Student Workbook1

10-1831-T
2005 Edition
Student
Test Packet
Automotive
Technology
Curriculum
Automotive
Technology
Curriculum
Module 3: Engine Performance
Section 1: Ignition Systems
70-1831-W
2005 Edition
Student
Workbook

ENGINE PERFORMANCE: IGNITION SYSTEMS
i
Automotive Technology
Student Workbook
Produced by the Instructional Materials Laboratory
1400 Rock Quarry Center
University of Missouri-Columbia
Columbia, MO 65211
(800) 669-2465
http://www.iml.missouri.edu
2005 Edition
Catalog no. 70-1831-W
2005. The Curators of the University of Missouri.
All Rights Reserved.
Technical
Consultant:
Robin Ferguson
Project
Coordinator:
Erica Kassel
Graphic
Artists:
Chris Benedict
Jacqueline Craig
AUTOMOTIVE TECHNOLOGY
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i i i
Name:
MODULE 3: ENGINE PERFORMANCE
SECTION 1: IGNITION SYSTEMS
STUDENT WORKBOOK TRACKING SHEET
Assignment
Sheet
Title of Assignment Sheet
Instructor
Guide
Page #
Student
Workbook
Page #
Date
Instructors
Initials
AS1-L1-UIII Computerized Engine Controls 141-144 W 49-50
AS1-L1-UIV Distributor Ignition Systems 225-228 W 71-72
AS1-L1-UV Electronic Ignition Systems 287-290 W 95-96
Job Sheet Title of Job Sheet
Instructor
Guide
Page #
Student
Workbook
Page #
Date
Instructors
Initials
JS1-L1-UII Complete a Work Order with Concern,
Cause, and Correction
31-32 W 1-2
JS2-L1-UII Identify and Interpret Engine Performance
Concern
33-34 W 3-4
JS3-L1-UII Perform a Preliminary Engine Inspection 35-38 W 5-8
JS1-L2-UII Perform Engine Absolute Manifold Pressure
Tests
53-56 W 9-12
JS2-L2-UII Perform a Cylinder Power Balance Test 57-60 W 13-16
JS3-L2-UII Perform Cranking Engine Cylinder
Compression Tests
61-64 W 17-20
JS4-L2-UII Perform a Running Engine Cylinder
Compression Test
65-68 W 21-24
JS5-L2-UII Perform a Cylinder Leakage Test 69-72 W 25-28
JS1-L3-UII Perform Engine System Diagnostic Tests
Using an Oscilloscope
91-94 W 29-32
JS2-L3-UII Perform an Exhaust Gas Diagnostic Test 95-96 W 33-34
JS3-L3-UII Verify Engine Operating Temperature 97-100 W 35-38
JS4-L3-UII Inspect, Test, and Service the Cooling
System
101-106 W 39-44
JS5-L3-UII Drain, Flush, and Refill the Cooling System 107-108 W 45-46
JS6-L3-UII Verify Correct Camshaft Timing 109-110 W 47-48
JS1-L2-UIII Obtain and Interpret Diagnostic Trouble
Codes and Scan Tool Data
155-156 W 51-52
JS2-L2-UIII Diagnose the Causes of Emissions or
Driveability Concerns Using Stored
Diagnostic Trouble Codes
157-158 W 53-54
JS3-L2-UIII Diagnose the Causes of Emissions or
Driveability Concerns with No Stored
Diagnostic Trouble Codes
159-160 W 55-56
JS4-L2-UIII Check for Module Communication Errors 161-162 W 57-58
JS1-L3-UIII Test and Service Computerized Engine
Controls Using a Digital Multimeter
191-194 W 59-62
Controls Using a Scan Tool
195-198 W 63-66
Controls Using a Graphing
Multimeter/Digital Storage Oscilloscope
199-202 W 67-70
JS1-L2-UIV Diagnose Ignition System Problems on a
Vehicle with a Distributor Ignition System
249-252 W 73-76
JS2-L2-UIV Inspect, Test, and Service the Primary
Circuit and Ignition Coil
253-256 W 77-80

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Name:
MODULE 3: ENGINE PERFORMANCE
SECTION 1: IGNITION SYSTEMS
STUDENT WORKBOOK TRACKING SHEET
Job Sheet Title of Job Sheet
Instructor
Guide
Page #
Student
Workbook
Page #
Date
Instructors
Initials
JS3-L2-UIV Check and Adjust Ignition Timing and
Timing Advance/Retard
257-260 W 81-84
JS4-L2-UIV Inspect, Test, and Service the Distributor 261-266 W 85-90
JS5-L2-UIV Inspect, Test, and Service Secondary Circuit
Wiring and Spark Plugs
267-270 W 91-94
JS1-L2-UV Diagnose Ignition Systems Problems on a
Vehicle with an Electronic Ignition System
299-302 W 97-100
JS2-L2-UV Inspect, Test, and Service the Primary
Circuit and Ignition Coils
303-306 W 101-104
JS3-L2-UV Inspect, Test, and Service Secondary Circuit
Wiring and Spark Plugs
307-310 W 105-108
JS1-L1-UVI Check and Adjust Valve Lash on Engines 337-338 W 109-110
JS2-L1-UVI Remove and Replace Timing Belt/Chain 339-340 W 111-112
JS3-L1-UVI Inspect, Test, and Service Thermostat and
Components
341-344 W 113-116
JS4-L1-UVI Inspect, Test, and Service Fans and Fan
Components
345-348 W 117-120
JS5-L1-UVI Perform Common Fastener and Thread
Repairs
349-350 W 121-122
JS6-L1-UVI Perform an Oil and Filter Change 351-354 W 123-126
JS7-L1-UVI Identify Hybrid Vehicle Internal
Combustion Engine Service Precautions
355-356 W 127-128
JS1-L2-UVI Heat and Cut Metal Using an Oxyfuel Torch 367-370 W 129-132

W 1
JS1-L1-UII
COMPLETE A WORK ORDER WITH CONCERN, CAUSE, AND
CORRECTION
Directions:
1. The instructor will list a repair. Complete the work order on the
following page for the repair.
To receive credit, all sections of the work order must be complete.
Credit received for completing work order
NAME:
DATE:
EVALUATION
W 2
Smiths Automotive Repair
Customers Name: Date: Invoice #:
Address: Phone:
Year/Make: Model: VIN: Mileage:
Service Writer: Technician:
Customer Authorization Signature:
Customer Concern:

Vehicle Service History Information:

Related Technical Service Bulletins:

Diagnostic Procedures Performed:

Cause:

Correction:

Labor Procedures and Costs Estimated Actual

Outside Labor Procedures and Costs

Total Labor Costs
Parts Costs
Quantity Part # Description

Total Parts Costs
Labor Total
Parts Total
Sales Tax
GRAND TOTAL
W 3
NAME:
DATE:
EVALUATION
JS2-L1-UII
IDENTIFY AND INTERPRET ENGINE PERFORMANCE CONCERN
Equipment:
Personal protective equipment (PPE)
Service information
Procedure:
1. Wear PPE while performing the procedures on this job sheet.
2. Ask the customer to describe the engine performance concern. Record
concern in the space provided.
3. Ask the customer the following series of questions. Record the answers in
the space provided.
a. When did the concern first occur?
b. Is the malfunction indicator light on or flashing?
c. Is the concern continuous or intermittent?
W 4
d. What are the driving conditions when the concern occurs?
e. Is the vehicle making any unusual noises or vibrations?
f. What is the recent service history of the vehicle?
4. Based on the answers to the questions, determine the next step in the
diagnostic process for the vehicle. Record in the space provided.
Average of the above evaluations
W 5
NAME:
DATE:
EVALUATION
JS3-L1-UII
PERFORM A PRELIMINARY ENGINE INSPECTION
Equipment:
Procedure:
CAUTION: Perform steps 4 and 5 outdoors because the tests must be done
without exhaust ventilation equipment connected to the tail pipe.
2. Research applicable vehicle service information such as vehicle service
history, VIN, certification labels, and calibration decals. Record the
necessary information in the space provided.
3. Perform a visual engine inspection. Complete the chart.

OK Not OK
Installation and routing of spark plug wires

Condition of primary wiring terminals and
connectors for secure connections

Battery terminals for corrosion or looseness

Cleanliness of air filter elements

Drive belts for looseness or wear

Oil leaks on the spark plug wires and other parts

Coolant level

Coolant leaks

Fuel leaks at the fuel tank, fuel lines, fuel pump, and
carburetor/fuel injectors

Other leaks

W 6
4. Start the engine. Listen for abnormal engine noises or vibrations using a
stethoscope, long screwdriver, or a section of vacuum hose for vacuum
and air pressure leaks. See Section III.C.3. for a description of various
engine noises or vibrations. Record observations in the space provided.
Shut off the engine.
5. Start the engine. Perform a visual inspection of the exhaust system. See
Section III.D. for normal occurences and problem indicators. Complete
the chart. Shut off the engine.

