPAIR name]
TEST | Testing
electrical SYSTEM
open and System
short
circuit to
determine faults.
PERFORMANCE CRITERIA
Workmanship/Performance POINTS
Quality of Work with application of safety measures
35 – Functional
25 – Not Functional
10 – None Functional
Accuracy of Performance under specified time limit
30 – All procedures are followed
20 – 3-5 procedures are followed
10 – more than 5 procedures are not followed
Proper use of tools/equipment with safety measures
35 – proper selection/use of tools/equipment
25 – wrong handling of tools
10 – tools are not suitable for the job.
TOTAL SCORE
Resources


AND REPAIR name]
TEST | Testing
electrical system
Repairand System
short
circuit to
determine faults.
Program / Course: Automotive Servicing NC 1
Unit of Competency: Service ignition system
Module Title: Servicing ignition system
In 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 nine (9) Learning outcomes (2) information
sheets and thirteen (13) 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 or

demonstrated 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 component

electrical system of open
SERVICE System
and short
IGNITION SYSTEM 73
circuit to
determine faults.
Pre Test
Directions: Identify the following. 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 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.
3. The rotating parts of the distributor assembly that distribute

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 a 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 thousands 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.
11.It is a wire connected from the distributor assembly lead wire

with insulated terminal to the negative sign of coil.
SERVICE IGNITION SYSTEM

[Type the company name] | Testing and Repairing Wiring/Lighting System 74
12.It prevents heat and helps to cool the coil.
13.It is the center of the ignition coil, a laminated soft iron or steel.
14.This winding is surrounded by the secondary coil windings

which is approximately 200 turn of 20-gauge wire.
15.It is winded in the core approximately 22,000 turns of very fine

wire.
[Type the company name] | Testing and Repairing Wiring/Lighting System 75

SERVICE IGNITION SYSTEM
Program/Course: Automotive Servicing NC I
Unit of Competency: SERVICE IGNITION SYSTEM
Module Title: Servicing Ignition System
Learning Outcome 1. Check Ignition System

Introduction:
In order to create fire or combustion, the fire triangle is needed;
fuel, air and heat. Inside the engine, the air and fuel mixture is
compressed by the piston, and it is ignited by the electric spark from
the ignition system. If the compressed air is not ignited, there will be
no fire or combustion because one factor of the fire triangle is mixing.
So it is important that there will be always ignition, a good ignition, to
operate the engine.
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.
Definition of Terms
Ignition - the action of the spark in starting the burning of the

compressed air-fuel mixture in the combustion chamber.
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.
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.
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.
[Type the company name] |SYSTEM-Check

SERVICE IGNITION Servicing Ignition
IgnitionSystem
System 76
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.
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.
Timing - in an engine delivery of the ignition spark or operation

of the valves (in relation to the piston position) for the power
stroke.
Ignition resistor - a resistance connected into the ignition

primary circuit to reduce battery voltage to the coil during
engine operation.
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.
Arcing - name given to the spark that jumps the air gap
between two electric conductors.
[Type the SERVICE

companyIGNITION
name] SYSTEM-Check Ignition System
| Servicing Ignition System 77
INFORMATION SHEET No.1
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 so that 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
A. BREAKER POINT TYPE
Most four-stroke engines have used a mechanically timed electrical

ignition system or breaker point type. The heart of the system is the
distributor. The distributor contains a rotating cam driven by the engine's
drive, a set of breaker points, a condenser, a rotor and a distributor cap.
External to the distributor is the ignition coil, the spark plugs and wires
linking the distributor to the spark plugs and ignition coil. (See fig.below)
The system is powered by a lead-acid battery, which is charged by the

car's electrical system using alternator. The engine operates contact breaker
points, which interrupt the current to an induction coil (known as the
ignition coil).
SERVICE IGNITION
[Type the company name] | SYSTEM-Check IgnitionSystem
Servicing Ignition System 78
Fig. 1 Components and circuit diagram of the breaker point type
ignition system. (http://en.wikipedia.org/wiki/Ignition_system)
Fig. 2 Dismantled breaker point type ignition distributor (Toyota Corp.U.S.A

IgnitionSystem
System 79
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.
Fig. 3 Top view of an electronic ignition distributor showing the

different parts. (Chysler Corporation)
[Type the company name] | SYSTEM-Check

IgnitionSystem
System 80
COMPARISSON BETWEEN BREAKERLESS TYPE AND BREAKER POINT TYPE IGNITION
SYSTEM
BREAKERLESS TYPE BREAKER POINT TYPE
(Electronic Ignition) (Mechanical Ignition System)
Electronic ignition module won't burn out Points burn out from normal use and need to be
under normal use. replaced many times over the life of the car.
Module won't burn out if ignition switch is
Points burn out if ignition switch is left in run
left in the run position (with ignition turned
position.
off).
Electronic ignition develops up to 30,000
Conventional system develop only 24,000 volts
volts at the spark plug when a car is running
when a car is running at 10 mph. But this
at 10 mph. This voltage remains at up to
voltage drops to 17,000 volts when the car
30,000 volts when the car reaches 100
reaches 100 mph. A detrimental 40% drop in
mph. In addition, many electronic ignition
voltage to fire the air/fuel mixture under high
systems maintain this voltage at speeds of
load conditions.
8,000 RPM.
Electronic ignition systems can operate as Conventional point's deterioration problems
high as 8 amps which further enhance the limit the primary current to the coil to about 4.5
performance of the overall ignition system. amps.
Maintenance-free (with higher ignition
voltage, more accurate timing, longer plug Constant adjustments (gapping) necessary to
life, increased fuel economy, faster starts, insure peak performance.
and improved performance)
Incorporates "Active Dwell" technology.
Note: "Dwell" is measured in degrees and is

