70-1831-W 10-1831-T

Module 3: Engine Performance
Section 1: Ignition Systems

Automotive Technology Curriculum

2005 Edition Student Test Workbook Packet

ENGINE PERFORMANCE: IGNITION SYSTEMS
Automotive Technology Module 3: Engine Performance Section 1: Ignition Systems Student Workbook
Technical Consultant: Robin Ferguson

Project Coordinator: Erica Kassel

Graphic Artists: Chris Benedict Jacqueline Craig

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.
i

AUTOMOTIVE TECHNOLOGY ii .

and Refill the Cooling System Verify Correct Camshaft Timing Obtain and Interpret Diagnostic Trouble Codes and Scan Tool Data Diagnose the Causes of Emissions or Driveability Concerns Using Stored Diagnostic Trouble Codes Diagnose the Causes of Emissions or Driveability Concerns with No Stored Diagnostic Trouble Codes Check for Module Communication Errors Test and Service Computerized Engine Controls Using a Digital Multimeter Test and Service Computerized Engine Controls Using a Scan Tool Test and Service Computerized Engine Controls Using a Graphing Multimeter/Digital Storage Oscilloscope Diagnose Ignition System Problems on a Vehicle with a Distributor Ignition System Inspect. and Service the Cooling System Drain. Test. Cause.ENGINE PERFORMANCE: IGNITION SYSTEMS Name: MODULE 3: ENGINE PERFORMANCE SECTION 1: IGNITION SYSTEMS STUDENT WORKBOOK TRACKING SHEET Assignment Sheet AS1-L1-UIII AS1-L1-UIV AS1-L1-UV Job Sheet JS1-L1-UII JS2-L1-UII JS3-L1-UII JS1-L2-UII JS2-L2-UII JS3-L2-UII JS4-L2-UII JS5-L2-UII JS1-L3-UII JS2-L3-UII JS3-L3-UII JS4-L3-UII JS5-L3-UII JS6-L3-UII JS1-L2-UIII JS2-L2-UIII Title of Assignment Sheet Computerized Engine Controls Distributor Ignition Systems Electronic Ignition Systems Title of Job Sheet Complete a Work Order with Concern. and Correction Identify and Interpret Engine Performance Concern Perform a Preliminary Engine Inspection Perform Engine Absolute Manifold Pressure Tests Perform a Cylinder Power Balance Test Perform Cranking Engine Cylinder Compression Tests Perform a Running Engine Cylinder Compression Test Perform a Cylinder Leakage Test Perform Engine System Diagnostic Tests Using an Oscilloscope Perform an Exhaust Gas Diagnostic Test Verify Engine Operating Temperature Inspect. Flush. and Service the Primary Circuit and Ignition Coil Instructor Guide Page # 141-144 225-228 287-290 Instructor Guide Page # 31-32 33-34 35-38 53-56 57-60 61-64 65-68 69-72 91-94 95-96 97-100 101-106 107-108 109-110 155-156 157-158 Student Workbook Page # W 49-50 W 71-72 W 95-96 Student Workbook Page # W 1-2 W 3-4 W 5-8 W 9-12 W 13-16 W 17-20 W 21-24 W 25-28 W 29-32 W 33-34 W 35-38 W 39-44 W 45-46 W 47-48 W 51-52 W 53-54 Date Instructor’s Initials Date Instructor’s Initials JS3-L2-UIII 159-160 W 55-56 JS4-L2-UIII JS1-L3-UIII JS2-L3-UIII JS3-L3-UIII 161-162 191-194 195-198 199-202 W 57-58 W 59-62 W 63-66 W 67-70 JS1-L2-UIV JS2-L2-UIV 249-252 253-256 W 73-76 W 77-80 iii . Test.

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

Complete the work order on the following page for the repair. AND CORRECTION Directions: 1. The instructor will list a repair. all sections of the work order must be complete. Credit received for completing work order NAME: DATE: EVALUATION W1 .ENGINE PERFORMANCE: IGNITION SYSTEMS JS1-L1-UII COMPLETE A WORK ORDER WITH CONCERN. To receive credit. CAUSE.

AUTOMOTIVE TECHNOLOGY Smith’s Automotive Repair Customer’s Name: Address: Year/Make: Service Writer: Customer Authorization Signature: Customer Concern: Model: VIN: Technician: Date: Invoice #: Phone: Mileage: 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 W2 .

Record the answers in the space provided. Wear PPE while performing the procedures on this job sheet. Is the concern continuous or intermittent? W3 . Ask the customer the following series of questions. When did the concern first occur? b. 3. Is the malfunction indicator light on or flashing? c. Ask the customer to describe the engine performance concern. a. 2. Record concern in the space provided.ENGINE PERFORMANCE: IGNITION SYSTEMS JS2-L1-UII IDENTIFY AND INTERPRET ENGINE PERFORMANCE CONCERN Equipment: Personal protective equipment (PPE) Service information EVALUATION DATE: NAME: Procedure: 1.

Record in the space provided. What is the recent service history of the vehicle? 4. Based on the answers to the questions. What are the driving conditions when the concern occurs? e. Is the vehicle making any unusual noises or vibrations? f. Average of the above evaluations W4 . determine the next step in the diagnostic process for the vehicle.AUTOMOTIVE TECHNOLOGY d.

EVALUATION 3. 1. 2. and carburetor/fuel injectors Other leaks Not OK W5 .ENGINE PERFORMANCE: IGNITION SYSTEMS JS3-L1-UII PERFORM A PRELIMINARY ENGINE INSPECTION DATE: NAME: Equipment: Personal protective equipment (PPE) Procedure: CAUTION: Perform steps 4 and 5 outdoors because the tests must be done without exhaust ventilation equipment connected to the tail pipe. Wear PPE while performing the procedures on this job sheet. VIN. fuel pump. Complete the chart. and calibration decals. fuel lines. Research applicable vehicle service information such as vehicle service history. 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. certification labels. Record the necessary information in the space provided. Perform a visual engine inspection.

5. See Section III. long screwdriver.AUTOMOTIVE TECHNOLOGY 4. See Section III. Start the engine. Perform a visual inspection of the exhaust system.D. Record observations in the space provided. Listen for abnormal engine noises or vibrations using a stethoscope. Shut off the engine.3. Shut off the engine. Complete the chart.C. or a section of vacuum hose for vacuum and air pressure leaks. for a description of various engine noises or vibrations. Start the engine. for normal occurences and problem indicators. 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 Not OK W6 .

determine the necessary action to correct any problems. Based on the preliminary engine inspection. Include further diagnosis and/or repairs.ENGINE PERFORMANCE: IGNITION SYSTEMS 6. Average of the above evaluations W7 .

AUTOMOTIVE TECHNOLOGY W8 .

Connect the vacuum gauge to an intake manifold vacuum source. d.ENGINE PERFORMANCE: IGNITION SYSTEMS JS1-L2-UII PERFORM ENGINE ABSOLUTE MANIFOLD PRESSURE TESTS DATE: NAME: Equipment: Exhaust ventilation equipment Personal protective equipment (PPE) Tachometer Vacuum gauge Vacuum hose Procedure: 1. Perform a vacuum gauge test. W9 . Shut off the engine. a. 4. Connect the exhaust ventilation equipment. and calibration decals. Wear PPE while performing the procedures on this job sheet. VIN. Connect a vacuum hose to an accessible intake manifold vacuum connector and extend it up to the vacuum gauge. Disconnect the test equipment. b. Record the necessary information in the space provided. Start the engine and allow it to reach normal operating temperature. CAUTION: Be sure to use approved exhaust ventilation equipment when operating the vehicle in an enclosed area. EVALUATION 3. Observe and record the reading with the engine at idle speed in the space provided. certification labels. c. Research applicable vehicle service information such as vehicle service history. 2.

Crank the engine. Disable the ignition system. Completely block the throttle valve so that air cannot enter.000 rpm for about 10 seconds or longer. Shut off the engine. c. Disconnect the test equipment. c.000 rpm. Shut off the engine. Observe and record the cranking vacuum. Perform a cranking vacuum test. W 10 . b. Connect the vacuum gauge to an intake manifold vacuum source. Start the engine and allow it to reach normal operating temperature. e. d. Observe and record the reading in the space provided. Observe and record the reading in the space provided. e. Perform an exhaust restriction test. Connect a tachometer to the engine. Gradually accelerate the engine rpm from idle to 2. a. a. d. Start the engine. 6. Connect a vacuum hose to an accessible intake manifold vacuum connector and extend it up to the vacuum gauge. Connect a vacuum gauge to a nonported vacuum source on the intake manifold. b.AUTOMOTIVE TECHNOLOGY 5. Maintain the engine speed at 2.

Unblock the throttle valve. Disconnect the vacuum gauge. Average of the above evaluations W 11 . determine the necessary action to correct any problems. g.ENGINE PERFORMANCE: IGNITION SYSTEMS f. Enable the ignition. 7. Based on the tests. Include further diagnosis and/or repairs. 8. Disconnect the exhaust ventilation equipment.

AUTOMOTIVE TECHNOLOGY W 12 .

2. and calibration decals. VIN. Connect a tachometer to the engine if it is not part of the cylinder balance tester. Wear PPE while performing the procedures on this job sheet.ENGINE PERFORMANCE: IGNITION SYSTEMS JS2-L2-UII PERFORM A CYLINDER POWER BALANCE TEST DATE: NAME: Equipment: Cylinder balance tester Exhaust ventilation equipment Personal protective equipment (PPE) Tachometer Procedure: 1. connect the cylinder balance tester to the engine. Using the procedure. Connect the exhaust ventilation equipment. locate a procedure for connecting a cylinder balance tester to the engine. 4. certification labels. EVALUATION 3. Have the instructor check the box to approve the procedure. Record the necessary information in the space provided. Using service information. Make sure the procedure is appropriate for the make and model of the vehicle. Research applicable vehicle service information such as vehicle service history. NOTE: This test may also be performed using an engine analyzer or scan tool. W 13 . CAUTION: Be sure to use the approved exhaust ventilation equipment when operating the vehicle in an enclosed area. 5.

