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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.
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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, Cause, 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, Test, and Service the Cooling System Drain, Flush, 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, Test, 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 Instructors Initials

Date

Instructors 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

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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, Test, and Service the Distributor Inspect, Test, and Service Secondary Circuit Wiring and Spark Plugs Diagnose Ignition Systems Problems on a Vehicle with an Electronic Ignition System Inspect, Test, and Service the Primary Circuit and Ignition Coils Inspect, Test, and Service Secondary Circuit Wiring and Spark Plugs Check and Adjust Valve Lash on Engines Remove and Replace Timing Belt/Chain Inspect, Test, and Service Thermostat and Components Inspect, Test, 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 Instructors Initials

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

DATE:

EVALUATION

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Smiths Automotive Repair Customers 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

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JS2-L1-UII IDENTIFY AND INTERPRET ENGINE PERFORMANCE CONCERN
Equipment: Personal protective equipment (PPE) Service information
EVALUATION DATE: NAME:

Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Ask the customer to describe the engine performance concern. Record concern in the space provided.

3.

Ask the customer the following series of questions. Record the answers in the space provided. a. When did the concern first occur?

b.

Is the malfunction indicator light on or flashing?

c.

Is the concern continuous or intermittent?

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d. What are the driving conditions when the concern occurs?

e.

Is the vehicle making any unusual noises or vibrations?

f.

What is the recent service history of the vehicle?

4.

Based on the answers to the questions, determine the next step in the diagnostic process for the vehicle. Record in the space provided.

Average of the above evaluations

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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. 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.
EVALUATION

3.

Perform a visual engine inspection. Complete the chart.

OK Installation and routing of spark plug wires Condition of primary wiring terminals and connectors for secure connections Battery terminals for corrosion or looseness Cleanliness of air filter elements Drive belts for looseness or wear Oil leaks on the spark plug wires and other parts Coolant level Coolant leaks Fuel leaks at the fuel tank, fuel lines, fuel pump, and carburetor/fuel injectors Other leaks

Not OK

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4. Start the engine. Listen for abnormal engine noises or vibrations using a stethoscope, long screwdriver, or a section of vacuum hose for vacuum and air pressure leaks. See Section III.C.3. for a description of various engine noises or vibrations. Record observations in the space provided. Shut off the engine.

5.

Start the engine. Perform a visual inspection of the exhaust system. See Section III.D. for normal occurences and problem indicators. Complete the chart. Shut off the engine.

OK 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

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6. Based on the preliminary engine inspection, determine the necessary action to correct any problems. Include further diagnosis and/or repairs.

Average of the above evaluations

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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. 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.

EVALUATION

3.

Connect the exhaust ventilation equipment. CAUTION: Be sure to use approved exhaust ventilation equipment when operating the vehicle in an enclosed area.

4.

Perform a vacuum gauge test. a. Connect the vacuum gauge to an intake manifold vacuum source. Connect a vacuum hose to an accessible intake manifold vacuum connector and extend it up to the vacuum gauge. Start the engine and allow it to reach normal operating temperature. Observe and record the reading with the engine at idle speed in the space provided.

b. c.

d.

Shut off the engine. Disconnect the test equipment. W9

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5. Perform an exhaust restriction test. a. Connect the vacuum gauge to an intake manifold vacuum source. Connect a vacuum hose to an accessible intake manifold vacuum connector and extend it up to the vacuum gauge. Connect a tachometer to the engine. Start the engine. Gradually accelerate the engine rpm from idle to 2,000 rpm. Observe and record the reading in the space provided.

b. c.

d.

Maintain the engine speed at 2,000 rpm for about 10 seconds or longer. Observe and record the reading in the space provided.

e. 6.

Shut off the engine. Disconnect the test equipment.

Perform a cranking vacuum test. a. b. c. d. e. Start the engine and allow it to reach normal operating temperature. Shut off the engine. Connect a vacuum gauge to a nonported vacuum source on the intake manifold. Disable the ignition system. Completely block the throttle valve so that air cannot enter. Crank the engine. Observe and record the cranking vacuum.

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f. g. 7. 8. Disconnect the vacuum gauge. Unblock the throttle valve. Enable the ignition.

Disconnect the exhaust ventilation equipment. Based on the tests, determine the necessary action to correct any problems. Include further diagnosis and/or repairs.

Average of the above evaluations

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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. 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.

EVALUATION

3.

Using service information, locate a procedure for connecting a cylinder balance tester to the engine. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.

Using the procedure, connect the cylinder balance tester to the engine. NOTE: This test may also be performed using an engine analyzer or scan tool. 4. 5. Connect a tachometer to the engine if it is not part of the cylinder balance tester. Connect the exhaust ventilation equipment. CAUTION: Be sure to use the approved exhaust ventilation equipment when operating the vehicle in an enclosed area.

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6. 7. 8. 9. 10. 11. Start the engine and allow it to reach normal operating temperature. Shut off the engine. Disconnect the oxygen sensor and unplug the exhaust gas recirculation (EGR) hose or connector. Restart the engine. Bring the engine speed to 1,000 rpm and maintain that speed. Select the cylinder shorting mode on the cylinder balance tester. Disable the idle air control on a fuel-injected engine. Short each cylinder for the same amount of time, about 2 seconds to 3 seconds. Give the engine about 5 seconds between each short. Observe the tachometer for the amount of rpm drop on each cylinder. Record the reading in the following chart.

Cylinder 1 2 3 4 5 6 7 8

Percent of rpm Drop

12. 13.

Shut off the engine. Disconnect the test equipment. Disconnect the exhaust ventilation equipment. Reconnect the oxygen sensor and the EGR hose or connector.

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14. 15. Clear the codes. Based on the tests, determine the necessary action to correct any problems. Include further diagnosis and/or repairs.

Average of the above evaluations

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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. 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.

EVALUATION

3.

Connect the exhaust ventilation equipment. CAUTION: Be sure to use approved exhaust ventilation equipment when operating the vehicle in an enclosed area.

4.

Perform a cranking engine cylinder compression test with the throttle closed. a. b. c. d. e. f. Start the engine and allow it to reach normal operating temperature. Shut off the engine. Disable the ignition and fuel systems. Remove the air filter. Use compressed air to blow debris away from the spark plugs. Remove the spark plugs. Install the compression gauge in one cylinder.

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g. Crank the engine at least four compression strokes. If the engine cranks slowly, the readings are not accurate. Charge the battery. Then, test the battery, starting, and charging systems. It may be necessary to keep a battery charger on the battery to perform this test. Observe the compression gauge. Record the readings of the first puff and at the highest point in the chart.
Cylinder 1 2 3 4 5 6 7 8 First "Puff" Reading Highest Point OK Yes or No

h.

i. j. 5.

Repeat the procedure for each cylinder. Record the readings in the chart. Remove the compression gauge. Reinstall the air filter and spark plugs. Enable the ignition and fuel systems.

Perform a cranking engine cylinder compression test with the throttle open. a. b. c. d. Start the engine and allow it to reach normal operating temperature. Shut off the engine. Disable the ignition and fuel systems. Remove the air filter.