OK Not OK
Engine started cold
Exhaust color
Exhaust sound
Exhaust odor
Engine at warm idle
Exhaust color
Exhaust sound
Exhaust odor
Engine speed at 2000 rpm
Exhaust color
Exhaust sound
Exhaust odor
W 7
6. Based on the preliminary engine inspection, determine the necessary
action to correct any problems. Include further diagnosis and/or repairs.
W 8
W 9
JS1-L2-UII
PERFORM ENGINE ABSOLUTE MANIFOLD PRESSURE TESTS
Equipment:
Exhaust ventilation equipment
Tachometer
Vacuum gauge
Vacuum hose
Procedure:
3. Connect the exhaust ventilation equipment.
CAUTION: Be sure to use approved exhaust ventilation equipment
when operating the vehicle in an enclosed area.
4. Perform a vacuum gauge test.
a. Connect the vacuum gauge to an intake manifold vacuum source.
Connect a vacuum hose to an accessible intake manifold vacuum
connector and extend it up to the vacuum gauge.
b. Start the engine and allow it to reach normal operating
temperature.
c. Observe and record the reading with the engine at idle speed in the
space provided.
d. Shut off the engine. Disconnect the test equipment.
NAME:
DATE:
EVALUATION
W 10
5. Perform an exhaust restriction test.
a. Connect the vacuum gauge to an intake manifold vacuum source.
Connect a vacuum hose to an accessible intake manifold vacuum
connector and extend it up to the vacuum gauge.
b. Connect a tachometer to the engine.
c. Start the engine. Gradually accelerate the engine rpm from idle to
2,000 rpm. Observe and record the reading in the space provided.
d. Maintain the engine speed at 2,000 rpm for about 10 seconds or
longer. Observe and record the reading in the space provided.
e. Shut off the engine. Disconnect the test equipment.
6. Perform a cranking vacuum test.
a. Start the engine and allow it to reach normal operating
temperature. Shut off the engine.
b. Connect a vacuum gauge to a nonported vacuum source on the
intake manifold.
c. Disable the ignition system.
d. Completely block the throttle valve so that air cannot enter.
e. Crank the engine. Observe and record the cranking vacuum.
W 11
f. Disconnect the vacuum gauge.
g. Unblock the throttle valve. Enable the ignition.
7. Disconnect the exhaust ventilation equipment.
8. Based on the tests, determine the necessary action to correct any
problems. Include further diagnosis and/or repairs.
W 12
W 13
NAME:
DATE:
EVALUATION
JS2-L2-UII
PERFORM A CYLINDER POWER BALANCE TEST
Equipment:
Cylinder balance tester
Tachometer
Procedure:
3. Using service information, locate a procedure for connecting a cylinder
balance tester to the engine. Make sure the procedure is appropriate for
the make and model of the vehicle. Have the instructor check the box to
approve the procedure.
Using the procedure, connect the cylinder balance tester to the engine.
NOTE: This test may also be performed using an engine analyzer or scan
tool.
4. Connect a tachometer to the engine if it is not part of the cylinder balance
tester.
CAUTION: Be sure to use the approved exhaust ventilation
equipment when operating the vehicle in an enclosed area.
W 14
6. Start the engine and allow it to reach normal operating temperature.
Shut off the engine.
7. Disconnect the oxygen sensor and unplug the exhaust gas recirculation
(EGR) hose or connector.
8. Restart the engine. Bring the engine speed to 1,000 rpm and maintain
that speed.
9. Select the cylinder shorting mode on the cylinder balance tester. Disable
the idle air control on a fuel-injected engine.
10. Short each cylinder for the same amount of time, about 2 seconds to 3
seconds. Give the engine about 5 seconds between each short.
11. Observe the tachometer for the amount of rpm drop on each cylinder.
Record the reading in the following chart.
Cylinder Percent of rpm Drop
1

2

3

4

5

6

7

8

12. Shut off the engine. Disconnect the test equipment. Disconnect the
exhaust ventilation equipment.
13. Reconnect the oxygen sensor and the EGR hose or connector.
W 15
14. Clear the codes.
W 16
W 17
NAME:
DATE:
EVALUATION
JS3-L2-UII
PERFORM CRANKING ENGINE CYLINDER COMPRESSION TESTS
Equipment:
Compressed air
Compression gauge
Procedure:
CAUTION: Be sure to use approved exhaust ventilation
4. Perform a cranking engine cylinder compression test with the throttle
closed.
temperature.
b. Shut off the engine.
c. Disable the ignition and fuel systems.
d. Remove the air filter.
e. Use compressed air to blow debris away from the spark plugs.
Remove the spark plugs.
f. Install the compression gauge in one cylinder.
W 18
g. Crank the engine at least four compression strokes. If the engine
cranks slowly, the readings are not accurate. Charge the battery.
Then, test the battery, starting, and charging systems. It may be
necessary to keep a battery charger on the battery to perform this
test.
h. Observe the compression gauge. Record the readings of the first
puff and at the highest point in the chart.
Cylinder

First "Puff"
Reading
Highest
Point
OK
Yes or No
1

2

3

4

5

6

7

8

i. Repeat the procedure for each cylinder. Record the readings in the
chart.
j. Remove the compression gauge. Reinstall the air filter and spark
plugs. Enable the ignition and fuel systems.
5. Perform a cranking engine cylinder compression test with the throttle
open.
temperature.
b. Shut off the engine.
c. Disable the ignition and fuel systems.
d. Remove the air filter.
W 19
e. Block the throttle valve to the wide open position.
f. Use compressed air to blow debris away from the spark plugs.
Remove the spark plugs.
g. Install the compression gauge in one cylinder.
h. Crank the engine at least four compression strokes. If the engine
cranks slowly, the readings are not accurate. Charge the battery.
Then, test the battery, starting, and charging systems. It may be
necessary to keep a battery charger on the battery to perform this
test.
i. Observe the compression gauge. Record the readings of the first
puff and at the highest point in the chart.
Cylinder

First "Puff"
Reading
Highest
Point
Change from
Closed Throttle
Yes or No
1

2

3

4

5

6

7

8

j. Repeat the procedure for each cylinder. Record the readings in the
chart.
k. Unblock the throttle valve.
l. Remove the compression gauge. Reinstall the air filter and spark
plugs. Enable the ignition and fuel systems.
W 20
W 21
JS4-L2-UII
PERFORM A RUNNING ENGINE CYLINDER COMPRESSION TEST
Equipment:
Compressed air
Compression gauge
Spark tester
Procedure:
5. Shut off the engine.
6. Use compressed air to blow debris away from the spark plugs. Remove
one spark plug and connect a spark tester to the plug wire.
7. Install the compression gauge in the cylinder.
8. Start the engine and allow it to idle.
9. Release the compression gauge pressure.
NAME:
DATE:
EVALUATION
W 22
10. Observe the reading at idle. Record the reading in the chart.
Cylinder

Idle
Compression
1500 rpm
Compression
Snap
Compression
1

2

3

4

5

6

7

8

11. Slowly raise the engine speed to 1,500 rpm. Observe the reading. Record
the reading in the chart.
12. Return the engine speed to idle.
13. Release the compression gauge pressure.
14. Snap the throttle open and then closed. Observe the reading. Record the
reading in the chart.
15. Repeat the procedure for each cylinder. Record the readings in the chart.
17. Remove the compression gauge. Remove the spark tester and reinstall the
spark plug.
W 23
W 24
W 25
JS5-L2-UII
PERFORM A CYLINDER LEAKAGE TEST
Equipment:
Compressed air
Cylinder leakage tester
Procedure:
6. Remove the air filter.
7. Block the throttle valve to the wide open position.
8. Use compressed air to blow debris away from the spark plugs. Remove
the spark plugs.
9. Remove the crankcase filler cap.
10. Check the coolant level. If necessary, refill the radiator.
11. Rotate the engine until the cylinder is at top dead center.
NAME:
DATE:
EVALUATION
W 26
12. Using service information, locate a procedure for calibrating and
connecting a cylinder leakage tester. Make sure the procedure is
appropriate for the make and model of the vehicle. Have the instructor
check the box to approve the procedure.
Using the procedure, calibrate and connect the cylinder leakage tester.
13. Observe and record the reading in the chart.
Cylinder Percent of Leakage
1

