Automotive Y3

Republic of the Philippines
Department of Education
PUBLIC TECHNICAL-
VOCATIONAL
HIGH SCHOOLS
PUBLIC TECHNICAL-
VOCATIONAL
HIGH SCHOOLS
Unit of Competency: SERVICE AUTOMOTIVE BATTERY
Module No.: 1 Module Title: Servicing Automotive Battery

TABLE OF CONTENTS
Page
How to Use this Module ………………………………………….. i

Introduction……………………………………………………………. ii
Technical Terms …………………………………………………….. iii
Learning Outcome 1 ………………………………………………… 1

Learning Experiences/ Activities ……………………….. 1
Information Sheet 1 ……………………………………….. 2
Self Check 1 … ………………………………………………. 4
Self Check 2…. ………………………………………………. 6
Operation Sheet 1... ……………………………………….. 7
Learning Outcome 2….……………………………………………… 9
Learning Activity ……………………………………………. 10
Self Check 1…. ………………………………………………. 12
Operation Sheet 1... ……………………………………….. 13
Information Sheet 1 ………………………………………. 18
Self Check 1…. ………………………………………………. 19
Operation Sheet 1... ……………………………………….. 21
Assessment Performance ………………………………… 23
Answer Key ………………………………………………….. 25
ii
HOW TO USE THIS MODULE
Welcome to the Module “Servicing Automotive Battery”. This module

contains training materials and activities for you to complete.
The unit of competency “Service Automotive Battery” contains the
knowledge, skills and attitudes required for Automotive Servicing NC 1
course required to obtain the National Certificate (NC) level & II.
You are required to go through a series of learning activities in order to
complete each of the learning outcomes of the module. In each learning
outcome there are Information Sheets,, Operation Sheets and Activity
Sheets. Do these activities on your own and answer the Self-Check at the
end of each learning activity.
If you have questions, don’t hesitate to ask your teacher for assistance.
Recognition of Prior Learning (RPL)
You have already some basic knowledge and skills covered in this module
because you have been working for some time; and already completed
training in this area.
If you can demonstrate competence to your teacher in a particular skill,
talk to your teacher so you don’t have to undergo the same training again. If
you have a qualification or Certificate of Competency from previous trainings
show it to him/her. If the skills you acquired are consistent with and
relevant to this module, they become part of the evidence. You can present
these for RPL. If you are not sure about your competence skills, discuss this
with your teacher.
After completing this module, ask your teacher to assess your
competence. Result of your assessment will be recorded in your competency
profile. All the learning activities are designed for you to complete at your
own pace.
In this module, you will find the activities for you to complete and
relevant information sheets for each learning outcome. Each learning
outcome may have more than one learning activity.
This module is prepared to help you achieve the required competency, in
receiving and relaying information. This will be the source of information
that will enable you to acquire the knowledge and skills in Arabic Language
and Values Education independently at your own pace with minimum
supervision from your teacher.
i
Program/Course: Automotive Servicing NC 1
Unit of Competency: SERVICE AUTOMOTIVE BATTERY
Module Title: Servicing Automotive Battery
INTRODUCTION:
This module contains information and suggested learning activities on

Servicing Automotive Batteries. It includes instructions and procedure
on how to test automotive battery, remove and replace batteries, service and
charge batteries and jump start vehicle.
Completion of this module will help you understand the succeeding

module on Test and Repair Wiring/Lighting System.
This module consists of four (4) learning outcomes. Each learning

outcome contains learning activities with instruction sheets. Before you
follow the instruction, read the information sheets and answer the self-
check and activities provided to assess your competence by your teacher.
He/she will check if you have acquired the knowledge necessary to perform
the skill portion of the particular learning outcome.
Upon completing this module, report to your teacher for assessment. If

you pass the assessment, you will be given a certificate of completion.
SUMMARY OF LEARNING OUTCOMES
Upon completion of the module, you should be able to:
LO1. test Automotive Battery;

LO2. remove and Replace Batteries;
LO3. service and Charge Batteries; and
LO4. jump Start Vehicle
ASSESSMENT CRITERIA
Refer to assessment criteria of learning outcomes 1-4 of this module.
ii
TECHNICAL TERMS:
BATTERY CELL the active unit of the battery
BATTERY HOLD DOWNS brackets that secure the battery to the chassis of
the vehicle.
BATTERY LEAKAGE TEST use to determine if current is discharging

across the top of the battery fuse.
BATTERY TERMINAL TEST checks for poor electrical connections between

the battery cables and terminals.
BATTERY TERMINALS terminals at the battery to which the positive and

the negative battery cables are connected. The terminals maybe posts or
threaded insert.
BATTERY CHARGER an equipment use to charge battery capacity given in

ampere hours.
ELECTROLYTE the liquid mixture of about 40% sulfuric acid and 60 %

water in a fully charge lead-acid storage bottle.
iii
Program/Course: Automotive Servicing
Unit of Competency: Service Automotive Battery
Learning Outcome 1: Test Automotive Battery
Assessment Criteria
1. Battery is tested to avoid damage to any workplace property or vehicle.

2. Correct Information is assessed and interpreted based on manufacturer’s
specifications.
3. Appropriate test equipment and instrument are selected.
4. Test Results are analyzed and interpreted.
5. Findings are reported to immediate supervisor/automotive instructor.
Resources
 Automotive Mechanics, 10th Edition
By: Crouse Anglin
 Automotive Electricity, Electronics and Computer Controls
By: Barry Hollembeak
LEARNING EXPERIENCES/ACTIVITIES
Learning Activities Special Instructions
1. Read the attached information  Answer the self-check without

sheet no. 1, battery construction looking at the information Sheet
and principle operation of battery.
2. Teaching demo on test  Return Demo
procedures.
3. Answer self-check no. 1 to test  Answer the self-check within the list
your knowledge and operation of possible time allotment.
the battery.
4. Check your answer using answer  Answer assessment criteria based on
key LO1 No. 1. operation sheet LO 1.
1
INFORMATION SHEET No.1
TITLE: BATTERY CONSTRUCTION AND PRINCIPLE OF OPERATION
The Automotive battery supplies electric current to operate the

starting motor and ignition system while starting the engine. It also acts as
a voltage stabilizer by supplying current for the lights, radio, and other
electrical accessories when the alternator is not handling the load. In
addition, the battery supplies a small current to the volatile ceremony in the
electronic control (ECM) while the Ignition key is off.
The battery is an electro chemical device which uses chemicals to

produce electricity, the amount of electricity it can produce is limited. As
the chemical in the battery is depleted the battery runs down and is
discharged. It can be recharged by supplying it with electric current from
the vehicle alternator or from a battery charger. The depleted chemicals are
restored to their original condition as the battery becomes recharged.
TYPES OF BATTERY
Below are two types of automotive batteries. On the left, caps

can be removed to check the battery state of charge and to add water if
needed. On the right, a maintenance-free battery that requires no
additional water. The charge indicator in the top shows the state of change.
Fig. 1 Two types of Automotive Battery (left) ordinary wet

Battery (right) maintenance free.
2
BATTERY CONSTRUCTION
The battery case is molded plastic. The plates are molded to plate straps
to form plate groups. To make a battery cell, a positive plate group fits into a
negative plate group. Porous separators are placed between the plates.
This prevents positive and negative plates from touching while allowing
electrolyte to circulate between the plate. The assembly of plate groups and
separators is an element. The elements fit into compartments in the battery
case to favor cells. Heavy leads connectors attach to the cell terminals and
connect the cells in series. A plastic cover forms the top of the battery.
Some batteries have openings in the cover from when filler plugs or vent
caps are removed to add water maintenance free batteries do not have
removable caps.
Fig. 2 Parts of Automotive Battery
WORKING SAFELY AROUND BATTERIES
Follow the safety cautions listed below when working with batteries,
testing or charging battery.
1. The sulfuric acid in the electrolyte is very corrosive. It will eat

holes in cloth. It can cause serious burn if it sets on your skin. It
can make you blind if it gets into your eyes. Wear eye protector
when working with testing or charging a battery. If you get battery
acid on your skin, flush it off at once with water. If you get battery
acid (electrolyte) into your eyes, flush them with water at once then
go to the school nurse, a doctor or hospital emergency room.
3
2. When disconnecting a battery, always disconnect the negative or
ground cable first.
3. If the battery has vent caps, make sure the vent holes are open
before charging. Cover the caps with a damp cloth. Discard the
cloth after the battery is charged.
4. Never lean over a changing battery.
5. Do not charge a frozen battery for maintenance-free battery

because the charge indicator dot shows light yellow or clear the
battery could explode.
SELF – CHECK No.1
LO 1. TEST AUTOMOTIVE BATTERY
Directions: Select the correct answer to each question and write the letter
on the blank provided for.
________1. The battery in an electro chemical device, this means the battery
a. makes chemicals by electronic means
b. uses chemicals to provide electricity
c. has non-chemical plates
d. does not use an electrolyte
________2. The battery performs the following EXCEPT

a. supplies current to crank the engine
b. supplies current when the charging system cannot handle the
lead
c. supplies current to the ignition system with the engine is off.
d. supplies current to the ECM while the engine is off
________3. When working around the battery be sure to;

a. Disconnect the negative first
b. Disconnect the positive first
c. Never disconnect the terminals
d. A and B
________4. A type of battery which do not have removable cups.

a. maintenance free battery
b. battery with caps
c. 3A battery
d. B and
4
INFORMATION SHEET No. 2
TITLE: Testing the battery
TOPIC: 2 WAYS OF TESTING THE BATTERY
Batteries are tested in two ways, for state of change and for
performance. The state of change of a vent – cap battery is determined with
the hydrometer. The built-in battery provides this information. The battery
load test indicates if the battery is capable of performing its job.
HYDROMETER TEST
Two types of Hydrometer:
1. Ball Hydrometer
2. Float Hydrometer
Ball hydrometer is similar to the ball type coolant hydrometer. Put

the rubber tube into the electrolyte, then squeeze and release the bulb.
Electrolyte will be drawn into the tube. If all balls float, the battery is fully
charged. If none, the battery is discharged. The more balls that floats, the
higher the battery state of charge.
The float hydrometer is used in the same way it will float in the
electrolyte drawn in. Marks on the float stem show the electrolyte specific
gravity. This indicates the state of charge, the more fully-charged the
battery, the higher the float.
PRECAUTION: Do not drip electrolyte on the car or on yourself.

Electrolyte will damage the paint and your cloth.
SPECIFIC GRAVITY
STAGE OF CHARGE
1.265 -1.299 Fully charged battery

1.235 -1.265 Three – fourths charged
1.205 -1.235 One-half charged
1.170 -1.205 One-fourth charged
1.140-1.170 Barely Operative
1.110-1.140 Completely discharged
Relationship between specific gravity and state of charge.
5
SPECIFIC GRAVITY STAGE OF CHARGE
1.100 18 [-8.2]
1.160 1 [-7.2]
1.200 -17 [-27.3]
1.220 -31 [-35]
1.260 -75 [-59.4]
1.300 -95 [-70.5]
Specific gravities and freezing temperatures for battery

electrolyte
SELF CHECK No. 2
LO 1. Test Automotive Battery
Directions: On the blank provided for, write the correct letter of your choice.
_________1. This type of hydrometer which is similar to bal type coolant

hydrometer.
a.) ball hydrometer
b.) flat hydrometer
c.) barometer
d.) A and B
_________2. A type of hydrometer which the state of charge marks on the

float stem to show electrolyte specific gravity.
a.) ball type hydrometer
b.) float hydrometer
c.) A and B
d.) None of the above
_________3. The indication if the battery is in full charge in using ball

hydrometer.
a.) all balls float
b.) no balls float
c.) A and B
6
_________4. The more fully charge the battery is the higher the float is
indicating the state of charge of.
a.) float hydrometer
b.) ball hydrometer
c.) A and B
d.) All of the above
_________5. The more balls float, the higher the state of charge is.
a.) ball hydrometer
b.) float hydrometer
c.) A and B
OPERATION SHEET No. 1
TITLE: TESTING AUTOMOTIVE BATTERY USING

HYDROMETER
Procedure:
The teacher will discuss the procedure with the student with the aid of
pictures and actual battery.
1. Remove all battery vent caps.

2. Check the electrolyte level, it must be high enough to withdraw the
correct amount of solution into the hydrometer.
3. Squeeze the bulb and place the pick-up tube into the electrolyte of
a cell.
4. Slowly release the bulb. Draw in enough solution until the float is
freely suspended in the barrel. Hold the hydrometer in the vertical
position.
5. List the test result.
7
Fig. 3 checking specific gravity of electrolyte using float
hydrometer.
8
Learning Outcome 2: Remove and Replace Batteries
Assessment Criteria
1. Battery is removed and replaced to avoid damage to any work place property or
vehicle.
2. Appropriate tools and equipment are selected.
3. Actions are taken to prevent loss of vehicles if electronic memory is applicable
Resources

By: Crouse Anglin
9
1. Read attached information sheet

no.1. Correct procedures in
connecting/disconnecting battery.
 Answer the self-check without
2. Answer self-check LO2-1 to test looking at the information sheet.
your knowledge in the correct
procedures in
connecting/disconnecting battery.
3. Check your answer to answer key  Refer to operation sheet no. 1

LO 2-1.
4. Teacher demo on removing and  Return demo

replacing battery.
10
Title : Correct Procedures in Connecting/Disconnecting a Battery.
Topic 1:
Connect a memory holder (a 9-volt battery and adaptor) to the
cigarette lighter to keep the volatile memories alive while the battery is
disconnected from the vehicle. Follow the manufacturer’s instruction to
avoid overloading the 9-volt battery.
Disconnect the ground cable clamp, use a box wrench or battery pliers.
Loosen the clamp ball then pull the clamp from the terminal. Do not use
other pliers or an open-end wrench. If the clamp sticks, use a battery clamp
puller, do not pry the clamp off with screw driver or pry bar. You might
break the cover. Next, disconnect the insulated cable from the battery.
Clean the terminals and cables clamp. Detach the spring ring cable clamp
squeeze a part the ends of the rings with pliers. Next, disconnect the
insulated cable from the battery clean the terminals and cable clamps
loosen the hold-down clamps and remove the battery. Clean the battery tray
and hold-down clamps if the parts are metal, clean them with stiff brush on
a solution of baking soda and water. Open the water drain holes in the
bottom of the tray, after rinsing and drying, paint the tray and other metal
parts with acid resistant paint.
When installing the battery, do not reverse the terminal connections.