the amount of 'time' the points stay closed.
When the points are closed, the coil is
building up charge (inductive). When the
points open the coil releases its charge.
Electronic ignitions also have dwell -it's
Points need adjusting to compensate for dwell
just controlled by the electronics in the
("dwell" is how long your points stay closed, or
module. The Breaker less incorporates "Active
"dwell" together, as the distributor shaft rotates).
Dwell" technology to maintain high RPM
spark energy; delivering
up to 30,000 volts with the
ignition coil, while reducing coil heating at
idle. Active dwell control is a very clever
[electronic] way to further increase the
output
of the coil.
Distributor cam requires periodic lubrication so
No maintenance necessary for the distributor cam wheel lobes can slide past the points. In
cam. addition the cam lobes will wear, eventually
causing performance problems.
Very reliable solid-state circuitry. Not reliable (for all of the above reasons).
Condenser is no longer necessary, and is Condenser can degrade and/or fail, needing
removed. replacement
Fig. 4. A chart showing the comparison between two types of ignition

system. (http://en.wikipedia.org/wiki/Ignition_system

IgnitionSystem
System 81
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

engine operation.

IgnitionSystem
System 82
4. Ignition Coil - the ignition system component that sets as
a transformer to step up(increase) the battery voltage
into many thousands of volts.
5. Distributor - any device that distributes. In the ignition

system, the rotary switch that directs 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.

Ignition System
System 83
7. Contact Points - the point in the distributor that opens &
closes
the primary circuit to build-up and 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.
SERVICE IGNITION
[Type the company name] | SYSTEM-Check IgnitionSystem
9. Distributor Cap top cover of distributor assembly that
prevents dirt or any particles from entering the
delicate parts.
10. High Tension Wires – serve as 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.

Ignition System
System 85
12. Vacuum Advancer - provides 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

IgnitionSystem
System 86
Fig. 5 Schematic diagram of the ignition system showing the
primary and secondary circuits. (http://www.google.com.ph)
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 drives 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.
Cars today use electronic means rather than mechanical breaker
points to bring about the “make and break” effect.

Ignition System
System 87
Fig. 6 Diagram showing the primary and secondary circuit.
Topic 6. SAFETY MEASURES IN CHECKING IGNITION SYSTEM
1. Do not use ordinary pliers for checking the spark plug

lead shorting to ground (earth) in order to sparking.
Instead use 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. Do not use jumper wire in checking the ignition system

for continuity, instead use appropriate instrument for
testing with VOM or multi-tester.
SERVICE IGNITION
[Type the company name] |SYSTEM-Check IgnitionSystem
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 which
lead might to explosion.
6. Avoid replacement of local parts, other brands and

different character rated for quality reason.
7. Make sure the parts and wires, are correctly connected to

their own designated point of contact.
Topic 7. SERVICING IGNITION SYSTEM COMPONENTS
Pointers to be followed by the technician before proceeding to

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 were been checked and detected
by the use of the appropriate instrument for diagnosing the
troubles. If possible use service repair manual as your guide
for the maintenance and servicing of contact point type of
ignition system.

IgnitionSystem
System 89
SELF-CHECK
Directions: Identify the following. 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 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.
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 a 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 thousands 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
Resources

SERVICE IGNITION
[Type the company name] |SYSTEM-Check Ignition System
Unit of Competency: Service ignition system
Learning Outcome 2. Perform Spark Test

Introduction:
To determine if the ignition system is generating spark, a spark
test must be performed. Safety measures must also be applied since it
deals with the high voltage surge of current.
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.
Definition of Terms:
Ground - the common negative connection of the vertical

system that is the point of the lowest voltage.
Ground circuit - an electrical defect that allows current to

return to ground before it reaches the intended load component.
Ground side - the portion of the circuit that is from the load
component to the negative side of the source.


stroke.
[Type the company name]

SERVICE | Servicing
IGNITION Ignition
SYSTEM-Perform System
Spark Test 91
TITLE: Performing Spark Test by cranking the engine
Conditions:
 Rug cloth
 Sand paper
Tools
 Screw Driver
 Insulated Pliers (special tool)
 Spark Plug wrench
 Feeler Gauge
Equipment
 Engine
 Battery Charger
 Mock – up
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.

SERVICE | Servicing
IGNITION Ignition
Spark Test 92
Note: Use a fully charged battery with a good cranking motor
capacity.
6. Proceed to spark plug no. 2, 3, and 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
Fig. 7 Making a spark test using insulated pliers and spark tester.
(ATW)

SERVICE | Servicing
IGNITION IgnitionSpark
Test 93
35 - Exemplary
25 - Adequate
TOTAL SCORES
Resources

http://auto.howstuffworks.com

SERVICE | Servicing
IGNITION Ignition
Spark Test 94
TITLE: Performing Spark Test while the engine is running
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
Procedures 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.