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e. f. g. h. Block the throttle valve to the wide open position. Use compressed air to blow debris away from the spark plugs. Remove the spark plugs. Install the compression gauge in one cylinder. Crank the engine at least four compression strokes. If the engine cranks slowly, the readings are not accurate. Charge the battery. Then, test the battery, starting, and charging systems. It may be necessary to keep a battery charger on the battery to perform this test. Observe the compression gauge. Record the readings of the first puff and at the highest point in the chart.
Cylinder First "Puff" Reading Highest Point Change from Closed Throttle Yes or No

i.

1 2 3 4 5 6 7 8

j. k. l. 6.

Repeat the procedure for each cylinder. Record the readings in the chart. Unblock the throttle valve. Remove the compression gauge. Reinstall the air filter and spark plugs. Enable the ignition and fuel systems.

Disconnect the exhaust ventilation equipment. W 19

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7. Based on the tests, determine the necessary action to correct any problems. Include further diagnosis and/or repairs.

Average of the above evaluations

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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. 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.

EVALUATION

3.

Connect the exhaust ventilation equipment. CAUTION: Be sure to use the approved exhaust ventilation equipment when operating the vehicle in an enclosed area.

4. 5. 6. 7. 8. 9.

Start the engine and allow it to reach normal operating temperature. Shut off the engine. Use compressed air to blow debris away from the spark plugs. Remove one spark plug and connect a spark tester to the plug wire. Install the compression gauge in the cylinder. Start the engine and allow it to idle. Release the compression gauge pressure.

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10. Observe the reading at idle. Record the reading in the chart.
Cylinder 1 2 3 4 5 6 7 8 Idle Compression 1500 rpm Compression Snap Compression

11. 12. 13. 14. 15. 16. 17. 18.

Slowly raise the engine speed to 1,500 rpm. Observe the reading. Record the reading in the chart. Return the engine speed to idle. Release the compression gauge pressure. Snap the throttle open and then closed. Observe the reading. Record the reading in the chart. Repeat the procedure for each cylinder. Record the readings in the chart. Shut off the engine. Remove the compression gauge. Remove the spark tester and reinstall the spark plug. Disconnect the exhaust ventilation equipment.

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19. Based on the tests, determine the necessary action to correct any problems. Include further diagnosis and/or repairs.

Average of the above evaluations

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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. 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.

EVALUATION

3.

Connect the exhaust ventilation equipment. CAUTION: Be sure to use the approved exhaust ventilation equipment when operating the vehicle in an enclosed area.

4. 5. 6. 7. 8. 9. 10. 11.

Start the engine and allow it to reach normal operating temperature. Shut off the engine. Remove the air filter. Block the throttle valve to the wide open position. Use compressed air to blow debris away from the spark plugs. Remove the spark plugs. Remove the crankcase filler cap. Check the coolant level. If necessary, refill the radiator. Rotate the engine until the cylinder is at top dead center.

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12. Using service information, locate a procedure for calibrating and connecting a cylinder leakage tester. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.

Using the procedure, calibrate and connect the cylinder leakage tester. 13. Observe and record the reading in the chart.

Cylinder 1 2 3 4 5 6 7 8

Percent of Leakage

14.

Repeat the procedure for each cylinder. Record the readings in the chart.

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15. If there is excessive cylinder leakage, listen at the different points to determine the source of the leak. See Section IV.A.13. for listening locations. Record the source of leakage in the space provided.

16. 17. 18. 19. 20.

Disconnect the cylinder leakage tester. Unblock the throttle valve. Reinstall the air filter and spark plugs. Replace the crankcase filler cap. Disconnect the exhaust ventilation equipment. Based on the tests, determine the necessary action to correct any problems. Include further diagnosis and/or repairs.

Average of the above evaluations

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JS1-L3-UII PERFORM ENGINE SYSTEM DIAGNOSTIC TESTS USING AN OSCILLOSCOPE
Equipment: Oscilloscope 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. Include pattern specifications. Record the necessary information in the space provided.
NAME:

DATE:

EVALUATION

3.

Using service information, locate a procedure for connecting an oscilloscope to the engine. Make sure the procedure is appropriate for the oscilloscope and make and model of the vehicle. Have the instructor check the box to approve the procedure.

Using the procedure, connect the oscilloscope to the engine. 4. Check service information for engine size, dwell time, and firing order. Record in the spaces provided. Engine Size Dwell Time Firing Order 5. Connect the exhaust ventilation equipment. CAUTION: Be sure to use approved exhaust ventilation equipment when operating the vehicle in an enclosed area. W 29

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6. 7. Start the engine and allow it to reach normal operating temperature. Check the primary raster pattern for dwell time, primary on, primary off, coil oscillations, and uneven primary off trace. Compare patterns to manufacturers specifications. Record observations in the space provided.

8.

Check the secondary parade pattern. Compare patterns to manufacturers specifications. Answer the questions. a. Are the firing spikes even (within 3 kilovolts of each other and between 5 kilovolts and 15 kilovolts in height)? Complete the chart.

Cylinder 1 2 3 4 5 6 7 8

Firing kilovolts

Burn kilovolts

Burn Time

b.

Are the firing lines normal?

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c. Are all cylinders similar?

9.

Check the secondary raster pattern for even firing lines, primary on, dwell time, and coil oscillations. Compare patterns to manufacturers specifications. Record observations in the space provided.

10. 11.

Shut off the engine and disconnect the oscilloscope. Disconnect the exhaust ventilation equipment. Based on the tests, determine necessary action to correct any problems. Include further diagnosis and/or repairs.

Average of the above evaluations

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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 manufacturers information, locate a procedure for connecting an exhaust gas analyzer. Have the instructor check the box to approve the procedure.

Using the procedure, connect the exhaust gas analyzer. NOTE: It may be necessary to block the source of air to the catalytic converter. A catalytic converter that works properly cleans the exhaust gases and makes it difficult to get an accurate reading. 4. 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.

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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

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JS3-L3-UII VERIFY ENGINE OPERATING TEMPERATURE
DATE: NAME:

Equipment: Digital multimeter with temperature probe Direct-read, probe-type (cooking) thermometer Noncontact infrared thermometer Personal protective equipment (PPE) Procedure: NOTE: There are three different methods for verifying engine operating temperature. The instructor will choose the appropriate method. 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.

EVALUATION

3.

Connect the exhaust ventilation equipment. CAUTION: Be sure to use approved exhaust ventilation equipment when operating a vehicle in an enclosed area.

4.

Verify engine operating temperature using a noncontact infrared thermometer. a. b. Start the engine and allow it to run until warm. Aim the infrared thermometer at the cylinder head and measure the temperature. Compare reading to manufacturers specifications. Record observations in the space provided.

c.

Shut off the engine. W 35

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5. Verify engine operating temperature using a digital multimeter with a temperature probe. a. Place the temperature probe on the engine near the thermostat, on the top radiator hose, or into the coolant in the radiator (not in the overflow recovery tank). CAUTION: Never remove a radiator cap unless the engine is sufficiently cool. Removing the radiator cap when the engine is hot can cause scalding hot coolant to be sprayed over a wide area, resulting in serious injury. b. c. Start the engine and allow it to run until warm. Monitor the temperature reading. Compare reading to manufacturers specifications. Record observations in the space provided.

d. 6.