Reconnect the insulated cable first then the ground cable – tighten the hold
down clamps, do not over-tighten.
BE CAREFUL: Never install a battery backward. The reversed

polarity may caused high current flow which will damage electrical
components.
Fig. 4 Loosen the clamp bolt, using open end wrench
11
SELF CHECK No. 3
Title : Removing and Replacing Battery
Directions: On the blank provided for write the correct letter of your choice.
______1. In disconnecting the battery the correct tools to be used is______.

a.) box wrench (12x13)
b.) open wrench
c.) battery pliers
d.) A and C
______2. The tool to be used to clamp the battery is _______.

a.) battery clamp puller
b.) screw driver
c.) pry bar
d.) B and C
______3. In cleaning the corrosion and foreign materials on the battery tray
you must clean with___________.
a.) brush with soda and water
b.) oil
c.) gasoline
d.) none of the above
______4. To disconnect the battery first ________.

a.) remove the vent plug
b.) disconnect the insulated cable from the battery
c.) disconnect the ground cable from the battery
d.) put the transmission in park or reverse
12
OPERATION SHEET No.1
TITLE: REMOVING AND REPLACING BATTERY
Condition
Supplies and materials
 Apron
 Gloves
 Soda solution
Tools
 Box wrench(12x13)
 Screw drivers
 Lifting clamp
Equipment
 Engine mock-up
 vehicle
PROCEDURE:
1. Prepare the tools and materials needed in removing the battery.
Fig 6 Prepared tools and materials
13
2. Place the fender cover on the vehicle to protect the body paint.
3. Loosen the clamp bolt for the negative cable using terminal pliers and
wrench of correct size. Be careful not to just excessive force against
the terminal.
Fig 7 Loosen the clamp bolt
4. Use the terminal puller to remove the cable from the terminal. Do not
pry the cable off the terminal.
Fig. 8 Remove cable using terminal puller
5. Locate the negative cable away from the battery.
Fig 9 Separate negative cable
14
6. Loosen the clamp bolt for the positive cable and use the terminal
puller to remove the cable.
Fig. 10 Remove cable using terminal puller
7. Disconnect the hold-down fixture(if available)
Fig. 11 Disconnect the hold down future
8. Using the battery lifting clamp. Remove the battery out from the tray.
Keep the battery away from your body. Wear protective clothing to
prevent acid spills onto your hands.
Fig 12 Remove battery out from the tray
15
9. Transport the battery to the bench. Keep it away from your clothes.
Fig 13 Transport the battery to the bench
PRECAUTIONS: Wear protective clothing to prevent acid spills onto

your hands.
Learning Outcome 3: Service and Charge Battery
Assessment Criteria
1. Battery is charged using the appropriate battery charger.
2. Electrolyte level is checked and tapped.
3. Battery and its terminals are cleaned.
Resources

By: Crouse Anglin
16
Learning Outcome 3: Service and Charge Battery
1. Read the attached information

sheet no.1, charge-indicator
condition, two methods of battery
charging.  Answer the self-check without
looking at the information sheet.
2. Answer self-check LO3-1 to test
your skills in the different battery
charge condition, methods of
battery charging.
3. Check your answer to the answer

key LO3-1.  Answer the self-check within the
least possible time allotment.
4. When you are ready you can
proceed to learning outcome no. 4
17
TITLE: Charging Batteries
Topic 1. Two Methods of Battery Charging:
Slow Charge: The battery is given a charge of a few amperes for several
hours.
Quick or Typical: A 30-ampere charging rate up to 30 minutes
For further charging, reduce the charging rate to 20 amp or less for up
to 3 hours longer. Change a maintenance free batter until the green dot
appears. To connect the charger to a side terminal battery, it may be
necessary to install bolts or adapters in the terminal bolt holes. When
charging a battery in a vehicle, disconnect the ground cable from the battery.
This protects electrical & electronic components from the high charging
voltage.
BE CAREFUL: Never connect the battery charge backward. The

reversed polarity may cause high-current flow which would damage
the vehicle electrical equipment.
WARNING:
Quick or fast charging two battery requires that the battery be
monitored at all times and the charging time must be controlled. Do no fast
charge a battery longer than tow hours. Excessive fast charging can damage
the battery. Do not allow the voltage of a 12-volt battery exceed 15.5 volts.
Also, do not allow temperature to rise above 125ºF.
CHARGE RATE
The charge rate required to recharge a battery depends on several

factors:
1. Battery capacity / high capacity batteries require longer charging time.

2. State of Charge
3. Battery Temperature
4. Battery Condition.
18
SELF CHECK No. 1
LO 3. SERVICE USED CHARGE BATTERY
Direction: On the blank before each number write the correct letter of your
choice.
________1 A method of charging the battery is given a charge of a few

amperes for several hours.
a.) slow charge
b.) fast charge
c.) A and B
________2.For further charging reduce the charging rate to.

a.) 20 amp or less for up to 3 hrs
b.) 30 amp or more
c.) 40 amp or less
d.) A and B
________3. A method of battery charging rate given a 30 amp charging rate

up to 30 minutes.
a.) quick or fast charge
b.) slow charge
c.) A and B
________4.When charging the battery in a vehicle, first

a.) disconnect the ground cable
b.) disconnect the positive cable
c.) A and B
19
Learning Outcome 4: Jump Start Vehicle
Assessment Criteria
1. Vehicle is jump started to avoid damage to any workplace property or vehicle.
2. Jumper leads are selected and used to ensure spark protection which is
employed when necessary.
3. Leads are connected /disconnected correctly according to sequence and

polarity.
Resources

By: Crouse Anglin
Learning Outcome 4: Jump start the vehicle
1. Read the operation sheet, jump

starting the vehicle LO 4-1
2. Upon reading, answer the  Answer the self-check sheet by

performance standard Lo4-1 labeling the points
3. Teacher Demo jump start the  Return Demo on jump starting
vehicle procedure in the actual battery.
20
TITLE: JUMP STARTING THE VEHICLE SAFELY
CONDITIONS
Supplies and Materials
 Correct size of cable wires
Tools
 Wrenches
 Pliers
Equipment
 Fully charge battery

 Vehicle
PROCEDURE
1. Attach one end of the positive jumper cable to the disabled battery’s
positive terminal.
2. Correct the other end of the positive jumper cable to the booster
battery’s positive terminal.
3. Attach one end of the negative jumper cable to the booster battery’s
negative terminal.
4. Attach the other end of the negative jumper cable to an engine ground
on the disabled vehicle.
21
NOTE: Do not connect this cable end to the battery negative
terminal. Doing so may create a spark that will cause the
battery to explode.
5. Start the disabled vehicle.

6. Once the disabled vehicle starts, disconnect the ground connected
negative jumper cable from its engine block.
7. Disconnect the negative jumper cable from the booster battery.
8. Disconnect the positive jumper cable from the booster battery then
from the other battery.
CAUTIONS: Do not use more than 16 volts to jump starting a vehicle

that is equipped with an engine control module (EICM). The excess
voltage may damage the electronic components.
22
ASSESSMENT PERFORMANCE
LO 2. Test Automotive battery
Workmanship/Performance Points
A. Quality of Work with Application of Safety Measures
35 - Exemplary
25 - Adequate
10 – Need improvement
B. Accuracy of Performance under specified time limit
30 – All work is complete and correct
20 – Minor mistake or error
10 – Some of the work maybe incomplete/misdirected
C. Proper use of tools/equipment with safety measures
35 – Select/use properly of tools/equipment
25 – Wrong handling of tools
10 – Tools is not suitable for the job
TOTAL SCORES
23
LO 4. Jump start vehicle
35 - Exemplary
25 - Adequate
TOTAL SCORES
24
ANSWER KEY
No. 1
1. b
2. c
3. a
4. a
No. 2
1. a
2. b
3. a
4. a
5. a
No. 3
1. D
2. A
3. A
4. C
No. 4
1. A
2. A
3. A
4. A
25
REFERENCES AND FURTHER READING:
1. Auto-Mechanics 10th Edition by Crouse/Anglin
2. Auto.-Trouble Shooting: Operation and maintenance/F.Francisco
3. Encarta Microsoft 2006
4. Diesel Mechanic/Erich J. Schulz
5. Modern Machining Technology/Richard Baril
26
ACKNOWLEDGMENT
It is a great privileged that this endeavour was given by the Task Force Tech-
Voc, Department of Education to the following participants of the
“Writeshop on the Refinement and Enrichment of Competency-Based
Curriculum (CBC), Contextual Learning Matrix (CLM) and Modules of
Arts and Trades”, conducted at Marikina Hotel on April 20-25, 2009. It is
the fervent hope of the writers that through their consolidated efforts they
are able to strengthen and enrich the Vocational Education curriculum to
fully prepare and equip Tech-Voc students to become locally and globally
competitive in the world of work.
TECHNOLOGY WRITERS:
Jonathan O. Diaz
TVE-Automotive-Technology Coordinator
San Pedro Relocation Center National High School
Langgam, San Pedro, Laguna
Romeo Q. Ibloguin Sr.

Teacher III
E. Rodriguez Vocational High School
Division of City Schools, Manila
Nagtahan, Sampaloc, Manila
Robert S. Domingo
Teacher I
AFG Bernardino Memorial Trade School
Lias, Marilao, Bulacan
Lino A. Olit
Teacher I
Community Vocational High School
Masipit, Calapan City, Oriental Mindoro
Arpil P. Medrano
Teacher I
Tanza National Trade School
Paradahan I, Tanza, Cavite
ACADEMIC WRITERS:
Araceli T. Bondoc
Head Teacher III (ENGLISH)
A.J. Villegas Vocational High School
27
Romhel C. Odtohan
Teacher I (ENGLISH)
AFG Bernardino Memorial Trade School
Lias, Marilao, Bulacan
Mary Ann P. Lait

Teacher I (SCIENCE)
Ragay National Agricultural and Fisheries School
Ragay, Camarines Sur
Helen U. Divina
Teacher I (SCIENCE)
General Mariano Alvarez Technical High School
Poblacion V, GMA, Cavite
Belen P. Caldez
Head Teacher VI (MATH)
E. Quirino High School
Arnie Lei M. Bangayan

Teacher I (MATH)
E. Quirino High School
Copyright Department of Education 2008
First Published JUNE 2008
This draft was prepared at the Competency-Based Learning Materials

Development Workshop conducted at the Development Academy of the Phils,
Tagaytay City on May 5-10, 2008.
This learning instrument was developed by the following personnel:
28
English:
Belen L. Tado
Tagum National High School
Tagum, Davao del Norte
Facilitator:
Beatrice A. Adriano
E. Rodriguez Vocational HS
Encoder
Rowena S. Fonacier
This work was produced with funding provided by the Department of

Education.
29
PUBLIC TECHNICAL-
VOCATIONAL
HIGH SCHOOLS
PUBLIC TECHNICAL-
VOCATIONAL
HIGH SCHOOLS
Unit of Competency: Test and Repair Electrical Wiring/Lighting

System
Module Title: Testing and Repairing
Module No.: 2
Wiring/Electrical System
0
TABLE OF CONTENTS
Page
How to Use this Module ………………………………………………... i

Introduction……………………………………………………………….. ii
Technical Terms…………………………………………………………... iii
Learning Outcome 1 ……………………………………………………… 1

Learning Experiences/ Activities ……………………………….. 2
Information Sheet 1 ……………………………………………. 2
Self Check 1 …..……………………………………………….. 10
Operation Sheet 1... ……………………………………………. 11
Learning Outcome 2….…………………………………………………… 12
Learning Activity ……………………………………………….. 12
Information Sheet 1 …………………………………………….. 13
Self Check 1 ……..…………………………………………….. 14
Operation Sheet 1... ………………………………….…………. 15
Assessment Performance ……………………………………….. 18
Learning Outcome 3………………………………………………………. 20
Learning Activity……………………………………………….. 21
Information Sheet 1……………………………………………… 22
Self Check 1……………………………………………………... 35
Self Check 2……………………………………………………... 35
Self Check 3……………………………………………………... 36
1
HOW TO USE THIS MODULE
Welcome to the Module “Testing and Repairing Wiring/Electrical

System”. This module contains training materials and activities for you to
complete.
The unit of competency “Test and Repair Electrical Wiring/Lighting
System” contains the knowledge, skills and attitudes required for
Automotive Servicing course required to obtain the National Certificate
(NC) level I & II.
You are required to go through a series of learning activities in order to
outcome there are Information Sheets,, Operation Sheets and Activity
Sheets. Do these activities on your own and answer the Self-Check at the
end of each learning activity.
If you have questions, don’t hesitate to ask your teacher for assistance.
Recognition of Prior Learning (RPL)
You have already some basic knowledge and skills covered in this module
because you have been working for some time; and already completed
training in this area.
If you can demonstrate competence to your teacher in a particular skill,
talk to your teacher so you don’t have to undergo the same training again. If
you have a qualification or Certificate of Competency from previous trainings
show it to him/her. If the skills you acquired are consistent with and
relevant to this module, they become part of the evidence. You can present
these for RPL. If you are not sure about your competence skills, discuss this
with your teacher.
After completing this module, ask your teacher to assess your
competence. Result of your assessment will be recorded in your competency
profile. All the learning activities are designed for you to complete at your
own pace.
In this module, you will find the activities for you to complete and
relevant information sheets for each learning outcome. Each learning
outcome may have more than one learning activity.
This module is prepared to help you achieve the required competency, in

receiving and relaying information. This will be the source of information
that will enable you to acquire the knowledge and skills in Testing and
Repairing Wiring/Lighting System independently at your own pace with
minimum supervision from your teacher.
2
Program/Course: AUTOMOTIVE SERVICING NC 1
Unit of Competency: Test and Repair Wiring/Lighting System
Module Title: Testing and Repairing Wiring/Lighting System
INTRODUCTION:
This module contains information and suggested learning activities on

testing and repairing electrical system. It includes instructions and
procedure on how to use hand tools and electrical instruments in
accordance to manual instructions and specification.
Completion of this module will help you understand the succeeding

module on Test and Repair Wiring/Lighting System.
This module consists of three (3) learning outcomes. Each learning

outcome contains learning activities with instruction sheets. Before you
follow the instruction, read the information sheets and answer the self-
check and activities provided to assess your competence by your teacher.
He/she will check if you have acquired the knowledge necessary to perform
the skill portion of the particular learning outcome.
Upon completing this module, report to your teacher for assessment. If

you pass the assessment, you will be given a certificate of completion.
SUMMARY OF LEARNING OUTCOMES
Upon completion of the module, you should be able to:
LO1. test electrical system for open and short circuits to determine faults;
LO2. repair electrical system; and
LO3. test and repair starting system.
ASSESSMENT CRITERIA
Refer to assessment criteria of learning outcomes 1-3 of this module.
PREREQUISITES
The learner should be able to read electrical diagram
3
TECHNICAL TERMS
AMMETER a test meter to measure current draw
BACK UP LIGHTS a light that illuminates the back of the car when the
transmission is shifted in reverse.
CONTINUITY refers to the circuit being continuous with no open.
DIMMER SWITCH a two position switch operated by the driver to select