8. Restart the engine. Select the cylinder shorting mode on the cylinder balance tester. 9. Reconnect the oxygen sensor and the EGR hose or connector. Record the reading in the following chart. Shut off the engine. Shut off the engine. Disconnect the exhaust ventilation equipment. Start the engine and allow it to reach normal operating temperature. 7. Bring the engine speed to 1.000 rpm and maintain that speed. Give the engine about 5 seconds between each short. W 14 . Disconnect the test equipment. 11. Short each cylinder for the same amount of time. about 2 seconds to 3 seconds.AUTOMOTIVE TECHNOLOGY 6. 10. Cylinder 1 2 3 4 5 6 7 8 Percent of rpm Drop 12. Observe the tachometer for the amount of rpm drop on each cylinder. 13. Disconnect the oxygen sensor and unplug the exhaust gas recirculation (EGR) hose or connector. Disable the idle air control on a fuel-injected engine.

determine the necessary action to correct any problems. Include further diagnosis and/or repairs. 15. Clear the codes.ENGINE PERFORMANCE: IGNITION SYSTEMS 14. Average of the above evaluations W 15 . Based on the tests.

AUTOMOTIVE TECHNOLOGY W 16 .

Record the necessary information in the space provided. c. Start the engine and allow it to reach normal operating temperature. Shut off the engine. VIN. Use compressed air to blow debris away from the spark plugs. a. f. CAUTION: Be sure to use approved exhaust ventilation equipment when operating the vehicle in an enclosed area. and calibration decals. Remove the spark plugs. 2. Perform a cranking engine cylinder compression test with the throttle closed. d. e. Wear PPE while performing the procedures on this job sheet. 4. b. Disable the ignition and fuel systems. Connect the exhaust ventilation equipment. Install the compression gauge in one cylinder. EVALUATION 3. Research applicable vehicle service information such as vehicle service history. certification labels.ENGINE PERFORMANCE: IGNITION SYSTEMS JS3-L2-UII PERFORM CRANKING ENGINE CYLINDER COMPRESSION TESTS DATE: NAME: Equipment: Compressed air Compression gauge Exhaust ventilation equipment Personal protective equipment (PPE) Procedure: 1. Remove the air filter. W 17 .

Remove the air filter. It may be necessary to keep a battery charger on the battery to perform this test. Remove the compression gauge. Disable the ignition and fuel systems. If the engine cranks slowly.AUTOMOTIVE TECHNOLOGY g. Record the readings of the first “puff” and at the highest point in the chart. Observe the compression gauge. c. Record the readings in the chart. test the battery. and charging systems. Perform a cranking engine cylinder compression test with the throttle open. the readings are not accurate. Enable the ignition and fuel systems. Then. b. d. W 18 . i. Shut off the engine. Cylinder 1 2 3 4 5 6 7 8 First "Puff" Reading Highest Point OK Yes or No h. Charge the battery. a. Crank the engine at least four compression strokes. 5. Repeat the procedure for each cylinder. starting. j. Start the engine and allow it to reach normal operating temperature. Reinstall the air filter and spark plugs.

the readings are not accurate. Observe the compression gauge. Remove the spark plugs. It may be necessary to keep a battery charger on the battery to perform this test. Block the throttle valve to the wide open position. starting. Disconnect the exhaust ventilation equipment. l. k.ENGINE PERFORMANCE: IGNITION SYSTEMS e. Install the compression gauge in one cylinder. 1 2 3 4 5 6 7 8 j. f. test the battery. 6. Charge the battery. h. If the engine cranks slowly. Repeat the procedure for each cylinder. Then. Enable the ignition and fuel systems. Remove the compression gauge. Cylinder First "Puff" Reading Highest Point Change from Closed Throttle Yes or No i. Record the readings of the first “puff” and at the highest point in the chart. Unblock the throttle valve. W 19 . Use compressed air to blow debris away from the spark plugs. and charging systems. Reinstall the air filter and spark plugs. Record the readings in the chart. g. Crank the engine at least four compression strokes.

Based on the tests. Include further diagnosis and/or repairs. determine the necessary action to correct any problems. Average of the above evaluations W 20 .AUTOMOTIVE TECHNOLOGY 7.

8. EVALUATION 3. Install the compression gauge in the cylinder. Use compressed air to blow debris away from the spark plugs. Research applicable vehicle service information such as vehicle service history. 2. Connect the exhaust ventilation equipment. 7. Release the compression gauge pressure. CAUTION: Be sure to use the approved exhaust ventilation equipment when operating the vehicle in an enclosed area. Start the engine and allow it to idle. Start the engine and allow it to reach normal operating temperature. and calibration decals. VIN. Record the necessary information in the space provided. 5. certification labels. 4. Wear PPE while performing the procedures on this job sheet.ENGINE PERFORMANCE: IGNITION SYSTEMS JS4-L2-UII PERFORM A RUNNING ENGINE CYLINDER COMPRESSION TEST DATE: NAME: Equipment: Compressed air Compression gauge Exhaust ventilation equipment Personal protective equipment (PPE) Spark tester Procedure: 1. Remove one spark plug and connect a spark tester to the plug wire. 6. Shut off the engine. W 21 . 9.

Disconnect the exhaust ventilation equipment. Release the compression gauge pressure. Observe the reading. Record the reading in the chart. Remove the compression gauge. 14. 18. 16. Cylinder 1 2 3 4 5 6 7 8 Idle Compression 1500 rpm Compression Snap Compression 11. 12. Record the reading in the chart. Repeat the procedure for each cylinder. Observe the reading at idle. Record the reading in the chart. Observe the reading. 15.500 rpm. Snap the throttle open and then closed. W 22 . 13. Remove the spark tester and reinstall the spark plug. Shut off the engine. Record the readings in the chart.AUTOMOTIVE TECHNOLOGY 10. 17. Slowly raise the engine speed to 1. Return the engine speed to idle.

Average of the above evaluations W 23 . determine the necessary action to correct any problems.ENGINE PERFORMANCE: IGNITION SYSTEMS 19. Based on the tests. Include further diagnosis and/or repairs.

AUTOMOTIVE TECHNOLOGY W 24 .

6. Connect the exhaust ventilation equipment. 2. Remove the spark plugs. certification labels. 5. 11. Remove the crankcase filler cap. Wear PPE while performing the procedures on this job sheet. If necessary. VIN. Remove the air filter. 8. Shut off the engine. Research applicable vehicle service information such as vehicle service history. Start the engine and allow it to reach normal operating temperature.ENGINE PERFORMANCE: IGNITION SYSTEMS JS5-L2-UII PERFORM A CYLINDER LEAKAGE TEST DATE: NAME: Equipment: Compressed air Cylinder leakage tester Exhaust ventilation equipment Personal protective equipment (PPE) Procedure: 1. 4. refill the radiator. W 25 . 7. Check the coolant level. 10. Use compressed air to blow debris away from the spark plugs. CAUTION: Be sure to use the approved exhaust ventilation equipment when operating the vehicle in an enclosed area. Record the necessary information in the space provided. Block the throttle valve to the wide open position. Rotate the engine until the cylinder is at top dead center. and calibration decals. EVALUATION 3. 9.

13. Make sure the procedure is appropriate for the make and model of the vehicle. Record the readings in the chart. Repeat the procedure for each cylinder. Cylinder 1 2 3 4 5 6 7 8 Percent of Leakage 14. calibrate and connect the cylinder leakage tester. Have the instructor check the box to approve the procedure. locate a procedure for calibrating and connecting a cylinder leakage tester.AUTOMOTIVE TECHNOLOGY 12. Observe and record the reading in the chart. Using service information. W 26 . Using the procedure.

listen at the different points to determine the source of the leak. Disconnect the exhaust ventilation equipment.ENGINE PERFORMANCE: IGNITION SYSTEMS 15. 17. If there is excessive cylinder leakage. Replace the crankcase filler cap. 20. 19. Disconnect the cylinder leakage tester. determine the necessary action to correct any problems. Record the source of leakage in the space provided. Based on the tests. See Section IV. 18. Reinstall the air filter and spark plugs. for listening locations. 16.13. Include further diagnosis and/or repairs. Unblock the throttle valve.A. Average of the above evaluations W 27 .

AUTOMOTIVE TECHNOLOGY W 28 .

2. CAUTION: Be sure to use approved exhaust ventilation equipment when operating the vehicle in an enclosed area. Engine Size Dwell Time Firing Order 5. VIN. 4. and calibration decals. W 29 . Have the instructor check the box to approve the procedure. Make sure the procedure is appropriate for the oscilloscope and make and model of the vehicle. certification labels. and firing order. locate a procedure for connecting an oscilloscope to the engine. Using service information. Connect the exhaust ventilation equipment. such as vehicle service history. dwell time. NAME: DATE: EVALUATION 3. Wear PPE while performing the procedures on this job sheet. connect the oscilloscope to the engine. Research applicable vehicle service information. Record in the spaces provided. Include pattern specifications. Check service information for engine size. Record the necessary information in the space provided.ENGINE PERFORMANCE: IGNITION SYSTEMS JS1-L3-UII PERFORM ENGINE SYSTEM DIAGNOSTIC TESTS USING AN OSCILLOSCOPE Equipment: Oscilloscope Personal protective equipment (PPE) Procedure: 1. Using the procedure.

Compare patterns to manufacturer’s specifications. primary off. Are the firing lines normal? W 30 . 7. Check the primary raster pattern for dwell time. primary on. Check the secondary parade pattern. Record observations in the space provided. Cylinder 1 2 3 4 5 6 7 8 Firing kilovolts Burn kilovolts Burn Time b. and uneven primary off trace. Answer the questions. 8. Are the firing spikes even (within 3 kilovolts of each other and between 5 kilovolts and 15 kilovolts in height)? Complete the chart. coil oscillations. Compare patterns to manufacturer’s specifications. Start the engine and allow it to reach normal operating temperature.AUTOMOTIVE TECHNOLOGY 6. a.

Shut off the engine and disconnect the oscilloscope. and coil oscillations. primary on. Disconnect the exhaust ventilation equipment. 10. Include further diagnosis and/or repairs. Compare patterns to manufacturer’s specifications.ENGINE PERFORMANCE: IGNITION SYSTEMS c. Average of the above evaluations W 31 . 11. dwell time. determine necessary action to correct any problems. Check the secondary raster pattern for even firing lines. Record observations in the space provided. Are all cylinders similar? 9. Based on the tests.