2

3

4

5

6

7

8

14. Repeat the procedure for each cylinder. Record the readings in the chart.
W 27
15. If there is excessive cylinder leakage, listen at the different points to
determine the source of the leak. See Section IV.A.13. for listening
locations. Record the source of leakage in the space provided.
16. Disconnect the cylinder leakage tester.
17. Unblock the throttle valve.
18. Reinstall the air filter and spark plugs. Replace the crankcase filler cap.
W 28
W 29
JS1-L3-UII
PERFORM ENGINE SYSTEM DIAGNOSTIC TESTS USING AN
OSCILLOSCOPE
Equipment:
Oscilloscope
Procedure:
2. Research applicable vehicle service information, such as vehicle service
history, VIN, certification labels, and calibration decals. Include pattern
specifications. Record the necessary information in the space provided.
3. Using service information, locate a procedure for connecting an
oscilloscope to the engine. Make sure the procedure is appropriate for the
oscilloscope and make and model of the vehicle. Have the instructor
check the box to approve the procedure.
Using the procedure, connect the oscilloscope to the engine.
4. Check service information for engine size, dwell time, and firing order.
Record in the spaces provided.
Engine Size
Dwell Time
Firing Order
when operating the vehicle in an enclosed area.
NAME:
DATE:
EVALUATION
W 30
7. Check the primary raster pattern for dwell time, primary on, primary off,
coil oscillations, and uneven primary off trace. Compare patterns to
manufacturers specifications. Record observations in the space provided.
8. Check the secondary parade pattern. Compare patterns to
manufacturers specifications. Answer the questions.
a. Are the firing spikes even (within 3 kilovolts of each other and
between 5 kilovolts and 15 kilovolts in height)? Complete the chart.
Cylinder Firing kilovolts Burn kilovolts Burn Time
1

2

3

4

5

6

7

8

b. Are the firing lines normal?
W 31
c. Are all cylinders similar?
9. Check the secondary raster pattern for even firing lines, primary on,
dwell time, and coil oscillations. Compare patterns to manufacturers
specifications. Record observations in the space provided.
10. Shut off the engine and disconnect the oscilloscope. Disconnect the
exhaust ventilation equipment.
11. Based on the tests, determine necessary action to correct any problems.
Include further diagnosis and/or repairs.
W 32
W 33
JS2-L3-UII
PERFORM AN EXHAUST GAS DIAGNOSTIC TEST
Equipment:
Exhaust gas analyzer
Procedure:
necessary information in the following space.
3. Using manufacturers information, locate a procedure for connecting an
exhaust gas analyzer. Have the instructor check the box to approve the
procedure.
Using the procedure, connect the exhaust gas analyzer.
NOTE: It may be necessary to block the source of air to the catalytic
converter. A catalytic converter that works properly cleans the exhaust
gases and makes it difficult to get an accurate reading.
4. Turn on the exhaust gas analyzer and allow it to warm up.
5. Zero and calibrate the exhaust gas analyzer.
NAME:
DATE:
EVALUATION
W 34
7. Check the exhaust gas analyzer readings. Compare readings to proper
8. Shut off the engine. Disconnect the exhaust gas analyzer.
9. Based on the test, determine necessary action to correct any problems.
W 35
JS3-L3-UII
VERIFY ENGINE OPERATING TEMPERATURE
Equipment:
Digital multimeter with temperature probe
Direct-read, probe-type (cooking) thermometer
Noncontact infrared thermometer
Procedure:
NOTE: There are three different methods for verifying engine operating
temperature. The instructor will choose the appropriate method.
when operating a vehicle in an enclosed area.
4. Verify engine operating temperature using a noncontact infrared
thermometer.
a. Start the engine and allow it to run until warm.
b. Aim the infrared thermometer at the cylinder head and measure the
temperature. Compare reading to manufacturers specifications.
Record observations in the space provided.
c. Shut off the engine.
NAME:
DATE:
EVALUATION
W 36
5. Verify engine operating temperature using a digital multimeter with a
temperature probe.
a. Place the temperature probe on the engine near the thermostat, on
the top radiator hose, or into the coolant in the radiator (not in the
overflow recovery tank).
CAUTION: Never remove a radiator cap unless the engine is
sufficiently cool. Removing the radiator cap when the engine is
hot can cause scalding hot coolant to be sprayed over a wide area,
resulting in serious injury.
b. Start the engine and allow it to run until warm.
c. Monitor the temperature reading. Compare reading to
manufacturers specifications. Record observations in the space
provided.
d. Shut off the engine.
6. Verify engine operating temperature using a direct-read, probe-type
(cooking) thermometer.
a. Place the thermometer probe into the coolant in the radiator or tape
the thermometer to the top radiator hose.
b. Start the engine and allow it to run until warm.
c. Observe the reading. Compare reading to manufacturers
d. Shut off the engine.
W 37
8. Based on the test, determine necessary action to correct any problems.
W 38
W 39
JS4-L3-UII
INSPECT, TEST, AND SERVICE THE COOLING SYSTEM
Equipment:
Combustion leak tester
Hand tools
Pressure tester
Procedure:
3. Inspect the cooling system. Complete the chart.
OK Not OK
Radiator cap
Hoses
Outer shell of the radiator
Coolant passages inside the radiator
Coolant recovery tank

4. Pressure test the cooling system for leaks.
a. Connect a pressure tester to the radiator filler neck.
CAUTION: Never remove a radiator cap unless the engine is
sufficiently cool. Removing the radiator cap when the engine is
hot can cause scalding hot coolant to be sprayed over a wide area,
resulting in serious injury.
NAME:
DATE:
EVALUATION
W 40
b. Pump the pressure tester until the pressure reaches the release
pressure mark on the radiator cap. Check the cooling system for
leaks. Complete the chart.
OK Not OK
Radiator tank and cooling fins and tubes
Heater core
On the ground
On the floor under the engine
On the right front carpet in the passenger
compartment

Water pump drive shaft where the pulley is connected
Hoses and hose connections
Engine and thermostat gaskets
Engine freeze (core) plugs
c. Check the engine oil and transmission fluid for coolant
contamination. Record observations in the space provided.
d. Monitor the reading for 15 minutes. Record observations in the
space provided.
e. Relieve the pressure and disconnect the pressure tester.
f. Connect the pressure tester to the radiator cap and test the pressure
release point. Compare to manufacturers specifications. Record
observations in the space provided.
g. Relieve the pressure and disconnect the pressure tester.
W 41
6. Test the cooling system for combustion gas leakage. The instructor will
select one of the three methods.
a. Test using a pressure tester.
1. Connect the pressure tester. Do not pressurize the cooling
system.
2. Start the engine and monitor the reading. Record observations
in the space provided.
3. Shut off the engine. Disconnect the pressure tester.
b. Test using a combustion leak tester.
1. Place the tester in the filler opening of the cooling system
(radiator or reservoir).
2. Start the engine. Squeeze and release the tester bulb to get an
air sample.
3. Observe the color of the test fluid in the tester. Record
c. Test using an exhaust gas analyzer.
1. Remove the filler cap (radiator or reservoir).
2. Start the engine. Place the exhaust gas analyzer probe near
the cooling system filler opening.
3. Observe the readings and increase engine speed. Record
W 42
CAUTION: Do not allow coolant to be sucked into the
exhaust gas analyzer. Coolant pulled into the analyzer will
damage the analyzer.
8. Inspect the condition of the coolant.
a. Remove the radiator cap.
b. Check the coolant color. Record observations in the space provided.
c. Feel the coolant between the fingers. Record observations in the
space provided.
d. Replace the radiator cap.
9. Test the coolant recovery system.
a. Obtain the instructors permission to perform a road test. Have the
instructor check the box to approve the road test.
b. Drive the vehicle for several miles.
c. Shut off the engine.
W 43
d. Observe the level in the coolant recovery tank. Record observations
e. Allow the cooling system to completely cool down.
f. Remove the radiator cap and check the coolant level. Record
g. Inspect the coolant recovery system if a problem is found.
Complete the chart.
OK Not OK
Hose and hose connections between the
radiator and the coolant recovery tank