High or low head light beam.
FUSE a replaceable circuit protection device that will melt. Should the
current passing through it exceeds its rating.
GROWLER test equipment used to test starter armatures for shorts and
grounds. It produces a very strong magnetic field that is capable of inducing
a current flow and magnetism in a conductor.
OHMMETER a test meter resistance and continuity in a circuit.
OPEN CIRCUIT a term used to indicate that current flow is stopped. By

opening the circuit, the path for electron flow is broken.
PARKING LIGHTS a light that marks the front of a parked vehicle and to
mark the front of a vehicle if a headlamp fails.
RESISTANCE opposition to current flow.
SHORT CIRCUIT an unwanted electrical path; sometimes this path goes

directly to ground.
SOLENOID CIRCUIT RESISTANCE TEST diagnostic test used to determine

the electrical condition of the solenoid and the control circuit of the starting
system.
STATOR the stationary coil of the ac generator in which current is

produced.
TURN SIGNAL LIGHTS a lights when indicates an intended change in

directions by flashing lights on the side towards which the turn will be made.
TROUBLESHOOTING the diagnostic procedure of locating and identifying

the cause of the fault. It is a step-by-step process of elimination by use of
cause-and-effect.
4
Learning Outcome 1: Test electrical system of open and short circuit to

determine faults.
Assessment Criteria
 Correct information is assessed and interpreted from appropriate

manufacturer’s specifications.
 Tests are to determine faults using appropriate tools and techniques.
 Faults are administered, interpreted and applied
 Tests are completed without causing damage to the workplace property or

vehicle.
Resources
 Basic Automotive Electricity

By: Felizardo Francisco & Orvil Molina

1
Learning Outcome 1: Test Electrical System
1. Read the attached information  Try to answer self-check without

sheet no. 1. Purpose of wiring looking at the information sheet.
lighting circuit and components.
2. Answer self-check no.1 to test your

knowledge on the purpose or
importance of wiring lighting  Try to answer the self-check with in
circuit and components. the least possible time allotment.
3. Compare your answer to answer

key LO 1.
 Try to answer assessment criteria
4. After completion, read the base on operation sheet no.1.
operation sheet no. 1.
5. Perform test wiring/lighting circuit  Return Demo

on wiring mock-up.
Automotive Lighting System and Components
The automobile uses electric lighting to provide the illumination

or light needed to safely operate the vehicle especially night time, the various
lights provide vision and information to the driver to other drivers and
pedestrians. The automotive lighting system consists of the components. A
wire, switches, relays that operate the interior and exterior lights on car.
2
Fig. 15 Schematic wiring diagram of automotive lighting system
Exterior Lights
Typically include the headlights, signal lights, stoplights,
parking lights, back up lights and side marker lights.
Interior Lights
Normally include the dome light, instrument light, in the dash
board, trunk light.
Fig. 16 Components of lighting system
3
Head Lamp Circuit
The headlight circuit is composed of the headlights, dimmer

switch, fuse, light switch, and storage battery. Although the ammeter
properly belong to the charging system, it may also be considered as part of
the lighting system if the current used in this system passes through the
ammeter. Note that the headlights have two filaments, one for the bright and
the other for dim lights. Both these filaments are connected to a common
ground terminal. However, only one of these filaments lights at a time.
Switching the headlights from bright to dim or from dim to
bright is accomplished by means of the dimmer switch. The fuse, which may
be found in a fuse box, protects the headlights from damage or burning out
due to grounded live wire. The fuse burns out to cut off the flow of excessive
current.
The light switch is the main switch of the lighting system. It
controls the flow of current to the headlight circuit, taillights, and
instrument panel lights
Fig. 16 Schematic diagram of headlight circuit
4
Head Lamp Switch- is an on/off switch and rheostat in the dash
panel or on the steering column.
Fig. 17 Exploded view of headlight switch
Dimmer Switch- controls the high and low head lamp beam function.
This switch may be mounted on the steering column or flow board.
HIGH__________
LOW___________
BATTTERY________
Dimmer Switch
Fig. 18 dimmer switch
Directional Light Circuit
The turn light system basically consists of a fuse, switch, flasher, unit,
turn light bulbs, indicator bulbs and related wiring. The turn signal light
are used by the driver of an automotive vehicle to indicate his intention of
driving either to the right or to the left. A directional signal light switch is
used by the driver to operate the right signal lights if his intention is to drive
to the drive to the right, or the left signal lights if his intention is to drive to
the left side.
5
Fig. 19 Turn signal light lever
Fig. 20 Schematic diagram of turn signal light circuit
Emergency Light System
The emergency light system also named hazard warning system,

the emergency light switch is normally mounted on the steering
column, it is usually a push-pull switch.
Stop Light Circuit
The stop light system is commonly made up of a fuse, brake

light switch, two rear lamps, and wiring. The brake light switch is
normally mounted on the brake pedal.
6
Fig. 21 (a) off position (b) on position of stoplight switch
Fig. 22 A typical schematic diagram of stoplights circuit
Back-up Light Circuit
A back-up is typically has a fuse, transmission mounted switch,

two back-up lamp and wiring to connect these component.
The back lamp switch closes the light circuit when the
transmission is shifted into reverse, to illuminate the area behind the
car.
7
Fig. 23 A simple diagram of back-up light circuit
Lighting Circuit Repair and Diagnosis
The lighting system of the vehicle is becoming very complex.

There may be over 50 light bulbs and hundreds of feet of wiring in the
lighting circuits. The circuits include circuit protectors, switches, lamps,
and connectors. Any failure requires a systematic approach to diagnose,
locate, and correct the fault in the minimum amount of time.
The importance of lighting system cannot be overemphasized.

The lighting system should be checked whenever the vehicle is brought into
the shop for repairs. Often a customer may not be aware of a light failure. If
a lighting circuit is not operating properly there is a potential danger to the
driver and other people. When today’s technician performs repairs on the
lighting systems, the repairs must assure vehicle safety and meet all
applicable laws. Be sure to use the correct lamp type and size for the
application.
Before performing any lighting system tests:

a. Check first the battery for state of charge.
b. Also be sure all cable connections are clean and tight.
c. Visually check the wires for damaged insulation, loose
connections, and improper routing.
When troubleshooting the lighting system, if only one bulb is
not operating it is usually faster to replace it with a known good unit
first. Check the connector for signs of corrosion. When testing the
circuit with a voltmeter, or test light, check those components that
can be easily accessed first.
8
9
SELF CHECK No. 1
LO 1. TEST ELECTRICAL SYSTEM
Direction: On your answer sheet, write the letter of your answer
_______ 1. The exterior lights consists of several components except

one
a. signal light c. parking light
b. stop light d. dome light
_______ 2. The type of switch that control the high and low head
lamp beam function
a. signal switch c. dimmer switch
b. hazard switch d. stop light switch
_______ 3. The components of exterior light which is mounted on the

the brake pedal
a. back-up light c. emergency light
b. stoplight d. signal light
_______ 4. The back-p light switch is mounted on the side of the..

a. transmission c. differential
b. engine d. brake pedal
_______ 5. Type of lighting system that permit the driver to turn

the vehicle to the left or right.
a. stop light system c. back-up light system
b. signal light system d. head lamp system
10
Connecting Back up Light Circuit
CONDITIONS:
 Automotive wires
Tools
 Electrical Pliers
 Long nose plier
 Test light
 Screw Driver
Equipment
 Battery 12 volts
 Electrical mock-up/Vehicle
Plan/Working Drawing
PROCEDURE
1. Prepare the necessary tools and materials/equipment
2. Connect a wire to the lamp specified as the back-up light to the back-
up switch found on the transmission.
3. Connect the other terminal to one terminal of the fuse box.
4. Connect a wire from the fuse box to the ACC terminal of the ignition
switch
.
5. Connect a wire from the fuse box to the AM terminal of the ignition
switch.
6. Connect a wire from AM terminal to the positive terminal of the

amphere, and a wire from negative terminal to the positive terminal of
the battery.
7. Connect the negative terminal of the battery to the ground a part of

the vehicle.
11
Learning Outcome 2. Repair Electrical Circuit
ASSESSMENT CRITERIA:
1. Correct information is assessed and interpreted using appropriate
tools and equipment
2. Necessary repairs are carried out using appropriate tools, techniques
and materials
3. Electrical circuit is repaired without causing damage to the work
place, property or vehicle
Resources


Learning Outcome 2: Repair Electrical Circuit
1. Read the attached information  Refer to manufacturer’s service

sheet no.1 Safety Measures in manuals on repairing electrical
Repairing Electrical Circuits. circuit.
2. Answer self check LO 2-1 to test  Answer the self check without looking
your knowledge. at the information sheet.
3. Compare your answer to answer  Try to answer the self check with in
key LO2-1. the least possible time allotted.
4. Read and perform operation sheet  Refer to operation sheet no.1.
no. 1 on repair/replace of electrical
system
5. Call your teacher for evaluation.
12
SAFETY MEASURE’S IN REPAIRING ELECTRICAL CIRCUIT
Safety is an inherent responsibility the teacher, he further outlined

that assignment of safety responsibility in all students is a basic
requirement. Most accidents can be prevented if all students cooperate in
eliminating unsafe condition and acts. To this end, each individual is
responsible for understanding and applying safety rules, standards, and
regulations in all activities safety consciousness will help prevent personal
injury and damage to property.
The lighting system of the vehicle should be check whenever the

vehicle is brought into the shop for repairs. Often a costumer may not be
aware of a light failure. If a lighting circuit is not operating properly there is
a potential danger to the driver and other people.
The electrical circuit of the vehicle is becoming very complex, there

maybe over 50 light bulbs and hundreds of feet of wiring in the lighting
circuits. The circuits include protectors, switches, lamps, and connectors.
Any failure requires a systematic approach to diagnose, locate and

repair or correct the fault in the minimum of time. When performing repairs
on the lighting or electrical circuits/systems, the repairs must assure
vehicle safety and meet all the applicable laws, be sure to use the correct
lamp type and size for the application.
Before performing any lighting systems test or repair, check the

battery connections, also be sure all cable connections are remove visually
check the wires for damage and insulation, loose connections and improper
routing.
13
SELF-CHECK No. 2
REPAIR ELECTRICAL SYSTEM
DIRECTION: On your answer sheet, write the letter of your answer.
__________1. Before performing any lighting system repairs or tests check

the following except one.
a.) battery b.) tire

c.) cable connection d.) wires for damage
_________ 2. All are the circuits include in the vehicle except.
a.) protectors b.) switches

c.) lamps d.) battery
______ ___3. The lighting systems of the vehicle should be checked to

avoid.
a.) danger to the driver and other people
b.) improper functioning of the lighting circuits
c.) prevent injury and damaged to property
d.) all of the above.
_________4. In repairing the lighting system of the vehicle the following

must be observed.
a.) be sure to use the correct lamp types
b.) size of the wire to be use
c.) assure safety at all times
d.) all of the above
_________5. How many light bulbs and feet of wiring in the lighting circuits.
a.) 10 bulbs and 2 feet of wire
b.) 15 bulbs and 3 feet of wire
c.) 50 bulbs and hundreds of feet of wiring
d.) 20 bulbs and 5 feet of wires
14
Connecting Back up Light Circuit
CONDITIONS:
Tools
 Electrical Pliers
 Long nose plier
 Test light
 Screw Driver
Equipment
 Battery 12 volts
Plan/Working Drawing
PROCEDURE
1. Prepare the necessary tools and materials/equipment.
2. Connect a wire to the lamp specified as the back-up light to the back-
up switch found on the transmission.
3. Connect the other terminal to one terminal of the fuse box.
4. Connect a wire from the fuse box to the ACC terminal of the ignition
switch.
5. Connect a wire from the fuse box to the AM terminal of the ignition
switch.
6. Connect a wire from AM terminal to the positive terminal of the

ampere, and a wire from negative terminal to the positive terminal of
the battery.
7. Connect the negative terminal of the battery to the ground a part of vehicle body.
15
OPERATION SHEET NO. 2
HEAD LIGHT REPAIR AND REPLACEMENT
CONDITIONS:
Supplies and Materials:

 Headlamp
 Test lamp
 Soldering iron
 Electrical tapes
 Wire terminal
Tools:
 Philip screw drivers
 Standard screw drivers
 Electrical pliers
 Wrenches(Box and Open)
Equipment:
 Battery (12 volts)
PROCEDURE:
The teacher will discuss the procedure with the students with the aid
of diagram and pictures demonstration. Then the students will do the
procedure themselves.
1. Place fender covers around the work area
2. This type of replacement usually requires the removal of the

bezel.( The bezel is the retaining trim around a component)
Fig. 24 Remove the light bezel.

3. Remove the retaining ring screws and the retaining trim. Do not turn
the two headlight aiming adjustment screw.
16
4. Remove the headlight from the shell assembly.
5. Disconnect the wire connector from the back of the lamp.
6. Check the wire connector for corrosion or other foreign materials.