Shut off the engine.

Verify engine operating temperature using a direct-read, probe-type (cooking) thermometer. a. b. c. Place the thermometer probe into the coolant in the radiator or tape the thermometer to the top radiator hose. Start the engine and allow it to run until warm. Observe the reading. Compare reading to manufacturers specifications. Record observations in the space provided.

d. 7.

Shut off the engine.

Disconnect the exhaust ventilation equipment.

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8. Based on the test, determine necessary action to correct any problems. Include further diagnosis and/or repairs.

Average of the above evaluations

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JS4-L3-UII INSPECT, TEST, AND SERVICE THE COOLING SYSTEM
DATE: NAME:

Equipment: Combustion leak tester Exhaust gas analyzer Hand tools Personal protective equipment (PPE) Pressure tester 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.

EVALUATION

3.

Inspect the cooling system. Complete the chart.

OK Radiator cap Hoses Outer shell of the radiator Coolant passages inside the radiator Coolant recovery tank
4. Pressure test the cooling system for leaks. a.

Not OK

Connect a pressure tester to the radiator filler neck. CAUTION: Never remove a radiator cap unless the engine is sufficiently cool. Removing the radiator cap when the engine is hot can cause scalding hot coolant to be sprayed over a wide area, resulting in serious injury.

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b. Pump the pressure tester until the pressure reaches the release pressure mark on the radiator cap. Check the cooling system for leaks. Complete the chart.
OK 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.

Check the engine oil and transmission fluid for coolant contamination. Record observations in the space provided.

d.

Monitor the reading for 15 minutes. Record observations in the space provided.

e. f.

Relieve the pressure and disconnect the pressure tester. Connect the pressure tester to the radiator cap and test the pressure release point. Compare to manufacturers specifications. Record observations in the space provided.

g. 5.

Relieve the pressure and disconnect the pressure tester.

Connect the exhaust ventilation equipment. CAUTION: Be sure to use approved exhaust ventilation equipment when operating a vehicle in an enclosed area.

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6. Test the cooling system for combustion gas leakage. The instructor will select one of the three methods. a. Test using a pressure tester. 1. 2. Connect the pressure tester. Do not pressurize the cooling system. Start the engine and monitor the reading. Record observations in the space provided.

3. b.

Shut off the engine. Disconnect the pressure tester.

Test using a combustion leak tester. 1. 2. 3. Place the tester in the filler opening of the cooling system (radiator or reservoir). Start the engine. Squeeze and release the tester bulb to get an air sample. Observe the color of the test fluid in the tester. Record observations in the space provided.

4. c.

Shut off the engine.

Test using an exhaust gas analyzer. 1. 2. 3. Remove the filler cap (radiator or reservoir). Start the engine. Place the exhaust gas analyzer probe near the cooling system filler opening. Observe the readings and increase engine speed. Record observations in the space provided.

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CAUTION: Do not allow coolant to be sucked into the exhaust gas analyzer. Coolant pulled into the analyzer will damage the analyzer. 4. 7. 8. Shut off the engine.

Disconnect the exhaust ventilation equipment. Inspect the condition of the coolant. a. b. Remove the radiator cap. Check the coolant color. Record observations in the space provided.

c.

Feel the coolant between the fingers. Record observations in the space provided.

d. 9.

Replace the radiator cap.

Test the coolant recovery system. a. Obtain the instructors permission to perform a road test. Have the instructor check the box to approve the road test.

b. c.

Drive the vehicle for several miles. Shut off the engine.

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d. Observe the level in the coolant recovery tank. Record observations in the space provided.

e. f.

Allow the cooling system to completely cool down. Remove the radiator cap and check the coolant level. Record observations in the space provided.

g.

Inspect the coolant recovery system if a problem is found. Complete the chart.
OK Hose and hose connections between the radiator and the coolant recovery tank Coolant recovery tank Radiator cap gasket and valve Not OK

10.

Determine the type of service that needs to be performed based on the inspections and test results. Record in the space provided.

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

Using the procedure, service defective cooling system components. Average of the above evaluations

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JS5-L3-UII DRAIN, FLUSH, AND REFILL THE COOLING SYSTEM
DATE: NAME:

Equipment: Coolant Exhaust ventilation equipment Fresh water Hand tools 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 space provided.

EVALUATION

3. 4.

Remove the radiator cap. Make sure the petcock can open freely. Remove the thermostat housing and the thermostat. Clean the mating surfaces of the thermostat housing and the engine to remove the old gasket/seal. Connect the exhaust ventilation equipment. CAUTION: Be sure to use approved exhaust ventilation equipment when operating a vehicle in an enclosed area.

5.

6. 7. 8.

Start the engine and allow it to reach normal operating temperature. Shut off the engine. Open the petcock, allowing the coolant to drain completely from the radiator. CAUTION: Used coolant is classified as toxic waste and must be disposed of according to law.

9.

Remove one of the heater hoses and connect a supply of fresh water to the hose end that leads into the heater. W 45

AUTOMOTIVE TECHNOLOGY
10. 11. 12. Allow the cooling system to fill. When the system is full, start the engine and allow it to idle. Adjust the water flow so that the radiator stays full while the drain is running wide open. Keep the engine and the fresh water running until the discharge fluid runs clear. Shut off the engine. 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. Center the thermostat in the housing. Install the new gasket/seal and thermostat housing. Use the correct sealer to install the gasket. Reconnect the heater hose. Using service information, select the correct coolant and determine coolant capacity for the vehicle. Have the instructor check the box to approve the coolant type. Record correct coolant and coolant capacity in the space provided.

13. 14.

15. 16.

17. 18. 19.

Using the correct coolant capacity, measure coolant at half this capacity and add to the radiator. Pour the coolant down the radiator filler neck. Continue to fill the radiator with clean, fresh water. Fill to proper specifications. Start the engine and allow it to reach normal operating temperature. The coolant should start to circulate and the upper radiator tank should become warm. Bleed the system, if necessary. If the cooling system is working properly, top off the radiator with clean water and replace the radiator cap. Shut off the engine. Disconnect the exhaust ventilation equipment.

20. 21.

Average of the above evaluations W 46

ENGINE PERFORMANCE: IGNITION SYSTEMS


JS6-L3-UII VERIFY CORRECT CAMSHAFT TIMING
DATE: NAME:

Equipment: Hand tools Personal protective equipment (PPE)


EVALUATION

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.

Determine the engine type of the vehicle. (For nonoverhead camshaft engines, go to step 4. For overhead camshaft engines, go to step 5.) Record in the space provided.

4.

Using service information, locate a procedure for verifying correct camshaft timing with the valve timing components located in the block (nonoverhead camshaft engine). Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see section V.A.)

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AUTOMOTIVE TECHNOLOGY
Using the procedure, verify correct camshaft timing with the valve timing components located in the block (nonoverhead camshaft engines). Record observations in the space provided.