AUTOMOTIVE TECHNOLOGY

W 32

ENGINE PERFORMANCE: IGNITION SYSTEMS
JS2-L3-UII PERFORM AN EXHAUST GAS DIAGNOSTIC TEST
DATE: NAME:

Equipment: Exhaust gas analyzer Exhaust ventilation equipment Personal protective equipment (PPE) Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information, such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.

EVALUATION

3.

Using manufacturer’s 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. 5. 6. Turn on the exhaust gas analyzer and allow it to warm up. Zero and calibrate the exhaust gas analyzer. Start the engine and allow it to reach normal operating temperature.

W 33

AUTOMOTIVE TECHNOLOGY
7. Check the exhaust gas analyzer readings. Compare readings to proper specifications. Record observations in the space provided.

8. 9.

Shut off the engine. Disconnect the exhaust gas analyzer. Based on the test, determine necessary action to correct any problems. Include further diagnosis and/or repairs.

Average of the above evaluations

W 34

and calibration decals. probe-type (cooking) thermometer Noncontact infrared thermometer Personal protective equipment (PPE) Procedure: NOTE: There are three different methods for verifying engine operating temperature. Start the engine and allow it to run until warm. 4. a. Shut off the engine. 1. b. EVALUATION 3. such as vehicle service history. W 35 . Wear PPE while performing the procedures on this job sheet. CAUTION: Be sure to use approved exhaust ventilation equipment when operating a vehicle in an enclosed area. VIN. certification labels. Record the necessary information in the space provided.ENGINE PERFORMANCE: IGNITION SYSTEMS JS3-L3-UII VERIFY ENGINE OPERATING TEMPERATURE DATE: NAME: Equipment: Digital multimeter with temperature probe Direct-read. Compare reading to manufacturer’s specifications. Connect the exhaust ventilation equipment. c. Verify engine operating temperature using a noncontact infrared thermometer. Aim the infrared thermometer at the cylinder head and measure the temperature. Research applicable vehicle service information. The instructor will choose the appropriate method. Record observations in the space provided. 2.

a. c. Record observations in the space provided. 7. Shut off the engine. on the top radiator hose. Disconnect the exhaust ventilation equipment. b.AUTOMOTIVE TECHNOLOGY 5. d. d. Verify engine operating temperature using a direct-read. W 36 . 6. Monitor the temperature reading. c. resulting in serious injury. a. Shut off the engine. Removing the radiator cap when the engine is hot can cause scalding hot coolant to be sprayed over a wide area. or into the coolant in the radiator (not in the overflow recovery tank). Start the engine and allow it to run until warm. probe-type (cooking) thermometer. Place the thermometer probe into the coolant in the radiator or tape the thermometer to the top radiator hose. Place the temperature probe on the engine near the thermostat. Start the engine and allow it to run until warm. b. Record observations in the space provided. Compare reading to manufacturer’s specifications. Verify engine operating temperature using a digital multimeter with a temperature probe. CAUTION: Never remove a radiator cap unless the engine is sufficiently cool. Compare reading to manufacturer’s specifications. Observe the reading.

Include further diagnosis and/or repairs. determine necessary action to correct any problems.ENGINE PERFORMANCE: IGNITION SYSTEMS 8. Average of the above evaluations W 37 . Based on the test.

AUTOMOTIVE TECHNOLOGY W 38 .

W 39 . Removing the radiator cap when the engine is hot can cause scalding hot coolant to be sprayed over a wide area. Record the necessary information in the space provided. Research applicable vehicle service information. certification labels. TEST. Wear PPE while performing the procedures on this job sheet. OK Radiator cap Hoses Outer shell of the radiator Coolant passages inside the radiator Coolant recovery tank 4. 2. and calibration decals. Complete the chart. resulting in serious injury. Inspect the cooling system. Not OK Connect a pressure tester to the radiator filler neck. Pressure test the cooling system for leaks. CAUTION: Never remove a radiator cap unless the engine is sufficiently cool.ENGINE PERFORMANCE: IGNITION SYSTEMS JS4-L3-UII INSPECT. AND SERVICE THE COOLING SYSTEM DATE: NAME: Equipment: Combustion leak tester Exhaust gas analyzer Hand tools Personal protective equipment (PPE) Pressure tester Procedure: 1. VIN. EVALUATION 3. such as vehicle service history. a.

Compare to manufacturer’s specifications. 5. g. Record observations in the space provided. d. Connect the pressure tester to the radiator cap and test the pressure release point. Complete the chart. CAUTION: Be sure to use approved exhaust ventilation equipment when operating a vehicle in an enclosed area. e.AUTOMOTIVE TECHNOLOGY b. Record observations in the space provided. OK Radiator tank and cooling fins and tubes Heater core 9 On the ground 9 On the floor under the engine 9 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 Not OK c. f. Monitor the reading for 15 minutes. Connect the exhaust ventilation equipment. Relieve the pressure and disconnect the pressure tester. Record observations in the space provided. W 40 . Check the engine oil and transmission fluid for coolant contamination. Check the cooling system for leaks. Pump the pressure tester until the pressure reaches the release pressure mark on the radiator cap. Relieve the pressure and disconnect the pressure tester.

Observe the readings and increase engine speed. Record observations in the space provided. Disconnect the pressure tester. Observe the color of the test fluid in the tester. Test the cooling system for combustion gas leakage. 1. Remove the filler cap (radiator or reservoir). Place the exhaust gas analyzer probe near the cooling system filler opening. Connect the pressure tester. Start the engine and monitor the reading. 4. a. Place the tester in the filler opening of the cooling system (radiator or reservoir). Record observations in the space provided.ENGINE PERFORMANCE: IGNITION SYSTEMS 6. Shut off the engine. 1. The instructor will select one of the three methods. 3. Shut off the engine. c. Record observations in the space provided. Start the engine. W 41 . 2. 1. Test using a combustion leak tester. Do not pressurize the cooling system. 2. Test using an exhaust gas analyzer. b. 3. 2. 3. Test using a pressure tester. Squeeze and release the tester bulb to get an air sample. Start the engine.

b. a. a. W 42 . Feel the coolant between the fingers.AUTOMOTIVE TECHNOLOGY CAUTION: Do not allow coolant to be sucked into the exhaust gas analyzer. Remove the radiator cap. b. Check the coolant color. d. Replace the radiator cap. Drive the vehicle for several miles. 4. Shut off the engine. Obtain the instructor’s permission to perform a road test. Record observations in the space provided. 7. Have the instructor check the box to approve the road test. Coolant pulled into the analyzer will damage the analyzer. Test the coolant recovery system. 8. c. Disconnect the exhaust ventilation equipment. 9. Shut off the engine. Inspect the condition of the coolant. Record observations in the space provided. c.

Allow the cooling system to completely cool down. OK Hose and hose connections between the radiator and the coolant recovery tank Coolant recovery tank Radiator cap gasket and valve Not OK 10. Record observations in the space provided. Record in the space provided. Determine the type of service that needs to be performed based on the inspections and test results.ENGINE PERFORMANCE: IGNITION SYSTEMS d. g. f. Inspect the coolant recovery system if a problem is found. Observe the level in the coolant recovery tank. Remove the radiator cap and check the coolant level. Record observations in the space provided. W 43 . e. Complete the chart.

Using service information. (For general procedures.) Using the procedure. service defective cooling system components.F. Have the instructor check the box to approve the procedure.AUTOMOTIVE TECHNOLOGY 11. Make sure the procedure is appropriate for the make and model of the vehicle. see section IV. Average of the above evaluations W 44 . locate a procedure for servicing defective cooling system components.

ENGINE PERFORMANCE: IGNITION SYSTEMS JS5-L3-UII DRAIN. 2. FLUSH. W 45 . Wear PPE while performing the procedures on this job sheet. 8. Shut off the engine. 7. 6. and calibration decals. Connect the exhaust ventilation equipment. allowing the coolant to drain completely from the radiator. Start the engine and allow it to reach normal operating temperature. Clean the mating surfaces of the thermostat housing and the engine to remove the old gasket/seal. Remove one of the heater hoses and connect a supply of fresh water to the hose end that leads into the heater. CAUTION: Used coolant is classified as toxic waste and must be disposed of according to law. such as vehicle service history. certification labels. Record the necessary information in the space provided. CAUTION: Be sure to use approved exhaust ventilation equipment when operating a vehicle in an enclosed area. Remove the thermostat housing and the thermostat. Make sure the petcock can open freely. AND REFILL THE COOLING SYSTEM DATE: NAME: Equipment: Coolant Exhaust ventilation equipment Fresh water Hand tools Personal protective equipment (PPE) Procedure: 1. Remove the radiator cap. VIN. 9. Research applicable vehicle service information. Open the petcock. EVALUATION 3. 4. 5.

20. Adjust the water flow so that the radiator stays full while the drain is running wide open. Using service information. Let the drain run until it stops and then close the petcock. Install the thermostat with the wax-filled pellet toward the inside of the engine. start the engine and allow it to idle. Start the engine and allow it to reach normal operating temperature. Disconnect the exhaust ventilation equipment. Use the correct sealer to install the gasket. Average of the above evaluations W 46 . Continue to fill the radiator with clean. 21. When the system is full. 17. 14. Shut off the engine. 18. The coolant should start to circulate and the upper radiator tank should become warm. if necessary. Install the new gasket/seal and thermostat housing. 16. Bleed the system. Center the thermostat in the housing. Shut off the engine. Have the instructor check the box to approve the coolant type. 11. Using the correct coolant capacity. Pour the coolant down the radiator filler neck. 15. Record correct coolant and coolant capacity in the space provided. Keep the engine and the fresh water running until the discharge fluid runs clear. fresh water. Reconnect the heater hose. top off the radiator with clean water and replace the radiator cap. Allow the cooling system to fill. 13. Fill to proper specifications. measure coolant at half this capacity and add to the radiator. select the correct coolant and determine coolant capacity for the vehicle. 12. 19.AUTOMOTIVE TECHNOLOGY 10. If the cooling system is working properly.