Clean as needed.
Fig. 25 Exploded view of headlight assembly.
7. Coat the connector terminals and the prongs of the new headlight
with the dielectric grease to prevent corrosion.
8. Install the wire connector to the headlight prongs and place the
headlight into the shell assembly. When positioning the headlight, be
sure the embossed number is at the top.
9. Install the retainer trim and fasteners.
10.Check the operation of the headlight.
11.Check headlight aiming as described.
12.Install the headlight bezel.
17
PERFORMANCE CRITERIA
LO 2. Repair Electrical Circuit
Workmanship/Performance POINTS
Quality of Work with application of safety measures
35 – Functional
25 – Not Functional
10 – None Functional
Accuracy of Performance under specified time limit
30 – All procedures are followed
20 – 3-5 procedures are followed
10 – more than 5 procedures are not followed
Proper use of tools/equipment with safety measures
35 – select/use properly of tool/equipment
25 – wrong handling of tools
10 – tools is not suitable for the job.
TOTAL SCORE
18
Learning Outcome 3. Test and Repair Starter Motor
1. Tests are carried out to determine faults using appropriate tools and techniques.
2. Faults are identified and preferred repair action determined.
3. Starting systems are repaired without causing damage to any workplace property or
vehicle.
4. Information is assessed and interpreted from appropriate manufacturer’s specification.
Resources

19
Learning Outcome 3: Test and Repair Starter Motor
6. Read the attached information  Refer to manufacturer’s service

sheet no.1 Starting system service manuals on repairing electrical
caution. circuit.
7. Read information sheet no.2  Answer the self check without looking
Testing starting system. at the information sheet.
8. Answer self check #1 and #2 to
assess your knowledge on testing
starting system.
9. Compare your answer to answer
key #1 and #2.
10.Read and perform operation sheet
no. 1 on disassembling starter
motor.
11.Read and perform operation sheet
no.2 on commutator test.
12.Call your teacher for evaluation.
TITLE: Starting System Service Cautions
Before beginning any service on the starter system, some

precautions must be observed.
1. Refer to the manufacturer’s manual for correct procedures for

disconnecting a battery. Some vehicles with onboard computers
must be supplied with an auxiliary power source.
2. Disconnect the battery ground cable before disconnecting any of
the starter circuit’s wires or removing the starter motor.
3. Be sure the vehicle is properly positioned on the hoist or on safety
jack stands.
4. Before performing any cranking test, be sure the vehicle is in park
or neutral and the parking brakes are applied.
5. Follow manufacturer’s directions for disabling the ignition system.
6. Be sure the test leads are clear of any moving engine components.
7. Never clean any electrical components in solvent or gasoline. Clean
with low pressure compressed air, denatured alcohol or wipe with
clean rags only.
20
Starting System Principles and Components
The internal combustion engine must be rotated before it will

run under its own power. The starting system is a combination of
mechanical and electrical parts that work together to start the engine. The
starting system is designed to convert electrical energy into mechanical
energy. To accomplish this conversion, a starter or cranking motor is used.
The starting system includes the following components: battery, cable and
wires, ignition switch, starter solenoid or relay, starter motor, starter drive
and flywheel ring gear, and starter safety switch.
Fig. 26 Starting system major components.
Major components of the starting system. The solid line represents the
starting circuit. The dashed line indicates the starter control circuit.
21
TITLE: TESTING THE STARTING SYSTEM
Insulated circuit resistance test
The insulated circuit resistance test is a voltage drop test that is used to locate high
resistance in the starter circuit. An electrical resistance will have a different pressure or
voltage on each side of the resistance. Voltage is dropped when current flows through
resistance. Most manufacturers design their starting systems to have very little resistance to
the flow of current to the starter motor. Most have less than 0.2 volt dropped on each side of
the circuit. This means the voltage across the starter input terminal to the starter ground
should be within 0.4 volt of battery voltage.
Voltage drops are measured by connecting a voltmeter in parallel with the circuit
section being tested. In order to obtain a voltage drop reading, a load on the circuit must be
applied. The following is the test procedures:
1. Set the volt selector to the 3V position.
2. Connect the test leads depending the type of system being tested.
3. The voltmeter should read off the scale to the right until a load is put on the circuit.
If the meter reads zero, reverse the leads.
4. Disable the ignition system to prevent the vehicle from starting. This may be done
by removing the ignition coil secondary wire from the distributor cap and putting
it to ground.
Fig. 27 Disabling ignition system
5. Crank the engine and observe the voltmeter scale.
This test for voltage drop in the entire circuit, so if voltage drop is excessive the
cause of the drop must be located. To locate cause of the excessive voltage drop,
move the voltmeter lead on the starter toward the battery. With each move of the test
lead, crank the engine while observing the voltmeter reading. Continue to test each
connection until a noticeable decrease in voltage drop is detected. The cause of the
preceding point.
22
Ground Circuit Test
A ground circuit test is performed to measure the voltage drop in the ground side of
the circuit. If the starter motor connection to ground is broken or loose, the circuit would be
opened. This could cause an intermediate starter system problem, or a starter motor that will
crank the engine. To perform the ground circuit test, connect the voltmeter leads across the
ground circuit and read voltage drop while cranking the engine. Follow these directions:
1. Set the volt selection to 3V.

2. Connect the positive volt test lead to the starter motor case and the negative test
lead to the ground battery terminal. Make sure any paint removed from the area
where the lead is connected to the case.
3. Crank the engine while observing the voltmeter.
Less than 0.2 volt indicates the ground circuit is good. If more than 0.2 volt is
observed, then there is a poor ground circuit connection. A poor ground circuit connection
could be the result of loose starter mounting bolts, paint on the starter motor case, or a bad
battery ground terminal post connection. Also check the ground cable for high resistance or
for being undersized.
Fig. 28 Connection of voltmeter in circuit ground test.
23
Procedure in Disassembling Starter Motor
1. Always have a clean and organized work area. Prepare tools and materials needed
2. Clean the case and scribe reference marks at each end of the starter and housing
and the frame.
3. Disconnect the field coil connection at the solenoids terminal.
24
4. Remove the two screws that attach the solenoid to the starter drive housing.
5. Rotate the solenoid until the locking flange of the solenoid is free, then remove
the solenoid.
6. Remove the through bolts from the end frame.
25
7. Remove screw from the cap.
8. Pull out lock and spring
26
9. Remove the end frame.
10. Pull out magnetic field
11. Remove the armature from the drive housing. Note: on some units it may be
necessary to remove the shift lever from the drive housing before removing the
armature.
27
12. Remove snap ring from the shaft.
13. Pull out retainer.
14. Pull out over running clutch
15. Remove bushing with a hammer and a special service tool (SST)
28
Note: In assembling starter motor, perform the reverse procedures in
disassembling.
PARTS OF STARTER MOTOR
Fig. 29 Component parts of starter motor.
29
BRONZE BUSHING
FRONT OR NOSE HOUSING
ARMATURE
FIELD COIL ASSEMBLY
PEAR HOUSING
30
SHIFT LEVER
MAGNETIC SWITCH
CARBON BRUSH HOLDER
CARBON BRUSH
31
THROUGH BOLTS
Commutator Tests
If a growler is not available, the armature commutator can be tested

for opens and grounds using an ohmmeter. The following procedures should
be followed:
Testing the armature for opens.
1. Set the selector knob of multitester to Rx1.
2. Connect the test leads to any two commutator sectors.
3. Note the reading. There should be zero ohms of resistance.
Note: The armature will have to be replaced if there is resistance.
Fig. 30 Testing the armature for opens.
Testing the armature for shorts to ground.

1. Place the multitester on the Rx2K.
2. Connect one of the test leads to the armature shaft.
3. Connect the other lead to the commutator segments.
4. Check each sector. There should be no continuity to ground.
Note: The armature will have to be replaced if there is continuity.
32
Fig. 31 Testing armature for short to ground.
PERFORMANCE CRITERIA
LO 3. Test and Repair Stating System
Workmanship/Performance POINTS
Quality of Work with application of safety measures
35 – Functional
25 – Not Functional
10 – None Functional
Accuracy of Performance under specified time limit
30 – All procedures are followed
20 – 3-5 procedures are followed
10 – more than 5 procedures are not followed
Proper use of tools/equipment with safety measures
35 – select/use properly of tool/equipment
25 – wrong handling of tools
10 – tools is not suitable for the job.
TOTAL SCORE
33
LO 3. Test and Repair Starting System
35 – Exemplary
25 – Adequate
TOTAL SCORES
34
Self Check No. 1
Answer each of the following answer with the word TRUE if the statement is
correct or FALSE if the statement is wrong. Answer before the number.
1. The starting system is a combination of mechanical and

electrical parts that work together to start the engine.
2. An electrical resistance will have a same pressure or
voltage on each side of the resistance.
3. Voltage drops are measured by connecting a voltmeter
in series with the circuit section being tested.
4. A ground circuit test is perform to measure the voltage drop
in the ground side of the circuit.
5. Less than 0.4 volt indicates the ground circuit is good.
Self Check No. 2
Direction: On the blank provided for, write the correct letter of your choice.
1. No cranking and no lights when the key is turned to start

may be caused all by the following EXCEPT
a. burned out light bulbs
b. an open circuit
c. a dead battery
d. an open fusible link
2. Voltage is dropped when current flows through __________.
a. Ohms
b. resistance
c. current
d. power
3. An electrical resistance will have difference pressure or
___________.
a. voltage
b. resistance
c. flow
d. current
4. A ground circuit test is performed to measure the __________.
a. pressure drop
35
b. resistance drop
c. voltage drop
d. heat drop
5. If the engine cranks slowly but does not start, a possible
cause _________
a. a discharged battery
b. low temperature
c. driver has row down the battery trying to start
d. any of the above
Self Check No. 3
Direction: Select the one correct, best or most probable answer to each
question.
1. Technician A says the starting system includes a low

current control circuit and a high – current motor circuit.
Technician B says the starting system includes a relay or
solenoid switch and a safety switch. Who is right?
a. A only
b. B only
c. both A and B
d. neither A and B
2. The overrunning clutch performs all the following except
a. transmits cranking torque to the engine
b. damage the armature if it fails to lock
c. prevents the engine from driving the pinion
d. acts as one – way clutch
3. The flow of battery connect in the starting motor circuit may
be controlled by means of a _________.
a. mechanical switch
b. electrical switch
c. dimmer switch
d. lock switch
4. A solenoid is an electromagnetic switching __________.
a. Device
b. Gadget
c. Tools
d. equipment
36
Answer Key
LO1
No. 1
1. d – dome light
2. c – dimmer switch
3. b – stoplight
4. a – transmission
5. b – signal light system
No. 2
1. B
2. D
3. D
4. D
5. C
LO3
Self Check No. 1
1. true
2. false
3. false
4. true
5. false3
Self Check No. 2
1. a
2. b
3. a
4. c
5. d
Self Check No.
1. b
2. d
3. a
4.
37
ACKNOWLEDGMENT
First Published JUNE 2008

Development Workshop conducted at the Development Academy of the Phils,
Tagaytay City on May 5-10, 2008.
Technology Teacher:
George C. Callanta
Don Alejandro Roces, Sr. Science-Technology High School
Quezon City
John M. Diego
Isabela School of Arts and Trades
Isabela
Robert S. Domingo
AFG Bernardino Malolos Trade School
Malolos, Bulacan
Lino A. Olit
Calapan Community Vocational HS
Calapan Mindoro
Romeo DQ. Ibloguin

E. Rodriguez Vocational HS
Sta. Mesa, Manila
Nelson C. Señedo
English:
Belen L. Tado
38
Facilitators:
Ms. Beatrice A. Adriano
Encoder:
Rowena S. Fonacier

Education.
REFERENCES AND FURTHER READING
1. Modern Automotive Service and System

By: James E. Duffy
2. Basic Automotive Service and System

By: Jay Webster
3. Automotive Mechanics, 10th Edition

By: William Crouse and Donald Anglin
4. Manufacturer’s Manual
By: Toyota Corporation
39
PUBLIC TECHNICAL-VOCATIONAL
HIGH SCHOOLS
PUBLIC TECHNICAL-VOCATIONAL
HIGH SCHOOLS
Unit of Competency: CHECK IGNITION SYSTEM
Module No.: 3 Module Title: Checking Ignition System
0
TABLE OF CONTENTS
Page
How to Use this Module ………………………………………….. i
Introduction……………………………………………………………. ii
Technical Terms …………………………………………………….. iii
Self Check ……..……………………………………………. 10
Learning Activity ……………………………………………. 12
Operation Sheet 1... ……………………………………….. 12
Operation Sheet 2... ……………………………………….. 14
Information Sheet 1 ………………………………………. 21
Self Check 1.1 ………………………………………………. 23
Operation Sheet 1... ……………………………………….. 24
1
Operation Sheet 1... ……………………………………….. 25
Operation Sheet 1 ……………………………………...….. 33
Operation Sheet 2 ……………………………………...….. 34
Operation Sheet 1 ……………………………………...….. 40
Operation Sheet 2 ……………………………………...….. 43
Operation Sheet 3 ……………………………………...….. 45
Operation Sheet 1 ……………………………………...….. 49
Operation Sheet 2 ……………………………………...….. 51
Operation Sheet 1 ……………………………………...….. 56
2
HOW TO USE THIS COMPETENCY BASED LEARNING MATERIAL.
This module contains training materials and activities for you to

complete.
The unit of competency “CHECK IGNITION SYSTEM” contains the

knowledge, skills and attitudes required for an Automotive Servicing course.
This is one of the common modules for national certificate level 1 (NC1).
You are required t go through a series of learning activities in order to

outcome there are Information sheets and operation sheets. Use reference
materials for further reading to help you better understand the required
activities. Follow these activities on your own and answer the self-check at
the end of each learning activity and for the operations master the
procedure.
This module is prepared to help you achieve the required competency,

servicing and repairing ignition system. This will be the source of
information that will enable you to acquire the knowledge and skills in this
particular trade independently at your own pace or with minimum
supervision or help from your teacher.
RECOGNITION OF PRIOR LEARNING (RPL)
You may already have some or most of the knowledge and skills
covered in this module because you have;
 Been working for some time.
 Already completed training in this area. If you can demonstrate to
your teacher that you are competent in a particular skill or skills, talk
to your teacher about having them formally recognized so you don’t
have to do the same training again. If you have a qualification or
certificate of competency from previous trainings show it to your
teacher. If the skills you acquired are still current and relevant to their
to this module, they may become part of the evidence you can present
for RPL. If you are not sure about the currency of your skills, discuss
this with your teacher.
After completing this module ask your teacher to assess your competency.
Result of your assessment will be recorded in your competency profile. All
the learning activities are designed for you to complete at your own pace.
3
Course Title : AUTOMOTIVE SERVICING
Unit of Competency: Service ignition system
Module Title: Servicing ignition system