Coolant recovery tank
Radiator cap gasket and valve

10. Determine the type of service that needs to be performed based on the
inspections and test results. Record in the space provided.
W 44
11. Using service information, locate a procedure for servicing defective
cooling system components. Make sure the procedure is appropriate for
the make and model of the vehicle. Have the instructor check the box to
approve the procedure. (For general procedures, see section IV.F.)
Using the procedure, service defective cooling system components.
W 45
JS5-L3-UII
DRAIN, FLUSH, AND REFILL THE COOLING SYSTEM
Equipment:
Coolant
Fresh water
Hand tools
Procedure:
3. Remove the radiator cap. Make sure the petcock can open freely.
4. Remove the thermostat housing and the thermostat. Clean the mating
surfaces of the thermostat housing and the engine to remove the old
gasket/seal.
8. Open the petcock, allowing the coolant to drain completely from the
radiator.
CAUTION: Used coolant is classified as toxic waste and must be
disposed of according to law.
9. Remove one of the heater hoses and connect a supply of fresh water to
the hose end that leads into the heater.
NAME:
DATE:
EVALUATION
W 46
10. Allow the cooling system to fill.
11. When the system is full, start the engine and allow it to idle.
12. Adjust the water flow so that the radiator stays full while the drain is
running wide open. Keep the engine and the fresh water running until
the discharge fluid runs clear.
13. Shut off the engine. Let the drain run until it stops and then close the
petcock.
14. Install the thermostat with the wax-filled pellet toward the inside of the
engine. Center the thermostat in the housing. Install the new gasket/seal
and thermostat housing. Use the correct sealer to install the gasket.
15. Reconnect the heater hose.
16. Using service information, select the correct coolant and determine
coolant capacity for the vehicle. Have the instructor check the box to
approve the coolant type. Record correct coolant and coolant capacity in
the space provided.
17. Using the correct coolant capacity, measure coolant at half this capacity
and add to the radiator. Pour the coolant down the radiator filler neck.
18. Continue to fill the radiator with clean, fresh water. Fill to proper
specifications.
19. Start the engine and allow it to reach normal operating temperature. The
coolant should start to circulate and the upper radiator tank should
become warm. Bleed the system, if necessary.
20. If the cooling system is working properly, top off the radiator with clean
water and replace the radiator cap.
21. Shut off the engine. Disconnect the exhaust ventilation equipment.
W 47
JS6-L3-UII
VERIFY CORRECT CAMSHAFT TIMING
Equipment:
Hand tools
Procedure:
3. Determine the engine type of the vehicle. (For nonoverhead camshaft
engines, go to step 4. For overhead camshaft engines, go to step 5.)
Record in the space provided.
4. Using service information, locate a procedure for verifying correct
camshaft timing with the valve timing components located in the block
(nonoverhead camshaft engine). Make sure the procedure is appropriate
for the make and model of the vehicle. Have the instructor check the box
to approve the procedure. (For a general procedure, see section V.A.)
NAME:
DATE:
EVALUATION
W 48
Using the procedure, verify correct camshaft timing with the valve timing
components located in the block (nonoverhead camshaft engines).
5. Using service information, locate a procedure for verifying correct
camshaft timing in an overhead camshaft engine. Make sure the
procedure is appropriate for the make and model of the vehicle. Have the
instructor check the box to approve the procedure. (For a general
procedure, see section V.B.)
Using the procedure, verify correct camshaft timing in an overhead
camshaft engine. Record observations in the space provided.
W 49
AS1-L1-UIII
COMPUTERIZED ENGINE CONTROLS
Directions Answer the following questions by writing all responses on this
sheet.
1. A. What is the function of the engine control computer?
B. What is the function of the instrumentation computer?
2. A. What is the purpose of RAM?
B. What is the purpose of the buffer?
3. Does a permanent magnet signal generator produce an AC or DC signal
to monitor speed and position of moving parts?
4. What is the purpose of the solenoid?
NAME:
DATE:
W 50
5. When is scan tool snapshot information used?
W 51
JS1-L2-UIII
OBTAIN AND INTERPRET DIAGNOSTIC TROUBLE CODES AND
SCAN TOOL DATA
Equipment:
Scan tool
Procedure:
3. Determine if the system uses on-board diagnostics generation one (OBD I)
or on-board diagnostics generation two (OBD II). Record in the space
provided.
4. Connect the scan tool to the data link connector.
5. Check the digital reading for stored diagnostic trouble codes (DTCs).
NAME:
DATE:
EVALUATION
W 52
6. Check the data stream information. Compare to manufacturers
specifications. Record in the space provided.
7. Check stored snapshot information. Record in the space provided.
8. Using available service information, interpret the scan tool data. Record
9. When applicable, clear the codes.
10. Disconnect the scan tool.
W 53
NAME:
DATE:
EVALUATION
JS2-L2-UIII
DIAGNOSE THE CAUSES OF EMISSIONS OR DRIVEABILITY
CONCERNS USING STORED DIAGNOSTIC TROUBLE CODES
Equipment:
Scan tool
Procedure:
provided.
5. Check the digital reading for stored diagnostic trouble codes (DTCs).
W 54
6. Check the datastream information for sensor output and actuator
operation relating to the DTCs or driveability concerns. Record abnormal
readings in the space provided.
7. With the scan tool, test for malfunction of interrelated systems. Complete
the chart.

OK Not OK
Cruise Control
Security System
Suspension Controls
Traction Controls
Heating System
Air Conditioning System
Automatic Transmission
Accessories not Installed by the Original Manufacturer
Similar Systems Particular to the Vehicle
8. Using available service information, interpret the scan tool data.
Determine necessary action to correct the emissions or driveability
concern. Record in the space provided.
9. When applicable, clear the DTCs.
W 55
NAME:
DATE:
EVALUATION
JS3-L2-UIII
DIAGNOSE THE CAUSES OF EMISSIONS OR DRIVEABILITY
CONCERNS WITH NO STORED DIAGNOSTIC TROUBLE CODES
Equipment:
Scan tool
Procedure:
provided.
5. Check the digital reading. If the vehicle has stored diagnostic trouble
codes (DTCs), see JS2-L2-UIII to continue diagnosis.
6. Check the datastream information for sensor output and actuator
operation relating to the DTCs or driveability concerns. Record abnormal
readings in the space provided.
W 56
7. Based on the datastream information and available service information,
determine necessary action to correct the emissions or driveability
concern. Include further diagnosis and/or repairs.
W 57
JS4-L2-UIII
CHECK FOR MODULE COMMUNICATION ERRORS
Equipment:
Scan tool
Procedure:
3. Connect the scan tool equipped with LAN and CAN capability to the
data link connector. If necessary, enter vehicle information.
4. Set the scan tool to check for LAN and CAN diagnostic trouble codes
(DTCs).
5. Check the digital reading for stored DTCs. Record in the space provided.
6. Using available service information, interpret the scan tool data.
Determine necessary action to correct module communication errors.
NAME:
DATE:
EVALUATION
W 58
7. When applicable, clear the DTCs.
W 59
JS1-L3-UIII
TEST AND SERVICE COMPUTERIZED ENGINE CONTROLS USING A
DIGITAL MULTIMETER
Equipment:
Digital multimeter (DMM)
Procedure:
3. Test the wiring and wiring circuits.
a. Check the reference voltage to the sensors.
1. Locate the sensor to be tested.
2. Determine the wire that carries reference voltage from the
powertrain control module (PCM) to the sensor, the wire that
returns the voltage signal, and the wire that grounds the
sensor.
3. Select the direct current (DC) voltage function on the DMM
and set to the proper range.
4. Connect the red probe to the harness connector of the
reference voltage wire and the black probe to the negative
battery cable.
NAME:
DATE:
EVALUATION
W 60
5. Check the reading. Compare to manufacturers specifications.
6. If reference voltage is nonexistent or not within specifications,
check for loose or corroded wire connections back to the PCM.
7. If the connections are not loose or corroded, check the
continuity of the reference voltage wiring back to the PCM.
8. Disconnect the DMM.
b. Check wiring continuity.
1. Select the resistance function on the DMM and set to the
lowest range.
2. Connect the red lead to the wire being tested and the black
lead to a good ground.
5. Repair the circuit if an open is found.
c. If the reference voltage circuit connections are good and the circuit
is continuous, perform an inspection of the electrical system that
sends current to the PCM.
W 61
4. Using service information, locate a procedure for testing sensors and
actuators with a DMM. Include specifications for hertz, volts, ohms, etc.
Make sure the procedure is appropriate for the make and model of the
vehicle. Have the instructor check the box to approve the procedure.
Using the procedure, test the sensors and actuators with a DMM.
Complete the chart.

