COMPETENCY BASED LEARNING

MATERIAL

Sector:

AUTOMOTIVE and LAND TRANSPORT

Distinctive Area of Competence and Qualifications:

Automotive Servicing NC I
Unit of Competency:

Check Ignition System

Module Title:

Servicing and Repairing Ignition System

Technical Education and Skills Development
Authority
East Service Road, South Superhighway, Taguig, Metro Manila

AUTOMOTIVE and LAND TRANSPORT

INDUSTRY SECTOR

NATIONAL CERTIFICATE LEVEL 1

QUALIFICATION LEVEL

COMPETENCY-BASED LEARNING MATERIALS

No.
Basic Competencies
1. Receive and Respond to
Workplace Communication
2. Work with Others
3. Demonstrate Work Values
4. Practice Housekeeping
Procedures

Module Title
Receiving and Responding to
Workplace Communication
Working with Others
Demonstrating Work Values
Practicing Housekeeping
Procedures

Code
500311101

No.
Common Competencies
1. Apply Appropriate
Sealant/Adhesive
2. Move and Position Vehicle
3. Perform Housekeeping
4. Perform Mensuration and
Calculation
5. Perform Safety Practices
6
Read, Interpret and Apply
Specifications and Manual

Module Title
Applying Appropriate
Sealant/Adhesive
Moving and Positioning Vehicle
Performing Housekeeping
Performing Mensuration and
Calculation
Performing Safety Practices
Reading, Interpreting and
Applying Specifications
and Manual
Using and Applying Lubricants/
Coolants
Perform Shop Maintenance

Code
ALT723201

Module Title
1. Performing Diesel Engine
Tune-up
2. Performing Gas Engine Tuneup
3. Servicing Automotive Battery

Code
ALT723301

7.

Use and Apply Lubricant/Coolant

8.

Perform Shop Maintenance

No.
Core Competencies
1. Performing Diesel Engine Tuneup
2. Perform Gas Engine Tune-up

500311102
500311103
500311104

ALT723202
ALT311201
ALT311202
ALT311203
ALT723203

ALT723204
ALT723205

ALT723302

3.

Service Automotive Battery

4.

Service Ignition System

4. Servicing Ignition
System

ALT723304

5.

Test and Repair Wiring/ Lighting

System
Perform Underchassis Preventive
Maintenance

5. Installing Automotive
Wiring/Lighting System
6. Performing Underchassis
Preventive Maintenance

ALT723305

6.

ALT723303

ALT723306

HOW TO USE THIS COMPETENCY BASED LEARNING MATERIAL

Welcome to the Module Servicing and Repairing Ignition System. This module
contains training materials and activities for you to complete.
The unit of competency Check Ignition System contains the knowledge, skills and
attitudes required for an Automotive Servicing course. This is one of the common modules
for National Certificate level I (NC I).
You are required to go through a series of learning activities in order to complete each of
the learning outcomes of the module. In each learning outcome there are Information
Sheets, Operation Sheets and job Sheets (Reference Materials for further reading to
help you better understand the required activities. Follow these activities on your own and
answer the self-check at the end of each learning activity.
If you have questions, dont hesitate to ask your facilitator for assistance.

Recognition of Prior Learning (RPL)

You may already have some or most of the knowledge and skills covered in this module
because you have:
been working for some time
already completed training in this area.
If you can demonstrate to your trainer that you are competent in a particular skill or skills,
talk to him/her about having them formally recognized so you dont have to do the same
training again. If you have a qualification or Certificate of Competency from previous
trainings show it to your trainer. If the skills you acquired are still current and relevant to this
module, they may become part of the evidence you can present for RPL. If you are not sure
about the currency of your skills, discuss this with your trainer.
After completing this module ask your trainer to assess your competency. Result of your
assessment will be recorded in your competency profile. All the learning activities are
designed for you to complete at your own pace.
Inside this module you will find the activities for you to complete and at the back are the
relevant information sheets for each learning outcome. Each learning outcome may have
more than one learning activities.
At the end of this module is a Learner Diary. Use this diary to record important dates,
jobs undertaken and other workplace events that will assist you in providing further details to
your trainer or an assessor. A Record of Achievement is provided for you by your trainer to
accomplish once you complete the module.

Code No.