SERVICE | Servicing
IGNITION Ignition
Spark Test 95
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 shows but the
engine does not continuously operate, maybe failure is
caused by other systems.
Fig. 8 Steps in making a spark testing while the engine is

running. (ATW)

SERVICE | Servicing
IGNITION Ignition
Spark Test 96
35 - Exemplary
25 - Adequate
TOTAL SCORES
Resources


SERVICE | Servicing
IGNITION Ignition
Spark Test 97
TITLE: Performing Spark Test by turning the ignition distributor
Conditions:
 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 is not

cranking or running
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

SERVICE | Servicing
IGNITION Ignition
Spark Test 98
lead 3/8” gap directly pointing to ground at the same time
spark occurred in the contact 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.
SAFETY MEASURES IN SPARK TEST/TRIGGERING TEST.
1. Do not use conductive pliers with only insulated handle. In

high-energy ignition system, the spark can jump even more
than one inch or (25.4mm).
2. The spark can jump around or through the insulation and

can give a dangerous shock as could kill a person with a
heart condition.
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 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.
Fig. 9 Typical scope patterns used in analyzing electric

spark. (Ford Motor Company)
SERVICE
[Type the company IGNITION
name] SYSTEM-Perform
| Servicing Spark
Ignition Test
System 99
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 the
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.
SERVICE
[Type the company IGNITION
name] SYSTEM-Perform
| Servicing IgnitionSpark Test
System 100
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
Spark tested safely when running engine. 100
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
Spark triggering tested safely by turning the distributor 100
assembly
 90-94% standard of specifications.
Resources
SERVICEname]
[Type the company IGNITION SYSTEM-Perform
| Servicing Spark
Ignition Test
System 101
Unit of Competency: Service Ignition System
Learning Outcome 3. Check Ignition Coil Resistance

Introduction:
To determine the condition of the ignition coil, ignition coil
resistance must be checked. Ignition coil is a series of coil that
converts the battery voltage into thousand volts. A high ignition coil
resistance means that the current cannot pass easily thus creates a
much lower voltage than the required voltage of the engine to ignite
the compressed air and fuel mixture.
1. Coil terminal of ignition coil is disconnected
2. Ignition coil resistance is checked
Definition of Terms
Ohm - unit of measure for resistance. One ohm is the
resistance of the conductor such that a constant current of one
ampere produces a voltage of one volt between its ends.
Ohmmeter - a test meter used to measure resistance and

continuity in a circuit.



SERVICE
[Type IGNITIONname]
the company SYSTEM-Check Ignition
| Servicing Coil Resistance
Ignition System 102
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 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 what 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.
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 - it is where the 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.
[Type the company

SERVICE IGNITIONname] | Servicing
SYSTEM-Check Ignition
Ignition System 103
Coil Resistance
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).
Fig. 10 Cut-away view of an ignition coil showing some internal

and external parts. (http://www.google.com.ph)
Topic 3. INTERPRETING SECONDARY AND PRIMARY CIRCUIT
1. Operation of the Primary Circuit When the ignition switch

is 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.
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
[Type the company

Ignition System 104
Coil Resistance
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.
Fig. 11 Schematic diagram of the ignition system showing

primary and secondary circuits. (http://www.google.com.ph)
[Type the company

Ignition System 105
Coil Resistance
Self-Check
Directions: 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 helps to cool the coil.
3. It is the center of the ignition coil, a laminated soft iron or steel.
4. This winding is surrounded by 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.
Resources

[Type the company

Ignition System 106
Coil Resistance
TITLE: Checking Ignition Coil Resistance
Conditions:
 Ball pen/pencil
 Bond paper
Tools
 Pliers
 VOM
 Multi tester
Equipment
 Engine mock-up
Procedure in checking ignition coil resistance:

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.
Fig. 12 Parts of the ignition

coil to be check.
[Type the company

Ignition System 107
Coil Resistance
3. Inspect / Check / Test the Primary Coil Resistance
a. Measure the following resistance
Without the use 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 open.
Fig.13 Shows how to

check primary coil
resistance without
resistor using ohmmeter.
(http://www.google.com.
ph)
b. With the use 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 appears higher than the

required ohms or higher resistance, the condition of
the primary coil is burn out, but if it is low than
specified ohms the condition is weak. But if the hand
of ohmmeter remains at infinity (∞)the condition of
primary coil maybe open.
[Type the company

Ignition System 108
Coil Resistance
4. Inspect/check/ test the secondary coil resistance.
c. Measure the following resistance

Without the use of resistor the reading of the secondary
must be 6.0 – 9.0 k ohms(references only)
Note: If the reading does not meet within the range of
minimum and maximum in the secondary coil resistance,
recommend 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 use 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 recommend for
replacement.
Cause: If the reading of ohmmeter shows 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.
[Type the company

Ignition System 109
Coil Resistance
50
A. Checked ignition coil safety when disconnected
from the circuit.

B. Checked the ignition coil safely, when 50

connected 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
Resources

 http://auto.howstuf
[Type the company

Ignition System 110
Coil Resistance
Learning Outcome 4. Check Ballast Resistor

Introduction:
The ballast resistor prevents the overflowing of current to
the ignition coil which if not prevented, reduces the service life of the
coil. To determine the functionality of the resistor, the resistor must
be checked in accordance with the manufacturer’s specification.
 Ballast resistor is checked as per requirement
Definition of Terms

engine operation.