Specifications Reading OK Not OK
SENSORS
CKP Sensor and Other Permanent
Magnet Signal Generators

Hall-effect Sensor

ECT Sensor

IAT Sensor

TP Sensor

Frequency-Signal MAP Sensor

Simple-Voltage MAP Sensor

Frequency-Signal MAF Sensor

Simple-Voltage MAF Sensor

VAF Sensor

O2S

KS

ACTUATORS
Solenoids

Relays

Servo Motor

W 62
5. Using service information, locate a procedure for servicing problems
found during testing with the computerized engine controls. Make sure
the procedure is appropriate for the make and model of the vehicle. Have
the instructor check the box to approve the procedure.
Using the procedure, service problems found during testing with the
computerized engine controls.
W 63
JS2-L3-UIII
SCAN TOOL
Equipment:
Bidirectional scan tool capable of performing actuator tests
Scan tool
Procedure:
3. Test the wiring and wiring circuits.
a. Check the reference voltage to the sensors.
1. Locate the sensor to be tested.
2. Determine the wire that carries reference voltage from the
powertrain control module (PCM) to the sensor, the wire that
returns the voltage signal, and the wire that grounds the
sensor.
3. Select the direct current (DC) voltage function on the DMM
and set to the proper range.
4. Connect the red probe to the harness connector of the
reference voltage wire and the black probe to the negative
battery cable.
NAME:
DATE:
EVALUATION
W 64
6. If reference voltage is nonexistent or not within specifications,
check for loose or corroded wire connections back to the PCM.
7. If the connections are not loose or corroded, check the
continuity of the reference voltage wiring back to the PCM.
b. Check wiring continuity.
1. Select the resistance function on the DMM and set to the
lowest range.
2. Connect the red lead to the wire being tested and the black
lead to a good ground.
5. Repair the circuit if an open is found.
c. If the reference voltage circuit connections are good and the circuit
is continuous, perform an inspection of the electrical system that
sends current to the PCM.
W 65
4. Using service information, locate a procedure for testing sensors and
actuators with a scan tool. Include specifications for hertz, volts, ohms,
etc. Make sure the procedure is appropriate for the make and model of
the vehicle. Have the instructor check the box to approve the procedure.
Using the procedure, test the sensors and actuators with a scan tool.
Complete the chart.

Specifications Reading OK Not OK
SENSORS

Hall-effect Sensor

ECT Sensor

IAT Sensor

TP Sensor





VAF Sensor (Use a DMM if
Necessary.)

O2S

KS

ACTUATORS
Solenoids

Relays

Servo Motor

W 66
5. Perform active tests of actuators using a bidirectional scan tool.
a. Connect the scan tool to the data link connector. Enter vehicle
information.
b. From the display, select Function Test or Special Functions.
c. From the display, select Actuator Test.
d. Select the actuator to be tested and follow the instructions for
performing the test.
e. Determine if the actuator responded correctly. Complete the chart.
OK Not OK
Solenoid
Relays
Servo Motor
f. If the actuator(s) did not respond correctly, determine necessary
action. Include further diagnosis and/or repair(s). Record in space
provided.
g. Disconnect the scan tool.
W 67
JS3-L3-UIII
GRAPHING MULTIMETER/DIGITAL STORAGE OSCILLOSCOPE
Equipment:
Graphing multimeter (GMM)/digital storage oscilloscope (DSO)
Procedure:
3. Using service information, locate a procedure for testing the electrical/
electronic circuits. Make sure the procedure is appropriate for the make
and model of the vehicle. Have the instructor check the box to approve
the procedure. (For general procedures, see section IV.A.)
Using the procedure, test the electrical/electronic circuits. Is the pattern
good? Record observations in the space provided.
NAME:
DATE:
EVALUATION
W 68
4. Using service information, locate a procedure for testing the sensors.
(For general procedures, see section IV.B.)
Using the procedure, test the sensors. Complete the chart.

OK Not OK

Hall-effect Sensor
ECT Sensor
IAT Sensor
TP Sensor
VAF Sensor
O
2
S
KS
5. Using service information, locate a procedure for testing the actuators.
(For general procedures, see section IV.C.)
W 69
Using the procedure, test the actuators. Complete the chart.
OK Not OK
Solenoid
Relays
Servo Motor
6. Using service information, locate a procedure for testing the powertrain
control module (PCM). Make sure the procedure is appropriate for the
make and model of the vehicle. Have the instructor check the box to
approve the procedure. (For general procedures, see section IV.D.)
Using the procedure, test the PCM. Is the pattern good? Record
W 70
W 71
AS1-L1-UIV
DISTRIBUTOR IGNITION SYSTEMS
sheet.
1. Define the following terms:
A. Base timing
B. Before top dead center
C. Firing order
D. Pre-ignition
E. Top dead center
2. What are the three performance capabilities of distributor ignition
systems?
A.
B.
C.
NAME:
DATE:
W 72
3. What is the optimum operating temperature of a spark plug?
4. What is the primary function of the distributor?
5. What type of ignition coil is shown in the following illustration?
W 73
JS1-L2-UIV
DIAGNOSE IGNITION SYSTEM PROBLEMS ON A VEHICLE WITH A
DISTRIBUTOR IGNITION SYSTEM
Equipment:
Scan tool
Secondary ignition tester or Spark tester
Procedure:
3. Identify ignition system concerns. Complete the chart.

Yes No
No-Start

Hard Start

Misfire
Poor Driveability

Spark Knock
Power Loss

Poor Mileage
Emissions Concerns
NAME:
DATE:
EVALUATION
W 74
4. Using service information, locate a procedure for testing the possible
causes of the concerns. Make sure the procedure is appropriate for the
Using the procedure, test the possible causes of the concerns. Record
5. Using a scan tool, check the diagnostic trouble codes, snapshot
information, and datastream information related to the concerns. Record
W 75
6. If there is a no-start condition, test the components and systems using a
DMM. Complete the chart.

OK Not OK
Crankshaft Position Sensor

Camshaft Position Sensor

Distributor Shaft Position Sensor

Ignition Control Module
Ignition Coils

Powertrain Control Module
Primary Circuit Wiring

Primary Circuit Voltage
Secondary Circuit Wiring
Secondary Circuit Voltage
Distributor Caps
Rotor
7. Perform an exhaust gas diagnostic test.
a. Connect the exhaust gas analyzer according to manufacturers
procedures.
b. Turn on the exhaust gas analyzer and allow it to warm up.
c. Zero and calibrate the exhaust gas analyzer.
d. Start the engine and allow it to reach normal operating
temperature.
e. Check the exhaust gas analyzer readings. Compare readings to
proper specifications. Record readings in the space provided.
f. Shut off the engine. Disconnect the exhaust gas analyzer.
W 76
W 77
JS2-L2-UIV
INSPECT, TEST, AND SERVICE THE PRIMARY CIRCUIT AND
IGNITION COIL
Equipment:
Hand tools
Procedure:
3. Inspect the primary circuit wiring. Complete the chart.

OK Not OK
Wiring Insulation

Terminals

Routing
4. Using service information, locate a procedure for testing the primary
circuit. Make sure the procedure is appropriate for the make and model
of the vehicle. Have the instructor check the box to approve the
procedure. (For general procedures, see section II.B.)
NAME:
DATE:
EVALUATION
W 78
Using the procedure, test the primary circuit. Answer the questions.
a. What is the voltage drop across the resistor bypass circuit while
cranking the engine?
b. What is the available voltage at the side of the ignition coil?
c. What is the voltage drop across the coil primary?
d. What is the voltage drop across the primary control circuit?
e. What is the voltage drop across the circuit between the ignition
switch and resistor?
f. Record in the space provided the tests that did not meet
specifications. Explain why the test did not meet specifications.
5. Inspect the ignition coils. Complete the following chart.

OK Not OK
Ignition Coil Cover

Primary Wiring

Secondary Coil Wire
Wiring Connections

Coil Tower
Coil Polarity
W 79
6. Using service information, locate a procedure for testing the ignition coil.
Include primary and secondary resistance specifications. Make sure the
instructor check the box to approve the procedure. (For general
procedures, see section III.B.)
Using the procedure, test the ignition coil. Record the resistance in the
spaces provided.
Primary resistance
Secondary resistance
Compare the resistance to manufacturers specifications. Determine if the
ignition coil is good or bad. Record in the space provided.
7. Using service information, locate a procedure for servicing or repairing
defective components. Make sure the procedure is appropriate for the
Using the procedure, service or repair defective components.
W 80
W 81
JS3-L2-UIV
CHECK AND ADJUST IGNITION TIMING AND TIMING ADVANCE/
RETARD
Equipment:
Distributor wrench
Tachometer
Timing light
Timing meter
Vacuum pressure pump
Procedure:
NOTE: Step 3 is the procedure for using a timing light. Step 4 is the
procedure for using a timing meter.
3. Using service information, locate a procedure for checking and adjusting
ignition timing and timing advance/retard using a timing light. Include
timing specifications and engine speed at which the timing is to be
checked and set. Make sure the procedure is appropriate for the make
the procedure. (For general procedures, see section IV.C.)
Using the procedure, check and adjust ignition timing and timing
advance/retard using a timing light. Answer the questions.
NAME:
DATE:
EVALUATION
W 82
a. Is base timing correct or incorrect? If base timing is incorrect, did
you adjust base timing to specifications?
b. Is base timing incorrect, but it cannot be adjusted? If base timing
could not be adjusted, explain why.
c. Is the centrifugal advance unit functioning normally?
d. Is the vacuum advance unit functioning normally?
ignition timing and timing advance/retard using a timing meter. Include
timing specifications and engine speed at which the timing is to be
checked and set. Include the timing meter offset degree setting. Make
sure the procedure is appropriate for the make and model of the vehicle.
Have the instructor check the box to approve the procedure. (For general
procedures, see section IV.D.)
Using the procedure, check and adjust ignition timing and timing
advance/retard using a timing meter. Answer the questions.
NOTE: Connect the timing meter to the engine as directed by the timing
meter manufacturer. If required, use the appropriate magnetic probe
adapter.
W 83
a. Is base timing correct or incorrect? If base timing is incorrect, did
you adjust base timing to specifications?
b. Is base timing incorrect, but it cannot be adjusted? If base timing
could not be adjusted, explain why.
c. Is the centrifugal advance unit functioning normally?
d. Is the vacuum advance unit functioning normally?
W 84
W 85
JS4-L2-UIV
INSPECT, TEST, AND SERVICE THE DISTRIBUTOR
Equipment:
Distributor wrench
Hand tools
Safety solvent
Timing equipment
Procedure:
3. Perform a visual inspection of distributor assembly. Record observations
NAME:
DATE:
EVALUATION
W 86
4. Using service information, locate a procedure for inspecting and testing
the distributor electronic components. Make sure the procedure is
appropriate for the distributor. Have the instructor check the box to
Using the procedure, inspect and test the distributor electronic
components. Record observations in the space provided.
5. If applicable, inspect and test the distributor advance component. Record
6. Inspect the distributor cap. Complete the chart.

