INFORMATION SHEET

Gasoline Engine Tune Up

Objective: After reading this information sheet, you must be able to performed Engine
Ignition System Servicing.
Purpose of Ignition System
The purpose of the ignition system is to ignite the compressed air-fuel mixture in
the engine combustion chambers. This should occur at the proper time for combustion
begin. To start combustion, the ignition system delivers an electric spark that jumps a
gap at the combustion- chamber ends of the spark plugs. The heat from this arc ignites
the compressed air-fuel mixture. The mixture burns, creating pressure through
explosion in the chamber that pushes the pistons down the cylinder so the engine runs.
The ignition system may be either a contact point ignition system or an electronic
ignition system. The ignition system includes the battery, ignition switch, ignition coil,
distributor, contact point, condenser, secondary wirings, and spark plugs.

Ignition Switch High Tension Cable

Ignition Coil

Distributor
1. Cap
2. Rotor Arm
3. Contact
Point
4. Condenser
5. Vacuum
Advance
6. Distributor
Assembly

Components of Contact Point Ignition System

1. Ignition Switch – The Ignition Switch connects the ignition coil to the battery when
the ignition key is on. When the key is turned to start, the starting motor cranks
the engine for starting.
2. Ignition Coil – The ignition coil serves as the step-up transformer that raises the
battery voltage to a high voltage that may reach 25,000 volts or more up to
47,000 volts. The high voltage causes sparks to jump the gap at the spark plugs.
The ignition system consists of two separate but related circuits: the low voltage
primary circuit and the high voltage secondary circuit. The ignition coil has two
windings. The primary winding of a few hundred turns of heavy wires is a part of
the primary circuit. The secondary winding of many thousands turns of fine wires
is part of the secondary circuit. When the ignition key is on and the contact point
closed, current flows through the primary winding. This produce a magnetic field
around the primary windings in the coil.
When the contact point open, current flow stops and the magnetic field
collapses. As it collapses, it cuts across the thousands of turns of wires in the coil
secondary winding. This produces a voltage in each turn. These add together to
produce the high voltage delivered through the secondary circuit to the spark
plugs.

3. Distributor – the distributor has to function. First, it has a set of contact points or
breaker points that work as a fast-acting switch. When the points close, current
flows through the coil. When the points open, current flow stop and the coil
produces a high voltage surge. A condenser connects across the points. It aids in
the collapse of the magnetic field and helps reduce arcing that burns away the
points. Second, the distributor distributes the high voltage surges to the spark
plugs in the correct firing order delivers the high voltage from the coil to the
center terminal of the distributor caps. Inside the cap, is a rotor on the top of the
distributor shaft. The distributor shaft is driven from the engine camshaft by a pair
of spiral gears. The rotor has a metal blade. One end of the blade contacts the
center terminal of the distributor cap.
When the rotor turns, the other ends passes close to the outer terminals in
the distributor cap. These are connected by high tension cables to the spark
plugs. The high voltage surge jumps the small gap from the rotor blade to the
terminals. The high tension cables carry the high voltage surge to the spark plug
in the cylinder that is ready to fire.
4. Contact Point – The contact point set mounts on a breaker plate in the distributor.
The points are operated by a breaker cam on top of the distributor shaft. The
cam has the same number of lobes as there are cylinders in the engine. As the
cam revolves and the points close and open, they act as mechanical switch to
make and break the primary circuit.
One contact point mounts on the grounded breaker plate and is stationary.
The other point mounts on the end of an insulated movable arm. The arm swings
back and forth on a pivot as the cam lobes push on the rubbing block to open the
points. A spring attached to the movable point arm closes the points.
When the points close, this connect the coil primary winding to the battery.
A magnetic field builds up in the coil. As the breaker cam rotates, the next lobe
pushes the movable arm away from the stationary contact point. This opens the
points and stop the current flow. The magnetic field collapses and a high voltage
surge results. The length of time in degrees of distributor shaft rotation that the
contact points remained close is the dwell. The distance that separates the points
when they are fully open is the gap. Points are normally adjusted by dwell or gap
measurements.
The distributor shaft and cam are driven by the engine camshaft which
turns at one-half crankshaft speed. It takes two complete revolutions of the
crankshaft to rotate the distributor shaft one complete revolution.

The relationship between piston position and spark plug firing is ignition timing.