ALT723304

Servicing and Repairing Ignition System

Date: Developed Date: Revised

Aug. 15, 2003

Page #

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

Talk to your trainer and agree on how you will both organize the training of this unit.
Read through the learning guide carefully. It is divided into sections which cover all the
skills and knowledge you need to successfully complete this module.

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

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

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

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

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

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

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

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

Code No.

ALT723304

Servicing and Repairing Ignition System

Date: Developed Date: Revised

Aug. 15, 2003

Page #

QUALIFICATION
: AUTOMOTIVE SERVICING NC I
UNIT OF COMPETENCY : CHECK IGNITION SYSTEM
MODULE TITLE
: CHECKING IGNITION SYSTEM
INTRODUCTION:
This module contains information and practices involved in checking the ignition system
of a vehicle. It includes instructions on how to check up an ignition system prior to trouble
shooting.
You need to complete this module before you can actually start the engine, since this
part is the primary system that lets the engine run.
LEARNING OUTCOMES:
At the end of this module you will be able to:
1. Identify and explain the function of the ignition system components
2. Check ignition coil, ballast resistor, high tension cable resistance
3. Check distributor assembly
ASSESSMENT CRITERIA:
1.
2.
3.
4.
5.
6.
7.

Ignition system components are identified

Functions of ignition system are understood
Standard clearance and resistance of ignition system components are determined
Operating principle of the ignition system is explained
VOM is properly used
Specified resistance value is obtained from service manual
Procedure in checking resistance is observed in accordance with the manual of
instructions
8. Distributor terminal and rotor tips are cleaned and lubricated
9. Rotor and distributor cap are checked for cracks / current leakage
10. Condenser is tested by charged and discharged process
11. Dwell angle is adjusted / set in accordance with the manual of specifications and
instructions
12. Cam lube is checked for wear
13. Rotor rotation is determined
14. Advance mechanism operation is checked in accordance with the manual of
instructions
PRE-REQUISITE: NONE

Code No.

ALT723304

Servicing and Repairing Ignition System

Date: Developed Date: Revised

Aug. 15, 2003

Page #

Program /Course
Unit of Competency
Module

Automotive Servicing NC I
CHECK IGNITION SYSTEM
CHECKING IGNITION SYSTEM

LEARNING OUTCOME #1
Identify and explain the function of ignition system components.

ASSESSMENT CRITERIA
1. Ignition system components are identified.
2. Functions of the ignition system are understood.
3. Standard clearance and resistance of ignition system components are determined.
4. Operating principle of the ignition system is explained.

RESOURCES

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

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

Internal Combustion Engine (ICE)

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Servicing and Repairing Ignition System

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

SPECIAL INSTRUCTIONS

What types of ignition systems have you worked?

1. Defining ignition system
1.1 Read Information sheet #1 Contact Point Ignition
System
For more information view
a) Purpose of the ignition system
CDX industrial light vehicle
b) Producing the spark
under ignition
c) Determining heat range & reach
Refer to Information Sheet #1
(Contact Point Ignition
After reading a, b and c answer the Self-Check.
System.)
Automotive Mechanics 10th
What science principles can help us understand
edition by Crouse & Anglin
more about ignition inside confined containers &
(textbook)
cylinders
Internal combustion engines
2. Identifying parts & components of the ignition system Automotive mechanics 10th
edition by Crouse & Anglin
2.1 Read a) Components of ignition system
(textbook)
3. Describing all functions of the different ignition CDX Industrial Light vehicle
(CD) ASE
components
From the ignition system
3.1 Identify a) Ignition switch
mock-up provided, pinpoint the
b) Ignition coil
components on the left.
c) high tension wire
d) spark plug
e) distributor assembly
f) condenser
g) fusible link
h) ballast resistor
4. Discuss safety procedures in handling high voltage
current

4.1 Outline procedures paragraph

a) refer to special instructions

5. Measuring clearance
a) contact points
5.1 measuring resistance
a ) primary
b ) secondary
c ) high tension wire
d ) ballast resistor
6. Experiment on Electro-magnetism
Read a) primary
b) secondary

Code No.