Inside this module you will find the activities for you to complete and at the
back are the relevant information and operation sheets for each learning
outcome. Each learning outcome may have more than one learning activity.
INTRODUCTION:
This module involves (9) nine Learning outcomes (2) information

sheets and (10) ten essential operation sheets. The information sheets are
composed of the following; servicing ignition timing, Checking ignition coil
resistance. While the operation sheets of this module will be operated by the
teacher concern are the following; Procedures in spark testing of the spark
plugs while cranking the engine. Procedure in spark testing while running
the engine. Procedure in performing triggering test while engine not
cranking or running. Procedures in checking ignition coil resistance.
Procedures in checking ballast resistor of ignition coil. Procedures in
adjusting contact point when the distributor assembly is installed to engine.
Procedures in adjusting contact point when distributor assembly removed
from engine. Procedures in checking ignition system components with the
use of ohmmeter. Procedures in checking ignition system components with
the use of voltmeter. Procedures in performing the wiring installation of
ignition system. Procedures in performing the initial ignition timing.
Procedures in performing the setting base ignition timing. Procedures in
maintaining, servicing, and repairing the ignition system components.
4
TECHNICAL TERMS
1. Ohm unit of measure for resistance. One ohm is the resistance of

the conductor such that a constant current of one ampere in it
produces a voltage of one volt between its ends.
2. Ohmmeter a test meter used to measure resistance and

continuity in a circuit.
3. Ground the common negative connection of the vertical system

that is the point of the lowest voltage.
4. Ground circuit an electrical defect that allows current to return to

ground before it has reached the intended load component.
5. Ground side the portion of the circuit that is from the load
component to the negative side of the source.
6. Ignition the action of the spark in staring the burning of the

compressed air-fuel mixture in the combustion chamber.
7. Ignition advance the moving forward, in time, of the ignition

spark relative to the piston position. TDC or one degree ATDC is
considered advanced as compared with 2 degrees ATDC.
8. Ignition timing the delivery of the spark from the coil to the spark
plug at the proper time for the power stroke, relative to the piston
position.
9. Centrifugal advance a rotating weight mechanisms in the

distributor that advances and retard ignition timing through the
centrifugal force resulting from changes in the rotational speed of
the engine distributor.
10. Condenser in the ignition system, a device that is also called a

capacitor, connected across the contact points to reduce arcing
by providing a storage place for electricity (electrons) as the
contact points open.
11. Dwell meter a precision electrical instrument used to measure

the cam angle, or dwell or number of degrees the distributor
points are closed while the engine is running.
12. Timing in an engine delivery of the ignition spark or operation of

the valves (in relation to the piston position) for the power stroke.
5
13. Timing light a light that can be connected to the ignition system
to flash each time the no.1 spark plug fires. Used for adjusting
the timing of the ignition spark.
14. Vacuum advance the advancing (or retarding) of ignition timing

by changes in intake-manifold vacuum. Reflecting throttle
opening and engine load. Also, a mechanism on the ignition
distributor that uses intake-manifold vacuum to advance the
timing of the spark to the spark plugs.
15. Arcing name given to the spark that jumps the air gap between
two electric conductors.
16. Dwell in a contact – point distributor, the number of degrees of

distributor – cam rotation that the points stay closed before they
open again. The length of time the points are closed and current
flows through the primary winding of the coil.
17. Ignition resistor a resistance connected into the ignition primary

circuit to reduce battery voltage to the coil during engine
operation.
18. Magnetic line of force the imaginary lines by which a magnetic

field maybe visualized.
19. Retard to delay the occurrence of the spark in the combustion

chamber.
6
Program/Course: Automotive Servicing NC I
Unit of Competency: SERVICE IGNITION SYSTEM
Module Title: Servicing Ignition System
Learning Outcome 1. Check Ignition System
1. Spark plug is checked and inspected in accordance with standard

testing procedure.
2. Ignition distributor and associated parts are checked/evaluated
according to standard procedure.
3. Ignition system harness is checked and inspected.
Resources
 Automotive Mechanics, 10th edition

By: Crouse/ Anglin
 Modern Automotive Technology
By: James E. Duffy
 Manufacturer’s Manual
Toyota Corporation
1
Learning Outcome 1: Check ignition system
1. Read and understand the information  See from topic 1 up to 7.

sheet carefully.
2. Familiarize the types of ignition system.  See only topic 2 of LO1.
3. Identify the parts and functions of the ignition system.
4. Classify the two interconnected electrical  See only topic 3 of LO1.
ignition system /circuits.
5. Analyze the operating principles of the  See only topic 4 of LO1.
ignition system.
6. Follow the safety measures in checking ignition system.  Read the topic 5 of LO1.
7. Perform the servicing ignition system
components.  Read the topic 6 of LO1.
 Read the topic 7 of LO1.
2
LO 1. SERVICE IGNITION SYSTEM
TITLE: Servicing Ignition System
Topic 1. FUNCTIONS OF THE IGNITION SYSTEM
The ignition system feeds high voltage surge to the spark plugs at
proper time. The three major functions are:
1. It must supply an electric spark with sufficient heat in order to

ignite the air fuel mixture in the combustion chamber of the
engine.
2. It must maintain the spark long enough to permit the combustion
of all fuel charges in the cylinder of the engine.
3. It must draw the spark to each cylinder combustion can begin at
specific time during the stroke of compression for every cylinder
engine.
Topic 2. TYPES OF IGNITION SYSTEM
The ignition system maybe a breaker point and a breaker less type
known as electronics, which is mostly applied in the ignition system
today. There is also a computerized type of ignition system and the
latest is the distributor less type
3
A. BREAKER POINT TYPE
The breaker point type distributor assembly consists of the following

parts: Contact point, condenser, springs, lobes, contact set attaching
screw, breaker plate, dwell-angle adjusting slot, vacuum advance unit
and primary lead.
B. BREAKERLESS TYPE
Breaker less type of distributor assembly is composed of the following

parts: pick-up coil assembly, reluctor, pick-up coil, pole piece, mounting
bracket, permanent magnet, reluctor teeth, cap clip, connector, pick up
coil lead and vacuum advance unit.
4
Topic 3. PARTS AND FUNCTIONS OF THE IGNITION SYSTEM
1. Battery supplies current to starter in order to crank the engine for

operation. It also supplies the required electric current to the
ignition system.
2. Ignition Switch the key-operated main power switch

that opens and closes the circuit that supplies
current to the ignition and other electrical system.
3. Ignition Resistor a resistor connected into the ignition

primary circuit to reduce battery voltage to the coil during
engine operation.
4. Ignition Coil the ignition system component that set as

a transformer to step up(increase) the battery voltage
into many thousands of volts.
5
5. Distributor any device that distribute. In the ignition
system, the rotary switch that direct high voltage surges
to engine cylinders in the proper sequence.
6. Rotor the rotating parts of the distributor assembly that

distributes high voltage from coil center cable to different
spark plug.
7. Contact Point the point in the distributor that opens & closes
the primary circuit to build-up & collapse the magnet line
of force.
8. Condenser connected across the contact point to prevent

arcing and burning. It also provides the storage
of electricity when breaker point is open.
9. Distributor Cap top cover of distributor assembly that

prevents dirt or any particles from entering the
delicate parts.
6
10. High Tension Wires bridges of high voltage to
the spark plugs.
11. Spark Plugs a device in the system that serves

as lighter to produce spark on the gap.
12. Vacuum Advancer provide advancing and

retarding the ignition timing by means of intake
manifold vacuum. It advances the timing just
to maintain the spark at top dead center.
Topic 4. The ignition system are of two interconnected electrical

circuits.
1. Primary ( low voltage )

1 Battery
2 Ignition Switch
3 Ballast Resistor or resistance wire
4 Ignition coil primary winding
5 Condenser
6 Contact Point
7 Ground
2. Secondary (high voltage circuits

1. Ignition coil
2. Secondary winding
3. Distributor cap
4. Rotor
5. Ignition cable or high tension wire
6. Spark plug
7
Topic 5. OPERATING PRINCIPLES OF THE IGNITION SYSTEM
When the breaker points are close, electric current flows from the
battery through the primary windings in the ignition coil and through the
points back to the ground. This is called the primary circuit. When a
high lobe of the cam pushes on the pivot arm and opens the points, the
primary circuit is broken. The magnetic field that was built up in the coil
while the primary current was flowing now collapses, including the
voltage in the secondary windings as the collapsing magnetic lines of
force sweep across them. Because there are many more secondary
windings than primary windings, the induced voltage is much higher
than the voltage that drove the primary current. This high voltage is sent
through the center wire of the coil to the center of the distributor cap,
which is always in contact with the rotor. The outer end of the rotor is
timed to arrive at the proper moment at the connection to the sparkplug
where a spark is desired. To obtain the correct spark, the distance
between the two electrodes of the spark plug must be “gapped” correctly.
The gap is shown exaggerated for clarity. Cars today use electronic
means rather than mechanical breaker points to bring about the “make
and break” effect.
8
Topic 6. SAFETY MEASURES IN CHECKING IGNITION SYSTEM
1. Do not used ordinary pliers for checking the spark plug lead
shorting to ground (earth) in order to sparking. Instead used
non-conductive pliers the appropriate one.
2. Disconnect first the negative cable of the battery when checking
resistance of coil, cut all wires connected from it to ensure the
correct reading of ohms. Note: Individual checking of ignition
parts are properly illustrated in LO.8
3. Does not used jumper wire in checking the ignition system for
continuity, Instead use appropriate instrument for testing with
VOM or multi-tester.
4. Be sure to wear proper working shoes and laboratory uniform in
order to avoid heated loose ground or live wires.
5. Avoid using spark test on common lead wire to earth when there
is leak gasoline to any part of fuel line that will lead for
explosion.
6. Avoid replacement of local parts, other brand and different
character rated for quality reason.
7. Make sure the parts and wires, is correctly connected to their
own designated point of contact.
Topic 7. SERVICING IGNITION SYSTEM COMPONENTS
Pointers to be followed by the technician before proceeded to the

servicing procedures
1. Gather information, regarding the problem to be serviced. If

possible ask the driver or the owner of the vehicle.
2. Apply visual view to inspect thoroughly the troubles.
3. List all parts or items that has been checked and detected by the
used of the appropriate instrument for diagnosing the troubles. If
possible used service repair manual being your guide for the
maintenance and servicing of contact point type of ignition system.
9
SELF-CHECK
Direction: Identify and fill-in the blanks with the correct answer. Write your
answers on a separate sheet.
_______________1. It is the point in the distributor assembly that

spark plug.
_______________2. It is a type of distributor assembly that consist of the
following parts; contact point, condenser, springs, lobes,
contact set attaching screw, breaker plate, dwell-angle
adjusting slot, vacuum advance unit and primary lead.
_______________3. The rotating parts of the distributor assembly that
spark plug.
_______________4. It is a key-operated main power switch that opens and
closes the circuit that supplies current to the ignition and
other electrical system.
_______________5. It is device connected into the ignition primary circuit to
reduce battery voltage to the coil during engine operation.
_______________6. A device that distributes in the ignition system, the rotary
switch that directs high voltage surges to engine cylinders
in the proper sequence.
_______________7. A type of distributor assembly composed of the following
parts: pick-up coil assembly, reluctor, pick-up coil, pole
piece, mounting bracket, permanent magnet, reluctor
teeth, cap clip, connector, pick up coil lead and vacuum
advance unit.
__ ____________8. It is the ignition system component that sets as a
transformer to step-up( increase) the battery voltage into
many thousand of volts.
___ ___________9. It is connected across the contact point to prevent arcing
and burning. It also provides the storage of electricity
when breaker point opens.
______________10. It is a device in the system that serves as lighter to
produce spark on the gap.
10
Learning Outcome 2. Perform Spark Test
1. Engine is started as per standard operating procedures.

2. Spark test is conducted in accordance with standard testing
procedures.
3. Safety measures are applied in accordance with standard testing
procedure.
Resources

By: Crouse/ Anglin
By: James E. Duffy
Toyota Corporation
11
Learning Outcome 2: Perform spark test
1. Familiarize the supplies, materials,  See operation sheet no.1.

tools, and equipment needed.
2. Perform spark testing by running the  Read operation sheet no.2 under
engine. LO2.
3. Perform spark testing by cranking the  See operation sheet no.2 under
engine. LO2.
4. Perform triggering test.
5. Follow the safety measures in spark  See operation sheet no.2 under
test and triggering test. LO2.
 See operation sheet no.2 under
LO2.
LO 2. PERFORM SPARK TEST
TITLE: Performing Spark Test
Conditions:
 Rug cloth
 Sand paper
Tools
 Screw Driver
 Insulated Pliers (special tool)
 Spark Plug wrench
 Feeler Gauge
Equipment
 Engine
 Battery Charger
 Mock – up
12
Procedure:
1. Prepare the supplies, materials, tools and equipment needed.
2. Connect battery both positive and negative terminal post, then,

switch on ignition switch.
Note: charge the battery if needed
3. Remove the spark plugs from the Engine by the use of spark plug
Wrench.
Note: Before spark testing clean the tip of the spark plugs with fine
nylon brush.
4. Connect the spark plug no. 1 to high tension. wire no. 1 then,
attach ground electrode of the spark plug to the engine ground.
Note: Do not interchange the cable wires.
5. Switch on key to crank the engine and watch the sparking across
the gap. Hold the plug no. 1 with insulated pliers.
Note: Use a fully charge battery with a good cranking motor
capacity.
6. Proceed to spark plug no. 2, 3, & 4 by performing the same step as
step no. 5.
7. Replace if defective, follow the required gap as specified in the

manual of the car model
13
Conditions:
Supplies and materials:
 Rug cloth
 Sandpaper
 Soft brush nylon
 Functional battery
 Functional starter motor
Tools:
 Set of box wrench

 Spark plug wrench fitted.
 Insulated/non conductive pliers
Equipment
 Functional vehicle
 Functional engine mock –up
 Battery charger
Procedure in spark testing while engine is running:
2. Before operating the engine turn it to correct direction of rotation

by hand with socket wrench and handle.
3. Disconnect the spark-plug cable from the spark plug one by one
while the engine is running.
4. Used non-conductive pliers /insulated pliers hold the extender

about 3/8 inch (10mm) the distance allowed directly to ground in
the black head engine.
5. While the engine is running , observe the sparking across the gap.
Bluish spark from no.1-4 end of cables shows that the ignition
system is at normal condition.
14
6. If there’s no spark, proceed to the triggering test of the primary
circuit to determine if there will be the opening and closing
operation in the circuit. (note: if spark show but the engine does
not continuously operating, maybe failure is in the other systems.
15
Conditions:
 Rug cloth
 Sandpaper
 Soft brush nylon
 Functional battery
 Functional starter motor
Tools
 Set of box wrench

 Spark plug wrench fitted.
 Insulated/non conductive pliers
Equipment
 Functional vehicle
 Functional engine mock –up
 Battery charger
Procedure in performing triggering test while engine not cranking or

running
2. Turn the crankshaft to correct direction of rotation in order to set

piston no.1 at compression stroke, both values closed.
3. Mark cut on crankshaft pulley align to the specified degrees of

spark. Example if 8º ignition timing required it must be aligned to
it.
4. Loosen the distributor assembly fixing adjusting bolt. Ignition

switch turn on, turn the distributor assembly go against rotor
rotation, see to it that gap adjusted correctly, then, turn the
assembly, by setting contact point gap about to open. Spark
occurred on gap, then, the common cable lead 3/8” gap directly
pointing to ground at the same time spark occurred in the contact
16
the finding of the primary circuit and parts are in good service
condition.
5. If spark does not occur, check contact point, condenser, ignition

coil, and insulator in the primary lead.
17
SAFETY MEASURES IN SPARK TEST/TRIGGERING TEST.
1. Do not use conductive pliers with only insulated handle. In high-

energy ignition system the spark will jump even more than one
inch or (25.4mm).
2. It will jump around or through the insulation and give a dangerous

shock that might kill a person with heart failure.
3. See to it that there is no fuel or fuel vapor near where the spark
will occur. The spark will ignite the fuel causing a fire or explosion.
4. Do not allow spark to short onto dipstick, cam/rocker cover or

battery as this can cause an explosion of oil or hydrogen fumes.
DETERMINING AND ANALYZING ELECTRIC SPARK.
A waveform, or trace, showing one complete spark-plug firing cycle.