Ballast System
Resistor 111
TITLE: CHECKING BALLAST RESISTOR
Conditions:
 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.

2. Disconnect wires connected from the ballast resistor
3. Check and test ballast resistor of ignition coil.
Fig. 17 Diagram of the ignition system showing the parts to be

checked. (ATW)
4. Turn the selector switch to R X 1 of the ohmmeter.
[Type the SERVICE

companyIGNITION
name] SYSTEM-
| Servicing Ignition
Check Ballast System
Resistor 112
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
The appropriate instrument used for testing and checking the

resistance expressed in ohms is no other than the ohmmeter tester.
If the resistance varies from .08 to 1.2 ohms, meaning the hand of
the tester will move and stop within the range, 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 the manual, the condition is
normal, but if the hand will move from (∞) infinity to (0) zero the
condition is weak. But when, the hand remains at (∞) infinity the
condition maybe open.
[Type the SERVICE

company name] SYSTEM-
IGNITION | Servicing Ignition
Check System 113
Ballast Resistor
Points
Workmanship/Performance
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
 39 to 44% standard of specification
 33 to 38% standard of specification.
B. Checked safely the ballast resistor when it is

connected in the coil, while engine is running. 50
 With 40 to 50% standard specifications.
 29 to 39% standard specifications.

Total=100
Resources

[Type the SERVICE

companyIGNITION
name] SYSTEM-
Check Ballast System
Resistor 114
Learning Outcome 5. Adjust Contact Point Clearance

Introduction:
Contact point clearance is very important in the ignition timing.
The clearance is one of the factors that determine if the ignition timing
is advances or retard through its opening which affects also the dwell
angle. Aside from this; and the most important function of the contact
point is that it opens and closes the primary circuit of the ignition
system which results to the collapse of the current flow in the primary
circuit and the current flows to the secondary circuit towards the
spark plug. Therefore, correct contact point clearance must be
obtained.
1. Contact point is adjusted per service manual specification
2. Contact point adjustment is analyzed and interpreted
Definition of Terms

current flows through the primary winding
of the coil.
[Type the company

SERVICE name] | Adjust
IGNITION SYSTEM- Servicing Ignition
Contact System 115
Point Clearance
TITLE: ADJUSTING CONTACT POINT CLEARANCE

(adjusting contact point when the distributor assembly is
installed to engine)
Conditions:
 Sand paper
 Rags
 Grease
Tools
 Set of screw driver

 Feeler gauge
 Set of wrench
Equipment
Procedures in adjusting contact point when the distributor

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

of correct size box or socket wrench that fits the 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 based on the kind
of screw.
5. Loosen the slightly lock and adjusting screw then, insert the
feller gauge with correct size of clearance. Follow what is in
the manual.
[Type the company

SERVICE name] | Adjust
IGNITION SYSTEM- Servicing Ignition
Contact System 116
Point Clearance
6. Tighten first the adjusting screw with two working screw
drivers for it to lock 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.
Fig.19: Adjusting the breaker point gap
[Type the company

SERVICE name] | Servicing
IGNITION SYSTEM- Ignition
Adjust Contact System 117
Point Clearance
Points
B. Checked safely the ballast resistor, when it is not



Total=100
Resources

SERVICE
[Type IGNITION SYSTEM-
the company name] | Adjust Contact
Servicing Point Clearance
Ignition System 118
TITLE: ADJUSTING CONTACT POINT CLEARANCE

(adjusting contact point when distributor assembly
removed from engine.)
Conditions:
 Sand paper
 Rags
 Grease
Tools
 Set of screw driver

 Feeler gauge
 Set of wrench
Equipment
Procedure in adjusting contact point when distributor assembly

removed from engine.
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. Use proper type and size of screw driver based on the kind of
screw.
5. Loosen slightly lock and adjusting screw then insert the feller
gauge with correct size of clearance. Follow what stated 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
SERVICE
Ignition System 119
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)
If dwell angle is below the 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 the
tachometer for setting the correct idling of engine.
Fig. 20 Illustration of dwell angle. (Chysler Corporation)
SERVICE
the company Adjust Contact
name] | Servicing Point Clearance
Ignition System 120
SAFETY MEASURES IN ADJUSTING CONTACT POINT.
1. When testing a vehicle, never use 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’s specifications.
5. Do not install locally manufactured contact points to the car

of your customers and replacement of parts should 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. Use the required capacitance or farad.
SERVICE
[Type IGNITION name]
the company SYSTEM- Adjust Contact
| Servicing Point Clearance
Ignition System 121
Adjust contact point clearance
A. Adjusted contact point safely as per service 50

manual specification when distributor
 With 45 to 50% standard of specification.
B. Adjusted contact point safely as per service

manual specification when distributor 50
assembly not installed to engine.
 With 45 to 50% standard of specification.

