AURETR031

DIAGNOSE AND REPAIR IGNITION

SYSTEMS

26/02/2021 1
 Introduction

• Nama
• Posisi
• Pengalaman Singkat (TCI/LCI/Others)
 Training requirement

Fasilitas Training

Situasi Darurat Rules

Proactive

Saling Menghormati

Saling membagi pengalaman

Saling menghargai

Mobile Phone Off/Vibrate

Policy

26/02/2021 4
Safety Essential

26/02/2021 5
Diagnose and repair ignition systems

CHAPTER 1
IGNITION SYSTEM FUNDAMENTALS

Training Objective

• Explain the operating principles of an automotive ignition

system.
• Compare contact point, electronic, and computer-controlled
ignition systems.
• Describe the function of major ignition system components.
• Explain vacuum, centrifugal, and electronic ignition timing
advance.
• Sketch the primary and secondary sections of an ignition
system.
• Compare ignition coil, spark plug, and distributor design
variations.

Thiess Training and Development

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Diagnose and repair ignition systems

Functions of an ignition system

An automotive ignition system has several functions:

1. Provide a method of turning a spark ignition petrol engine ON and OFF.

2. Be capable of operating on various supply voltages (battery or alternator
voltage).
3. Produce a high voltage arc at the spark plug electrodes to start
combustion.
4. Distribute high voltage pulses to each spark in the correct sequence

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Basic Ignition System

1. IGNITION SWITCH (allows driver to turn ignition and engine on

and off).
2. IGNITION COIL (changes battery voltage into 30,000 volts or
more).
3. SWITCHING DEVICE (contact points or electronic circuit that
operates ignition coil).
4. SPARK PLUG (air gap in combustion chamber for electric arc).
5. IGNITION SYSTEM WIRES (conductors that connect
components).

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Basic Ignition System

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Basic Ignition System

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Basic Ignition System

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Ignition switch

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Primary and Secondary Circuits

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Ignition Coil

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IGNITION COIL OPERATION

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Ignition Distributors
Ignition distributor functions:
1. It actuates the ON/OFF cycles of current flow through the ignition coil primary windings.

2. It distributes the coil's high voltage pulses to each spark plug Wire.

3. It must cause the spark to occur at each plug earlier on the compression stroke as engine speed
increases and vice versa.

4. It changes spark timing with changes in engine load. As more load is placed on the engine, the
spark timing must occur later in the compression stroke to prevent spark knock (abnormal
combustion).

5. Sometimes, the bottom of the distributor shaft powers the engine oil pump.

6. Some distributors (unitised distributors) house the ignition coil and electronic switching circuit. Refer
to Fig. 35-8.

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Ignition Distributors

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Distributor types

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Contact Point Ignition System

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POINT DWELL (CAM ANGLE)

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Electronic Ignition System

An electronic ignition system, also called a solid state or transistor ignition system,
uses an electronic control circuit and a distributor pickup coil to operate the ignition
coil. Refer to Fig. 35-12.

An electronic ignition is more dependable than a contact point type. There are no
mechanical breakers to wear or bum. This helps avoid trouble with Ignition timing
and dwell.

An electronic ignition is also capable of producing much higher secondary voltages.

This is an advantage because wider spark plug gaps and higher voltages are
needed to ignite lean air-fuel mixtures. Lean mixtures are now used for reduced
exhaust emissions and fuel consumption.

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Electronic Ignition System

Trigger wheel

The trigger wheel, also called reluctor

or pole piece, is fastened to the upper
end of the distributor shaft. See Fig.
35-12. The trigger wheel replaces the
distributor cam used in a contact point
distributor'. One tooth is normally
provided on the wheel for each engine
cylinder

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Electronic Ignition System

Pickup coil

The pickup coil, also termed sensor

assembly or sensor coil, produces
tiny voltage pulses for the ignition
system's electronic control unit
(module or amplifier). Look at Fig.
35-13. The sensor assembly is a
small set of windings forming a coil.

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Electronic Ignition System

Hall effect pickup

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Electronic Ignition System

Hall effect pickup

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Electronic Ignition System

Hall effect pickup

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IGNITION SWITCH ECU

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IGNITION SWITCH ECU

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Secondary (High Voltage)

Components

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Distributor cap and rotor

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Spark plugs

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Spark plug gap

Spark plug gap is the

distance between the
centre and side
electrodes, Normal gap
specs range from 0.5
mm to 1.0 mm.

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Spark plug heat range

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Ignition Timing

There are three basic methods used to control

ignition system spark timing:

1. DISTRIBUTOR CENTRIFUGAL ADVANCE

(controlled by engine speed), Fig. 35-23.

2. DISTRIBUTOR VACUUM ADVANCE (con-

trolled by engine intake manifold vacuum and
engine load), Fig. 35-23.

3. ELECTRONIC (COMPUTER) ADVANCE

(controlled by various engine sensors: engine
rpm, temperature, intake manifold vacuum,
throttle position, etc.).

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Distributor Type
Distributor Centrifugal Advance

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Centrifugal advance operation

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Distributor vacuum advance

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Vacuum delay valve

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Electronic Spark Advance

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Crankshaft Triggered Ignition

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Crankshaft triggered ignition operation

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Computer-Coil (Distributor less) Ignition

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Computer-Coil (Distributor less) Ignition

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Advantages of a distributor less

ignition

• No rotor nor distributor cap to burn, crack, or fail.

• Computer controlled advance. No mechanical weights to stick or wear. No vacuum
advance" diaphragm to rupture and leak.
• Play in timing chain and distributor drive gear eliminated as a problem that could upset
ignition timing. The crank sensor is not affected by slack in timing chain or gears.
• More dependable because there are fewer moving parts to wear and malfunction.
• Requires less maintenance. Ignition timing is usually NOT adjustable.

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Engine Firing Order

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TOPIC 2
IGNITION SYSTEM REPAIR, TESTING, DIAGNOSIS

Training Objective

• Explain how to replace or repair ignition system parts.

• Summarise contact point and pickup coil adjustments.

• Adjust ignition timing.

• Diagnose typical ignition system problems.

• List the symptoms produced by faulty ignition system components.

• Describe common tests used to find ignition system troubles.

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Spark Plug Service

Faulty spark plugs can cause a wide range

of problems: misfiring, lack of power, poor
fuel economy, and hard starting. After,
prolonged use, the spark plug tip can
become coated with ash, oil, and other
substances. Also, the plug electrodes can
bum and widen the gap. This can make it
more difficult for the ignition system to
produce an arc between the electrodes.

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Spark plug removal

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Reading spark plugs Bosch

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Reading spark plugs

Thread length spark position

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Reading spark plugs

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Reading spark plugs

NGK

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Cleaning spark plugs

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Gapping spark plugs

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Spark plug wire removal

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Secondary wire resistance test

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Secondary wire insulation test

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Distributor Service

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Distributor cap and rotor replacement

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