4. Wear PPE while performing the procedures on this job sheet. VIN. 2. (For a general procedure. 3. locate a procedure for verifying correct camshaft timing with the valve timing components located in the block (nonoverhead camshaft engine).A. go to step 4. Determine the engine type of the vehicle.ENGINE PERFORMANCE: IGNITION SYSTEMS JS6-L3-UII VERIFY CORRECT CAMSHAFT TIMING DATE: NAME: Equipment: Hand tools Personal protective equipment (PPE) EVALUATION Procedure: 1. and calibration decals. Research applicable vehicle service information. such as vehicle service history. Have the instructor check the box to approve the procedure.) Record in the space provided. (For nonoverhead camshaft engines. Using service information.) W 47 . go to step 5. see section V. Make sure the procedure is appropriate for the make and model of the vehicle. certification labels. For overhead camshaft engines. Record the necessary information in the space provided.

verify correct camshaft timing with the valve timing components located in the block (nonoverhead camshaft engines). Record observations in the space provided. Make sure the procedure is appropriate for the make and model of the vehicle. see section V. 5. Record observations in the space provided.) Using the procedure. verify correct camshaft timing in an overhead camshaft engine. Have the instructor check the box to approve the procedure.AUTOMOTIVE TECHNOLOGY Using the procedure. Using service information. locate a procedure for verifying correct camshaft timing in an overhead camshaft engine. Average of the above evaluations W 48 . (For a general procedure.B.

What is the function of the instrumentation computer? 2. Does a permanent magnet signal generator produce an AC or DC signal to monitor speed and position of moving parts? 4. What is the function of the engine control computer? NAME: DATE: B. 1. A. What is the purpose of the solenoid? W 49 . What is the purpose of the buffer? 3.ENGINE PERFORMANCE: IGNITION SYSTEMS AS1-L1-UIII COMPUTERIZED ENGINE CONTROLS Directions — Answer the following questions by writing all responses on this sheet. A. What is the purpose of RAM? B.

AUTOMOTIVE TECHNOLOGY 5. When is scan tool snapshot information used? W 50 .

W 51 . 5. certification labels. such as vehicle service history.ENGINE PERFORMANCE: IGNITION SYSTEMS JS1-L2-UIII OBTAIN AND INTERPRET DIAGNOSTIC TROUBLE CODES AND SCAN TOOL DATA Equipment: Personal protective equipment (PPE) Scan tool Procedure: 1. NAME: DATE: EVALUATION 3. Determine if the system uses on-board diagnostics generation one (OBD I) or on-board diagnostics generation two (OBD II). 4. Research applicable vehicle service information. Check the digital reading for stored diagnostic trouble codes (DTCs). VIN. Record in the space provided. Record the necessary information in the following space. 2. Wear PPE while performing the procedures on this job sheet. and calibration decals. Connect the scan tool to the data link connector. Record in the space provided.

8. Record in the space provided. 7. Compare to manufacturer’s specifications. interpret the scan tool data. When applicable. Record in the space provided. 10. Disconnect the scan tool.AUTOMOTIVE TECHNOLOGY 6. Check stored snapshot information. clear the codes. Record in the space provided. 9. Average of the above evaluations W 52 . Check the data stream information. Using available service information.

Check the digital reading for stored diagnostic trouble codes (DTCs). Record the necessary information in the following space. Record in the space provided. Record in the space provided. 5. W 53 .ENGINE PERFORMANCE: IGNITION SYSTEMS JS2-L2-UIII DIAGNOSE THE CAUSES OF EMISSIONS OR DRIVEABILITY CONCERNS USING STORED DIAGNOSTIC TROUBLE CODES Equipment: Personal protective equipment (PPE) Scan tool Procedure: 1. certification labels. Connect the scan tool to the data link connector. Wear PPE while performing the procedures on this job sheet. Determine if the system uses on-board diagnostics generation one (OBD I) or on-board diagnostics generation two (OBD II). and calibration decals. VIN. NAME: DATE: EVALUATION 3. 2. Research applicable vehicle service information. 4. such as vehicle service history.

Using available service information. Check the datastream information for sensor output and actuator operation relating to the DTCs or driveability concerns.AUTOMOTIVE TECHNOLOGY 6. 9. Determine necessary action to correct the emissions or driveability concern. 7. Average of the above evaluations W 54 . clear the DTCs. interpret the scan tool data. Disconnect the scan tool. With the scan tool. When applicable. Complete the chart. Record in the space provided. 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 Not OK 8. Record abnormal readings in the space provided. test for malfunction of interrelated systems. 10.

such as vehicle service history. Record abnormal readings in the space provided. certification labels. Determine if the system uses on-board diagnostics generation one (OBD I) or on-board diagnostics generation two (OBD II). 2. If the vehicle has stored diagnostic trouble codes (DTCs). VIN. see JS2-L2-UIII to continue diagnosis. Check the digital reading. NAME: DATE: EVALUATION 3.ENGINE PERFORMANCE: IGNITION SYSTEMS JS3-L2-UIII DIAGNOSE THE CAUSES OF EMISSIONS OR DRIVEABILITY CONCERNS WITH NO STORED DIAGNOSTIC TROUBLE CODES Equipment: Personal protective equipment (PPE) Scan tool Procedure: 1. 6. 5. Research applicable vehicle service information. Wear PPE while performing the procedures on this job sheet. Connect the scan tool to the data link connector. Check the datastream information for sensor output and actuator operation relating to the DTCs or driveability concerns. and calibration decals. W 55 . 4. Record the necessary information in the following space. Record in the space provided.

AUTOMOTIVE TECHNOLOGY 7. determine necessary action to correct the emissions or driveability concern. 8. Include further diagnosis and/or repairs. Based on the datastream information and available service information. Disconnect the scan tool. Average of the above evaluations W 56 .

6. Using available service information. Check the digital reading for stored DTCs. Determine necessary action to correct module communication errors. Record in the space provided. If necessary. such as vehicle service history. interpret the scan tool data. Connect the scan tool equipped with LAN and CAN capability to the data link connector. enter vehicle information. W 57 . Set the scan tool to check for LAN and CAN diagnostic trouble codes (DTCs). VIN. 5. Research applicable vehicle service information. 2.ENGINE PERFORMANCE: IGNITION SYSTEMS JS4-L2-UIII CHECK FOR MODULE COMMUNICATION ERRORS DATE: NAME: Equipment: Personal protective equipment (PPE) Scan tool EVALUATION Procedure: 1. 3. and calibration decals. Record the necessary information in the following space. certification labels. 4. Wear PPE while performing the procedures on this job sheet.

8. When applicable. clear the DTCs.AUTOMOTIVE TECHNOLOGY 7. Disconnect the scan tool. Average of the above evaluations W 58 .

Test the wiring and wiring circuits. Determine the wire that carries reference voltage from the powertrain control module (PCM) to the sensor. 3. 2. Locate the sensor to be tested. Wear PPE while performing the procedures on this job sheet. and the wire that grounds the sensor. W 59 . Research applicable vehicle service information such as vehicle service history. 1. certification labels. VIN. Check the reference voltage to the sensors. Connect the red probe to the harness connector of the reference voltage wire and the black probe to the negative battery cable.ENGINE PERFORMANCE: IGNITION SYSTEMS JS1-L3-UIII TEST AND SERVICE COMPUTERIZED ENGINE CONTROLS USING A DIGITAL MULTIMETER Equipment: Digital multimeter (DMM) Personal protective equipment (PPE) Procedure: 1. 2. 4. the wire that returns the voltage signal. and calibration decals. a. Select the direct current (DC) voltage function on the DMM and set to the proper range. NAME: DATE: EVALUATION 3. Record the necessary information in the space provided.

Record observations in the space provided. Compare to manufacturer’s specifications. perform an inspection of the electrical system that sends current to the PCM. Connect the red lead to the wire being tested and the black lead to a good ground. If the reference voltage circuit connections are good and the circuit is continuous. b. Check the reading.AUTOMOTIVE TECHNOLOGY 5. 3. 4. 7. 2. Repair the circuit if an open is found. Record observations in the space provided. Compare to manufacturer’s specifications. If reference voltage is nonexistent or not within specifications. Disconnect the DMM. If the connections are not loose or corroded. Select the resistance function on the DMM and set to the lowest range. check for loose or corroded wire connections back to the PCM. Record observations in the space provided. 1. check the continuity of the reference voltage wiring back to the PCM. Disconnect the DMM. 8. 5. Check the reading. 6. Record observations in the space provided. W 60 . c. Check wiring continuity.

etc. locate a procedure for testing sensors and actuators with a DMM. Have the instructor check the box to approve the procedure. test the sensors and actuators with a DMM.ENGINE PERFORMANCE: IGNITION SYSTEMS 4. Specifications 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 Reading OK Not OK W 61 . volts. ohms. Complete the chart. Using the procedure. Include specifications for hertz. Make sure the procedure is appropriate for the make and model of the vehicle. Using service information.

Make sure the procedure is appropriate for the make and model of the vehicle. locate a procedure for servicing problems found during testing with the computerized engine controls. Have the instructor check the box to approve the procedure. Using service information. service problems found during testing with the computerized engine controls. Using the procedure.AUTOMOTIVE TECHNOLOGY 5. Average of the above evaluations W 62 .

Test the wiring and wiring circuits. and the wire that grounds the sensor. certification labels. Check the reference voltage to the sensors. Locate the sensor to be tested.ENGINE PERFORMANCE: IGNITION SYSTEMS JS2-L3-UIII TEST AND SERVICE COMPUTERIZED ENGINE CONTROLS USING A SCAN TOOL Equipment: Bidirectional scan tool capable of performing actuator tests Digital multimeter (DMM) Personal protective equipment (PPE) Scan tool Procedure: 1. and calibration decals. the wire that returns the voltage signal. 3. 1. 2. 2. a. W 63 . Connect the red probe to the harness connector of the reference voltage wire and the black probe to the negative battery cable. 4. Research applicable vehicle service information such as vehicle service history. Record the necessary information in the space provided. Select the direct current (DC) voltage function on the DMM and set to the proper range. Determine the wire that carries reference voltage from the powertrain control module (PCM) to the sensor. Wear PPE while performing the procedures on this job sheet. NAME: DATE: EVALUATION 3. VIN.