5.

Using service information, locate a procedure for verifying correct camshaft timing in an overhead camshaft engine. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see section V.B.)

Using the procedure, verify correct camshaft timing in an overhead camshaft engine. Record observations in the space provided.

Average of the above evaluations

W 48

ENGINE PERFORMANCE: IGNITION SYSTEMS


AS1-L1-UIII COMPUTERIZED ENGINE CONTROLS
Directions Answer the following questions by writing all responses on this sheet. 1. A. What is the function of the engine control computer?
NAME:

DATE:

B.

What is the function of the instrumentation computer?

2.

A.

What is the purpose of RAM?

B.

What is the purpose of the buffer?

3.

Does a permanent magnet signal generator produce an AC or DC signal to monitor speed and position of moving parts?

4.

What is the purpose of the solenoid?

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

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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. 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.
NAME:

DATE:

EVALUATION

3.

Determine if the system uses on-board diagnostics generation one (OBD I) or on-board diagnostics generation two (OBD II). Record in the space provided.

4. 5.

Connect the scan tool to the data link connector. Check the digital reading for stored diagnostic trouble codes (DTCs). Record in the space provided.

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AUTOMOTIVE TECHNOLOGY
6. Check the data stream information. Compare to manufacturers specifications. Record in the space provided.

7.

Check stored snapshot information. Record in the space provided.

8.

Using available service information, interpret the scan tool data. Record in the space provided.

9. 10.

When applicable, clear the codes. Disconnect the scan tool.

Average of the above evaluations

W 52

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. 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.
NAME:

DATE:

EVALUATION

3.

Determine if the system uses on-board diagnostics generation one (OBD I) or on-board diagnostics generation two (OBD II). Record in the space provided.

4. 5.

Connect the scan tool to the data link connector. Check the digital reading for stored diagnostic trouble codes (DTCs). Record in the space provided.

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AUTOMOTIVE TECHNOLOGY
6. Check the datastream information for sensor output and actuator operation relating to the DTCs or driveability concerns. Record abnormal readings in the space provided.

7.

With the scan tool, test for malfunction of interrelated systems. Complete the chart.
OK 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.

Using available service information, interpret the scan tool data. Determine necessary action to correct the emissions or driveability concern. Record in the space provided.

9. 10.

When applicable, clear the DTCs. Disconnect the scan tool.

Average of the above evaluations W 54

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. 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.
NAME:

DATE:

EVALUATION

3.

Determine if the system uses on-board diagnostics generation one (OBD I) or on-board diagnostics generation two (OBD II). Record in the space provided.

4. 5. 6.

Connect the scan tool to the data link connector. Check the digital reading. If the vehicle has stored diagnostic trouble codes (DTCs), see JS2-L2-UIII to continue diagnosis. Check the datastream information for sensor output and actuator operation relating to the DTCs or driveability concerns. Record abnormal readings in the space provided.

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AUTOMOTIVE TECHNOLOGY
7. Based on the datastream information and available service information, determine necessary action to correct the emissions or driveability concern. Include further diagnosis and/or repairs.

8.

Disconnect the scan tool.

Average of the above evaluations

W 56

ENGINE PERFORMANCE: IGNITION SYSTEMS


JS4-L2-UIII CHECK FOR MODULE COMMUNICATION ERRORS
DATE: NAME:

Equipment: Personal protective equipment (PPE) Scan tool


EVALUATION

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.

3. 4. 5.

Connect the scan tool equipped with LAN and CAN capability to the data link connector. If necessary, enter vehicle information. Set the scan tool to check for LAN and CAN diagnostic trouble codes (DTCs). Check the digital reading for stored DTCs. Record in the space provided.

6.

Using available service information, interpret the scan tool data. Determine necessary action to correct module communication errors.

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AUTOMOTIVE TECHNOLOGY
7. 8. When applicable, clear the DTCs. Disconnect the scan tool.

Average of the above evaluations

W 58

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. 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.
NAME:

DATE:

EVALUATION

3.

Test the wiring and wiring circuits. a. Check the reference voltage to the sensors. 1. 2. Locate the sensor to be tested. Determine the wire that carries reference voltage from the powertrain control module (PCM) to the sensor, the wire that returns the voltage signal, and the wire that grounds the sensor. Select the direct current (DC) voltage function on the DMM and set to the proper range. Connect the red probe to the harness connector of the reference voltage wire and the black probe to the negative battery cable.

3. 4.

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AUTOMOTIVE TECHNOLOGY
5. Check the reading. Compare to manufacturers specifications. Record observations in the space provided.

6.

If reference voltage is nonexistent or not within specifications, check for loose or corroded wire connections back to the PCM. Record observations in the space provided.

7.

If the connections are not loose or corroded, check the continuity of the reference voltage wiring back to the PCM. Record observations in the space provided.

8. b.

Disconnect the DMM.

Check wiring continuity. 1. 2. 3. Select the resistance function on the DMM and set to the lowest range. Connect the red lead to the wire being tested and the black lead to a good ground. Check the reading. Compare to manufacturers specifications. Record observations in the space provided.

4. 5. c.

Disconnect the DMM. Repair the circuit if an open is found.

If the reference voltage circuit connections are good and the circuit is continuous, perform an inspection of the electrical system that sends current to the PCM. W 60

ENGINE PERFORMANCE: IGNITION SYSTEMS


4. Using service information, locate a procedure for testing sensors and actuators with a DMM. Include specifications for hertz, volts, ohms, etc. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.

Using the procedure, test the sensors and actuators with a DMM. Complete the chart.

Specifications 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

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

Using the procedure, service problems found during testing with the computerized engine controls. Average of the above evaluations

W 62

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. 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.
NAME:

DATE:

EVALUATION

3.

Test the wiring and wiring circuits. a. Check the reference voltage to the sensors. 1. 2. Locate the sensor to be tested. Determine the wire that carries reference voltage from the powertrain control module (PCM) to the sensor, the wire that returns the voltage signal, and the wire that grounds the sensor. Select the direct current (DC) voltage function on the DMM and set to the proper range. Connect the red probe to the harness connector of the reference voltage wire and the black probe to the negative battery cable.

3. 4.

W 63

AUTOMOTIVE TECHNOLOGY
5. Check the reading. Compare to manufacturers specifications. Record observations in the space provided.

6.

If reference voltage is nonexistent or not within specifications, check for loose or corroded wire connections back to the PCM. Record observations in the space provided.

7.

If the connections are not loose or corroded, check the continuity of the reference voltage wiring back to the PCM. Record observations in the space provided.

8. b.

Disconnect the DMM.

Check wiring continuity. 1. 2. 3. Select the resistance function on the DMM and set to the lowest range. Connect the red lead to the wire being tested and the black lead to a good ground. Check the reading. Compare to manufacturers specifications. Record observations in the space provided.

4. 5. c.

Disconnect the DMM. Repair the circuit if an open is found.