Note that the “dwell section” is the period during which the points are
closed or the electronic control unit is maintaining a complete circuit
between the battery and ignition coil.
1. Reading the Patterns
The patterns show different troubles that occur in the ignition

system. The pattern of any cylinder’s ignition-circuit voltage
shows what voltages are occurring in that circuit. The way that
the voltage varies from normal shows you where the electrical
problem exists. For example, the scope can detect wide or narrow
spark-plug gaps, open spark-plug wires, shorted coils or
18
condensers, arcing contact points improper contact-point dwell,
and so on. Many abnormal engine conditions change the voltage
needed to fire the plug. This, too, shows up on the scope. When
you work in a shop that has an oscilloscope, you will have
instructions on how to use it.
LO 2. Perform spark test
A. Spark tested when cranking the engine safely.

100
 With 95-100% standard of specifications. All

spark plugs are spark tested correctly
 90-94% standard of specifications. Three spark

plugs are spark tested correctly
 85-89% standard of specifications. Two spark
plugs are spark tested correctly
 80-84% standard of specifications. One spark
plug is spark tested correctly
 75-79% standard of specifications. None
 B. Spark tested safely when running engine. 100
 With 95-100% standard of specifications. All

high tension wires are spark tested properly
 90-94% standard of specifications. Three high
tension wires are spark tested properly
 85-89% standard of specifications. Two high
tension wires are spark tested properly
 80-84% standard of specifications. One high
tension wires is spark tested properly
 75-79% standard of specifications. None
19
 Spark triggering tested safety while engine not
cranking or running
 With 95-100% standard of specifications. 100
Within1 to 3 minutes.
 90-94% standard of specifications. Within 3 to 6
minutes.
minutes.
minutes.
 75-79% standard of specifications. Within 12 to
15 minutes.
Learning Outcome 3. Check Ignition Coil Resistance
1. Coil terminal of ignition coil is disconnected
2. Ignition coil resistance is checked
Resources

By: Crouse/ Anglin
By: James E. Duffy
Toyota Corporation
20
Learning Outcome 3: Check ignition coil resistance
1. Read and understand the functions  Look at the topic 1 of LO3.

of ignition coil.
2. Identify the parts and function of  Look at the topic 2 of LO3.
ignition.
3. Interpret the primary and  See topic 3 of LO3.
secondary circuit.
4. Perform to check and test the  See information sheet 4 under
ignition coil resistance. LO3.
LO 3. CHECK IGNITION COIL RESISTANCE
TITLE: Checking Ignition Coil Resistance
Topic 1. FUNCTIONS OF IGNITION COIL
Ignition coil is considered as the heart of the Ignition System. It

works in the same of the pulse transformer to step up the low voltage
of 12.6 volts to a voltage high enough to ionize (electrically charge) the
spark plug gap and ignite the fuel charges. The coil has the capacity
to produce approximately 30,000 to 60,000 volts. However, the
amount of voltage produced is dependent on many factors. The coil
will produce current depending on many factors. The coil will produce
only sufficient voltage required to overcome these factors; plug gap,
air/fuel ratio, plugs wire resistance, engine speed, compression ratio,
and so forth. The margin of voltage which can be produced above that
which is required to fire the spark plug represents the electrical
reserve built into the ignition system. As plugs wear and other
resistances in the system increase, the ignition system is capable of
compensating for this through the electrical reserve.
Topic 2. PARTS OF IGNITION COIL
1. Soft iron core is the center of the Ignition coil, a laminated soft
iron or steel.
21
2. Primary coil winding These are several hundred turns of heavy
wire, wrapped around or near the secondary.(approximately 200
turns of gauge wire)
3. Secondary coil windings These are several thousand turns of very
fine wire located inside or near the primary
windings.(approximately 22,000 turns of very fine wire)
4. Oil in the coil that prevents heat and help cool the coil.
Note: E-coil – this type of core does not use oil. It uses an air-
cooled, epoxy-sealed
5. Positive terminal where wire connected from ignition terminal of
switch to the + sign or the ballast resistor + sign side of it.
6. Negative terminal It is wire connected from the distributor
assembly lead wire with insulated terminal to the negative sign of
coil.
7. Center pole negative this is the plug polarity, negative plug
polarity requires less voltage to ionize the plug than does positive
polarity. This is because of the relative temperature between the
center electrode (hot) and the ground electrode (cold).
Topic 3. INTERPRETING SECONDARY AND PRIMARY CIRCUIT
1. Operation of the Primary Circuit When the Ignition switch on or

it is in the run position, current from the battery flows through the
ignition switch and primary circuit resistor to the primary winding
of the ignition coil. From there, it passes through some type of
switching device that can be mechanically or electronically
controlled by a triggering device. The current flow in the Ignition
Coil primary winding creates a magnetic field. The switching
device or control module interrupts this current flow at
predetermined times, when it does, the magnetic field in the
primary winding collapses, this collapse generates a high-voltage
surge in the secondary winding of the ignition coil. The secondary
circuit of the system begins at this point.
Schematic of the primary circuit in the contact point ignition system
22
2. Operation of Secondary Circuit The secondary circuit carries
high voltage to the spark plugs. The exact manner in which the
secondary circuit delivers these high-voltages surges depends on
the system design. Until 1984 all ignition systems used some type
of distributor to accomplish this job. However, in an effort to
reduce emissions, improve fuel economy, and boost component
reliability, most auto manufacturers are now using distributor less
or electronic ignition (EI) system.
Simplified secondary circuit means that

coil secondary winding is connected through
the distributor cap, rotor, and wiring to
the spark plugs.
Self-check
Direction: Identify the following.
1. _________ It is a wire connected from the distributor assembly lead wire
with insulated terminal to the negative sign of coil.
2. __________It prevents heat and help to cool the coil.
3. __________It is the center of the ignition coil, a laminated soft iron or steel.
4. __________This winding is surrounded the secondary coil windings which

is approximately 200 turn of 20-gauge wire.
5. __________It is winded in the core approximately 22,000 turns of very fine

wire.
23
LO 3. CHECK IGNITION COIL RESISTANCE
TITLE: Checking Ignition Coil Resistance
Conditions:
 Ball pen/pencil
 Bond paper
Tools
 Pliers
 VOM
 Multi tester
Equipment
 Engine mock-up
Procedure in checking ignition coil resistance:
2. Inspect the Ignition coil
a. Clean the coil and inspect it

for carbon paths around the
terminals and check the
outside body for cracks.
b. Inspect the high tension

cord insertion hole for
carbon deposit or corrosion.
24
3. Inspect / Check / Test the Primary Coil Resistance
a. Measure the following resistance
With out the used of resistor the

reading must be 2.6 – 4.0 ohm. This is
the primary coil resistance (reference
only)
Note: If the reading is not within
the specified resistance replace the
coil.
Causes: If the readings show the

specified ohms or very high
resistance the condition of the
primary coil is burn. But if it is
low, the condition will be weak,
but if the hand, remains at infinity
(∞) the condition of primary winding is
b. With theopen.
used of resistor
The reading must be 1.3 – 1.6
ohms this is the primary coil resistance
(reference only)
Note: If the reading is not within
the specified resistance replace the
coil.
Causes: If the reading appear

higher than the required ohms or
higher resistance, the condition of
primary coil is burn out, but if it is
low than specified ohms the
condition is weak, but if the hand
of ohmmeter remain at infinity ∞
the condition of primary coil
maybe open.
25
4. Inspect/check/ test the secondary coil resistance.
c. Measure the following resistance

With out the used of resistor the
reading must be 6.0 – 9.0 k ohms, the
secondary coil resistance (references
only)
Note: If the reading does not meet
within the range of minimum and
maximum in the secondary coil
resistance that will be
recommended for replacement.
Cause: If the reading of
ohmmeter show more than the
specified ohms the condition will
be burn out winding, but if it is
lower reading, the coil is weak, but
if remain at infinity (∞) the
condition of secondary coil maybe
opened.
b. With the used of resistor

The reading must be 9.5 – 14.5 k
ohms, the secondary coil resistance
(references only)
Note: If the reading does not meet
the minimum and maximum of
secondary coil resistance that will
be recommended for replacement.
Cause: If the reading of
ohmmeter show more than the
specified ohms the condition is
burn out, if lower reading the coil
is weak, but if remain at infinity
(∞) the condition of secondary coil
maybe opened.
26
LO 3. Check ignition coil resistance
50
A. Checked ignition coil safety when disconnected

from the circuit.
 With 45-50% standard of specifications. Within

1 to 3 minutes including the test results and
conditions of coil.

16 minutes including the test results and
condition of coil
 33-38% standard of specifications Within 6 to 9

minutes including the test results and the
condition of coil
12 minutes including the test results and the
condition coil.

15 minutes including the test results and the
condition coil.
B. Checked the ignition coil safely, when connected 50

in the circuit, while engine is functioning
 With 45-50% standard of specifications. It was

checked properly with the correct instrument
 38-44% standard of specifications. It was not

checked correctly with the instrument.
 32-37% standard of specifications. It was not
checked correctly without instrument.
Total=100
27
Learning Outcome 4. Check Ballast Resistor
1. Ballast resistor is checked as per requirement
Resources

By: Crouse/ Anglin
By: James E. Duffy
Toyota Corporation
Learning Outcome 4: Check ballast resistor
1. Check and test the resistance of  See the operation sheet no.5.
ballast resistor.
 See the operation sheet no.5. under

2. Analyze the resistance test results LO 4.
of ballast resistor.
28
LO 4. CHECK BALLAST RESISTOR
TITLE: CHECKING BALLAST RESISTOR
Conditions:
 Ball-pen/pencil
 Bond paper
Tools:
 Box wrench
 Screw driver
 VOM tester
 Multi-tester
 Screw drive
Equipment:
 Ignition mock-up
 Engine mock-up
A. PROCEDURES IN CHECKING BALLAST OF IGNITION COIL.

2. Disconnect wires connected from the ballast resistor
3. Check and test ballast resistor of ignition coil.
29
4. Turn the selector switch to R X 1 of the ohmmeter.
5. Both test prods of the ohmmeter will be injected to both ends of the
ballast resistor.
6. If the readings show 0.8 – 1.2 ohms the ballast resistance is normal.
7. But if the readings show infinity or does not move the hand of the
tester, the condition is open
8. If the reading is not within the specified resistance replace the resistor.
B. ANALYSIS OF RESISTANCE TEST RESULTS
Appropriate instrument used for testing and checking the resistance

express in ohms is no other than ohmmeter tester. If the resistance varies
from .08 to 1.2 ohms meaning the hand of the tester will move and stop
with in the range, to be sure in the measurement, possible see the manual
of the Ballast resistor specifying the resistance of the ignition resistor.
When you turn the selector to RX1, the hand will move from (∞) infinity to
the correct range given from manual, the condition will be normal, but if
the hand will move from (∞) infinity to (0) zero the condition is weak or
leak but then, the hand remain at (∞) infinity the condition maybe open.
30
LO 4. Check ballast resistor
A. Checked safely the ballast resistor, when it is not

connected from the coil as per requirements. 50
 With 45 to 50% standard of specification.

Within 2 to 5 minutes including the test results
and conditions.
 39 to 44% standard of specification. Within 6

to 10 minutes including the test results and
conditions.
 33 to 38% standard of specification. Within 10

minutes or more including the test results and
the condition.
B. Checked safely the ballast resistor when it is
connected in the coil, while engine is running.
50
 With 40 to 50% standard specifications. Within

5 to 10 minutes. The ballast resistor was tested
properly while the engine is running
 29 to 39% standard specifications. Within 10 to

15 minutes. The ballast resistor was tested
improperly while the engine is functioning
Total=100
31
Learning Outcome 5. Adjust Contact Point Clearance
1. Contact point is adjusted per service manual specification

2. Contact point adjustment is analyzed and interpreted
Resources

By: Crouse/ Anglin
By: James E. Duffy
Toyota Corporation
Learning Outcome 5: Adjust contact point clearance
1. Perform the adjusting contact point  See the operation sheet no.6.
when the distributor assembly is
installed to engine
 See the operation sheet no.7. under
2. Perform the adjusting contact point LO 5
when the distributor assembly
remove from the engine.
3. Follow the safety measures in  Read the operation sheet no.7.under

adjusting contact point. LO 5
32
LO 5. ADJUST CONTACT POINT CLEARANCE
TITLE: ADJUSTING CONTACT POINT CLEARANCE
Conditions:
 Sand paper
 Rags
 Grease
Tools
 Set of screw driver

 Feeler gauge
 Set of wrench
Equipment
Procedures adjusting contact point when the distributor assembly

is install to engine.
2. Turn the engine to correct direction of rotation by the use of correct

size box or socket wrench that fit to crankshaft pulley fixing bolt.
3. Position the contact point to be set in highest portion of the cam

lobe in distributor shaft.
4. Use proper type, and size of screw driver prior to the screw head
kind.
5. Loosen the slightly lock and adjusting screw then, insert the feller
gauge with correct size of clearance, follow what is in the manual.
6. Tighten first the adjusting screw with two working screw drivers for
it to locks then, lastly tighten the lock screw. If possible check it
thoroughly again by retightening the adjuster and locker screws.
33
7. Test run then, proceed to next operation sheet.
Fig.1: Adjusting the breaker point gap
LO 5. ADJUST CONTACT POINT CLEARANCE
TITLE: ADJUSTING CONTACT POINT CLEARANCE
Conditions:
 Sand paper
 Rags
 Grease
Tools
 Set of screw driver