ALT723304

Servicing and Repairing Ignition System

OHS (Occupational Health &

Safety
Take actual resistance of the
following components &
circuits
Refer to service manual

See Electricity master

experiment manual

Date: Developed Date: Revised

Aug. 15, 2003

Page #

INFORMATION SHEET #1
CONTACT POINT IGNITION SYSTEM
PURPOSE OF IGNITION SYSTEM
The purpose of the ignition system is to ignite the compressed alt-fuel mixture in the engine
combustion chambers. This should occur at the proper time for combustion to begin. To start
combustion, the ignition system delivers an electric spark that jumps a gap at the combustionchamber ends of the spark plugs. The heat from this arc ignites the compressed air-fuel
mixture. The mixture burns, creating pressure that pushes the pistons down the cylinders so the
engine runs. The ignition system may be either a contact-point ignition system or an electronic
ignition system. This chapter describes the contact-point ignition system.
COMPONENTS IN CONTACT-POINT IGNITION SYSTEM
The ignition system (Fig. 1) includes the battery, ignition switch, ignition coil, ignition
distributor (with contact points and condenser), secondary wiring, and spark plugs.

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

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Servicing and Repairing Ignition System

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1. IGNITION SWITCH The ignition switch connects

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

Fig.2 Ignition coil, cutaway to show the windings.

(Delco-Remy Division of General Motors
Corporation)

3. IGNITION DISTRIBUTOR The ignition

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

Fig. 3 Ignition distributor with vacuum-advance

unit and cap (Delco-Remy Division of General
Motors Corporation)

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Servicing and Repairing Ignition System

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

Fig. 4 Cutaway ignition distributor and vacuumadvance unit, with rotor and cap in place.

In most contact-point distributors, the distributor

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

Fig. 5 Simplified secondary circuit, The coil

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

Code No.

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Servicing and Repairing Ignition System

Date: Developed Date: Revised

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4. SECONDARY IGNITION CABLES The second

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

Fig. 6 Silicone resistance cable or spark-plug

wire (left) now used on all vehicles compared
with older solid-conductor (right) spark-plug wire,
(AC-Delco Division of General Motors
Corporation)

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

PRODUCING THE SPARK

The ignition system consists of two separate
but related circuits: the low-voltage primary
circuit and the high-voltage secondary circuit.
The ignition coil (Fig. 1) has two windings.
The primary winding of a few hundred turns of
heavy wire is part of the primary circuit. The
secondary winding at many thousand turns of
fine wire is part of the secondary circuit, When
the ignition key is ON and the contact points
closed, current flows through the primary
winding (Fig. 7). This produces a magnetic
field around the primary windings in the coil.
Code No.

ALT723304

Fig 7. Schematic of the primary circuit in the contactpoint ignition system (ATW).

Servicing and Repairing Ignition System

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When the contact points open, current flow steps and the magnetic field collapses. As it
collapses, it cuts across the thousands of turns of wire in the coil secondary winding.
This produces a voltage in each turn. These add together to produce the high voltage delivered
through the secondary circuit to the spark plug (Fig. 5).
CONTACT POINTS
The contact-point set mounts on the breaker
plate in the distributor (Fig. 7). The points are
operated by a breaker cam on top of the
distributor shaft. The cam has the same number
of lobes as there are cylinders in the engine. As
the cam revolves and the points close and
open, they act as mechanical switch to make
and break the primary circuit.
One contact point mounts on the grounded
breaker plate and is stationary. The other point
mounts on the end of an insulated movable
arm. The arm swings back and forth on a pivot
as the cam lobes push on the rubbing block to
open the points. A spring attached to the
movable-point arm closes the points.
When the points close, this connects the coil
primary winding to the battery. A magnetic field
builds up in the coil. As the breaker cam rotates,
the next lobe pushes the movable arm away
from the stationary contact point. This opens
the points and stops the current flow. The
magnetic field collapses and a high-voltage
surge results. The length of time in degrees of
distributor-shaft rotation that the contact points
remained closed in the dwell. The distance that
separates the points when they are fully open is
the gap. Points are normally adjusted by dwell
or gap measurements.
The distributor shaft and cam are driven by the
engine camshaft which turns at one-half
crankshaft speed. It takes two complete
revolutions of the crankshaft to rotate the
distributor shaft one complete revolution.

Fig. 8. Top view of a contact-point ignition distributor

with the cap and rotor removed. Note that the cam has
six lobes (for a six cylinder engine). The drawings at
the top show the cam action. When a lobe moves
under the rubbing block, the contact arm is moved,
separating the points. (Delco-Remy Division of
General Motors Corp).