If the reference voltage circuit connections are good and the circuit is continuous, perform an inspection of the electrical system that sends current to the PCM. W 64

ENGINE PERFORMANCE: IGNITION SYSTEMS


4. Using service information, locate a procedure for testing sensors and actuators with a scan tool. Include specifications for hertz, volts, ohms, etc. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.

Using the procedure, test the sensors and actuators with a scan tool. Complete the chart.

Specifications 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.) O2S KS ACTUATORS Solenoids Relays Servo Motor

Reading

OK

Not OK

W 65

AUTOMOTIVE TECHNOLOGY
5. Perform active tests of actuators using a bidirectional scan tool. a. b. c. d. e. Connect the scan tool to the data link connector. Enter vehicle information. From the display, select Function Test or Special Functions. From the display, select Actuator Test. Select the actuator to be tested and follow the instructions for performing the test. Determine if the actuator responded correctly. Complete the chart.
OK Solenoid Relays Servo Motor Not OK

f.

If the actuator(s) did not respond correctly, determine necessary action. Include further diagnosis and/or repair(s). Record in space provided.

g. 6.

Disconnect the scan tool.

Using service information, locate a procedure for servicing problems found during testing with the computerized engine controls. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.

Using the procedure, service problems found during testing with the computerized engine controls. Average of the above evaluations W 66

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. 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.
NAME:

DATE:

EVALUATION

3.

Using service information, locate a procedure for testing the electrical/ electronic circuits. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For general procedures, see section IV.A.)

Using the procedure, test the electrical/electronic circuits. Is the pattern good? Record observations in the space provided.

W 67

AUTOMOTIVE TECHNOLOGY
4. Using service information, locate a procedure for testing the sensors. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For general procedures, see section IV.B.)

Using the procedure, test the sensors. Complete the chart.

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.

Not OK

Using service information, locate a procedure for testing the actuators. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For general procedures, see section IV.C.)

W 68

ENGINE PERFORMANCE: IGNITION SYSTEMS


Using the procedure, test the actuators. Complete the chart.

OK Solenoid Relays Servo Motor


6.

Not OK

Using service information, locate a procedure for testing the powertrain control module (PCM). Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For general procedures, see section IV.D.)

Using the procedure, test the PCM. Is the pattern good? Record observations in the space provided.

7.

Using service information, locate a procedure for servicing problems found during testing with the computerized engine controls. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.

Using the procedure, service problems found during testing with the computerized engine controls. Average of the above evaluations

W 69

AUTOMOTIVE TECHNOLOGY

W 70

ENGINE PERFORMANCE: IGNITION SYSTEMS


AS1-L1-UIV DISTRIBUTOR IGNITION SYSTEMS
Directions Answer the following questions by writing all responses on this sheet. 1. Define the following terms: A. Base timing
NAME:

DATE:

B.

Before top dead center

C.

Firing order

D.

Pre-ignition

E.

Top dead center

2.

What are the three performance capabilities of distributor ignition systems? A.

B.

C.

W 71

AUTOMOTIVE TECHNOLOGY
3. What is the optimum operating temperature of a spark plug?

4.

What is the primary function of the distributor?

5.

What type of ignition coil is shown in the following illustration?

W 72

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. 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.
NAME:

DATE:

EVALUATION

3.

Identify ignition system concerns. Complete the chart.

Yes No-Start Hard Start Misfire Poor Driveability Spark Knock Power Loss Poor Mileage Emissions Concerns

No

W 73

AUTOMOTIVE TECHNOLOGY
4. Using service information, locate a procedure for testing the possible causes of the concerns. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.

Using the procedure, test the possible causes of the concerns. Record observations in the space provided.

5.

Using a scan tool, check the diagnostic trouble codes, snapshot information, and datastream information related to the concerns. Record observations in the space provided.

W 74

ENGINE PERFORMANCE: IGNITION SYSTEMS


6. If there is a no-start condition, test the components and systems using a DMM. Complete the chart.

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.

Perform an exhaust gas diagnostic test. a. b. c. d. e. Connect the exhaust gas analyzer according to manufacturers procedures. 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. Check the exhaust gas analyzer readings. Compare readings to proper specifications. Record readings in the space provided.

f.

Shut off the engine. Disconnect the exhaust gas analyzer.

W 75

AUTOMOTIVE TECHNOLOGY
8. Based on the tests, determine necessary action to correct any problems. Include further diagnosis and/or repairs.

Average of the above evaluations

W 76

ENGINE PERFORMANCE: IGNITION SYSTEMS


JS2-L2-UIV INSPECT, TEST, AND SERVICE THE PRIMARY CIRCUIT AND IGNITION COIL
Equipment: Digital multimeter (DMM) Hand tools 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 space provided.
NAME:

DATE:

EVALUATION

3.

Inspect the primary circuit wiring. Complete the chart.


OK Wiring Insulation Terminals Routing Not OK

4.

Using service information, locate a procedure for testing the primary circuit. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For general procedures, see section II.B.)

W 77

AUTOMOTIVE TECHNOLOGY
Using the procedure, test the primary circuit. Answer the questions. a. What is the voltage drop across the resistor bypass circuit while cranking the engine?

b.

What is the available voltage at the side of the ignition coil?

c.

What is the voltage drop across the coil primary?

d.

What is the voltage drop across the primary control circuit?

e.

What is the voltage drop across the circuit between the ignition switch and resistor?

f.

Record in the space provided the tests that did not meet specifications. Explain why the test did not meet specifications.

5.

Inspect the ignition coils. Complete the following chart.


OK Ignition Coil Cover Primary Wiring Secondary Coil Wire Wiring Connections Coil Tower Coil Polarity Not OK

W 78

ENGINE PERFORMANCE: IGNITION SYSTEMS


6. Using service information, locate a procedure for testing the ignition coil. Include primary and secondary resistance specifications. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For general procedures, see section III.B.)

Using the procedure, test the ignition coil. Record the resistance in the spaces provided. Primary resistance Secondary resistance Compare the resistance to manufacturers specifications. Determine if the ignition coil is good or bad. Record in the space provided.

7.

Using service information, locate a procedure for servicing or repairing defective components. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.

Using the procedure, service or repair defective components. Average of the above evaluations

W 79

AUTOMOTIVE TECHNOLOGY

W 80

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. Step 4 is the procedure for using a timing meter. 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.
NAME:

DATE:

EVALUATION

3.

Using service information, locate a procedure for checking and adjusting ignition timing and timing advance/retard using a timing light. Include timing specifications and engine speed at which the timing is to be checked and set. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For general procedures, see section IV.C.)

Using the procedure, check and adjust ignition timing and timing advance/retard using a timing light. Answer the questions.

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AUTOMOTIVE TECHNOLOGY
a. Is base timing correct or incorrect? If base timing is incorrect, did you adjust base timing to specifications?

b.

Is base timing incorrect, but it cannot be adjusted? If base timing could not be adjusted, explain why.

c.

Is the centrifugal advance unit functioning normally?

d.

Is the vacuum advance unit functioning normally?

4.

Using service information, locate a procedure for checking and adjusting ignition timing and timing advance/retard using a timing meter. Include timing specifications and engine speed at which the timing is to be checked and set. Include the timing meter offset degree setting. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For general procedures, see section IV.D.)