Select the resistance function on the DMM and set to the lowest range. 1. Disconnect the DMM. b. 2. W 64 . Record observations in the space provided. Compare to manufacturer’s specifications. Check the reading. If the reference voltage circuit connections are good and the circuit is continuous. c. 8. If the connections are not loose or corroded. 6. 4. Compare to manufacturer’s specifications. 3. Disconnect the DMM. 5. Connect the red lead to the wire being tested and the black lead to a good ground. If reference voltage is nonexistent or not within specifications. check the continuity of the reference voltage wiring back to the PCM. perform an inspection of the electrical system that sends current to the PCM. Record observations in the space provided. Check wiring continuity. Record observations in the space provided.AUTOMOTIVE TECHNOLOGY 5. Record observations in the space provided. 7. check for loose or corroded wire connections back to the PCM. Check the reading. Repair the circuit if an open is found.

Make sure the procedure is appropriate for the make and model of the vehicle.) O2S KS ACTUATORS Solenoids Relays Servo Motor Reading OK Not OK W 65 . volts. Have the instructor check the box to approve the procedure. etc. Specifications 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 (Use a DMM if Necessary. test the sensors and actuators with a scan tool. Using service information. locate a procedure for testing sensors and actuators with a scan tool.ENGINE PERFORMANCE: IGNITION SYSTEMS 4. Using the procedure. Include specifications for hertz. Complete the chart. ohms.

determine necessary action.AUTOMOTIVE TECHNOLOGY 5. d. locate a procedure for servicing problems found during testing with the computerized engine controls. Average of the above evaluations W 66 . Have the instructor check the box to approve the procedure. Determine if the actuator responded correctly. select “Actuator Test. Using the procedure. 6. g. e. From the display. c. Complete the chart. Make sure the procedure is appropriate for the make and model of the vehicle. Perform active tests of actuators using a bidirectional scan tool. a. Using service information. OK Solenoid Relays Servo Motor Not OK f. select “Function Test” or “Special Functions. Enter vehicle information. Include further diagnosis and/or repair(s). b.” Select the actuator to be tested and follow the instructions for performing the test. Disconnect the scan tool.” From the display. Connect the scan tool to the data link connector. Record in space provided. If the actuator(s) did not respond correctly. service problems found during testing with the computerized engine controls.

VIN. Record the necessary information in the space provided. NAME: DATE: EVALUATION 3.ENGINE PERFORMANCE: IGNITION SYSTEMS JS3-L3-UIII TEST AND SERVICE COMPUTERIZED ENGINE CONTROLS USING A GRAPHING MULTIMETER/DIGITAL STORAGE OSCILLOSCOPE Equipment: Graphing multimeter (GMM)/digital storage oscilloscope (DSO) Personal protective equipment (PPE) Procedure: 1. Using service information. Wear PPE while performing the procedures on this job sheet. test the electrical/electronic circuits. Have the instructor check the box to approve the procedure.) Using the procedure. certification labels. and calibration decals. W 67 . 2. see section IV. locate a procedure for testing the electrical/ electronic circuits. Research applicable vehicle service information such as vehicle service history. Make sure the procedure is appropriate for the make and model of the vehicle. (For general procedures.A. Is the pattern good? Record observations in the space provided.

test the sensors. see section IV. locate a procedure for testing the actuators.C.) Using the procedure. (For general procedures. Make sure the procedure is appropriate for the make and model of the vehicle.B. Using service information.) W 68 . Have the instructor check the box to approve the procedure. see section IV. Make sure the procedure is appropriate for the make and model of the vehicle. locate a procedure for testing the sensors. Not OK Using service information. Have the instructor check the box to approve the procedure. Complete the chart. (For general procedures. OK 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 5.AUTOMOTIVE TECHNOLOGY 4.

test the PCM. see section IV. locate a procedure for testing the powertrain control module (PCM). Make sure the procedure is appropriate for the make and model of the vehicle. 7. Is the pattern good? Record observations in the space provided. (For general procedures. locate a procedure for servicing problems found during testing with the computerized engine controls.ENGINE PERFORMANCE: IGNITION SYSTEMS Using the procedure. test the actuators. Make sure the procedure is appropriate for the make and model of the vehicle. Not OK Using service information.) Using the procedure. Complete the chart. Average of the above evaluations W 69 . OK Solenoid Relays Servo Motor 6.D. Using the procedure. Using service information. Have the instructor check the box to approve the procedure. service problems found during testing with the computerized engine controls. Have the instructor check the box to approve the procedure.

AUTOMOTIVE TECHNOLOGY W 70 .

Define the following terms: A. Before top dead center — C. Top dead center — 2. 1. B.ENGINE PERFORMANCE: IGNITION SYSTEMS AS1-L1-UIV DISTRIBUTOR IGNITION SYSTEMS Directions — Answer the following questions by writing all responses on this sheet. Pre-ignition — E. Firing order — D. W 71 . Base timing — NAME: DATE: B. C. What are the three performance capabilities of distributor ignition systems? A.

AUTOMOTIVE TECHNOLOGY 3. What is the primary function of the distributor? 5. What is the optimum operating temperature of a spark plug? 4. What type of ignition coil is shown in the following illustration? W 72 .

Identify ignition system concerns. Record the necessary information in the space provided. VIN. and calibration decals.ENGINE PERFORMANCE: IGNITION SYSTEMS JS1-L2-UIV DIAGNOSE IGNITION SYSTEM PROBLEMS ON A VEHICLE WITH A DISTRIBUTOR IGNITION SYSTEM Equipment: Digital multimeter (DMM) Exhaust gas analyzer Personal protective equipment (PPE) Scan tool Secondary ignition tester or Spark tester Procedure: 1. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history. Yes No-Start Hard Start Misfire Poor Driveability Spark Knock Power Loss Poor Mileage Emissions Concerns No W 73 . Complete the chart. certification labels. 2. NAME: DATE: EVALUATION 3.

AUTOMOTIVE TECHNOLOGY 4. test the possible causes of the concerns. Record observations in the space provided. W 74 . 5. Make sure the procedure is appropriate for the make and model of the vehicle. Record observations in the space provided. Have the instructor check the box to approve the procedure. Using a scan tool. and datastream information related to the concerns. locate a procedure for testing the possible causes of the concerns. Using service information. snapshot information. Using the procedure. check the diagnostic trouble codes.

Shut off the engine. e. b. Start the engine and allow it to reach normal operating temperature. Connect the exhaust gas analyzer according to manufacturer’s procedures. Disconnect the exhaust gas analyzer. Complete the chart. Record readings in the space provided. Zero and calibrate the exhaust gas analyzer. Turn on the exhaust gas analyzer and allow it to warm up. c. f. Perform an exhaust gas diagnostic test. 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 Not OK 7. Compare readings to proper specifications. a.ENGINE PERFORMANCE: IGNITION SYSTEMS 6. Check the exhaust gas analyzer readings. If there is a no-start condition. test the components and systems using a DMM. d. W 75 .

determine necessary action to correct any problems. Based on the tests. Include further diagnosis and/or repairs.AUTOMOTIVE TECHNOLOGY 8. Average of the above evaluations W 76 .

2. Wear PPE while performing the procedures on this job sheet. VIN. Make sure the procedure is appropriate for the make and model of the vehicle. AND SERVICE THE PRIMARY CIRCUIT AND IGNITION COIL Equipment: Digital multimeter (DMM) Hand tools Personal protective equipment (PPE) Procedure: 1. certification labels. Research applicable vehicle service information such as vehicle service history. NAME: DATE: EVALUATION 3. OK Wiring Insulation Terminals Routing Not OK 4. Complete the chart. Record the necessary information in the space provided. TEST. Inspect the primary circuit wiring. locate a procedure for testing the primary circuit. and calibration decals. see section II. (For general procedures.) W 77 .ENGINE PERFORMANCE: IGNITION SYSTEMS JS2-L2-UIV INSPECT. Using service information. Have the instructor check the box to approve the procedure.B.

Inspect the ignition coils. 5.AUTOMOTIVE TECHNOLOGY Using the procedure. test the primary circuit. a. Explain why the test did not meet specifications. 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. What is the available voltage at the side of the ignition coil? c. Complete the following chart. OK Ignition Coil Cover Primary Wiring Secondary Coil Wire Wiring Connections Coil Tower Coil Polarity Not OK W 78 . What is the voltage drop across the resistor bypass circuit while cranking the engine? b. What is the voltage drop across the primary control circuit? e. Answer the questions. What is the voltage drop across the coil primary? d.

) Using the procedure. locate a procedure for testing the ignition coil.B. Average of the above evaluations W 79 . Determine if the ignition coil is good or bad. see section III. Using service information. (For general procedures. Have the instructor check the box to approve the procedure. locate a procedure for servicing or repairing defective components. 7. Include primary and secondary resistance specifications. Make sure the procedure is appropriate for the make and model of the vehicle. Record the resistance in the spaces provided. Record in the space provided. Primary resistance Secondary resistance Compare the resistance to manufacturer’s specifications. Using the procedure. Make sure the procedure is appropriate for the make and model of the vehicle.ENGINE PERFORMANCE: IGNITION SYSTEMS 6. Using service information. Have the instructor check the box to approve the procedure. service or repair defective components. test the ignition coil.

AUTOMOTIVE TECHNOLOGY W 80 .