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

Code No.

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10

PRIMARY RESISTANCE
Excessive current flow in the primary circuit causes arcing and burning of the contact points. To
prevent this, a resistance is placed between the ignition switch and the coil primary winding.
The resistance may be a separate resistor or a special resistance wire. For easier starting, the
resistance is bypassed and full battery voltage reaches the coil during cranking. After the
engine starts, the resistance reduces coil voltage to 5 to 8 volts.
SECONDARY VOLTAGE
The high voltages and high rate of charge
prevent many voltmeters from measuring
secondary voltage. Figure 9 shows a
computerized engine analyzer that
includes two cathode-ray tubes (CRTs).
The CRT on the left is a oscilloscope or
scope. It can display the primary and
secondary voltage patterns and the
length of time this occur.
Figure 10 shows the basic pattern for on
spark plug firing cycle in the secondary
circuit. At the left, the points open. This
stops the current flow through the coil
primary winding. The magnetic field then
collapses, causing a sudden high voltage
(A to B) in the secondary winding. This is
the firing voltage that starts the spark
jumping the gap at the spark plug. The
volts quickly drops from B to C because it
takes less voltage to sustain the spark
than it does to start it. The spark
continues from C to D, where it stops.
This is the spark line burn time. It lasts for
about 20 degrees of crankshaft rotation,
or 1 to 2 milliseconds (thousands of a
second). The remaining energy causes
voltage ripples or oscillations from D to E
in Fig. 10. However, the voltage is not
great enough to restart the spark. At E,
the points close and current starts flowing
through the coil primary winding. The
expanding magnetic lines of force pass
through the primary winding, creating a
slight alternating voltage in it. This is
shown by the dip and small ripples to the
right of E in Fig. 10.
From E to F is the dwell section.

Code No.

ALT723304

Figure 9. Computerized Engine Analyzer.

Figure10. Oscilloscope waveform or trace, showing one

complete spark-plug firing cycle in the secondary circuit. The
dwell section is the time period during which current flows
through the primary circuit.

Servicing and Repairing Ignition System

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11

Dwell is the length of time the points are closed and current flows through the primary winding
of the coil. Then at F, the points open and the cycle begins again at A as the spark occurs at the
spark plug. The whole procedure repeats continuously as long as the engine runs.
ADVANCING THE SPARK
When the engine is idling, the spark is timed to reach the spark plug just before the piston
reaches TDC on the compression stroke. At higher speeds, the spark must occur earlier. If it
does not, the piston will be past TDC and moving down on the power stroke before combustion
pressure reaches its maximum. The piston is ahead of the pressure rise which results in a weak
power stroke. This wastes much o the energy in the fuel.
To better use the energy in the fuel, the spark takes place earlier as engine speed increases.
This spark advance causes the mixture to burn producing maximum pressure just as the piston
moves through TDC. Most contact-point distributors have two mechanisms to control spark
advance. A centrifugal-advance mechanism adjusts the spark based on the engine speed. A
vacuum advance mechanism adjusts the spark based on engine load. On the engine, both work
together to provide the proper spark advance for the engine operating conditions.
CENTRIFUGAL ADVANCE
The centrifugal-advance mechanism
advances the spark by pushing the
breaker cam ahead as the engine
speed increases. Two advance weights,
two weight springs, and a cam
assembly provide this action. The cam
assembly includes the breaker cam and
an oval-shaped advance cam (Fig. 11).
At low speed, the springs hold the
weights in. As engine speed increases,
centrifugal force causes the weights to
overcome the spring force and pivot
outward (Fig. 12). This pushes the cam
assembly ahead. The contact points
open and close earlier, advancing the
spark.

Figure 11. Parts of a centrifugal-advance mechanism for a

contact-point distributor.
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12

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

Figure 12. Centrifugal-advance mechanism in

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

The vacuum-advance mechanism

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

Figure 13. When the throttle valve is closed, there is no vacuum

advance. The ported vacuum passage is above the closed throttle
valve.