Yes No
Cracks or Carbon Tracking

Burned Contacts

Corrosion in the Coil Towers
Tight Wire Connections

a. Using a DMM, measure the resistance of the contacts to the coil
towers. Compare to manufacturers specifications. Record
resistance and if resistance meets specifications in the space
provided.
W 87
7. Inspect and test the rotor. Complete the chart.

Yes No
Cracks or Carbon Tracking

Burn-through

Excessive Burning of the Rotor Tip
Tension and Wear of the Spring Contact
a. Using a DMM, measure resistance. Compare to manufacturers
specifications. Record resistance and if resistance meets
specifications in the space provided.
8. Remove the distributor.
a. Clean debris from around the base of the distributor housing.
b. If equipped, disconnect the vacuum advance hose.
c. Disconnect the primary wiring.
d. Remove the distributor cap.
NOTE: If removing spark plug wires, mark their position for proper
reassembly.
e. Crank the engine until the rotor is in position to fire the Number 1
cylinder and the timing mark is aligned with the top dead center
mark.
NOTE: If the timing marks are not visible, mark the distributor
housing at the point at which the rotor is pointing. Then make
another mark on the distributor housing and a corresponding mark
on the engine block.
f. Remove the distributor hold-down clamp.
g. Remove the distributor.
h. Place a clean towel over the hole in the engine where the distributor
was removed.
W 88
9. Service the distributor.
a. Using service information, locate a procedure for disassembling the
distributor. Make sure the procedure is appropriate for the
distributor. Have the instructor check the box to approve the
procedure. (For general procedures, see section V.G.1.)
Using the procedure, disassemble the distributor.
b. Using safety solvent, clean the distributor housing, distributor shaft,
and centrifugal advance components. Blow dry.
c. Inspect the distributor shaft and bushing for wear. Record
d. Inspect the drive gear for scoring or excessive wear. Record
e. Using service information, locate a procedure for repairing or
replacing defective or worn components including the distributor
advance component, distributor cap, and rotor. Make sure the
procedure is appropriate for the distributor. Have the instructor
check the box to approve the procedure. (For general procedures,
see section V.G.5.)
Using the procedure, repair or replace defective or worn
components.
W 89
f. Using service information, locate a procedure for replacing defective
electronic components. Make sure the procedure is appropriate for
the distributor. Have the instructor check the box to approve the
procedure.
Using the procedure, replace defective electonic components.
g. Using service information, locate a procedure for reassembling and
lubricating the distributor. Make sure the procedure is appropriate
for the distributor. Have the instructor check the box to approve the
procedure. (For general procedures, see section V.G.7.)
Using the procedure, reassemble and lubricate the distributor.
10. Install the distributor.
a. Remove the towel and place the distributor back in the engine.
Align the marks that were made during removal.
b. Install the distributor hold-down clamp and bolt. Snug, but do not
tighten, the hold-down bolt.
c. Install the distributor cap, vacuum advance line, and primary
wiring.
d. Connect the exhaust ventilation equipment.
equipment when operating a vehicle in an enclosed area.
e. Start the engine and set timing to specifications. (For general
procedures, see section IV.)
f. Shut off the engine and disconnect the exhaust ventilation
equipment.
W 90
W 91
JS5-L2-UIV
INSPECT, TEST, AND SERVICE SECONDARY CIRCUIT WIRING AND
SPARK PLUGS
Equipment:
Hand tools
Spark plug gap gauge
Spark plug socket
Procedure:
3. Inspect the secondary wiring. Complete the chart.

OK Not OK
Wiring Insulation

Wire Boots

Loose Wiring
Routing

Wiring in Retaining/Mounting Clips
4. Test the resistance of the spark plugs.
a. Connect one DMM lead to each end of the spark plug wire.
NAME:
DATE:
EVALUATION
W 92
b. Check the reading. Compare to manufacturers specifications.
c. Disconnect the DMM.
5. Repair or replace secondary circuit wiring and spark plug wires that are
damaged or not within specifications. (For general procedures, see
section VI.C.)
6. Remove the spark plugs.
a. Grasp the spark plug wire by the wire boot and remove by gently
twisting and pulling. Remove all spark plug wires. If necessary,
label the wires with tape for proper reinstallation.
b. Use compressed air to blow dirt or other contaminants from around
each spark plug.
c. Select the proper spark plug socket.
d. Remove each spark plug. If any of the spark plugs are excessively
tight, apply a penetrating lubricant to the base of the spark plug.
NOTE: Keep the spark plugs in order so that any problems found
can be traced to the proper cylinder.
W 93
7. Inspect the spark plugs. Check each plug for electrode condition,
electrode gap, fouling, insulator damage, and conditions that can shorten
the life of the spark plug or indicate engine problems. Complete the
chart.
Spark Plugs OK Not OK
1

2

3

4

5

6

7

8

8. Replace damaged spark plugs.
9. Install the spark plugs.
a. Adjust the electrode gap of each spark plug to specification. Use the
spark plug gap gauge to bend the side electrode to adjust the spark
plug gap.
b. If the spark plugs are the gasket-seat type, check that the gasket is in
place.
c. Install the spark plugs finger tight in the cylinder head.
d. Tighten spark plugs to specified torque with a spark plug socket and
torque wrench.
W 94
W 95
AS1-L1-UV
ELECTRONIC IGNITION SYSTEMS
sheet.
1. What is the function of the camshaft position sensor?
2. What is the function of the PCM?
3. On what strokes does the ignition coil deliver the spark in wasted-spark
systems?
A.
B.
4. Where are the ignition coils mounted on unit ignition systems?
A.
B.
NAME:
DATE:
W 96
5. What are three advantages of EI systems?
A.
B.
C.
W 97
JS1-L2-UV
DIAGNOSE IGNITION SYSTEM PROBLEMS ON A VEHICLE WITH AN
ELECTRONIC IGNITION SYSTEM
Equipment:
Scan tool
Secondary ignition tester or spark tester
Procedure:
3. Identify ignition system concerns. Complete the chart.

Yes No
No-Start

Hard Start

Misfire
Poor Driveability

Spark Knock
Power Loss

Poor Mileage
Emissions Concerns
NAME:
DATE:
EVALUATION
W 98
4. Using service information, locate the procedure for testing the possible
causes of the concerns. Make sure the procedure is appropriate for the
Using the procedure, test the possible causes of the concerns. Record
5. Using a scan tool, check diagnostic trouble codes, snapshot information,
and datastream information related to the concerns. Record observations
W 99
6. If there is a no-start condition, test the components and systems using a
DMM. Complete the chart.

OK Not OK
Camshaft Position Sensor

Crankshaft Position Sensor

Knock Sensor

Electronic Coil Module
Ignition Coils

Powertrain Control Module
Primary Circuit Wiring

Primary Circuit Voltage
Secondary Circuit Wiring
Secondary Circuit Voltage

7. Perform an exhaust gas diagnostic test.
a. Connect the exhaust gas analyzer according to manufacturers
procedures.
b. Turn on the exhaust gas analyzer and allow it to warm up.
c. Zero and calibrate the exhaust gas analyzer.
d. Start the engine and allow it to reach normal operating
temperature.
e. Check the exhaust gas analyzer readings. Compare readings to
proper specifications. Record readings in the space provided.
f. Shut off the engine. Disconnect the exhaust gas analyzer.
W 100
W 101
NAME:
DATE:
EVALUATION
JS2-L2-UV
INSPECT, TEST, AND SERVICE THE PRIMARY CIRCUIT AND
IGNITION COILS
Equipment:
Scan tool
Procedure:
3. Using a scan tool, check diagnostic trouble codes, snapshot information,
and datastream information for readings. Record observations in the
space provided.
4. Inspect the primary circuit wiring. Complete the chart.