Make sure the procedure is appropriate for the make and model of the vehicle. and calibration decals. NAME: DATE: EVALUATION 3. Wear PPE while performing the procedures on this job sheet. Using service information. W 81 . VIN. see section IV. Step 4 is the procedure for using a timing meter.) Using the procedure. locate a procedure for checking and adjusting ignition timing and timing advance/retard using a timing light.ENGINE PERFORMANCE: IGNITION SYSTEMS JS3-L2-UIV CHECK AND ADJUST IGNITION TIMING AND TIMING ADVANCE/ RETARD Equipment: Distributor wrench Exhaust ventilation equipment Personal protective equipment (PPE) Tachometer Timing light Timing meter Vacuum pressure pump Procedure: NOTE: Step 3 is the procedure for using a timing light. Include timing specifications and engine speed at which the timing is to be checked and set. Record the necessary information in the space provided. 1. Research applicable vehicle service information such as vehicle service history. check and adjust ignition timing and timing advance/retard using a timing light.C. certification labels. Have the instructor check the box to approve the procedure. (For general procedures. 2. Answer the questions.

explain why. check and adjust ignition timing and timing advance/retard using a timing meter.AUTOMOTIVE TECHNOLOGY a. Is the vacuum advance unit functioning normally? 4. did you adjust base timing to specifications? b.D. NOTE: Connect the timing meter to the engine as directed by the timing meter manufacturer. If required. but it cannot be adjusted? If base timing could not be adjusted. W 82 . Answer the questions. locate a procedure for checking and adjusting ignition timing and timing advance/retard using a timing meter.) Using the procedure. Is the centrifugal advance unit functioning normally? d. Have the instructor check the box to approve the procedure. see section IV. c. Include timing specifications and engine speed at which the timing is to be checked and set. (For general procedures. Include the timing meter offset degree setting. Is base timing incorrect. Using service information. Is base timing correct or incorrect? If base timing is incorrect. use the appropriate magnetic probe adapter. Make sure the procedure is appropriate for the make and model of the vehicle.

but it cannot be adjusted? If base timing could not be adjusted. c. Is base timing correct or incorrect? If base timing is incorrect. Is base timing incorrect.ENGINE PERFORMANCE: IGNITION SYSTEMS a. did you adjust base timing to specifications? b. Is the vacuum advance unit functioning normally? Average of the above evaluations W 83 . explain why. Is the centrifugal advance unit functioning normally? d.

AUTOMOTIVE TECHNOLOGY W 84 .

certification labels. TEST. and calibration decals. Research applicable vehicle service information such as vehicle service history. VIN. EVALUATION 3. Perform a visual inspection of distributor assembly. W 85 . Record the necessary information in the space provided. Wear PPE while performing the procedures on this job sheet. 2.ENGINE PERFORMANCE: IGNITION SYSTEMS JS4-L2-UIV INSPECT. Record observations in the space provided. AND SERVICE THE DISTRIBUTOR DATE: NAME: Equipment: Digital multimeter (DMM) Distributor wrench Exhaust ventilation equipment Hand tools Personal protective equipment (PPE) Safety solvent Timing equipment Procedure: 1.

6. W 86 . Record resistance and if resistance meets specifications in the space provided. Make sure the procedure is appropriate for the distributor. Using service information. Compare to manufacturer’s specifications. inspect and test the distributor electronic components. Yes Cracks or Carbon Tracking Burned Contacts Corrosion in the Coil Towers Tight Wire Connections No a. measure the resistance of the contacts to the coil towers. Record observations in the space provided. inspect and test the distributor advance component. Have the instructor check the box to approve the procedure. Using a DMM. Inspect the distributor cap. Using the procedure.AUTOMOTIVE TECHNOLOGY 4. Complete the chart. Record observations in the space provided. locate a procedure for inspecting and testing the distributor electronic components. 5. If applicable.

Yes Cracks or Carbon Tracking Burn-through Excessive Burning of the Rotor Tip Tension and Wear of the Spring Contact No a. Remove the distributor hold-down clamp. Record resistance and if resistance meets specifications in the space provided. 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. disconnect the vacuum advance hose. Using a DMM. Inspect and test the rotor. b. W 87 . Compare to manufacturer’s specifications. mark their position for proper reassembly. NOTE: If the timing marks are not visible. Remove the distributor. NOTE: If removing spark plug wires. If equipped. e. Disconnect the primary wiring. g.ENGINE PERFORMANCE: IGNITION SYSTEMS 7. Remove the distributor cap. Clean debris from around the base of the distributor housing. measure resistance. Place a clean towel over the hole in the engine where the distributor was removed. Complete the chart. h. f. c. a. mark the distributor housing at the point at which the rotor is pointing. d. 8. Then make another mark on the distributor housing and a corresponding mark on the engine block. Remove the distributor.

a.) Using the procedure. Inspect the drive gear for scoring or excessive wear. distributor cap. Have the instructor check the box to approve the procedure. (For general procedures. Blow dry.1. locate a procedure for repairing or replacing defective or worn components including the distributor advance component. (For general procedures. Using service information. Make sure the procedure is appropriate for the distributor. distributor shaft. Using safety solvent. Make sure the procedure is appropriate for the distributor. Using service information. d. locate a procedure for disassembling the distributor.) Using the procedure. c. Record observations in the space provided. W 88 . repair or replace defective or worn components. Service the distributor. b. and centrifugal advance components.AUTOMOTIVE TECHNOLOGY 9.G.5. e. see section V. Have the instructor check the box to approve the procedure. and rotor. disassemble the distributor. see section V. clean the distributor housing. Inspect the distributor shaft and bushing for wear.G. Record observations in the space provided.

10. b. Make sure the procedure is appropriate for the distributor. e. but do not tighten.) Shut off the engine and disconnect the exhaust ventilation equipment. Install the distributor cap. Connect the exhaust ventilation equipment.7. d. locate a procedure for replacing defective electronic components. and primary wiring. locate a procedure for reassembling and lubricating the distributor.ENGINE PERFORMANCE: IGNITION SYSTEMS f. (For general procedures. g. vacuum advance line. Align the marks that were made during removal. the hold-down bolt. see section V. Snug. reassemble and lubricate the distributor. Using service information. Using the procedure. f. (For general procedures. Start the engine and set timing to specifications. a. Average of the above evaluations W 89 . replace defective electonic components. Using service information. see section IV. Make sure the procedure is appropriate for the distributor. Install the distributor hold-down clamp and bolt. Install the distributor.G.) Using the procedure. Remove the towel and place the distributor back in the engine. Have the instructor check the box to approve the procedure. c. Have the instructor check the box to approve the procedure. CAUTION: Be sure to use approved exhaust ventilation equipment when operating a vehicle in an enclosed area.

AUTOMOTIVE TECHNOLOGY W 90 .

certification labels. OK Wiring Insulation Wire Boots Loose Wiring Routing Wiring in Retaining/Mounting Clips Not OK 4. Wear PPE while performing the procedures on this job sheet. Complete the chart. VIN.ENGINE PERFORMANCE: IGNITION SYSTEMS JS5-L2-UIV INSPECT. W 91 . and calibration decals. TEST. Record the necessary information in the space provided. a. 2. Research applicable vehicle service information such as vehicle service history. AND SERVICE SECONDARY CIRCUIT WIRING AND SPARK PLUGS Equipment: Digital multimeter (DMM) Hand tools Personal protective equipment (PPE) Spark plug gap gauge Spark plug socket Procedure: 1. Test the resistance of the spark plugs. Connect one DMM lead to each end of the spark plug wire. Inspect the secondary wiring. NAME: DATE: EVALUATION 3.

5. NOTE: Keep the spark plugs in order so that any problems found can be traced to the proper cylinder. label the wires with tape for proper reinstallation. c. If necessary. Select the proper spark plug socket. Record observations in the space provided.) Remove the spark plugs. d.C. Remove all spark plug wires. Disconnect the DMM. Compare to manufacturer’s specifications. c. a. W 92 . 6. Check the reading. Grasp the spark plug wire by the wire boot and remove by gently twisting and pulling. apply a penetrating lubricant to the base of the spark plug. Use compressed air to blow dirt or other contaminants from around each spark plug. Remove each spark plug. b. see section VI. If any of the spark plugs are excessively tight.AUTOMOTIVE TECHNOLOGY b. (For general procedures. Repair or replace secondary circuit wiring and spark plug wires that are damaged or not within specifications.

check that the gasket is in place. If the spark plugs are the gasket-seat type. Average of the above evaluations W 93 . Replace damaged spark plugs. b. 9. Install the spark plugs. Inspect the spark plugs. Use the spark plug gap gauge to bend the side electrode to adjust the spark plug gap. a. Check each plug for electrode condition. electrode gap. Complete the chart. d. Spark Plugs 1 2 3 4 5 6 7 8 OK Not OK 8. Adjust the electrode gap of each spark plug to specification. Install the spark plugs finger tight in the cylinder head. insulator damage. c.ENGINE PERFORMANCE: IGNITION SYSTEMS 7. fouling. Tighten spark plugs to specified torque with a spark plug socket and torque wrench. and conditions that can shorten the life of the spark plug or indicate engine problems.

AUTOMOTIVE TECHNOLOGY W 94 .

4. W 95 .ENGINE PERFORMANCE: IGNITION SYSTEMS AS1-L1-UV ELECTRONIC IGNITION SYSTEMS Directions — Answer the following questions by writing all responses on this sheet. 1. What is the function of the camshaft position sensor? NAME: DATE: 2. What is the function of the PCM? 3. B. On what strokes does the ignition coil deliver the spark in wasted-spark systems? A. B. Where are the ignition coils mounted on unit ignition systems? A.

C. What are three advantages of EI systems? A. B. W 96 .AUTOMOTIVE TECHNOLOGY 5.

and calibration decals. VIN. Complete the chart. Yes No-Start Hard Start Misfire Poor Driveability Spark Knock Power Loss Poor Mileage Emissions Concerns No W 97 . Identify ignition system concerns. 2. Record the necessary information in the space provided. Research applicable vehicle service information such as vehicle service history.ENGINE PERFORMANCE: IGNITION SYSTEMS JS1-L2-UV DIAGNOSE IGNITION SYSTEM PROBLEMS ON A VEHICLE WITH AN ELECTRONIC IGNITION SYSTEM Equipment: Digital multimeter (DMM) Exhaust gas analyzer Personal protective equipment (PPE) Scan tool Secondary ignition tester or spark tester Procedure: 1. Wear PPE while performing the procedures on this job sheet. NAME: DATE: EVALUATION 3. certification labels.

5. snapshot information. Make sure the procedure is appropriate for the make and model of the vehicle. Using the procedure. and datastream information related to the concerns. W 98 . Record observations in the space provided. Using a scan tool. Have the instructor check the box to approve the procedure. Record observations in the space provided. locate the procedure for testing the possible causes of the concerns. check diagnostic trouble codes. test the possible causes of the concerns.AUTOMOTIVE TECHNOLOGY 4. Using service information.