Figure 14. Operation of the vacuum-advance unit. When the

throttle valve moves past the port, intake-manifold vacuum is
admitted to the vacuum-advance unit on the distributor. The
breaker plate then rotates to advance the spark.
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COMBINED CENTRIFUGAL AND VACUUM ADVANCE

At any speed above idle, there is some
centrifugal advance. Depending on intakemanifold vacuum, there may also be some
vacuum advance. The total advance curve in
Fig. 15 shows how the centrifugal and
vacuum advance combine. At 40 miles per
hour (64 km/h), there are 15 degrees of
centrifugal advance. The vacuum advance
can produce up to 15 degrees of additional
advance at part throttle. The advances
shown in Fig. 15 combine to produce a
maximum advance of 30(15 + 15) degrees.
When the engine runs at wide-open throttle,
intake manifold vacuum drops to zero. There
is no vacuum advance. Normally, the total
advance varies between the straight line
(centrifugal advance) and the curved line
(centrifugal plus vacuum advance) in Fig.15.
Figure 15. Centrifugal and vacuum advance curves for
one engine.

SPARK PLUGS
The spark plug has a metal outer shell
enclosing a ceramic insulator. Centered in
the insulator is the center electrode which
carries the high-voltage current from the
ignition coil. A ground electrode attaches to
the metal shell and is bent inward to produce
the proper spark gap. The gap varies from
0.035 inch (0.9 mm) for contact-point ignition
systems to 0.080 inch (2.03 mm) for some
electronic ignition systems. The spark jumps
from the center electrode to the ground
electrode. The wider the gap, the higher the
voltage required to jump it.
Spark plugs may have a suppressor or
resistance built into the center electrode (Fig.
16). It reduces television and radio
interference (static) caused by the ignition
system. Spark plugs may require gaskets
when installed to assure a leakproof seal.
Many engines use spark plugs with tapered
seats which seal without a gasket. Spme
spark-plug threads are coated with an
antiseize compound. This makes plug
removal easier, especially from aluminum
cylinder heads.
Code No.

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Figure 16. Cutaway resistor-type spark plug. The center

electrode is insulated. The side electrode is grounded
through the engine. (AC Spark Plug Division of General
Motors Corporation)

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14

Some engines have two spark plugs in each

combustion chamber. Both plugs may fire
together or one slightly ahead of the other.
The additional plugs help reduce exhaust
emissions and increase engine power.
Most spark plugs have electrodes made of
nickel and chrome alloys that resist
corrosion. Some ground and lower center
electrodes have a copper core. Other also
have a thin-wire platinum tip. These foul and
misfire less often, last longer, and have a
greater heat range than other plugs.

Figure 17. Spark plugs with center electrodes that have a

(A) copper core and a (B) platinum tip. (Robert Bosch
Corporation)

SPARK PLUG HEAT RANGE AND REACH

Spark plugs are made in different heat
ranges (Fig 18). The heat range indicates
how fast the plug transfers heat from the
combustion chamber to the cylinder head.
This is primarily determined by the length of
the lower insulator. The longer the head path,
the hotter the plug will run. A short path
transfers the heat faster so the plug runs
cooler.
Sooty deposits accumulate on the firing end
of the spark plug if it runs too cold. The end
does not get hot enough to burn away the
deposits. Then the high-voltage surges short
across the deposits instead of jumping the
spark-plug gap. A plug that runs too hot
burns away the electrodes more rapidly. This
can widen the gap so much that the spark
cannot jump it and miss occurs.
Spark plug reach is the distance from the
shell gasket seat (or top of the tapered seat
to the end of the threads. If the reach is too
long, the plug electrodes too far into the
combustion chamber The plug could interfere
with moisture turbulence or be struck by
valve or piston. A plug that does not reach far
enough fail to will fail to ignite the mixture
properly. The recommended spark plugs for
an engine have the correct reach.

Code No.