Total=100
Resources

SERVICE
Ignition System 122
Unit of Competency SERVICE IGNITION SYSTEM
Learning Outcome 6. Perform Ignition Wiring Installation
Introduction:
Ignition wiring installation is the process of connecting the ignition
system peripherals correctly. The correct firing order of the engine
must be observed to the deliver the spark to the correct cylinder at
proper time.
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.
Definition of Terms


stroke.
SERVICE
[Type IGNITION
the companySYSTEM-
name]Perform Ignition Ignition
| Servicing Wiring Installation
System 123
Title: Performing Ignition Wiring Installation
Conditions

 Soldering leads
 Wire terminals
 Electrical tape
Tools:
 Set of screwdriver
 Wire stripper
 Soldering iron
Equipment:
 Engine mock-up
 Vehicle
PROCEDURES IN CHECKING IGNITION COMPONENTS WITH THE

USE OF OHMETER:
2. Disconnect negative terminal of battery.
3. Check ignition switch, by the use of ohmmeter, RX1 one prod

to AM while the other prod to Ignition. If the hand will move
from infinity to zero in two pull positions of ignition key,then
the system is in proper condition.
4. Test auto wire from ignition of switch to positive terminal of

coil,
RX1, hand should move from infinity to near zero. If this
happens, then it is in proper condition.
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 is 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.
SERVICE
[Type IGNITION
the companySYSTEM-
System 124
Fig. 21 Diagram indicating the partsof the ignition system to be
checked using ohmmeter.
6 Test/check condenser by using ohmmeter, RX1. Connect one

prod to the eye tail of condenser, and the other prod to the
body ground parts. If the hand of the meter will move a little
bit abruptly to zero side then back to infinity side of tester
then it is in proper condition. If it does not moves or remain at
infinity, it is defective. The condenser is to be replaced.
Fig. 22 Using an ohmmeter to check the condenser in the

ignition system. (http://www.google.com.ph)
8. Test/check high tension wire individually by using used

ohmmeter RX 25Ω. Both prods of the meter will be
connected at both ends. See that the reading must be on the
specified ohms at all cords.
SERVICE IGNITION
[Type the companySYSTEM-
System 125
Fig. 23 Checking the high
tension wire using an
ohmmeter. (Chysler
Corporation)
9. Check the adjustment of spark plug gap by using the of

feeler gauge. Follow the gap specification in the manual.
Fig. 24 Picture of spark plug showing different parts and how to

measure the clearance using the spark plug gap adjustment tool.
(http://rmfletcher.hubpages.com)
GAP ADJUSTMENT
Check the plug gap with plug gap gauge. If it is not
according
to the 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
SERVICE
[Type IGNITION
the companySYSTEM-
System 126
Points
C. Checked safely the ballast resistor, when it is not



Total=100
Resources

SERVICE
[Type IGNITION
the companySYSTEM-
System 127
TITLE: PERFORMING IGNITION WIRING INSTALLATION
Conditions

 Soldering leads
 Wire terminals
 Electrical tape
Tools:
 Set of screwdriver
 Wire stripper
 Soldering iron
Equipment:
 Engine mock-up
Procedure in checking ignition system components with the

use of voltmeter:
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 to 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 about 9.5 volts).
5. If the voltage is too low then 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.
SERVICE IGNITION
System 128
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 specifications 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.
Fig. 25 Diagram showing the different

component of the ignition system to needs to
be checked using the voltmeter.
Note: In this ignition circuit the teacher will demonstrate
the procedure using the voltmeter
SERVICE
[Type IGNITION
the companySYSTEM-
System 129
Points
D. Checked safely the ballast resistor, when it is not



Total=100
Resources

SERVICE
[Type IGNITION
the companySYSTEM-
System 130
TITLE: PERFORMING IGNITION WIRING INSTALLATION
Conditions:
 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 new 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 connected 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, and
then to positive terminal of coil.
Note: But in order to complete the circuit to crank

the engine to start, connect auto wire size no. 14
SERVICE IGNITION
System 131
from ST terminal of switch to ST terminal of the
solenoid starter switch.
5. Use auto wire size no. 14 from negative terminal of

coil to insulated lead terminal in the distributor
assembly.
Note: See to it that the 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 the rotor points to no.1 terminal cap it could
be the no.1 spark plug. Then follow according to the
firing order given.
7. All wires should be provided with an eye terminals

to ensure proper contact.
8. Crank the engine and run it, for further trouble

shooting.
Fig. 26 Diagram showing the different wiring connections of the

ignition system. (http://en.wikipedia.org/wiki/Ignition_system)
SERVICE IGNITION
System 132
SAFETY MEASURES IN WIRING INSTALLATION
1. Do not use the ohmmeter, in testing resistance into the ignition

circuit, if battery connected. Otherwise, the meter will be
damaged.
2. Always connect the battery to ground if negative while 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.
4. Provide fuse for the ignition circuit.
5. Eye terminal of every end wires, must be soldered properly in

order to ensure that 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

these components will be busted.
SERVICE IGNITION
System 133
A. Checked ignition system components safely with

the use of ohmmeter. 100
 With 95-100% standard of

specifications.
 75% standard of specifications.
 50% below.
B. Checked ignition system safely with the use of
voltmeter.
 50% below.
C. Performed wiring installation of ignition

circuit/system safely.