5. Spark Plugs – The spark plug has a metal outer shell enclosing a ceramic
insulator. Centered in the insulator is the center electrode which carries the high
voltage current from the ignition coil. Ground electrode attaches to the metal shell
and is bent inward to produce the proper spark gap. The gap varies from 0.035
inch (0.9 mm) for contact point ignition system to 0.080 inch (2.03 mm) for some
electronic ignition system. The spark jumps from the center electrode to the
ground electrode. The wider the gap, the higher the voltage required to jump it.
Spark plugs may have a suppressor or resistance built into the center
electrode. It reduces television and radio interference (static) caused by the
ignition system. Spark plugs may require gaskets when installed to assure a leak
proof seal. Many engines use spark plugs with tapered seats which seal without
a gasket. Some spark plug thread are coated with an anti-seize compound. This
makes plugs removal easier, especially from aluminum cylinder heads.
 Some engines have two spark plugs in each combustion chamber. Both
plugs may fire together or one slightly ahead of the other. The additional plugs
help reduce exhaust emissions and increase engine power.
Most spark plugs have electrodes made of nickel and chrome alloys that resist
corrosion. Some ground and lower center electrodes have a copper core. Others
also have a thin-wire platinum tip. These foul and misfire less often, last longer,
and have a greater heat range than other plugs.

6. Condenser – condenser serves as capacitor connected across the contact point to reduce
arcing by providing a storage place for electricity (electrons) as the contact points open.

7. Battery – battery is an electrochemical device for storing energy in chemical form so that it
can be release as electricity for cranking the engine and powering the electrical load.
 Amaya School of Home Industries

Sahud-Ulan, Tanza, Cavite

G11-Automotive Servicing NCI

Name: __________________________________ Date: ________________

Gr & Sec. ________________________________

Job sheet # 1

Valve Tappet Clearance

I. Objective:
Check/inspect and adjust valve tappet clearance

II. Tools and Materials:

Box wrench 12, 14, 19 mm Spark Plug Wrench

Flat screw driver Feeler Gauge

Rachet

Rag Gasoline

III. Procedure

1. Prepare all the tools and materials needed.

2. Open the valve cover.
3. Set piston no. 1 compression stroke firing position 0 degree in timing mark.
4. Check/inspect and adjust valve clearance using feeler gauge.
Note: .08 for intake valve
.12 for exhaust valve
5. By following the firing order repeat step no. 1 to no.3 no. 4 and no. 2.
6. Cover the valve and tighten the bolts.

IV. Table

5 3 1
1. Proficiency 5 3 1
2. Accuracy 5 3 1
3. Completeness 5 3 1
4. Safety 5 3 1
Total 20
 Amaya School of Home Industries

Sahud-Ulan, Tanza, Cavite

G11-Automotive Servicing NCI

Name: __________________________________ Date: ________________

Gr & Sec. ________________________________

Job sheet # 2

SPARKPLUG CHECKING AND TESTING

I. Objective
Test and adjust sparkplug

II. Tools and Materials

Spark Plug Wrench Feeler Gauge

Rachet Sand Paper
Rag New Set of Spark Plugs

III. Procedure

1. Prepare all the tools and materials needed

2. Remove the sparkplug one by one using sparkplug wrench
3. Check the gap and adjust according to specification using feeler gauge. (18mm)
4. Return the sparkplug properly according to their sparkplug hole.
5. Connect the high tension wire by following the firing order 1-3-4-2.

IV. Table

5 3 1
1. Proficiency 5 3 1
2. Accuracy 5 3 1
3. Completeness 5 3 1
4. Safety 5 3 1
Total 20
 Amaya School of Home Industries

Sahud-Ulan, Tanza, Cavite

G11-Automotive Servicing NCI

Name: __________________________________ Date: ________________

Gr & Sec. ________________________________

Job sheet # 3

CHECKING/REPLACING FUEL FILTER & AIR CLEANER

I. Objective
Check/replace fuel filter and air cleaner

II. Tools and Materials

Set of Screw Drivers Set of Combination Wrench

New fuel filter New Air Cleaner Filter Element
Rag

III. Procedure

1. Prepare all the tools and materials needed.

2. Locate the fuel filter.
Note: Location of the fuel filter depends on the model of the engine
3. Loosen the filter hose clamp up and down.
4. Install a new fuel filter. Connect/ tighten the filter hose clamp.
5. Remove the air cleaner
6. Replace it by installing a new element.