ALT723304

Figure 18. Heat range and reach of spark plugs. The

longer the heat path, as indicated by arrows, the hotter
the plug runs. (AC Spark plug Division of General Motors
Corporation)

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15

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

Figure 19. Combination ignition-switch and steering-wheel lock,

showing the opening mechanism inside the steering column.
(General Motors Corporation)

In most cars, the ignition key is placed in the ignition lock or lock cylinder in the steering column
(Fig. 19). The ignition switch may attach to the lock, or go further down the steering column
Turning the ignition key moves an actuator rod that operates the ignition switch.
The five positions of the ignition lock are ACCESSORY, LOCK, OFF, RUN, and START. Figure 19
shows how the ignition lock operates the steering-wheel lock. The notched disk is splined to the
top end of the steering shaft. With the automatic transmission in PARK, the driver turns the key
to LOCK. The spring-loaded plunger moves up into a notch in the disk, locking the steering
wheel. This also locks the transmission in park.
If the key will not move to LOCK, turn the
steering wheel until the plunger and a notch
align. Then the spring will force the plunger
up and the key will turn to LOCK. Turning the
key from LOCK to OFF pulls the plunger out of
the notch in the disk. This unlocks the
steering wheel and the transmission.

Code No.

ALT723304

Figure 20. Ignition-system oscilloscope pattern.

Servicing and Repairing Ignition System

Date: Developed Date: Revised

Aug. 15, 2003

Page #

16

SELF CHECK
I. Multiple Choice Test
Instruction: Select the best answer to each question
1. The ignition system performs all the following jobs except
a. controls the compression pressure
b. produces the spark that jumps the spark-plug gap
c. ignites the compressed air-fuel mixture
d. delivers the spark at the proper time
2. The contact-point distributor has two major jobs
a. to advance and retard spark
b. to distribute the high voltage surges and switch the current to the coil on
and off
c. to distribute the battery voltage and switch the current to the spark plugs
on and off
d. to provide centrifugal advance and vacuum advance
3. Technician A says the spark occurs when the contact points open. Technician B
says the spark occurs when the coil magnetic field collapses. Who is right?
a. A only
b. B only
c. both A and B
d. neither A nor B
4. Cross-firing may be caused by all the following except
a. wet distributor cap or rotor
b. defective insulation on secondary cables
c. improper routing of spark-plug cables
d. a fouled spark-plug
II. Identification
1. List the five (5) major components in the contact point ignition system

Code No.

ALT723304

Servicing and Repairing Ignition System

Date: Developed Date: Revised

Aug. 15, 2003

Page #

17

Answer Key
I.
1. a
2. b
3. c
4. d

II.
1. ignition switch
2. ignition coil
3. distributor assembly
4. secondary cable/high tension cables
5. spark plugs

Code No.

ALT723304

Servicing and Repairing Ignition System

Date: Developed Date: Revised

Aug. 15, 2003

Page #

18

QUALIFICATION

AUTOMOTIVE SERVICING NC I

UNIT OF COMPETENCY :

CHECK IGNITION SYSTEM

MODULE TITLE

CHECKING IGNITION SYSTEM

LEARNING OUTCOME #2:

Check Ignition coil, ballast resistor, and high tension cable

resistance

ASSESSMENT CRITERIA :
1. VOM is properly used
2. Specified resistance value is obtained from service manual
3. Procedure in checking resistance is observed in accordance with
manual instruction
RESOURCES

Code No.

ALT723304

Servicing and Repairing Ignition System

Date: Developed Date: Revised

Aug. 15, 2003

Page #

19

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

SPECIAL INSTRUCTIONS

Differentiate analog from digital testers

Have you tried using VOM testers

The next activity will require you to take actual resistance

of the following ignition system components.
1. Conducting ignition system component system testing - refer to self check on LO2-1 (see
on:
back portion for table)
a. ignition coil
b. ballast resistor
c. high tension cable

Code No.

ALT723304

Servicing and Repairing Ignition System

Date: Developed Date: Revised

Aug. 15, 2003

Page #

20

QUALIFICATION

AUTOMOTIVE SERVICING NC I

UNIT OF COMPETENCY :

CHECK IGNITION SYSTEM

MODULE TITLE

CHECKING IGNITION SYSTEM

LEARNING OUTCOME #3 :

Check Distributor Assembly

ASSESSMENT CRITERIA :
1. Distribution terminals & rotor tip cleaned & lubricated
2. Rotor and distributor cap check for crack / current leakage
3. Condenser is tested by charged and discharged process
4. Dwell angle is adjusted / set in accordance to manual
specifications & instructions
5. Cam lube is check for wear
6. Rotor rotation is determined
7. Advance mechanism operation is checked in accordance to
manual instructions
RESOURCES

Code No.