 50% below.
Total=100
Resources

[Type the
SERVICE company
IGNITION name]
SYSTEM- | Servicing
Perform Ignition Ignition System
Wiring Installation 134

Learning Outcome 7. Perform Ignition Timing
Introduction:
Ignition timing is the process of setting the ignition system
components in correct timing in order to deliver the high voltage surge
of current in correct time.
1. Ignition Timing procedure is applied per engine requirement
2. Ignition timing is checked per ignition specifications
3. Safety measures are applied
Definition of Terms

stroke.
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.
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.
Retard - to delay the occurrence of the spark in the combustion

chamber.
[Type theSERVICE
companyIGNITION
name]SYSTEM- Perform
| Servicing IgnitionSystem
Ignition Timing 135
TITLE: PERFORM IGNITION TIMING
CONDITION:
 Rags
 White chalk
Tools
 Box wrenches
Equipment
 Engine mock-up
 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 marks
coincide and 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 to 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 if the contact point is about to open

use
[Type theSERVICE
companyIGNITION
Ignition Timing 136
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.
Fig. 27 Top view of the ignition distributor showing the dwell

angle and related parts. (ATW)
Ignition Timing. Set the initial ignition timing in order that the spark
will reach spark gap at the proper time.
Fig. 28 Initial setting of the ignition system.
[Type theSERVICE
companyIGNITION
Ignition Timing 137
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. Is is usually expressed in crankshaft degrees before or
after the top dead center (TDC) at the end of the compression stroke.
Fig. 29 Using the timing light in setting ignition timing .
[Type theSERVICE
company name]SYSTEM-
Perform System
Ignition Timing 138
Points
E. Checked safely the ballast resistor, when it is not



Total=100
Resources

[Type theSERVICE
Perform IgnitionSystem
Timing 139
TITLE: PERFORM IGNITION TIMING
CONDITION:
 Rags
 White chalk
Tools
 Box wrenches
Equipment
 Engine mock-up
 Vehicle
 Ignition timing light
 Dwell meter
 Tachometer
Procedure in performing the setting base ignition timing.
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 and 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 is 3 degrees
before top dead center, the timing is retarded or off by 7
degrees.
[Type theSERVICE
Timing 140
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 test in the highways.
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 from 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.
[Type theSERVICE
Timing 141
LO 7. Perform ignition timing
B. Performed initial ignition timing safely using 100

only a 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 use of stroboscopic timing light, 100
dwell meter, and tachometer.
 95-100% of all the steps
 75% only of the steps
 50% only of the steps
Total=100
Resources

[Type theSERVICE
companyIGNITION
Ignition Timing
System 142
Learning Outcome 8. Repair Non-electronic Ignition System

and/or Component
Introduction:
Returning back the normal operating condition of an automobile
has two ways; repair or replace. If after diagnosis, the problem can be
repaired, repair process should be done or else replacement of a new
part will be performed. There are problems that only needs minor
repair and some also needs major repair including the replacement of
the defective parts.
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.
Definition of Terms






SERVICE IGNITION
[TypeSYSTEM- Repair non-electronic
the company ignition system/component
name] | Servicing Ignition System 143

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.


stroke.
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.
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.

current flows through the primary winding of the coil.

engine operation.
Magnetic line of force - the imaginary lines by which a

magnetic field maybe visualized.
Retard - to delay the occurrence of the spark in the combustion

chamber
[TypeSYSTEM-
SERVICE IGNITION the company name] | Servicing
Repair non-electronic Ignition System
ignition system/component 144
TITLE: Repairing non-electronic ignition system and/or

Component
CONDITION
 Rags
 Paint brush
 Soldering lead
 Wire
 Fine sand paper
Tools
 Set of box wrenches
 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.
2. Repair wiring harness if needed; for burnt, 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 g. distributor insulated terminal and h. high
tension wires and spark plugs.
4. Check, inspect mechanical partss and check, Test electrical
parts using the ohmmeter tester.
[TypeSYSTEM-
IGNITION SYSTEM COMPONENT
a. Electrical Testing Procedures:
TESTING IGNITION SWITCH

Ohmmeter tester selector
AM
switch to RX1, the hand will
move from infinity to zero, on
ACC ignition switch to Position click
ST
IGN two.
Fig.32 Testing the ignition
switch using an
ohmmeter
RX1
TESTING BALLAST RESISTOR
Ohmmeter tester switch to

RX1 test prod as shown:
External resistor resistance
is 1.3-1.7 Ω (Reference
only) see Testing
Fig.33 manual.the ballast
resistor using an
ohmmeter
TESTING COIL RESISTANCE
Ohmmeter Tester Switch to

R X 10k test prods 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.
Fig.34 Testing the ignition coil
resistance using an ohmmeter.
[TypeSYSTEM-
TESTING PRIMARY COIL RESISTANCE
Ohmmeter Tester Switch
to RX1 test prod as shown:
w/o resistor type 2.6 – 4.0
Ω
w/ resistor type 1.3 – 1.6
Ω
To be sure see manual.
Note: IfTesting
Fig.35 the reading is not
the primary
within the specified
coil resistance using an
résistance, replace coil.
ohmmeter
TESTING INSULATION RESISTANCE

VOM Tester switch to RX10M
Ω at 500V – Test Prod as
shown
Insulation resistance
Fig.36 testing over
the insulation
TESTING HIGH TENSION WIRES 10M Ω at 500V.
resistance of the ignition coil
an ohmmeter
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.
Fig.37 Testing the resistance
of the high tension cable.
[TypeSYSTEM-
TESTING CONDENSER
VOM tester switch to

RX1 Ω
Test prod as shown
The hand of the meter
will move abruptly then
back to infinity.(∞)
Note: If hand does not
RX1 move replace the
condenser.
Fig.38 Testing the condenser
using an ohmmeter.
TESTING DISTRIBUTOR TERMINAL INSULATION
Ohmmeter Tester Switch to