 Feeler gauge
 Set of wrench
34
Equipment
Procedure in adjusting contact point when distributor assembly

remove from engine.
2. Position correctly and firmly the distributor assembly in the Bench

vise.
3. Position the contact point to be set on the highest part camlobe in

distributor shaft.
4. Used proper type, and size of screw driver prior to the screw head
kind.
5. Loosen slightly lock and adjusting screw then, insert the feller
gauge with correct size of clearance, follow what state in the
manual.
6. Tighten first the adjusting screw with two working screw drivers for
it, to locks then, lastly tighten the lock screw. If possible check it
thoroughly again by retightening the adjuster and locker screws.
7. Set engine correctly then install the distributor assembly, time it

properly, see the steps of initial ignition timing.
8. Test run, then check if dwell angles is within the specified value, by
the used of the dwell meter, follow the dwell of 4 cylinders is 51⁰
(50⁰ - 52⁰)
POINT GAP ADJUSTMENT (W/O IGNITER)

1. If the points are excessively burnt or fitted, replace
the breaker points.
2. Adjust point gap.

Point gap 0.45 mm (0.18 in)
35
IF dwell angle below specified degrees point gap is too big. But if the
dwell angle above specified degrees point gap is too small, readjust the point
clearance to make it with the correct dwell angle, by the used of dwell meter
for dwell angle while for the R.P.M used tachometer for setting the correct
idling of engine.
B. SAFETY MEASURES IN ADJUSTING CONTACT POINT.
1. When testing a vehicle, never short plug lead to the dipstick,

cam/rocker arm cover, battery or other components, which may
not be directly earthed. This can cause an explosion of oil fumes or
hydrogen.
2. Beware of the danger from rotating components of ignition system.
3. Never bend movable point arm with your hand.
4. Do not use the car, if the contact breaker point is not exactly
adjusted to the manufacturer specifications.
5. Do not install local contact point to the car of your customers and
replacement of part be checked thoroughly, to avoid any trouble?
6. Use the proper screw driver for right head of bolt screw.
7. In replacing contact points do the same with the condenser or

capacitor used the required capacitance or farad.
36
LO 5. Adjust contact point clearance
A. Adjusted contact point safely as per service 50

manual specification when distributor assembly
is installed to engine.
 With 45 to 50% standard of specification. 5

to 10 minutes.
 39 to 44% standard of specification. 11 to 15

minutes.
 33 to 38% standard of specification. 16 to up

minutes.
B. Adjusted contact point safely as per service
manual specification when distributor assembly
50
not installed to engine.
 With 45 to 50% standard of specification. 15

to 30 minutes.
 39 to 44% standard of specification. 30

minutes to 1 hour.
 33 to 38% standard of specification. 1 hour

and more.
Total=100
37
Learning Outcome 6. Perform Ignition Wiring Installation
1. Tools and ignition wiring materials are checked and evaluated per standard
specifications.
2. Ignition wirings are installed based on a required diagram.
3. Safety measures are applied in installing wirings of the ignition system in
accordance with OHS policy.
Resources

By: Crouse/ Anglin
By: James E. Duffy
Toyota Corporation
38
Learning Outcome 6: Perform Ignition Wiring Installation
1. Perform the checking of ignition  See the operation sheet no. 8

circuit system components with the under LO6.
use of ohm meter.
 See the operation sheet no.9
2. Perform the checking Ignition under LO9.
components with the use of volt
meter.  See the operation sheet no.9
under LO10.
3. Perform the wiring circuit
installation of ignition system.  See the operation sheet no.9
under LO10.
4. Follow the safety measures in
wiring installation of ignition circuit
system.
39
LO 6. PERFORM IGNITION WIRING INSTALLATION
TITLE: PERFORMING IGNITION WIRING INSTALLATION
Conditions

 Soldering leads
 Wire terminals
 Electrical tape
Tools:
 Set of screwdriver
 Wire stripper
 Soldering iron
Equipment:
 Engine mock-up
 Vehicle
PROCEDURES IN CHECKING IGNITION COMPONENTS WITH THE USE

OF OHMETER:
2. Disconnect negative terminal of battery.
3. Check Ignition switch by the use of ohmmeter, RX1 one prod to AM

while other prod to Ignition. Hand will move from infinity to zero in
two pull position of ignition key – it’s okay.
4. Test auto wire from Ignition of switch to positive terminal of coil,

RX1, hand move to infinity to near zero – then it’s in proper.
40
5. Test auto wire from negative terminal of coil to ground part of
distributor assembly open the cap see the position of contact point,
RX1, if the contact point open the hand remain infinity – then it’s
proper if hand will move to zero the condition is grounded contact
point. If breaker points close the hand will move near to zero – then
it’s proper.
6 Test/check condenser, used ohmmeter, RX1, connect one prod to

the eye tail of condenser, and the other prod to the body ground
parts, the hand of meter will move little bit abrupt to zero side then,
back to infinity side of tester it’s proper – if does not move or remain
at infinity it is defective, condenser is to be replaced
41
7 Test/check high tension wire individually used ohmmeter RX 25Ω.
Both prods of the meter will be connected at both ends. See the
reading must be on the specified ohms at all cords.
8 Check the adjustment of spark plug gap by the used of feeler gauge
follow the gap specification in the manual.
GAP ADJUSTMENT
Check the plug gap with plug gap gauge. If not
to specified value, adjust by bending
the ground (outer) electrode.
Plug gap 0.8 mm (0.031 in)
1.0 mm (0.039 in for USA
42
Conditions

 Soldering leads
 Wire terminals
 Electrical tape
Tools:
 Set of screwdriver
 Wire stripper
 Soldering iron
Equipment:
 Engine mock-up
Procedure in checking ignition system components with the use of

voltmeter:
2. Connect the voltmeter positive lead to the positive terminal of the ignition
coil. Connect the negative lead to engine ground.
3. Set the voltmeter to a scale that will read 12 volts accuracy.
4. Turn the ignition switch to the “start” position while observing the
voltmeter reading. Check manufacturer’s specification for proper voltage
reading (usually bout 9.5 volts).
5. If the voltage is too low than there is a resistance in the supply circuit to
the coil. This could be caused by any of the following.
a. Battery condition.
b. Excessive starter draw.
c. Excessive resistance in the ballast by pass circuit.
d. Excessive resistance in the ignition switches start
circuit.
e. Excessive resistance in the starter relay to the pass
circuit.
43
6. With the voltmeter still connected as in step one, turn the ignition switch
to the “run” position. The voltmeter reading should now be about7.5
volts (or factor specifications).
7. If the reading is below specification it could be due to
a. Battery condition
b. Ignition switch resistance
c. Excessive resistance in the ballast resistor circuit.
If the results of this test show that the coil supply

circuit is operating properly then the coil should be
tested.
Note: In this ignition circuit the teacher

will demonstrate using voltmeter
44
Conditions:
 Soldering lead 40/60

 Auto wires size no. 12 & 14
 Eye terminals
 Electrical tape
 Fuse/ fuse box
 Wire harness flexible hose
 Battery clamp / cables
 Battery log
Tools
 Cutter pliers
 Wire’s stripper
 Soldering rod / Iron
 Set of insulated pliers
 Set of screw drivers
Equipment

 Functional Engine mock –up for ignition wiring
circuit.
Procedure:
2. Connect newly battery cables to earthly ground, from negative post

and battery cable live from positive post to battery solenoid
terminal.
3. Auto wire size no. 12 will be converted from battery terminal

solenoid to the positive side of ammeter and from negative side to
Bat/AM terminal of Ignition switch.
4. Auto wire size no. 14 will be connected from ignition terminal of

ignition switch to ballast resistor, from then, to positive terminal of
coil.
Note: But in order to complete the circuit to crank the engine for
starting, connect auto wire size no. 14 from ST terminal of
switch to ST terminal of the solenoid starter switch.
45
5. Used auto wire size no. 14 from negative terminal of coil to insulated
lead terminal in the distributor assembly.
Note: See to it that engine and distributor assembly are set
properly and contact point adjusted to specified gap.
6. Proceed to the proper connection of high tension wires from center

lead of coil to center terminal of cap. If rotor pointing no.1 terminal
cap it could be the no.1 spark plug then followed prior to the firing
order given.
7. All end wires in provided with eye terminals and solenoid the wires
with the eye to ensure proper contact.
8. Crank the engine and run it, for further trouble shooting
SAFETY MEASURES IN WIRING INSTALLATION
1. Do not use ohmmeter, in the testing resistance into the ignition

circuit, if battery connected, other wise the meter will be damaged.
2. Always connect the battery to ground if negative white to live wire if

positive, do not invert the connection. Otherwise the harness will be
burnt or affected.
3. Always shield the ignition circuit harness with electrical tape or

flexible hose wires if required.
46
4. Provide fuse for the ignition circuit.
5. Eye terminal of every end wires, must be soldered properly in order

to ensure the contact between terminal points is good.
6. Avoid open wires, unshielded wires and overloaded terminals within

the circuit.
7. Avoid using jumper wire or short circuiting of parts, otherwise those

components will be busted.
LO 6. Perform ignition wiring installation
A. Checked ignition system components safely with 100

the use of ohmmeter.
 With 95-100% standard of specifications.
 75% standard of specifications.
 50% below.
B. Checked ignition system safely with the used of

voltmeter.
 50% below.
47
C. Performed wiring installation of ignition
circuit/system safely.
 50% below.
Total=100
Learning Outcome 7. Perform Ignition Timing
1. Ignition Timing procedure is applied per engine requirement

2. Ignition timing is checked per ignition specifications
3. Safety measures are applied
Resources

By: Crouse/ Anglin
By: James E. Duffy
Toyota Corporation
48
Learning Outcome 7: Perform ignition timing
 Read the operation sheet no.11

1. Interpret the ignition timing. under LO7.
 See the operation sheet no.12under

2. Perform the initial ignition timing. LO7.
 See the operation sheet no.12 under

3. Perform the process of setting the
LO7.
base of the ignition timing.
 See the operation sheet no.12 under

4. Follow the safety measures in LO7.
performing ignition timing.
LO 7. PERFORM IGNITION TIMING
TITLE: PERFORM IGNITION TIMING
CONDITION:
 Rags
 White chalk
Tools
 Box wrenches
Equipment
 Engine mock-up
49
 Vehicle
 Ignition timing light
 Dwell meter
 Tachometer
Procedure in performing the initial ignition timing
1. Prepare the supplies, materials, tools and equipment

needed.
2. Piston no. 1 TDC the compression stroke, timing mark
coincide, aligned.
Note: Before installing distributor to the engine adjust the
contact point to the correct specified contact point
gap or set point to specification.
3. Set the contact point ready to open or just beginning to
open.
4. Install rotor and cap arrange high-tension wire in cap
according to the firing order.
5. Run engine and check timing with power timing light at
idling speed.
Note: To determine the contact point it is about to
open
a) Spark test method b) Ignition timing light
Dwell angle or Cam angle

The time in degrees by which contact point remain
closed for the magnetic built up of ignition coil.
50
Ignition Timing: Type initial setting in order the spark will reach
spark gap at the right time.
Interpreting ignition timing – is the delivery of spark from the coil to the
spark plug at the proper time for the power stroke relative to the piston
position. Usually expressed in crankshaft degrees before or after top dead
center (TDC) at the end of the compression stroke.
LO 7. PERFORM IGNITION TIMING
TITLE: PERFORM IGNITION TIMING
CONDITION:
 Rags
 White chalk
51
Tools
 Box wrenches
Equipment
 Engine mock-up
 Vehicle
 Ignition timing light
 Dwell meter
 Tachometer
Procedure in performing the setting base ignition timing.
NOTE: Use a stroboscopic timing light to check the timing.

Follow these steps for ignition timing adjustment.]
2. Connect the timing light, and start the engine.
3. The engine must be idling at the manufacturer’s recommended rpm

end all other timing procedures must be followed.
4. Aim the timing light marks at the timing indicator, and observe the
timing marks. Compare this reading to the manufacturer’s
specifications. For example if the specification reads 10 degrees
before top dead center and the reading found is 3 degrees before
top dead center, the timing is retarded or off by 7 degrees.
5. If the timing mark is not at the specified location, rotate the

distributor until the mark is at the specified location.
6. Tighten the distributor hold-down bolt to the specified torque, and

recheck the timing mark position.
7. Connect the vacuum advance hose and any other connectors,

hoses, or components that were disconnected for the timing
procedure.
8. Road testing in the highways.
9.
a) Timing marks illuminated by a timing light and
showing 10 degrees BTDC.
52
b) Timing marks at 3 degrees BTDC.
c) The timing light flashes every time the number 1

spark plug fires.
53
SAFETY MEASURES IN PERFORMING IGNITION TIMING
1. Do not puncture cables or nipples with test probes. This will ruin
the cables of ignition timing light.
2. Do not point laser flashes of stroboscopic light to any body due to
the strong ultraviolet rays, especially to eyes.
3. Keep off your hands to the rotating parts of the engine in
performing the test.
4. Remove necklace, rings, and watches or wear suitable working
uniform in conducting the ignition timing with stroboscopic light.
5. See to it that the test probes of timing light and other connections
are tight, set and connected correctly.
6. Always use the manual as your guide for the adjustment.
7. Be sure your concentration is given fully to the job in performing
gasoline ignition timing.
LO 7. Perform ignition timing
B. Performed initial ignition timing safely using only a 100

pair of tools.
 95-100% of all the steps.
 75% only of the steps.
 50% only of the steps.
Total=100
C. Performed setting base ignition timing safely with

the used of stroboscopic timing light, dwell meter, 100
and tachometer.
 95-100% of all the steps
 75% only of the steps
 50% only of the steps
Total=100
54
Learning Outcome 8. Repair Non-electronic Ignition System and/or

Component
1. Parts and components of non-electronic ignition system are identified

and located.
2. Ignition system/components are repaired without causing any damage
on them.
Resources

By: Crouse/ Anglin

By: James E. Duffy
Toyota Corporation
55
Learning Outcome 8: Repair non-electronic ignition system and or
component
1. Perform the maintenance,  See the operation sheet no.13 under

servicing, and repairing of the LO8.
ignition system components.
2. Perform electrical testing and  See the operation sheet no.13 under
checking. LO8.
3. Perform mechanical inspection,  See the operation sheet no.13 under
maintenance and repair. LO8.
4. Perform the installation and  See the operation sheet no.13 under
adjustment of distributor LO8.
assembly.
5. Diagnosing non-electronic ignition  See the operation sheet no.13 under
system. LO8.
6. Follow safety measures in
maintaining and repairing the non-  See the operation sheet no.13 under
electronic ignition system. LO8.
LO 8. REPAIR NON-ELECTRONIC IGNITION SYSTEM AND/OR
COMPONENT
TITLE: Repairing non-electronic ignition system and/or
Component
CONDITION
 Rags
 Paint brush
 Soldering lead
56
 Wire
 Fine sand paper
Tools
 Set of box wrenches

 Pliers
 Volt meter
 Soldering iron/gun
Equipment
 Ignition system mock-up

 Running engine with complete ignition system
 Vehicle
Procedure in maintaining, servicing, and repairing for ignition system

components.