Using the procedure, check and adjust ignition timing and timing advance/retard using a timing meter. Answer the questions. NOTE: Connect the timing meter to the engine as directed by the timing meter manufacturer. If required, use the appropriate magnetic probe adapter.

W 82

ENGINE PERFORMANCE: IGNITION SYSTEMS


a. Is base timing correct or incorrect? If base timing is incorrect, did you adjust base timing to specifications?

b.

Is base timing incorrect, but it cannot be adjusted? If base timing could not be adjusted, explain why.

c.

Is the centrifugal advance unit functioning normally?

d.

Is the vacuum advance unit functioning normally?

Average of the above evaluations

W 83

AUTOMOTIVE TECHNOLOGY

W 84

ENGINE PERFORMANCE: IGNITION SYSTEMS


JS4-L2-UIV INSPECT, TEST, 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. 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.

EVALUATION

3.

Perform a visual inspection of distributor assembly. Record observations in the space provided.

W 85

AUTOMOTIVE TECHNOLOGY
4. Using service information, locate a procedure for inspecting and testing the distributor electronic components. Make sure the procedure is appropriate for the distributor. Have the instructor check the box to approve the procedure.

Using the procedure, inspect and test the distributor electronic components. Record observations in the space provided.

5.

If applicable, inspect and test the distributor advance component. Record observations in the space provided.

6.

Inspect the distributor cap. Complete the chart.


Yes Cracks or Carbon Tracking Burned Contacts Corrosion in the Coil Towers Tight Wire Connections No

a.

Using a DMM, measure the resistance of the contacts to the coil towers. Compare to manufacturers specifications. Record resistance and if resistance meets specifications in the space provided.

W 86

ENGINE PERFORMANCE: IGNITION SYSTEMS


7. Inspect and test the rotor. Complete the chart.
Yes Cracks or Carbon Tracking Burn-through Excessive Burning of the Rotor Tip Tension and Wear of the Spring Contact No

a.

Using a DMM, measure resistance. Compare to manufacturers specifications. Record resistance and if resistance meets specifications in the space provided.

8.

Remove the distributor. a. b. c. d. Clean debris from around the base of the distributor housing. If equipped, disconnect the vacuum advance hose. Disconnect the primary wiring. Remove the distributor cap. NOTE: If removing spark plug wires, mark their position for proper reassembly. e. Crank the engine until the rotor is in position to fire the Number 1 cylinder and the timing mark is aligned with the top dead center mark. NOTE: If the timing marks are not visible, mark the distributor housing at the point at which the rotor is pointing. Then make another mark on the distributor housing and a corresponding mark on the engine block. f. g. h. Remove the distributor hold-down clamp. Remove the distributor. Place a clean towel over the hole in the engine where the distributor was removed.

W 87

AUTOMOTIVE TECHNOLOGY
9. Service the distributor. a. Using service information, locate a procedure for disassembling the distributor. Make sure the procedure is appropriate for the distributor. Have the instructor check the box to approve the procedure. (For general procedures, see section V.G.1.)

Using the procedure, disassemble the distributor. b. c. Using safety solvent, clean the distributor housing, distributor shaft, and centrifugal advance components. Blow dry. Inspect the distributor shaft and bushing for wear. Record observations in the space provided.

d.

Inspect the drive gear for scoring or excessive wear. Record observations in the space provided.

e.

Using service information, locate a procedure for repairing or replacing defective or worn components including the distributor advance component, distributor cap, and rotor. Make sure the procedure is appropriate for the distributor. Have the instructor check the box to approve the procedure. (For general procedures, see section V.G.5.)

Using the procedure, repair or replace defective or worn components.

W 88

ENGINE PERFORMANCE: IGNITION SYSTEMS


f. Using service information, locate a procedure for replacing defective electronic components. Make sure the procedure is appropriate for the distributor. Have the instructor check the box to approve the procedure.

Using the procedure, replace defective electonic components. g. Using service information, locate a procedure for reassembling and lubricating the distributor. Make sure the procedure is appropriate for the distributor. Have the instructor check the box to approve the procedure. (For general procedures, see section V.G.7.)

Using the procedure, reassemble and lubricate the distributor. 10. Install the distributor. a. b. c. d. Remove the towel and place the distributor back in the engine. Align the marks that were made during removal. Install the distributor hold-down clamp and bolt. Snug, but do not tighten, the hold-down bolt. Install the distributor cap, vacuum advance line, and primary wiring. Connect the exhaust ventilation equipment. CAUTION: Be sure to use approved exhaust ventilation equipment when operating a vehicle in an enclosed area. e. f. Start the engine and set timing to specifications. (For general procedures, see section IV.) Shut off the engine and disconnect the exhaust ventilation equipment.

Average of the above evaluations W 89

AUTOMOTIVE TECHNOLOGY

W 90

ENGINE PERFORMANCE: IGNITION SYSTEMS


JS5-L2-UIV INSPECT, TEST, 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. 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.
NAME:

DATE:

EVALUATION

3.

Inspect the secondary wiring. Complete the chart.


OK Wiring Insulation Wire Boots Loose Wiring Routing Wiring in Retaining/Mounting Clips Not OK

4.

Test the resistance of the spark plugs. a. Connect one DMM lead to each end of the spark plug wire.

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b. Check the reading. Compare to manufacturers specifications. Record observations in the space provided.

c. 5.

Disconnect the DMM.

Repair or replace secondary circuit wiring and spark plug wires that are damaged or not within specifications. (For general procedures, see section VI.C.) Remove the spark plugs. a. Grasp the spark plug wire by the wire boot and remove by gently twisting and pulling. Remove all spark plug wires. If necessary, label the wires with tape for proper reinstallation. Use compressed air to blow dirt or other contaminants from around each spark plug. Select the proper spark plug socket. Remove each spark plug. If any of the spark plugs are excessively tight, apply a penetrating lubricant to the base of the spark plug. NOTE: Keep the spark plugs in order so that any problems found can be traced to the proper cylinder.

6.

b. c. d.

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7. Inspect the spark plugs. Check each plug for electrode condition, electrode gap, fouling, insulator damage, and conditions that can shorten the life of the spark plug or indicate engine problems. Complete the chart.
Spark Plugs 1 2 3 4 5 6 7 8 OK Not OK

8. 9.

Replace damaged spark plugs. Install the spark plugs. a. Adjust the electrode gap of each spark plug to specification. Use the spark plug gap gauge to bend the side electrode to adjust the spark plug gap. If the spark plugs are the gasket-seat type, check that the gasket is in place. Install the spark plugs finger tight in the cylinder head. Tighten spark plugs to specified torque with a spark plug socket and torque wrench.

b. c. d.

Average of the above evaluations

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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.

On what strokes does the ignition coil deliver the spark in wasted-spark systems? A.

B.

4.

Where are the ignition coils mounted on unit ignition systems? A.

B.

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5. What are three advantages of EI systems? A.

B.

C.