RX1. Test Prod connection
as shown.
If contact point opens
hand of the meter remain
RX1 infinity. ∞
Note: If hand move to zero
O the insulation of the
terminal is broken.
Fig.39 Testing the distributor

terminals with open contact
points. .
Ohmmeter Tester Switch to RX1

Test Prod connection as shown.
If contact point is closed, hand of
the meter will move from infinity
∞ to zero O.
RX1 Note: The condition is normal.
Fig.40 Testing the distributor

terminals with closed contact
points .
SERVICE IGNITION
b. Mechanical Inspection and repair procedures
Distributor Cap
Inspect for cracks, carbon
tracks, burnt or corroded
terminals, and check center
Fig.41 Inspection
contact for wear. of the
distributor cap for damage.
Distributor Rotor
Inspect for cracks, carbon
tracks, burnt or corroded
terminals.
Fig.42 Inspection of rotor.
Breaker Plate
Check breaker plate
for smooth rotation.
Fig.43 Inspection of the

breaker plate.
Governor weights and pin

Check the fitting portions of
governor weights with support
pins for binding.
Fig.44 Inspection of governor

weights and pin of the
distributor.
[Type
SERVICE IGNITION the company
SYSTEM- name] | Servicing
Vacuum Advancer
Diaphragm
Suck the tube with your
mouth. The diaphragm
should move.
Note: If it does not move,
replace the diaphram.
Fig.45 Checking the vacuum

diaphragm by sucking.
Cam and Shaft

Inspect cam for
wear, damage, and
fit between cam
and shaft.
Fig.46 Checking the

cam and shaft of the
distributor for damage.
Governor Shaft and

Housing
1. Check shaft
thrust clearance.
Thrust clearance
should be 0.15-
0.5mm
(0.006-0.020in)
[Type
2. Remove Gear
and Pin
Grind off the pin
end, then
remove the pin
and gear.
3. Inspect
governor shaft
for wear and
damage.
4. Inspect housing
bushings, and O ring
for wear,
deformation, and
damage.
5. Assemble washers in
order as shown.
[Type
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.
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.
[TypeSYSTEM-
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
1.0mm (0.039in) for
USA
Refer Manual
c. Installation and adjustment of distributor assembly

components procedures;
Install governor
springs in the
direction as shown.
Install breaker points and

adjust the gap.
Point gap 0.45mm (0.018in)
Set the octane

selector at standard
line.
SERVICE IGNITION
C. 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.
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.
SERVICE IGNITION
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 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.
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 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.
SERVICE IGNITION
 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 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.
SERVICE IGNITION
Fig. 47 Illustration showing the spark plug conditions.
[TypeSYSTEM-
D. The basic steps to building the high tension wires are as
follows.
1. Attach wire to plug and layout wire to the coil. Measure for
length and strip.
2. Slide wire through coil terminal boot.
3. Bend conductor and attach terminal.
4. Crimp terminal.
5. Bend terminal 90º.
6. Pull terminal back into boot.
Fig. 48 Steps repairing high tension wires or cables.

http://www.stealth316.com/2-msd-ignwires.htm
E. Safety Measures in Repairing Ignition Component Parts.
1. In pulling out the

high tension cord
from the spark
plug, grip the end
of the plug cord
properly then, pull
suddenly the cable.
SERVICE IGNITION
2. Match 15 mark with
stopper, fit it on the
cam and tighten with
screw.
3. Remove with
care the high
tension cable by
way of pulling
the rubber boat.
4. Do not bend
cords that will
cause the
conductor to be
broken.
5. Use insulated
pliers or non-
conductive pliers
in conducting
spark test for
ground.
[Type
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 of
insulator and threads
[TypeSYSTEM-
LO 8. Repair non-electronic ignition system and/ or component
A. Repaired, maintained and serviced safely the 100

ignition system parts and components.
Total=100
Resources

SERVICE IGNITION
Answer Key
Servicing Automotive Battery
Self Check No. 1

1. b
2. c
3. a
4. a
Self Check No. 2

1. a
2. b
3. a
4. a
5. a
Self Check No. 3

1. D
2. A
3. A
4. C
Self Check No. 4
1. A
2. A
3. A
4. A
5. B
Testing and Repairing Wiring/Lighting System
Self Check No. 1
1. d – dome light
2. c – dimmer switch
3. b – stoplight
4. a – transmission
5. b – signal light system
Self Check No. 2
1. B
2. D
3. D
4. D
5. C
ANSWER
[Type the company name] | Servicing Ignition KEY
System 162
LO3 Self Check No. 1
1. true
2. false
3. false
4. true
5. false
Self Check No. 2
1. a
2. b
3. a
4. c
5. d
Self Check No.
1. b
2. d
3. a
Servicing Ignition System
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
[Type the company name] | Servicing Ignition

ANSWERSystem
KEY 163
REFERENCES FOR FURTHER READINGS


[Type the company name] | Servicing Ignition System 164

REFERENCES
ACKNOWLEDGEMENT
It is a great privileged that this endeavor was given by the Task

Force Tech-Voc, Department of Education to the following participants
of the “Writeshop on the Refinement and Enrichment of
Competency-Based Curriculum (CBC), Contextual Learning Matrix
(CLM) and Modules of Arts and Trades”, conducted at Marikina
Hotel on April 20-25, 2009. It is the fervent hope of the writers that
through their consolidated efforts they are able to strengthen and
enrich the Vocational Education curriculum to fully prepare and equip
Tech-Voc students to become locally and globally competitive in the
world of work.
Copyright Department of Education 2008
First Published JUNE 2008. Revised December 2011
This draft was prepared at the Competency-Based Learning

Materials Development Workshop conducted at the Development
Academy of the Phils, Tagaytay City on May 5-10, 2008.
This learning instrument was developed by the following personnel:
Jonathan O. Diaz
TVE-Automotive-Technology Coordinator
San Pedro Relocation Center National High School
Langgam, San Pedro, Laguna
Romeo Q. Ibloguin Sr.