OK Not OK
Wiring Insulation

Terminals
Routing

W 102
5. Using service information, locate a procedure for testing the primary
circuit using a DMM. Make sure the procedure is appropriate for the
approve the procedure. (For general procedures, see section II.C.)
Using the procedure, test the primary circuit using a DMM. Record
6. Inspect the electronic coil module and ignition coils. Complete the chart.

OK Not OK
Electronic Coil Cover

Electronic Coil Module

Primary Wiring

Secondary Coil Wire
Wiring Connections

Coil Tower
Coil Polarity

7. Using service information, locate a procedure for testing the ignition coils.
Include primary and secondary resistance specifications. Make sure the
instructor check the box to approve the procedure. (For general
procedures, see section III.B.)
W 103
Using the procedure, test the ignition coils. Record the resistance in the
spaces provided.
Primary resistance
Secondary resistance
Compare resistance to manufacturers specifications. Determine if the
ignition coil is good or bad. Record in the space provided.
8. Using service information, locate a procedure for servicing or repairing
defective components. Make sure the procedure is appropriate for the
Using the procedure, service or repair defective components.
W 104
W 105
NAME:
DATE:
EVALUATION
JS3-L2-UV
INSPECT, TEST, AND SERVICE SECONDARY CIRCUIT WIRING AND
SPARK PLUGS
Equipment:
Hand tools
Spark plug gap gauge
Spark plug socket
Procedure:
3. Inspect the secondary wiring. Complete the chart.

OK Not OK
Wiring Insulation

Wire Boots

Loose Wiring
Routing

Wiring in Retaining/Mounting Clips
4. Test the resistance of the spark plug wires.
a. Use service information to locate the proper resistance specifications
for the spark plug wires.
b. Connect one DMM lead to each end of the spark plug wire.
W 106
c. Check the reading. Compare to manufacturers specifications.
d. Disconnect the DMM.
5. Repair or replace secondary circuit wiring and spark plug wires that are
damaged or not within specifications. (For general procedures, see
section V.C.)
6. Remove the spark plugs.
a. Grasp the spark plug wire by the wire boot and remove by gently
twisting and pulling. Remove all spark plug wires. If necessary,
label the wires with tape for proper reinstallation.
b. Use compressed air to blow dirt or other contaminants from around
each spark plug.
c. Select the proper spark plug socket.
d. Remove each spark plug. If any of the spark plugs are excessively
tight, apply a penetrating lubricant to the base of the spark plug.
NOTE: Keep the spark plugs in order so that any problems found
can be traced to the proper cylinder.
W 107
7. Inspect the spark plugs. Check each plug for electrode condition,
electrode gap, fouling, insulator damage, and conditions that can shorten
the life of the spark plug or indicate engine problems. Complete the
chart.
Spark Plugs Diagnosis
1

2

3

4

5

6

7

8

8. Replace damaged spark plugs.
9. Install the spark plugs.
a. Adjust the electrode gap of each spark plug to specification. Use the
spark plug gap gauge to bend the side electrode to adjust the spark
plug gap.
b. If the spark plugs are the gasket-seat type, check that the gasket is in
place.
c. Install the spark plugs finger tight in the cylinder head.
d. Tighten spark plugs to specified torque with a spark plug socket and
torque wrench.
W 108
W 109
JS1-L1-UVI
CHECK AND ADJUST VALVE LASH ON ENGINES
Equipment:
Feeler gauge set
Procedure:
3. Determine if the engine has mechanical or hydraulic lifters. Record in the
space provided.
NOTE: For an engine with mechanical lifters, go to step 4. For an engine
with hydraulic lifters, go to step 5.
valve lash on mechanical lifters. Make sure the procedure is appropriate
for the make and model of the vehicle. Have the instructor check the box
to approve the procedure. (For general procedures, see section I.A.)
NAME:
DATE:
EVALUATION
W 110
Using the procedure, check and adjust valve lash on mechanical lifters.
5. Using service information, locate a procedure for measuring valve lash on
hydraulic lifters. Make sure the procedure is appropriate for the make
the procedure. (For general procedures, see section I.B.)
Using the procedure, measure valve lash on hydraulic lifters. Record
W 111
JS2-L1-UVI
REMOVE AND REPLACE TIMING BELT/CHAIN
Equipment:
Procedure:
3. Using service information, locate a procedure for removing the timing
belt/chain. Make sure the procedure is appropriate for the make and
model of the vehicle. Have the instructor check the box to approve the
procedure. (For general procedures, see section II.A.)
Using the procedure, remove the timing belt/chain.
4. Using service information, locate a procedure for installing the timing
belt/chain. Include a procedure for verifying correct camshaft timing.
(For general procedures, see section II.B.)
NAME:
DATE:
EVALUATION
W 112
Using the procedure, install the timing belt/chain. Verify correct
camshaft timing. Record observations in the space provided.
W 113
NAME:
DATE:
EVALUATION
JS3-L1-UVI
INSPECT, TEST, AND SERVICE THERMOSTAT AND COMPONENTS
Equipment:
Instrument for testing engine operating temperature
Procedure:
3. Use service information to locate the thermostat.
4. Inspect the thermostat housing and gasket for leakage or damage.
5. Test the thermostat.
a. Verify engine operating temperature. (For procedures, see
JS3-L3-UII.)
b. Check the circulation within the cooling system.
W 114
2. Start the engine. Take off the radiator cap and look down the
radiator neck.
CAUTION: Never remove a radiator cap unless the engine
is sufficiently cool. Removing the radiator cap when the
engine is hot can cause scalding-hot engine coolant to be
sprayed over a wide area, resulting in serious injury.
3. When the engine reaches normal operating temperature, the
thermostat should open. Observe the engine coolant as it
circulates through the radiator tank. Record observations in
the space provided.
4. If possible, check the circulation through the upper hose when
the engine is gunned and while the thermostat is open.
5. Shut off the engine. Disconnect the exhaust ventilation
equipment.
6. Replace the thermostat.
a. Drain the cooling system.
b. Remove the thermostat housing and thermostat.
c. Clean the mating surfaces of the thermostat housing and engine,
removing the old gasket/seal.
d. Install the new thermostat with the wax-filled pellet toward the
inside of the engine. Center the thermostat in the housing.
e. Install the new gasket/seal and thermostat housing. Use the correct
sealer to install the gasket.
f. Refill the cooling system and bleed air, if required.
W 115
g. Connect the exhaust ventilation equipment.
h. Start the engine and check cooling system operation. Record
i. Shut off the engine. Disconnect the exhaust ventilation equipment.
W 116
W 117
NAME:
DATE:
EVALUATION
JS4-L1-UVI
INSPECT, TEST, AND SERVICE FANS AND FAN COMPONENTS
Equipment:
NOTE: The different types of fans are covered on this job sheet. Select the
appropriate steps based on the type of fan on the vehicle to be serviced.
Procedure:
3. Inspect the mechanical (belt-driven) fan. Complete the chart.
CAUTION: Radiator fans are very dangerous. Keep hands away from
the fan during operation. Disconnect the negative battery cable when
inspecting and servicing a mechanical fan. Only connect the negative
battery cable when observing fan operation.
Yes No
Runs Quietly (No Growling or
Grinding Noises)

Bent Blades, Cracks, or Other Defects
Spins Without Noticeable Wobble
No More Than 3/8-in Play in the Fan
No Signs of Oil Leaking from the
Clutch Assembly (Clutch Fan)

W 118
4. Test the clutch fan.
a. Connect the exhaust ventilation equipment.
b. Start the engine.
c. Observe fan operation. Answer the questions in the spaces
provided.
1. Does the fan slip before the engine warms?
2. Does the clutch engage and air begin to flow through the
radiator and over the engine when the engine warms?
d. Shut off the engine and disconnect the exhaust ventilation
equipment.
5. Inspect the electric radiator fan. Complete the chart.
CAUTION: Electric radiator fans can come on without warning.
Make sure the fan and negative battery cable are disconnected before
inspecting, servicing, or working close to an electric fan. Only connect
the fan and negative battery cable when observing fan operation.
Yes No
Runs Quietly (No Growling or Grinding Noises)
Bent Blades, Cracks, or Other Defects
Spins Without Noticeable Wobble
No More Than 3/8-in Play in the Fan

W 119
a. Using service information, locate a procedure for energizing the fan.
Make sure the procedure is appropriate for the make and model of
the vehicle. Have the instructor check the box to approve the
procedure.
Using the procedure, energize the fan. Record observations in the
space provided.
b. Using service information, locate a procedure for checking the
sensors and controls that operate the fan. Make sure the procedure
is appropriate for the make and model of the vehicle. Have the
instructor check the box to approve the procedure.
Using the procedure, check the sensors and controls that operate the
fan. Record observations in the space provided.
6. Inspect the fan shroud. Complete the chart.