2. Repair wiring harness if needed; for burn, loose, cut wires and
wires not shielded with electrical tape. Rewire if necessary the
circuit with a wire flexible hose.
3. Inspect and repair the spare parts such as; ignition switch, ballast
resistor, ignition coil, distributor component assembly; a. contact
point b. condenser c. spring d.cam lobe e. rotor distributor cap
and g. distributor insulated terminal. High tension wires and spark
plugs.
4. Check, inspect mechanical parts and check, Test Electrical parts
using ohmmeter tester.
IGNITION SYSTEM COMPONENT
a. Electrical Testing Procedures:
TESTING IGNITION SWITCH
Ohmmeter tester selector switch to RX1, the

hand will move from infinity to zero, on
ignition switch to Position click two.
AM
ACC
ST
IGN
57
RX1
TESTING BALAST RESISTOR
Ohmmeter tester switch to RX1 test prod as

shown
external resistor resistance
1.3 – 1.7 Ω (Reference only)
see manual.
TESTING COIL RESISTANCE
Ohmmeter Tester Switch to R X 10k test

prod as shown
w/o resistor type 6.0 – 9.0 k Ω
w/ resistor type 9.5 – 14.5 k Ω (Reference Only)

see manual.
TESTING PRIMARY COIL RESITANCE
Ohmmeter Tester Switch to RX1 test prod as

shown
w/o resistor type 2.6 – 4.0 Ω

(Reference Only)
w/ resistor type 1.3 – 1.6 Ω
To be sure see manual.
Note: If the reading is not within the specified

résistance, replace coil.
58
TESTING INSULATION RESISTANCE
VOM Tester switch to RX10M Ω at 500V –
Test Prod as shown
Insulation resistance over 10M Ω at 500V.
TESTING HIGH TENSION WIRES
Ohmmeter tester switch to RX100K Ω
Resistance less than 25K Ω
To be sure see manual
Note: If the reading exceeds the limit replace the

cord.
TESTING CONDENSER
VOM tester switch to RX1 Ω
Test prod as shown
The hand of the meter will move abrupt then back

to infinity.(∞)
Note: If hand does not move replace the condenser.
RX1
59
TESTING DISTRIBUTOR TERMINAL INSULATION
Ohmmeter Tester Switch to RX1. Test Prod

connection as shown.
If contact point opens hand of the meter remain

infinity. ∞
Note: If hand move to zero O the insulation of the

terminal is broken.
RX1
Ohmmeter Tester Switch to RX1 Test Prod

connection as shown.
If contact point close. Hand of the meter will move

from infinity ∞ to zero O.
Note: The condition is normal.
RX1
b. Mechanical Inspection and repair procedures
Distributor Cap
Inspect for cracks, carbon tracks, burnt or corroded

terminals, and check center contact for wear.
60
Distributor Rotor
Inspect for cracks, carbon tracks, burnt or corroded

terminals.
Breaker Plate
Check breaker plate for smooth rotation.
Governor weights and pin
Check the fitting portions of governor weights with

support pins for binding.
Vacuum Advancer Diaphragm
Suck the tube with mouth. The diaphragm should

move.
Note: If it does not move, replace the diaphram.
61
Cam and Shaft
Inspect cam for wear, damage, and fit between cam

and shaft.
Governor Shaft and Housing
1. Check shaft thrust clearance.

Thrust clearance 0.15-0.5mm
(0.006-0.020in)
2. Remove Gear and Pin
Grind off the pin end, then remove the pin

and gear.
3. Inspect governor shaft for wear and

damage.
62
4. Inspect housing bushings, and O ring for
wear, deformation, and damage.
5. Assemble washers in order as shown.
6. Assemble washers and gear in order as

shown and check thrust clearance. If it
exceeds specified value, adjust the
clearance with steel washer.
7. Peen both pin ends with a vise Inspect for the

following Items. Clean or replace plugs if
necessary.
63
1. Cracks or damages in the threads or
insulator.
2. Damaged or deteriorated gaskets.
3. Wear on the electrodes.
4. Burnt condition of electrode and amount of

carbon deposit.
Check the plug gap with plug gap gauge. If not to

specified value, adjust by bending the ground
(outer) electrode.
Spark plug 0.8 mm (0.031in) for Japan
1.0 mm (0.039in) for USA

Refer Manual
c. Installation and adjustment of distributor assembly components

procedures;
Install governor springs in the direction as shown.
64
Install breaker points and adjust the gap.
Point gap 0.45mm (0.018in)
Set the octane selector at standard line.
B. Diagnosing Non-Electronic Ignition Component
1. Causes of Ignition Failures
Ignition failure results from normal wear of the contact points,

sparkplugs, and other components. Ignition failure can be
classified under three headings.
a. Loss of energy in the primary circuit due to defective.
a. Resistance in the primary circuit due to defective leads,

bad connections, burned distributor contact points or
switch, or open coil primary.
b. Points not properly set.
c. Discharged battery or defective alternator.
d. Defective condenser (shorted, low insulation resistance,
high series resistance).
e. Grounded primary circuit in coil, wiring, or distributor.
b. Loss of energy in the secondary circuit.
a. Plugs fouled, broken, or out of adjustment.

b. Defective high-voltage wiring, which allows high voltage
leaks.
65
c. High-voltage leakage across coil head, distributor cap, or
rotor.
d. Defective connections in high-voltage circuits.
e. Defective ignition coil
c. Out of time
a. Timing not set properly

b. Distributor bearing or shaft worn, or shaft bent.
c. Vacuum advance defective.
d. Centrifugal advance defective.
e. Pre-ignition, due to plugs of wrong heat range, fouled
plugs. Etc.
2. Quick checks of Ignition System.
a. Engine does not run. If the engine cranks at normal speed but
does not start, the trouble could be in either the ignition or the
fuel system. To check the ignition system, disconnect the lead
from one spark plug (or from the center distributor-cap terminal).
Use insulated pliers to hold it about 3/16 inch [4.76 mm] from the
engine block. Crank the engine. If a good spark occurs, chances
are that the ignition system is in reasonable condition (although
the timing could be off). If no spark occurs, check the ignition
system further.
Connect a test ammeter into the ignition-coil primary circuit,

and watch it while cranking the engine. If there is a small, steady
reading that fluctuates somewhat, the primary circuit is probably
all right. The trouble is probably a defective coil secondary or
secondary leads, a defective condenser, or high-voltage leakage
across the cap, rotor, or coil head.
If the ammeter shows a fairly high a steady reading:
1. The contact points are out of adjustment.

2. The condenser is shorted.
3. The coil primary circuit is grounded.
If there is no ammeter reading, the primary circuit is open.
This could be due to out-of-adjustment contact points, a loose
connection, defective wiring or switch, or an open coil primary
winding.
b. Engine misses. Missing is caused by such defects in the

ignition system as:
a. Worn or out-of-adjustment contact points.

66
b. Defective condenser.
c. Centrifugal or vacuum advance malfunctioning.
d. Defective secondary wiring.
e. Defective ignition coil.
f. Poor connections.
g. High-voltage leakage across ignition-coil head, rotor, or
cap.
h. Defective spark plugs.
The wrong ignition coil for the engine, or reversed connection

to the ignition coil, may also cause misfiring. Putting a battery in
backwards can also cause misfiring, because this also reverses the
polarity of the coil.
c. Overheating and Spark. These conditions may be caused by

Improper Ignition Timing.
3. Ignition Troubles Various troubles that will occur mostly to the

NON-ELECTRONIC IGNITION SYSTEM COMPONENT.
a. Burned or oxidized contact points. It is normal for ignition-

distributor contact points gradually to burn away over a long
period of time. Rapid burning or oxidizing of the points may be due
to several conditions.
 Excessive resistance in the condenser circuit caused by

high series resistance in the condenser or by a loose
mounting or connection.
 High voltage produces by a high-voltage-regulator setting.
 Dwell angle is too large (point opening too small). If the
points, are too closed it will burned rapidly.
 Weak spring tension that causes the contact points to
bounce and arc.
 Oil or crankcase vapors entering the distributor housing are
deposited on the pint surfaces, causing them to burn
rapidly. A glance at the breaker plate usually discloses this
condition. It causes a black smudge on the breaker plate
under the points. Clogged engine crankcase PCV valves or
hoses and worn distributor bearings can produce this
trouble.
b. Sooty, burned, or cracked spark-plug insulator. Spark plugs
may fail for a variety of reasons. Spark-plug manufacturers
usually recommend replacement of spark plugs at 10,000 mile
[16,090-km] intervals. This will help prevent failure and maintain
the engine at food operating efficiency. One cause of spark plug
67
trouble is the installation of plugs o f the wiring heat caused by
careless installation of the plug or by careless adjustment of the
plug gap.
Spark plug visual check
Condition is good if none of the following

defects are present.
1. Cracks or damages in the threads or

insulator.
2. Wear on the electrodes.
3. Damaged or deteriorated gaskets.
4. Burnt condition of electrode and
undesirable carbon deposit.
C. Safety Measures in Repairing Ignition Component Parts.
1. In pulling out the high tension cord from the

spark plug, grip it properly the end of plug cord
then, pull suddenly the cable.
2. Match 15 mark with stopper, fit on the cam and

tighten with screw.
3. Remove with care the high tension cable by

way of pulling the rubber boat.
68
4. Do not bend cords that will cause the
conductor be broken.
5. Used insulated pliers or non-conductive pliers in

conducting spark test for ground.
6. Wires, Cord, Cables, Resistance, Capacitance,

Fuses and switches for shorts, Ground, open
wrenches and continuity as well.
7. Do not use any kind of cleaning solvents

for cleaning the spark plugs. Use only
the recommended spark plug cleaner.
Cleaning
1. Do not use spark plug cleaner longer

than necessary.
2. Blow off cleaning compound and
carbon on the threads thoroughly
with air.
3. Clean off dirt from the outer surface
of insulator and threads 69
LO 8. Repair non-electronic ignition system and/ or component
A. Repaired, maintained and serviced safely the 100

ignition system parts and components.
 90-94% standard of specifications.
Total=100
70
Answer Key
LO1
1. contact point
2. breaker point type
3. rotor
4. ignition switch
5. ignition resistor
6. distributor
7. breaker less type
8. ignition coil
9. condenser
10. spark plugs
LO3
1. negative terminal
2. oil in the coil
3. soft iron core
4. primary coil winding
5. secondary coil winding
71
ACKNOWLEDGMENT
First Published May 2008

Development Workshop conducted at the Development of the Philippines on
May 5-10, 2008.
Technology Teachers:
TEAM LEADER: GEORGE CALLANTA
Members : ROBERT DOMINGO
JOHN DIEGO
LINO OLIT
ROMEO IBLOGUIN
NELSON SENEDO
ENGLISH : BELEN TADO
72
Facilitator: Beatriz Adriano

Education.
REFERENCES AND FURTHER READING:
Modern Automotive Service and System

James E. Duffy
Basic Automotive Service and System

Jay Webster
Automotive Mechanics
10th Edition
William Crouse and Donald Anglin
Manufacturer’s Manual
Toyota Corporation
73

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Republic of the Philippines

Unit of Competency: SERVICE AUTOMOTIVE BATTERY

Module No.: 1 Module Title: Servicing Automotive Battery

How to Use this Module ………………………………………….. i

Learning Outcome 1 ………………………………………………… 1

Welcome to the Module “Servicing Automotive Battery”. This module

Recognition of Prior Learning (RPL)

Unit of Competency: SERVICE AUTOMOTIVE BATTERY

Module Title: Servicing Automotive Battery

This module contains information and suggested learning activities on

Completion of this module will help you understand the succeeding

This module consists of four (4) learning outcomes. Each learning

Upon completing this module, report to your teacher for assessment. If

SUMMARY OF LEARNING OUTCOMES

Upon completion of the module, you should be able to:

LO1. test Automotive Battery;

Refer to assessment criteria of learning outcomes 1-4 of this module.

BATTERY CELL the active unit of the battery

BATTERY LEAKAGE TEST use to determine if current is discharging

BATTERY TERMINAL TEST checks for poor electrical connections between

BATTERY TERMINALS terminals at the battery to which the positive and

BATTERY CHARGER an equipment use to charge battery capacity given in

ELECTROLYTE the liquid mixture of about 40% sulfuric acid and 60 %

Unit of Competency: Service Automotive Battery

Module Title: Servicing Automotive Battery

Learning Outcome 1: Test Automotive Battery

1. Battery is tested to avoid damage to any workplace property or vehicle.

Learning Outcome 1: Test Automotive Battery

Learning Activities Special Instructions

1. Read the attached information  Answer the self-check without

TITLE: BATTERY CONSTRUCTION AND PRINCIPLE OF OPERATION

The Automotive battery supplies electric current to operate the

The battery is an electro chemical device which uses chemicals to

Below are two types of automotive batteries. On the left, caps

Fig. 1 Two types of Automotive Battery (left) ordinary wet

Fig. 2 Parts of Automotive Battery

WORKING SAFELY AROUND BATTERIES

1. The sulfuric acid in the electrolyte is very corrosive. It will eat

4. Never lean over a changing battery.

5. Do not charge a frozen battery for maintenance-free battery

SELF – CHECK No.1

LO 1. TEST AUTOMOTIVE BATTERY

________2. The battery performs the following EXCEPT

________3. When working around the battery be sure to;

________4. A type of battery which do not have removable cups.

TITLE: Testing the battery

TOPIC: 2 WAYS OF TESTING THE BATTERY

Two types of Hydrometer:

Ball hydrometer is similar to the ball type coolant hydrometer. Put

PRECAUTION: Do not drip electrolyte on the car or on yourself.

1.265 -1.299 Fully charged battery

Relationship between specific gravity and state of charge.

Specific gravities and freezing temperatures for battery

SELF CHECK No. 2

LO 1. Test Automotive Battery

_________1. This type of hydrometer which is similar to bal type coolant

_________2. A type of hydrometer which the state of charge marks on the

_________3. The indication if the battery is in full charge in using ball

OPERATION SHEET No. 1

TITLE: TESTING AUTOMOTIVE BATTERY USING

1. Remove all battery vent caps.

Unit of Competency: Service Automotive Battery

Module Title: Servicing Automotive Battery

Learning Outcome 2: Remove and Replace Batteries

1. In disconnecting the battery the correct tools to be used is.

2. The tool to be used to clamp the battery is _.

4. To disconnect the battery first __.