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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. 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.
NAME:

DATE:

EVALUATION

3.

Identify ignition system concerns. Complete the chart.


Yes No-Start Hard Start Misfire Poor Driveability Spark Knock Power Loss Poor Mileage Emissions Concerns No

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4. Using service information, locate the procedure for testing the possible causes of the concerns. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.

Using the procedure, test the possible causes of the concerns. Record observations in the space provided.

5.

Using a scan tool, check diagnostic trouble codes, snapshot information, and datastream information related to the concerns. Record observations in the space provided.

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6. If there is a no-start condition, test the components and systems using a DMM. Complete the chart.
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.

Perform an exhaust gas diagnostic test. a. b. c. d. e. Connect the exhaust gas analyzer according to manufacturers procedures. 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. Check the exhaust gas analyzer readings. Compare readings to proper specifications. Record readings in the space provided.

f.

Shut off the engine. Disconnect the exhaust gas analyzer.

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8. Based on the tests, determine necessary action to correct any problems. Include further diagnosis and/or repairs.

Average of the above evaluations

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JS2-L2-UV INSPECT, TEST, AND SERVICE THE PRIMARY CIRCUIT AND IGNITION COILS
Equipment: Digital multimeter (DMM) Personal protective equipment (PPE) Scan tool 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.
NAME:

DATE:

EVALUATION

3.

Using a scan tool, check diagnostic trouble codes, snapshot information, and datastream information for readings. Record observations in the space provided.

4.

Inspect the primary circuit wiring. Complete the chart.


OK Wiring Insulation Terminals Routing Not OK

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5. Using service information, locate a procedure for testing the primary circuit using a DMM. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For general procedures, see section II.C.)

Using the procedure, test the primary circuit using a DMM. Record observations in the space provided.

6.

Inspect the electronic coil module and ignition coils. Complete the chart.
OK Electronic Coil Cover Electronic Coil Module Primary Wiring Secondary Coil Wire Wiring Connections Coil Tower Coil Polarity Not OK

7.

Using service information, locate a procedure for testing the ignition coils. Include primary and secondary resistance specifications. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For general procedures, see section III.B.)

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Using the procedure, test the ignition coils. Record the resistance in the spaces provided. Primary resistance Secondary resistance Compare resistance to manufacturers specifications. Determine if the ignition coil is good or bad. Record in the space provided.

8.

Using service information, locate a procedure for servicing or repairing defective components. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.

Using the procedure, service or repair defective components. Average of the above evaluations

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JS3-L2-UV INSPECT, TEST, 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. 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.
NAME:

DATE:

EVALUATION

3.

Inspect the secondary wiring. Complete the chart.


OK Wiring Insulation Wire Boots Loose Wiring Routing Wiring in Retaining/Mounting Clips Not OK

4.

Test the resistance of the spark plug wires. a. b. Use service information to locate the proper resistance specifications for the spark plug wires. Connect one DMM lead to each end of the spark plug wire.

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c. Check the reading. Compare to manufacturers specifications. Record observations in the space provided.

d. 5.

Disconnect the DMM.

Repair or replace secondary circuit wiring and spark plug wires that are damaged or not within specifications. (For general procedures, see section V.C.) Remove the spark plugs. a. Grasp the spark plug wire by the wire boot and remove by gently twisting and pulling. Remove all spark plug wires. If necessary, label the wires with tape for proper reinstallation. Use compressed air to blow dirt or other contaminants from around each spark plug. Select the proper spark plug socket. Remove each spark plug. If any of the spark plugs are excessively tight, apply a penetrating lubricant to the base of the spark plug. NOTE: Keep the spark plugs in order so that any problems found can be traced to the proper cylinder.

6.

b. c. d.

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7. Inspect the spark plugs. Check each plug for electrode condition, electrode gap, fouling, insulator damage, and conditions that can shorten the life of the spark plug or indicate engine problems. Complete the chart.
Spark Plugs 1 2 3 4 5 6 7 8 Diagnosis

8. 9.

Replace damaged spark plugs. Install the spark plugs. a. Adjust the electrode gap of each spark plug to specification. Use the spark plug gap gauge to bend the side electrode to adjust the spark plug gap. If the spark plugs are the gasket-seat type, check that the gasket is in place. Install the spark plugs finger tight in the cylinder head. Tighten spark plugs to specified torque with a spark plug socket and torque wrench.

b. c. d.

Average of the above evaluations

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JS1-L1-UVI CHECK AND ADJUST VALVE LASH ON ENGINES
DATE: NAME:

Equipment: Feeler gauge set Personal protective equipment (PPE)


EVALUATION

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.

Determine if the engine has mechanical or hydraulic lifters. Record in the space provided.

NOTE: For an engine with mechanical lifters, go to step 4. For an engine with hydraulic lifters, go to step 5. 4. Using service information, locate a procedure for checking and adjusting valve lash on mechanical lifters. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For general procedures, see section I.A.)

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Using the procedure, check and adjust valve lash on mechanical lifters. Record observations in the space provided.

5.

Using service information, locate a procedure for measuring valve lash on hydraulic lifters. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For general procedures, see section I.B.)

Using the procedure, measure valve lash on hydraulic lifters. Record observations in the space provided.

Average of the above evaluations

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JS2-L1-UVI REMOVE AND REPLACE TIMING BELT/CHAIN
DATE: NAME:

Equipment: Exhaust ventilation equipment Personal protective equipment (PPE)


EVALUATION

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.

Using service information, locate a procedure for removing the timing belt/chain. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For general procedures, see section II.A.)

Using the procedure, remove the timing belt/chain. 4. Using service information, locate a procedure for installing the timing belt/chain. Include a procedure for verifying correct camshaft timing. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For general procedures, see section II.B.)

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Using the procedure, install the timing belt/chain. Verify correct camshaft timing. Record observations in the space provided.

Average of the above evaluations

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JS3-L1-UVI INSPECT, TEST, AND SERVICE THERMOSTAT AND COMPONENTS
DATE: NAME:

Equipment: Exhaust ventilation equipment Instrument for testing engine operating temperature 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 space provided.

EVALUATION

3. 4.

Use service information to locate the thermostat. Inspect the thermostat housing and gasket for leakage or damage. Record observations in the space provided.

5.

Test the thermostat. a. b. Verify engine operating temperature. (For procedures, see JS3-L3-UII.) Check the circulation within the cooling system. 1. Connect the exhaust ventilation equipment. CAUTION: Be sure to use approved exhaust ventilation equipment when operating a vehicle in an enclosed area.

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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.

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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

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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

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4. Test the clutch fan. a. Connect the exhaust ventilation equipment. CAUTION: Be sure to use approved exhaust ventilation equipment when operating a vehicle in an enclosed area. b. c. Start the engine. Observe fan operation. Answer the questions in the spaces provided. 1. Does the fan slip before the engine warms?

2.

Does the clutch engage and air begin to flow through the radiator and over the engine when the engine warms?

d. 5.

Shut off the engine and disconnect the exhaust ventilation equipment.