IV. Table

5 3 1
1. Proficiency 5 3 1
2. Accuracy 5 3 1
3. Completeness 5 3 1
4. Safety 5 3 1
Total 20
 Amaya School of Home Industries
Sahud-Ulan, Tanza, Cavite

G11-Auto Servicing NCI

Name: __________________________________ Date: ________________

Gr & Sec. ________________________________

Job Sheet # 4
INSPECT/ REPLACE CONTACT POINT & CONDENSER

I. Objective:

Check/inspect and replace contact points and condenser

II. Tools and Materials

New sets of breaker points New Condenser

Feeler Gauge Set of Screw Drivers
Vehicle service manual Rag
Running condition vehicle or mock-up

III. Procedure
1. Prepare all the tools and materials needed.
2. Remove the distributor cap, you will find there are two springs.
3. Insert a screw driver between each clip and then simply lifts off, do not remove the
spark plug wires from the distributor cap.
4. Remove the rotor by pulling it straight up off the distributor shaft.
5. Remove the plastic dust cover by lifting it off the distributor.
6. Remove the old contact point, you will see there is a screw that holds the points, you
will see that.
7. Loosen and remove these screw, unplug the wire from the points from the black plastic
plug that is connected to, just pull it straight off.
8. Now withdraw the points and they are fitted/excessively worn, replace them, but if they
are still in good condition, keep them as your spare for an emergency.
9. Remove the condenser, the condenser or outside the distributor. There is one screw
may hold the condenser on itself. And there is another which holds the black plastic plug
of the distributor body both of these screw are readily accessible so remove them and
the little metal plug clip and then remove the condenser and plug from the distributor.

IV. Table

5 3 1
1. Proficiency 5 3 1
2. Accuracy 5 3 1
3. Completeness 5 3 1
4. Safety 5 3 1
 Total 20

Amaya School of Home Industries

Sahud-Ulan, Tanza, Cavite

G11-Auto Servicing NCI

Name: __________________________________ Date: ________________

Gr & Sec. ________________________________

Job Sheet # 5
CHECK AND ADJUST DISTRIBUTOR SETTING

I. Objective:

Check and adjust distributor setting

II. Tools and materials

Box wrench 12, 14, 19mm Feeler Gauge
Timing Light Set of Screw Drivers
Rachet Battery
Rag Gasoline
Mock-up Running condition

III. Procedure
1. Prepare all the tools and materials needed.
2. Set piston no. 1 Top dead center compression stroke firing position.
3. Mount the distributor assembly by setting rotor at 1 o’clock timing.
Note: Oil pump slot must be set also at 1’ o clock timing and the distributor vacuum
advancer is parallel to the engine cylinder.
4. Turn the distributor assembly counter clockwise until contact point is about to open.
5. Lock the distributor assembly by placing the hold down clamp and tighten the hold
screw.
6. Place the distributor cap.
7. Connect the high tension wires by following engine firing order and ignition timing.
(1-3-4-2)

V. Table

5 3 1
1. Proficiency 5 3 1
2. Accuracy 5 3 1
3. Completeness 5 3 1
4. Safety 5 3 1
Total 20
 Amaya School of Home Industries
Sahud-Ulan, Tanza, Cavite

G11-Auto Servicing NCI

Name: __________________________________ Date: ________________

Gr & Sec. ________________________________

Job Sheet # 6
IGNITION TIMING

I. Tools and Materials

Box Wrench 12, 14, 19 mm Rachet

Timing Light Feeler Gauge
Flat Screw Driver Battery
Rag Gasoline
Mock-up

II. Procedure
1. Prepare all the tools and materials needed.
2. Set piston no.1 TDC compression stroke firing position.
3. Mount the distributor assembly by setting rotor at 1 o’clock timing.
Note: Oil pump slot must be set also at 1 o’clock timing and the distributor vacuum
advancer parallel to the engine cylinder block.
4. Turn the distributor assembly counter clockwise until the contact point beginning or
about to open.
5. Lock the distributor assembly by placing the hold down clamp and tightening the hold
down screw.
6. Place the distributor cap.
7. Connect the high tension wire by following engine firing order (1-3-4-2).
8. Test ignition timing by starting the engine.

III. Table

5 3 1
1. Proficiency 5 3 1
2. Accuracy 5 3 1
3. Completeness 5 3 1
4. Safety 5 3 1
Total 20
PERFORMANCE CRITERIA CHECKLIST NO.

LEARNING ACTIVITIES