Teacher III
E. Rodriguez Vocational High School
Division of City Schools, Manila
Nagtahan, Sampaloc, Manila
Robert S. Domingo
Teacher I
AFG Bernardino Memorial Trade School
Lias, Marilao, Bulacan
Lino A. Olit
Teacher I
Community Vocational High School
Masipit, Calapan City, Oriental Mindoro
Arpil P. Medrano
Teacher I

ACKNOWLEDGEMENT
Tanza National Trade School
Paradahan I, Tanza, Cavite
This work was produced with funding provided by the Department

of Education.
Revised and Edited at the Development Academy of the Philippines,

Tagaytay City, November 20-26 2011 and December 4-10, 2011)
JULIUS J. JARDIOLIN
Head Teacher III
Antonio J. Villegas Vocational High School
Manila
NCR
DEO L. TARNATE
Teacher III
San Grabriel Vocational High School
San Gabriel, La Union
Region I
JERSON G. SARSUEDA
Alona Trade High School
Alona Misamis Occidental
Region X

ACKNOWLEDGEMENT

Automotive Servicing NC 1 Service Automotive Battery Servicing Automotive Battery

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Automotive Servicing NC 1 Service Automotive Battery Servicing Automotive Battery

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Program / Course: Automotive Servicing NC 1

Unit of Competency Service Automotive Battery

This module contains information and suggested learning activities on

Completion of this module will help you understand the succeeding

This module consists of four (4) learning outcomes. Each learning

SUMMARY OF LEARNING OUTCOMES

Upon completion of the module, you should be able to:

LO1. Test Automotive Battery;

[Type text] SERVICING AUTOMOTIVE BATTERY Page 1

LO 1. TEST AUTOMOTIVE BATTERY

1. The battery in an electro chemical device, this means the battery

2. The battery performs the following EXCEPT

3. When working around the battery be sure to;

4. A type of battery which do not have removable caps.

7. The indication if the battery is in full charge in using ball hydrometer.

[Type the company

10. In disconnecting the battery the correct tools used are______.

[Type the company

Unit of Competency: Service Automotive Battery

Module Title: Servicing Automotive Battery

Learning Outcome 1: Test Automotive Battery

An automotive battery is a type of rechargeable battery that supplies

BATTERY CELL - the active unit of the battery

BATTERY LEAKAGE TEST - test used to determine if current is discharging

BATTERY TERMINAL TEST - test that checks for poor electrical

BATTERY TERMINALS - terminals at the battery to which the positive and

BATTERY CHARGER - an equipment that is use to charge battery capacity

ELECTROLYTE - Any solution that conducts an electric current. In a car

TEST AND REPAIR WIRING/LIGHTING SERVICING

TITLE: BATTERY CONSTRUCTION AND PRINCIPLE OF OPERATION

An automotive battery is a type of rechargeable battery that supplies

Lead-acid batteries are made up of plates of lead and separate plates

Battery recycling of automotive batteries reduces resources required

TEST AND REPAIR WIRING/LIGHTING SERVICING

Fig. 2 Parts of Automotive Battery. (Courtesy of Toyota Motor

TEST AND REPAIR WIRING/LIGHTING SERVICING

1. The sulfuric acid in the electrolyte is very corrosive. It will make

2. When disconnecting a battery, always disconnect the negative or

4. Never lean over a changing battery.

5. Do not charge a frozen battery for maintenance-free battery

LO 1. TEST AUTOMOTIVE BATTERY

________2. The battery performs the following EXCEPT

________3. When working around the battery be sure to;

________4. A type of battery which do not have removable caps.

[Type the company

TITLE: TESTING THE BATTERY

TOPIC: TWO WAYS OF TESTING THE BATTERY

Two types of Hydrometer:

Ball hydrometer is similar to the ball type coolant hydrometer. Put

PRECAUTION: Do not drip electrolyte on the car or on yourself.

1.265 -1.299 Fully charged battery

Relationship between specific gravity and state of charge.

TEST AND REPAIR WIRING/LIGHTING SERVICING

Specific gravities and freezing temperatures for battery electrolyte.

TEST AND REPAIR WIRING/LIGHTING SERVICING

LO 1. TEST AUTOMOTIVE BATTERY

_________1. This type of hydrometer which is similar to ball type coolant

TEST AND REPAIR WIRING/LIGHTING SERVICING

TITLE: TESTING AUTOMOTIVE BATTERY USING

1. Remove all battery vent caps.

TEST AND REPAIR WIRING/LIGHTING SERVICING

[Type the company

A. Quality of Work with Application of Safety Measures

1. In disconnecting the battery the correct tools used are.

2. The tool to be used to clamp the battery is _.

4. To disconnect the battery first __.