Inspect the electric radiator fan. Complete the chart. CAUTION: Electric radiator fans can come on without warning. Make sure the fan and negative battery cable are disconnected before inspecting, servicing, or working close to an electric fan. Only connect the fan and negative battery cable when observing fan operation.
Yes 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

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a. Using service information, locate a procedure for energizing the fan. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.

Using the procedure, energize the fan. Record observations in the space provided.

b.

Using service information, locate a procedure for checking the sensors and controls that operate the fan. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.

Using the procedure, check the sensors and controls that operate the fan. Record observations in the space provided.

6.

Inspect the fan shroud. Complete the chart.


OK Not OK

Cracks or Damage Shroud-to-Fan Fit and Clearance Condition of Mounting Brackets and Bolts

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7. Inspect the cooling system air dams and mounting brackets for damage. Record observations in the space provided.

8.

Using service information, locate a procedure for servicing and repairing/ replacing any problems found during the inspections and testing. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.

Using the procedure, service and repair/replace any problems found during the inspections and testing. Average of the above evaluations

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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. 2. Wear PPE while performing the procedures on this job sheet. Inspect all threaded openings. Determine what repairs need to be made. Determine what tools are needed. Record in the space provided.

NOTE: Select the proper steps based on the repairs that need to be made. 3. 4. 5. Use a tap to correct small imperfections on internal threads. Use a die on external threads. Use a helicoil or thread insert to repair stripped threads. Inspect and clean threads and bolts. Record observations in the space provided.

6. 7.

Use various taps to clean the threads of all threaded holes. Clean all the nuts and bolts used to assemble the engine.

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8. Inspect the nuts and bolts for signs of stretching and stripping and for rounded corners on bolts and nuts. Record observations in the space provided.

9.

Use a screw extractor to remove any broken bolts. a. b. c. Drill a hole in the center of the broken bolt. Insert a screw extractor in the hole. Use the tap handle to rotate the extractor and bolt counterclockwise. Remove both as a unit from the bolt hole.

Average of the above evaluations

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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. 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.

EVALUATION

3.

Connect the exhaust ventilation equipment. CAUTION: Be sure to use approved exhaust ventilation equipment when operating a vehicle in an enclosed area.

4.

Start the vehicle and allow it to reach normal operating temperature. Turn off the engine. If the vehicle is turbocharged, allow the engine to idle during the last few minutes of operation. Lift the vehicle in order to get to the underside. CAUTION: When lifting a vehicle, always use proper lifting equipment and observe all safety precautions. Never work under a vehicle supported by only a jack. A frame-type lift or safety stand is the only acceptable support for a vehicle. Failure to comply with all safety rules could result in fatal injuries.

5.

6.

Place a drain pan or drain bucket under the crankcase drain plug.

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7. Remove the oil drain plug or plugs and catch the oil in the drain pan or bucket. Allow the oil to drain for a few minutes. CAUTION: Do not allow hot oil to contact the skin. 8. While the oil is draining, check the following. a. b. c. 9. Inspect the drain plug, oil pan threads, and drain plug gasket. Replace if worn or damaged. Check the suspension and steering joints in the vehicle and lubricate, if required. Check the grease in the rear axle (or final drive) and the lubricant in manual transmissions.

Use an oil filter wrench to remove the oil filter. Catch oil in the drain pan or drain bucket. Clean the area where the oil filter gasket will seal and make sure that the oil gasket is not still stuck there. Reinstall the drain plug(s) and tighten securely. Do not over torque or cross thread the drain plug. Replace worn or damaged gaskets at this time. Install the new oil filter. Lubricate the gasket with clean engine oil. Tighten the oil filter according to manufacturers specifications. Recheck all work and make sure that the drain plug(s) are installed tightly. Also make sure that the oil filter is on tightly. Lower the vehicle to the floor. Select the correct type and weight of oil. Open the hood and add the proper amount of new oil to the engine. Perform lubrication service under the hood as required. In some vehicles, the throttle and other control linkages should be lubricated at this time. CAUTION: Be sure to add the correct amount of oil to the engine. Adding too much or too little oil can result in severe engine damage.

10.

11. 12. 13. 14. 15.

16.

Start the engine and allow to idle for a few seconds. If the engine does not show signs of developing oil pressure within 10 seconds, shut off the engine immediately. Locate and correct the problem. Double-check that oil was put in the engine.

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

Average of the above evaluations

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JS7-L1-UVI IDENTIFY HYBRID VEHICLE INTERNAL COMBUSTION ENGINE SERVICE PRECAUTIONS
Equipment: Personal protective equipment (PPE) Safety cones for the work area 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.
NAME:

DATE:

EVALUATION

3.

Using service information, determine the locations of the high-voltage system components, including the high-voltage cables and service plug. Record in the space provided.

4.

Using service information, determine if special care is needed when handling any components of the high-voltage system. Record in the space provided.

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5. Using service information, locate a procedure for deactivating the highvoltage system. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For general procedures for a Honda hybrid electric vehicle, see section VII.D.3.)

Using the procedure, deactivate the high-voltage system. Average of the above evaluations

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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 4 is cutting a straight line. Step 5 is cutting a bevel. Step 6 is cutting a circle. If only one or two cuts are assigned, skip the appropriate other step(s) and move to Step 7, shutting down the oxyfuel outfit. Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Inspect equipment, materials, and work area to ensure safe and correct operation. Remove items or materials that could cause a potentially dangerous situation. Using service information, locate a procedure for setting up and shutting down the oxyfuel outfit. Have the instructor check the box to approve the procedure.

EVALUATION

3.

Using the procedures, set up the oxyfuel outfit. 4. Cut a straight line. a. b. c. d. Position the plate on the worktable and mark a cutting line using a soapstone and straightedge. Clamp angle iron to the plate at a right angle, just off the cutting line, to serve as a guide. Light the torch using a spark lighter. Adjust the flame to a neutral flame with and without the oxygen lever pressed. W 129

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e. Position the torch over the edge of the metal, with the center of the cutting tip in line with the cutting line and angled slightly away from the work. The preheat flames should be just above the top of the plate. Use the free hand to steady the cutting hand. When the plate has reached cutting temperature, press the cutting oxygen lever and move the torch steadily across the plate to complete the cut. Make additional cuts if instructed.

f.

5.

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

f.

6.

Cut a circle. a. b. c. d. Position the plate on the worktable and mark a cutting line using a soapstone. Light the torch using a spark lighter. Adjust the flame to a neutral flame with and without the oxygen lever pressed. Use the oxyfuel outfit to pierce steel by holding the torch at a right angle to the work with the cutting tip near the center of the circle. The preheat flames should be just above the top of the plate.

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e. f. g. When the plate reaches cutting temperature, raise the cutting tip 1/2 in or more and slowly press the cutting lever. Rotate the torch until the flame cuts through the metal. Lower the torch into normal cutting position and cut out to the cutting line and complete the cut. Use the hand that is not operating the cutting lever to steady the cutting hand. Make additional cuts if instructed.

7. 8.

Using the procedure from Step 3, shut down the oxyfuel outfit. Return materials and equipment to the proper places.

Average of the above evaluations

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