OK Not OK
Cracks or Damage
Shroud-to-Fan Fit and Clearance
Condition of Mounting Brackets and Bolts

W 120
7. Inspect the cooling system air dams and mounting brackets for damage.
8. Using service information, locate a procedure for servicing and repairing/
replacing any problems found during the inspections and testing. Make
sure the procedure is appropriate for the make and model of the vehicle.
Have the instructor check the box to approve the procedure.
Using the procedure, service and repair/replace any problems found
during the inspections and testing.
W 121
JS5-L1-UVI
PERFORM COMMON FASTENER AND THREAD REPAIRS
Equipment:
Tools for performing fastener and thread repairs
Procedure:
2. Inspect all threaded openings. Determine what repairs need to be made.
Determine what tools are needed. Record in the space provided.
NOTE: Select the proper steps based on the repairs that need to be made.
3. Use a tap to correct small imperfections on internal threads. Use a die on
external threads.
4. Use a helicoil or thread insert to repair stripped threads.
5. Inspect and clean threads and bolts. Record observations in the space
provided.
6. Use various taps to clean the threads of all threaded holes.
7. Clean all the nuts and bolts used to assemble the engine.
NAME:
DATE:
EVALUATION
W 122
8. Inspect the nuts and bolts for signs of stretching and stripping and for
rounded corners on bolts and nuts. Record observations in the space
provided.
9. Use a screw extractor to remove any broken bolts.
a. Drill a hole in the center of the broken bolt.
b. Insert a screw extractor in the hole.
c. Use the tap handle to rotate the extractor and bolt
counterclockwise. Remove both as a unit from the bolt hole.
W 123
JS6-L1-UVI
PERFORM AN OIL AND FILTER CHANGE
Equipment:
Drain pan or drain bucket
Oil filter wrench
Vehicle lifting equipment
Procedure:
4. Start the vehicle and allow it to reach normal operating temperature.
Turn off the engine. If the vehicle is turbocharged, allow the engine to
idle during the last few minutes of operation.
5. Lift the vehicle in order to get to the underside.
CAUTION: When lifting a vehicle, always use proper lifting
equipment and observe all safety precautions. Never work under a
vehicle supported by only a jack. A frame-type lift or safety stand is
the only acceptable support for a vehicle. Failure to comply with all
safety rules could result in fatal injuries.
6. Place a drain pan or drain bucket under the crankcase drain plug.
NAME:
DATE:
EVALUATION
W 124
7. Remove the oil drain plug or plugs and catch the oil in the drain pan or
bucket. Allow the oil to drain for a few minutes.
CAUTION: Do not allow hot oil to contact the skin.
8. While the oil is draining, check the following.
a. Inspect the drain plug, oil pan threads, and drain plug gasket.
Replace if worn or damaged.
b. Check the suspension and steering joints in the vehicle and
lubricate, if required.
c. Check the grease in the rear axle (or final drive) and the lubricant in
manual transmissions.
9. Use an oil filter wrench to remove the oil filter. Catch oil in the drain pan
or drain bucket. Clean the area where the oil filter gasket will seal and
make sure that the oil gasket is not still stuck there.
10. Reinstall the drain plug(s) and tighten securely. Do not over torque or
cross thread the drain plug. Replace worn or damaged gaskets at this
time.
11. Install the new oil filter. Lubricate the gasket with clean engine oil.
Tighten the oil filter according to manufacturers specifications.
12. Recheck all work and make sure that the drain plug(s) are installed
tightly. Also make sure that the oil filter is on tightly.
13. Lower the vehicle to the floor.
14. Select the correct type and weight of oil.
15. Open the hood and add the proper amount of new oil to the engine.
Perform lubrication service under the hood as required. In some vehicles,
the throttle and other control linkages should be lubricated at this time.
CAUTION: Be sure to add the correct amount of oil to the engine.
Adding too much or too little oil can result in severe engine damage.
16. Start the engine and allow to idle for a few seconds. If the engine does
not show signs of developing oil pressure within 10 seconds, shut off the
engine immediately. Locate and correct the problem. Double-check that
oil was put in the engine.
W 125
17. Allow the engine to idle for a few minutes. While the engine is idling, lift
the vehicle and check the drain plug(s) and the oil filter for leaks.
18. Lower the vehicle and record on a windshield/door tag the vehicles
mileage, the date, and precisely what service was performed.
19. Shut off the engine. Disconnect the exhaust ventilation equipment.
20. Dispose of the used oil according to the United States Environmental
Protection Agency (EPA) guidelines.
W 126
W 127
JS7-L1-UVI
IDENTIFY HYBRID VEHICLE INTERNAL COMBUSTION ENGINE
SERVICE PRECAUTIONS
Equipment:
Safety cones for the work area
Procedure:
3. Using service information, determine the locations of the high-voltage
system components, including the high-voltage cables and service plug.
4. Using service information, determine if special care is needed when
handling any components of the high-voltage system. Record in the
space provided.
NAME:
DATE:
EVALUATION
W 128
5. Using service information, locate a procedure for deactivating the high-
voltage system. Make sure the procedure is appropriate for the make and
model of the vehicle. Have the instructor check the box to approve the
procedure. (For general procedures for a Honda hybrid electric vehicle,
see section VII.D.3.)
Using the procedure, deactivate the high-voltage system.
W 129
JS1-L2-UVI
HEAT AND CUT METAL USING AN OXYFUEL TORCH
Equipment:
Oxyfuel outfit
Soapstone and straightedge
Spark lighter
NOTE: The instructor will assign the specific cut(s). Step 4 is cutting a
straight line. Step 5 is cutting a bevel. Step 6 is cutting a circle. If only one or
two cuts are assigned, skip the appropriate other step(s) and move to Step 7,
shutting down the oxyfuel outfit.
Procedure:
2. Inspect equipment, materials, and work area to ensure safe and correct
operation. Remove items or materials that could cause a potentially
dangerous situation.
3. Using service information, locate a procedure for setting up and shutting
down the oxyfuel outfit. Have the instructor check the box to approve
the procedure.
Using the procedures, set up the oxyfuel outfit.
4. Cut a straight line.
a. Position the plate on the worktable and mark a cutting line using a
soapstone and straightedge.
b. Clamp angle iron to the plate at a right angle, just off the cutting
line, to serve as a guide.
c. Light the torch using a spark lighter.
d. Adjust the flame to a neutral flame with and without the oxygen
lever pressed.
NAME:
DATE:
EVALUATION
W 130
e. Position the torch over the edge of the metal, with the center of the
cutting tip in line with the cutting line and angled slightly away
from the work. The preheat flames should be just above the top of
the plate. Use the free hand to steady the cutting hand.
f. When the plate has reached cutting temperature, press the cutting
oxygen lever and move the torch steadily across the plate to
complete the cut. Make additional cuts if instructed.
5. Cut a bevel.
soapstone and straightedge.
b. Clamp angle iron to the plate at an angle, just off the cutting line, to
serve as a guide.
c. Light the torch using a spark lighter.
d. Adjust the flame to a neutral flame with and without the oxygen
lever pressed.
e. Position the torch over the edge of the metal, with the center of the
cutting tip in line with the cutting line and pointed slightly away
from the work. The preheat flames should be just above the top of
the plate. Hold the whole torch at the angle of the desired cut and
guide by the angle iron. Use the hand that is not operating the
cutting lever to steady the cutting hand.
f. When the plate has reached cutting temperature, press the cutting
oxygen lever and move the torch steadily across the plate to
complete the cut. Make additional cuts if instructed.
6. Cut a circle.
soapstone.
b. Light the torch using a spark lighter.
c. Adjust the flame to a neutral flame with and without the oxygen
lever pressed.
d. Use the oxyfuel outfit to pierce steel by holding the torch at a right
angle to the work with the cutting tip near the center of the circle.
The preheat flames should be just above the top of the plate.
W 131
e. When the plate reaches cutting temperature, raise the cutting tip
1/2 in or more and slowly press the cutting lever.
f. Rotate the torch until the flame cuts through the metal.
g. Lower the torch into normal cutting position and cut out to the
cutting line and complete the cut. Use the hand that is not
operating the cutting lever to steady the cutting hand. Make
additional cuts if instructed.
7. Using the procedure from Step 3, shut down the oxyfuel outfit.
8. Return materials and equipment to the proper places.
W 132

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