W 99 . Turn on the exhaust gas analyzer and allow it to warm up. Perform an exhaust gas diagnostic test. Zero and calibrate the exhaust gas analyzer. Compare readings to proper specifications. f. 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 Not OK 7.ENGINE PERFORMANCE: IGNITION SYSTEMS 6. Record readings in the space provided. b. If there is a no-start condition. test the components and systems using a DMM. Complete the chart. c. d. Connect the exhaust gas analyzer according to manufacturer’s procedures. Shut off the engine. Check the exhaust gas analyzer readings. e. Disconnect the exhaust gas analyzer. Start the engine and allow it to reach normal operating temperature. a.

Average of the above evaluations W 100 . determine necessary action to correct any problems. Based on the tests. Include further diagnosis and/or repairs.AUTOMOTIVE TECHNOLOGY 8.

check diagnostic trouble codes. snapshot information. Inspect the primary circuit wiring. Research applicable vehicle service information such as vehicle service history. OK Wiring Insulation Terminals Routing Not OK W 101 . Record the necessary information in the space provided. TEST. and calibration decals.ENGINE PERFORMANCE: IGNITION SYSTEMS JS2-L2-UV INSPECT. 2. 4. Using a scan tool. Record observations in the space provided. VIN. Wear PPE while performing the procedures on this job sheet. AND SERVICE THE PRIMARY CIRCUIT AND IGNITION COILS Equipment: Digital multimeter (DMM) Personal protective equipment (PPE) Scan tool Procedure: 1. certification labels. and datastream information for readings. NAME: DATE: EVALUATION 3. Complete the chart.

AUTOMOTIVE TECHNOLOGY 5. locate a procedure for testing the ignition coils. see section II. Using service information. (For general procedures. test the primary circuit using a DMM. Complete the chart. Have the instructor check the box to approve the procedure.B. Record observations in the space provided.) W 102 . Have the instructor check the box to approve the procedure. Make sure the procedure is appropriate for the make and model of the vehicle.) Using the procedure. Make sure the procedure is appropriate for the make and model of the vehicle. 6. OK Electronic Coil Cover Electronic Coil Module Primary Wiring Secondary Coil Wire Wiring Connections Coil Tower Coil Polarity Not OK 7. Include primary and secondary resistance specifications. see section III. (For general procedures. Using service information. Inspect the electronic coil module and ignition coils. locate a procedure for testing the primary circuit using a DMM.C.

Record the resistance in the spaces provided. Using service information. Make sure the procedure is appropriate for the make and model of the vehicle. Using the procedure. Have the instructor check the box to approve the procedure. Primary resistance Secondary resistance Compare resistance to manufacturer’s specifications. test the ignition coils. Average of the above evaluations W 103 .ENGINE PERFORMANCE: IGNITION SYSTEMS Using the procedure. 8. locate a procedure for servicing or repairing defective components. Determine if the ignition coil is good or bad. Record in the space provided. service or repair defective components.

AUTOMOTIVE TECHNOLOGY W 104 .

b. Test the resistance of the spark plug wires. 2. and calibration decals. Inspect the secondary wiring. a. OK Wiring Insulation Wire Boots Loose Wiring Routing Wiring in Retaining/Mounting Clips Not OK 4. Wear PPE while performing the procedures on this job sheet. VIN. certification labels. TEST. Complete the chart. NAME: DATE: EVALUATION 3. AND SERVICE SECONDARY CIRCUIT WIRING AND SPARK PLUGS Equipment: Digital multimeter (DMM) Hand tools Personal protective equipment (PPE) Spark plug gap gauge Spark plug socket Procedure: 1. W 105 . Record the necessary information in the space provided. Connect one DMM lead to each end of the spark plug wire.ENGINE PERFORMANCE: IGNITION SYSTEMS JS3-L2-UV INSPECT. Use service information to locate the proper resistance specifications for the spark plug wires. Research applicable vehicle service information such as vehicle service history.

label the wires with tape for proper reinstallation. If any of the spark plugs are excessively tight. 5. Use compressed air to blow dirt or other contaminants from around each spark plug. 6. b. Disconnect the DMM. Select the proper spark plug socket.AUTOMOTIVE TECHNOLOGY c. Grasp the spark plug wire by the wire boot and remove by gently twisting and pulling. Check the reading. NOTE: Keep the spark plugs in order so that any problems found can be traced to the proper cylinder. (For general procedures. c. d.) Remove the spark plugs. see section V. Compare to manufacturer’s specifications. W 106 . Remove each spark plug. Repair or replace secondary circuit wiring and spark plug wires that are damaged or not within specifications. Remove all spark plug wires. If necessary. apply a penetrating lubricant to the base of the spark plug.C. a. d. Record observations in the space provided.

d. Adjust the electrode gap of each spark plug to specification. Inspect the spark plugs. electrode gap. a. 9. Use the spark plug gap gauge to bend the side electrode to adjust the spark plug gap. and conditions that can shorten the life of the spark plug or indicate engine problems. fouling. Check each plug for electrode condition. Install the spark plugs. Tighten spark plugs to specified torque with a spark plug socket and torque wrench. Install the spark plugs finger tight in the cylinder head. Spark Plugs 1 2 3 4 5 6 7 8 Diagnosis 8. Complete the chart. c. Replace damaged spark plugs. check that the gasket is in place. Average of the above evaluations W 107 . insulator damage. If the spark plugs are the gasket-seat type. b.ENGINE PERFORMANCE: IGNITION SYSTEMS 7.

AUTOMOTIVE TECHNOLOGY W 108 .

ENGINE PERFORMANCE: IGNITION SYSTEMS JS1-L1-UVI CHECK AND ADJUST VALVE LASH ON ENGINES DATE: NAME: Equipment: Feeler gauge set Personal protective equipment (PPE) EVALUATION Procedure: 1.) W 109 . see section I. Using service information. Research applicable vehicle service information such as vehicle service history. (For general procedures. Record the necessary information in the space provided. Wear PPE while performing the procedures on this job sheet. and calibration decals. go to step 5. locate a procedure for checking and adjusting valve lash on mechanical lifters. 4. Make sure the procedure is appropriate for the make and model of the vehicle. go to step 4. Record in the space provided.A. VIN. Have the instructor check the box to approve the procedure. 2. certification labels. For an engine with hydraulic lifters. Determine if the engine has mechanical or hydraulic lifters. NOTE: For an engine with mechanical lifters. 3.

AUTOMOTIVE TECHNOLOGY Using the procedure. 5. locate a procedure for measuring valve lash on hydraulic lifters. Record observations in the space provided. Using service information.) Using the procedure. measure valve lash on hydraulic lifters.B. Record observations in the space provided. Average of the above evaluations W 110 . Make sure the procedure is appropriate for the make and model of the vehicle. (For general procedures. Have the instructor check the box to approve the procedure. check and adjust valve lash on mechanical lifters. see section I.

2.B.) Using the procedure. Using service information. Wear PPE while performing the procedures on this job sheet. 4. locate a procedure for removing the timing belt/chain. VIN. certification labels. Have the instructor check the box to approve the procedure. locate a procedure for installing the timing belt/chain. Research applicable vehicle service information such as vehicle service history. Make sure the procedure is appropriate for the make and model of the vehicle. Using service information.) W 111 . see section II. remove the timing belt/chain. (For general procedures.A. and calibration decals. Make sure the procedure is appropriate for the make and model of the vehicle. Record the necessary information in the space provided. 3. see section II. (For general procedures. Have the instructor check the box to approve the procedure.ENGINE PERFORMANCE: IGNITION SYSTEMS JS2-L1-UVI REMOVE AND REPLACE TIMING BELT/CHAIN DATE: NAME: Equipment: Exhaust ventilation equipment Personal protective equipment (PPE) EVALUATION Procedure: 1. Include a procedure for verifying correct camshaft timing.

Verify correct camshaft timing. Record observations in the space provided.AUTOMOTIVE TECHNOLOGY Using the procedure. install the timing belt/chain. Average of the above evaluations W 112 .

TEST. W 113 . VIN. Connect the exhaust ventilation equipment. Inspect the thermostat housing and gasket for leakage or damage. 5. AND SERVICE THERMOSTAT AND COMPONENTS DATE: NAME: Equipment: Exhaust ventilation equipment Instrument for testing engine operating temperature Personal protective equipment (PPE) Procedure: 1. Use service information to locate the thermostat. 4. see JS3-L3-UII. b. Test the thermostat. certification labels. Record observations in the space provided. Record the necessary information in the space provided. a. (For procedures. 2. Verify engine operating temperature. Wear PPE while performing the procedures on this job sheet. EVALUATION 3. Research applicable vehicle service information such as vehicle service history.) Check the circulation within the cooling system. 1. CAUTION: Be sure to use approved exhaust ventilation equipment when operating a vehicle in an enclosed area. and calibration decals.ENGINE PERFORMANCE: IGNITION SYSTEMS JS3-L1-UVI INSPECT.

AUTOMOTIVE TECHNOLOGY
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. Record observations in the space provided.

5. 6.

Shut off the engine. Disconnect the exhaust ventilation equipment.

Replace the thermostat. a. b. c. d. e. f. Drain the cooling system. Remove the thermostat housing and thermostat. Clean the mating surfaces of the thermostat housing and engine, removing the old gasket/seal. Install the new 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. Refill the cooling system and bleed air, if required.

W 114

ENGINE PERFORMANCE: IGNITION SYSTEMS
g. Connect the exhaust ventilation equipment. CAUTION: Be sure to use approved exhaust ventilation equipment when operating a vehicle in an enclosed area. h. Start the engine and check cooling system operation. Record observations in the space provided.

i.

Shut off the engine. Disconnect the exhaust ventilation equipment.

Average of the above evaluations

W 115

AUTOMOTIVE TECHNOLOGY

W 116

ENGINE PERFORMANCE: IGNITION SYSTEMS
JS4-L1-UVI INSPECT, TEST, AND SERVICE FANS AND FAN COMPONENTS
DATE: NAME:

Equipment: Exhaust ventilation equipment Personal protective equipment (PPE)
EVALUATION

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: 1. 2. Wear PPE while performing the procedures on this job sheet. 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.