ALT723304

Servicing and Repairing Ignition System

Date: Developed Date: Revised

Aug. 15, 2003

Page #

21

LEARNING EXPERIENCES
Learning Outcome #3 : LO3 CHECK DISTRIBUTOR ASSEMBLY
LEARNING ACTIVITIES

SPECIAL INSTRUCTIONS

Have you tried removing the distributor from the

engine
1. Servicing the distributor cap & rotor
1.1 removing the distributor cap & rotor

Refer to manufacturer service

manual on distributor servicing

1.2 cleaning of terminals & tips

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

Self-check see LO3-1 (see

back for table)

2.1 removing the condenser without damaging

rebated parts.
2.2 replacing the condenser with the approved
replacement

Refer to manufacturer service

manual

2.3 testing the newly replaced condenser

accurately
2.4 adjust dwell angle according to specification

Have you seen the internal parts of the distributor

Have you tried disassembling its pats
3. Inspecting Internal parts of the distributor
3.1 Inspect a) cam lobe for wear
b) rotor for rotation
c) advance mechanism for normal
operation

Refer to manufacturer service

manual
Read p. 392 fig. 3-11 of
Automotive Mechanic Crouse
& Anglin 10th ed.
Read Auto Repair Manual for
Toyota Corolla Series by
Haynes for general procedures
on disassembling &
assembling

After disassembling all of the parts under 3.1 you can

now going to apply the procedure suggested in the
service manual
Note: Inform your trainer after you have completed
the assembling procedure.

See self-check LO3-1

3.2 Answer self-check after assembling

Code No.

ALT723304

Servicing and Repairing Ignition System

Date: Developed Date: Revised

Aug. 15, 2003

Page #

22

SELF-CHECK
Answer the following test items
1. Enumerate briefly the disassembly-assembly procedures that you have performed
1.1____________________________________________
1.2____________________________________________
1.3____________________________________________
1.4____________________________________________
1.5____________________________________________
1.6____________________________________________
1.7____________________________________________
1.8____________________________________________
1.9____________________________________________
2.0____________________________________________
2. State your inspection results in the table provided below
PARTS

RESULT/DESCRIPTION

Cam Lobe
Rotor
Advance
Mechanism
Please record your actual data on the space provided under reading
CAPACITOR TEST
TEST

READING

REMARKS

Charging

Discharging

Leak

Code No.

ALT723304

Servicing and Repairing Ignition System

Date: Developed Date: Revised

Aug. 15, 2003

Page #

23

SELF-CHECK
Answer the following test items
I. Enumerate briefly the disassembly-assembly procedures that you have just performed
1.1___________________________________________
1.2___________________________________________
1.3___________________________________________
1.4___________________________________________
1.5___________________________________________
1.6___________________________________________
1.7___________________________________________
1.8___________________________________________
1.9___________________________________________
2.0___________________________________________

Code No.

ALT723304

Servicing and Repairing Ignition System

Date: Developed Date: Revised

Aug. 15, 2003

Page #

24

PERFORMANCE TEST
Learner's Name

Date

Competency: Check Ignition System

Test Attempt
1st
2nd

Directions:

OVERALL EVALUATION

CALL INSTRUCTOR and ask

him/her to assess your
performance in the following critical
task and performance criteria
indicated below

Level
Achieved

You will be rated based on the

overall evaluation outlined on the
right side.

PERFORMANCE LEVELS

4 - Can perform this skill without supervision and with

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

PERFORMANCE STANDARDS
For acceptable achievement, all items should receive a "Yes" or
"N/A" response.
Ignition system components are identified
Functions of ignition system are understood
Standard clearance and resistance of ignition system components are
determined
Operating principle of the ignition system is explained
VOM is properly used
Specified resistance value is obtained from service manual
Procedure in checking resistance is observed in accordance with the
manual of instructions
Distributor terminal and rotor tips are cleaned and lubricated
Rotor and distributor cap are checked for cracks / current leakage
Condenser is tested by charged and discharged process
Dwell angle is adjusted / set in accordance with the manual of
specifications and instructions
Cam lube is checked for wear
Rotor rotation is determined
Advance mechanism operation is checked in accordance with the
manual of instructions

Code No.

ALT723304

3rd

Servicing and Repairing Ignition System

Yes No

Date: Developed Date: Revised

Aug. 15, 2003

N/A

Page #

25

Learners diary
DIARY NOTES
Record important dates, jobs undertaken and other workplace events that will assist you in providing further
details to an Assessor.
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Code No.