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 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) No

W 117

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

b. Have the instructor check the box to approve the procedure. Have the instructor check the box to approve the procedure. Using service information. Make sure the procedure is appropriate for the make and model of the vehicle. Using service information.ENGINE PERFORMANCE: IGNITION SYSTEMS a. locate a procedure for checking the sensors and controls that operate the fan. Using the procedure. Record observations in the space provided. energize the fan. Inspect the fan shroud. Complete the chart. 6. locate a procedure for energizing the fan. Using the procedure. Record observations in the space provided. OK Not OK Cracks or Damage Shroud-to-Fan Fit and Clearance Condition of Mounting Brackets and Bolts W 119 . Make sure the procedure is appropriate for the make and model of the vehicle. check the sensors and controls that operate the fan.

Make sure the procedure is appropriate for the make and model of the vehicle. 8.AUTOMOTIVE TECHNOLOGY 7. Average of the above evaluations W 120 . Have the instructor check the box to approve the procedure. Inspect the cooling system air dams and mounting brackets for damage. Using the procedure. service and repair/replace any problems found during the inspections and testing. Record observations in the space provided. locate a procedure for servicing and repairing/ replacing any problems found during the inspections and testing. Using service information.

W 121 . 5. 3. Determine what tools are needed. Use a die on external threads. Record in the space provided. Wear PPE while performing the procedures on this job sheet. Use a tap to correct small imperfections on internal threads. 7. Determine what repairs need to be made.ENGINE PERFORMANCE: IGNITION SYSTEMS JS5-L1-UVI PERFORM COMMON FASTENER AND THREAD REPAIRS DATE: NAME: Equipment: Personal protective equipment (PPE) Tools for performing fastener and thread repairs EVALUATION Procedure: 1. 6. NOTE: Select the proper steps based on the repairs that need to be made. Inspect all threaded openings. 4. Inspect and clean threads and bolts. Use various taps to clean the threads of all threaded holes. Clean all the nuts and bolts used to assemble the engine. 2. Use a helicoil or thread insert to repair stripped threads. Record observations in the space provided.

Inspect the nuts and bolts for signs of stretching and stripping and for rounded corners on bolts and nuts. Use the tap handle to rotate the extractor and bolt counterclockwise. Drill a hole in the center of the broken bolt. Record observations in the space provided. b. a.AUTOMOTIVE TECHNOLOGY 8. Remove both as a unit from the bolt hole. Average of the above evaluations W 122 . Use a screw extractor to remove any broken bolts. Insert a screw extractor in the hole. c. 9.

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. Wear PPE while performing the procedures on this job sheet.ENGINE PERFORMANCE: IGNITION SYSTEMS JS6-L1-UVI PERFORM AN OIL AND FILTER CHANGE DATE: NAME: Equipment: Drain pan or drain bucket Exhaust ventilation equipment Oil filter wrench Personal protective equipment (PPE) Vehicle lifting equipment Procedure: 1. 4. Connect the exhaust ventilation equipment. always use proper lifting equipment and observe all safety precautions. W 123 . 5. Failure to comply with all safety rules could result in fatal injuries. Start the vehicle and allow it to reach normal operating temperature. VIN. CAUTION: When lifting a vehicle. EVALUATION 3. Research applicable vehicle service information such as vehicle service history. CAUTION: Be sure to use approved exhaust ventilation equipment when operating a vehicle in an enclosed area. 6. Turn off the engine. certification labels. Lift the vehicle in order to get to the underside. If the vehicle is turbocharged. allow the engine to idle during the last few minutes of operation. Record the necessary information in the space provided. 2. and calibration decals. Place a drain pan or drain bucket under the crankcase drain plug.

if required. Recheck all work and make sure that the drain plug(s) are installed tightly. oil pan threads. Open the hood and add the proper amount of new oil to the engine. the throttle and other control linkages should be lubricated at this time. If the engine does not show signs of developing oil pressure within 10 seconds. 14. CAUTION: Be sure to add the correct amount of oil to the engine. Replace if worn or damaged. Locate and correct the problem. 9. Also make sure that the oil filter is on tightly. c. Tighten the oil filter according to manufacturer’s specifications. Select the correct type and weight of oil. Perform lubrication service under the hood as required. Remove the oil drain plug or plugs and catch the oil in the drain pan or bucket. Catch oil in the drain pan or drain bucket. 8. Use an oil filter wrench to remove the oil filter. Lubricate the gasket with clean engine oil. Start the engine and allow to idle for a few seconds. b. and drain plug gasket. 16. W 124 . Lower the vehicle to the floor. Replace worn or damaged gaskets at this time. Clean the area where the oil filter gasket will seal and make sure that the oil gasket is not still stuck there. 12. Inspect the drain plug. CAUTION: Do not allow hot oil to contact the skin. 10. While the oil is draining. Do not over torque or cross thread the drain plug. Reinstall the drain plug(s) and tighten securely. 13. Check the suspension and steering joints in the vehicle and lubricate. 15. 11. check the following. shut off the engine immediately. Adding too much or too little oil can result in severe engine damage. Double-check that oil was put in the engine. In some vehicles.AUTOMOTIVE TECHNOLOGY 7. Check the grease in the rear axle (or final drive) and the lubricant in manual transmissions. Install the new oil filter. a. Allow the oil to drain for a few minutes.

Disconnect the exhaust ventilation equipment. lift the vehicle and check the drain plug(s) and the oil filter for leaks. 19. Shut off the engine. 18. While the engine is idling. Dispose of the used oil according to the United States Environmental Protection Agency (EPA) guidelines. 20. Allow the engine to idle for a few minutes. Average of the above evaluations W 125 . the date.ENGINE PERFORMANCE: IGNITION SYSTEMS 17. Lower the vehicle and record on a windshield/door tag the vehicle’s mileage. and precisely what service was performed.

AUTOMOTIVE TECHNOLOGY W 126 .

VIN. including the high-voltage cables and service plug. Record the necessary information in the space provided. 2. determine if special care is needed when handling any components of the high-voltage system. determine the locations of the high-voltage system components. certification labels. W 127 . NAME: DATE: EVALUATION 3. Using service information. Wear PPE while performing the procedures on this job sheet.ENGINE PERFORMANCE: IGNITION SYSTEMS JS7-L1-UVI IDENTIFY HYBRID VEHICLE INTERNAL COMBUSTION ENGINE SERVICE PRECAUTIONS Equipment: Personal protective equipment (PPE) Safety cones for the work area Procedure: 1. Using service information. Record in the space provided. Research applicable vehicle service information such as vehicle service history. Record in the space provided. 4. and calibration decals.

deactivate the high-voltage system.D. Average of the above evaluations W 128 . Using service information.AUTOMOTIVE TECHNOLOGY 5. (For general procedures for a Honda hybrid electric vehicle.3. locate a procedure for deactivating the highvoltage system. see section VII.) Using the procedure. Have the instructor check the box to approve the procedure. Make sure the procedure is appropriate for the make and model of the vehicle.

just off the cutting line. Light the torch using a spark lighter. Cut a straight line. Using the procedures. Procedure: 1. c. W 129 . b. Step 5 is cutting a bevel. Have the instructor check the box to approve the procedure. Remove items or materials that could cause a potentially dangerous situation. If only one or two cuts are assigned. 2. a. Step 4 is cutting a straight line. materials.ENGINE PERFORMANCE: IGNITION SYSTEMS JS1-L2-UVI HEAT AND CUT METAL USING AN OXYFUEL TORCH DATE: NAME: Equipment: Oxyfuel outfit Personal protective equipment (PPE) Soapstone and straightedge Spark lighter NOTE: The instructor will assign the specific cut(s). Step 6 is cutting a circle. Using service information. d. and work area to ensure safe and correct operation. Position the plate on the worktable and mark a cutting line using a soapstone and straightedge. 4. to serve as a guide. Clamp angle iron to the plate at a right angle. Wear PPE while performing the procedures on this job sheet. locate a procedure for setting up and shutting down the oxyfuel outfit. skip the appropriate other step(s) and move to Step 7. set up the oxyfuel outfit. Adjust the flame to a neutral flame with and without the oxygen lever pressed. EVALUATION 3. Inspect equipment. shutting down the oxyfuel outfit.

When the plate has reached cutting temperature. a. c. b. The preheat flames should be just above the top of the plate. to serve as a guide. Cut a bevel. d. Position the plate on the worktable and mark a cutting line using a soapstone and straightedge. Clamp angle iron to the plate at an angle. press the cutting oxygen lever and move the torch steadily across the plate to complete the cut. Make additional cuts if instructed. Adjust the flame to a neutral flame with and without the oxygen lever pressed. f. d. When the plate has reached cutting temperature. Position the torch over the edge of the metal. Light the torch using a spark lighter. Light the torch using a spark lighter. Use the hand that is not operating the cutting lever to steady the cutting hand. c. 5. Adjust the flame to a neutral flame with and without the oxygen lever pressed. Make additional cuts if instructed. a. W 130 . e. press the cutting oxygen lever and move the torch steadily across the plate to complete the cut. f. 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. b. Cut a circle. Use the free hand to steady the cutting hand. The preheat flames should be just above the top of the plate. The preheat flames should be just above the top of the plate. Position the plate on the worktable and mark a cutting line using a soapstone.AUTOMOTIVE TECHNOLOGY e. Position the torch over the edge of the metal. Hold the whole torch at the angle of the desired cut and guide by the angle iron. just off the cutting line. 6. with the center of the cutting tip in line with the cutting line and angled slightly away from the work. with the center of the cutting tip in line with the cutting line and pointed slightly away from the work.

g. Lower the torch into normal cutting position and cut out to the cutting line and complete the cut. 8. raise the cutting tip 1/2 in or more and slowly press the cutting lever. 7. Rotate the torch until the flame cuts through the metal. Return materials and equipment to the proper places. Using the procedure from Step 3. Make additional cuts if instructed. Average of the above evaluations W 131 . shut down the oxyfuel outfit.ENGINE PERFORMANCE: IGNITION SYSTEMS e. When the plate reaches cutting temperature. Use the hand that is not operating the cutting lever to steady the cutting hand. f.

AUTOMOTIVE TECHNOLOGY W 132 .

Sign up to vote on this title
UsefulNot useful