ALT723304

Servicing and Repairing Ignition System

Date: Developed Date: Revised

Aug. 15, 2003

Page #

26

Record of Achievement
Module: Checking Ignition System
LO#1: Identify and explain the function of the ignition system components.
Performance Criteria:
1. Ignition system components are identified.
2. Functions of ignition system are understood.
3. Standard clearance and resistance of ignition system components are determined.
4. Operating principle of the ignition system is explained.
Comments:
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Learner has satisfied the above performance criteria.
Learners signature:.......................................................................
Trainers signature:........................................................................
Date:..............................................................................................

Code No.

ALT723304

Servicing and Repairing Ignition System

Date: Developed Date: Revised

Aug. 15, 2003

Page #

27

Record of Achievement
Module: Checking Ignition System
LO#2: Check ignition coil, ballast resistor, high tension cable resistance.
Performance Criteria:
1. VOM is properly used.
2. Specified resistance value is obtained from service manual
3. Procedure in checking resistance is observed in accordance with the manual of
instructions
Comments:
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Learner has satisfied the above performance criteria.

Learners signature:.......................................................................
Trainers signature:........................................................................
Date:..............................................................................................

Code No.

ALT723304

Servicing and Repairing Ignition System

Date: Developed Date: Revised

Aug. 15, 2003

Page #

28

Record of Achievement
Module: Checking Ignition System
LO#3: Check distributor assembly.
Performance Criteria:
1.
2.
3.
4.

Distributor terminal and rotor tips are cleaned and lubricated

Rotor and distributor cap are checked for cracks / current leakage
Condenser is tested by charged and discharged process
Dwell angle is adjusted / set in accordance with the manual of specifications and
instructions
5. Cam lube is checked for wear
6. Rotor rotation is determined
7. Advance mechanism operation is checked in accordance with the manual of
instructions
Comments:
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Learner has satisfied the above performance criteria.
Learners signature:.......................................................................
Trainers signature:........................................................................
Date:..............................................................................................

Code No.

ALT723304

Servicing and Repairing Ignition System

Date: Developed Date: Revised

Aug. 15, 2003

Page #

29

Record of Achievement
Module: Testing and Servicing Automotive Battery
LO#3: Demonstrate the correct procedure on how to remove and replace batteries.
Performance Criteria:
1. Battery is removed without causing damage to the workplace, property or vehicle.
2. Proper procedure is followed in removing/ replacing battery.
3. Proper procedure is followed to prevent loss of vehicle electronics memory as per
manufacturers standards (if applicable.)
4. Appropriate tools and equipment are used.
5. Personal safety in removing and replacing battery is observed.
Comments:
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Learner has satisfied the above performance criteria.
Learners signature:.......................................................................
Trainers signature:........................................................................
Date:..............................................................................................

Code No.

ALT723304

Servicing and Repairing Ignition System

Date: Developed Date: Revised

Aug. 15, 2003

Page #

30

Terms and Definitions

Battery - an electrochemical device for storing energy in chemical form so that it can be
released as electricity for cranking the engine and powering the electrical load.
Battery Acid the electrolyte used in a battery; a mixture of sulfuric acid and water.
Battery Charger an equipment used to charge battery capacity given in ampere hours.
Cell tester a testing device used to measure the voltage of each cell of battery.
Circuit the complete path of an electric current including current source.
Corrosion a process of combining one metal with oxygen producing an undesirable
product.
Electrolyte - the liquid mixture of about 40% sulfuric acid and 60% water in a fully charged
lead-acid storage battery.
Hydrometer a testing device used to measure the specific gravity of battery electrolyte.
Load tester- an instrument used to measure the capacity or load of a battery.
Multi-tester a device used to measure two or more instruments.
Plate Strap a part of a battery which is composed of both negative and positive
accessories
Polarity - the quality of an electric component or circuit that determines the direction of
current flow.
Side Terminal the positive or negative terminal found in a maintenance free battery type.
Volt meter an instrument used to measure the electromotive force or voltage of a battery.

Code No.

ALT723304

Servicing and Repairing Ignition System

Date: Developed Date: Revised

Aug. 15, 2003

Page #

31