Professional Documents
Culture Documents
Automotive Y3
Automotive Y3
Department of Education
PUBLIC TECHNICAL-
VOCATIONAL
TABLE OF
CONTENTS
Page
Learning Outcome 1
…………………………………………………
Learning Experiences/ Activities
……………………….. 1
Information Sheet 1
……………………………………….. 2
Self Check 1 …
………………………………………………. 4
Information Sheet 2
……………………………………….. 5
Self Check 2….
………………………………………………. 6
Operation Sheet 1...
……………………………………….. 7
Learning Outcome 2….
………………………………………………
Learning Activity
……………………………………………. 10
Information Sheet 1
……………………………………….. 11
Self Check 1….
………………………………………………. 12
Operation Sheet 1...
……………………………………….. 13
Learning Outcome 3….
………………………………………………
Learning Experiences/ Activities
……………………….. 17
Information Sheet 1
………………………………………. 18
Self Check 1….
………………………………………………. 19
Learning Outcome 4….
………………………………………………
Learning Experiences/ Activities
……………………….. 20
Operation Sheet 1...
……………………………………….. 21
Assessment Performance
………………………………… 23
Assessment Performance
………………………………… 24
Answer Key
………………………………………………….. 25
HOW TO USE THIS MODULE
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
INTRODUCTION:
ASSESSMENT CRITERIA
ii
TECHNICAL TERMS:
BATTERY HOLD DOWNS brackets that secure the battery to the chassis of
the vehicle.
iii
iv
Program/Course: Automotive Servicing
Assessment Criteria
Resources
• Automotive Mechanics, 10th Edition
By: Crouse Anglin
• Automotive Electricity, Electronics and Computer Controls
By: Barry Hollembeak
LEARNING EXPERIENCES/ACTIVITIES
1
operation sheet LO 1.
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.
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.
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
3
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. 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.
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
4
d. A and B
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
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.
SPECIFIC GRAVITY
STAGE OF CHARGE
5
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
Directions: On the blank provided for, write the correct letter of your choice.
6
_________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
_________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
d.) None of the above
Procedure:
The teacher will discuss the procedure with the student with the aid of
pictures and actual battery.
7
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.
8
Program/Course: Automotive Servicing
Assessment Criteria
1. Battery is removed and replaced to avoid damage to any work place property
or vehicle.
Resources
9
• Automotive Mechanics, 10th Edition
By: Crouse Anglin
• Automotive Electricity, Electronics and Computer Controls By:
Barry Hollembeak
LEARNING EXPERIENCES/ACTIVITIES
10
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.
• Return demo
Topic 1:
11
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.
12
Title : Removing and Replacing Battery
Directions: On the blank provided for write the correct letter of your choice.
______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
13
OPERATION SHEET No.1
Condition
• Apron
• Gloves
• Soda solution
Tools
• Box wrench(12x13)
• Screw drivers
• Lifting clamp
Equipment
• Engine mock-up
• vehicle
PROCEDURE:
14
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.
4. Use the terminal puller to remove the cable from the terminal. Do not pry
the cable off the terminal.
15
Fig 9 Separate negative cable
6. Loosen the clamp bolt for the positive cable and use the terminal puller to
remove the cable.
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.
16
Fig 12 Remove battery out from the tray
9. Transport the battery to the bench. Keep it away from your clothes.
Assessment Criteria
17
3. Battery and its terminals are cleaned.
Resources
LEARNING EXPERIENCES/ACTIVITIES
18
INFORMATION SHEET No. 1
Slow Charge: The battery is given a charge of a few amperes for several hours.
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.
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
19
The charge rate required to recharge a battery depends on several
factors:
Direction: On the blank before each number write the correct letter of your
choice.
20
b.) disconnect the positive cable
c.) A and B
d.) None of the above
Assessment Criteria
2. Jumper leads are selected and used to ensure spark protection which is
employed when necessary.
Resources
21
• Automotive Electricity, Electronics and Computer Controls By:
Barry Hollembeak
LEARNING EXPERIENCES/ACTIVITIES
CONDITIONS
Tools
• Wrenches
• Pliers
Equipment
PROCEDURE
22
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.
23
ASSESSMENT PERFORMANCE
Workmanship/Performance Points
35 - Exemplary
25 - Adequate
10 – Need improvement
24
10 – Tools is not suitable for the job
TOTAL SCORES
ASSESSMENT PERFORMANCE
Workmanship/Performance Points
35 - Exemplary
25 - Adequate
10 – Need improvement
25
10 – Some of the work maybe incomplete/misdirected
TOTAL SCORES
ANSWER KEY
No. 1
1. b
2. c
3. a
4. a
No. 2
26
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
It is a great privileged that this endeavour was given by the Task Force
TechVoc, Department of Education to the following participants of the
27
“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
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
Division of City Schools, Manila
28
Romhel C. Odtohan
Teacher I (ENGLISH)
AFG Bernardino Memorial Trade School
Lias, Marilao, Bulacan
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
Division of City Schools, Manila
29
English:
Belen L. Tado
Tagum National High School
Tagum, Davao del Norte
Facilitator:
Beatrice A. Adriano
E. Rodriguez Vocational HS
Encoder
Rowena S. Fonacier
30
Republic of the Philippines
Department of Education
PUBLIC TECHNICAL-
VOCATIONAL
0
TABLE OF CONTENTS
Page
1
HOW TO USE THIS MODULE
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.
2
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.
INTRODUCTION:
ASSESSMENT CRITERIA
PREREQUISITES
TECHNICAL TERMS
BACK UP LIGHTS a light that illuminates the back of the car when the
transmission is shifted in reverse.
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.
PARKING LIGHTS a light that marks the front of a parked vehicle and to
mark the front of a vehicle if a headlamp fails.
4
SHORT CIRCUIT an unwanted electrical path; sometimes this path goes
directly to ground.
5
Program/Course: Automotive Servicing
Assessment Criteria
Resources
1
LEARNING EXPERIENCES/ACTIVITIES
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.
3
Fig. 16 Components of lighting system
4
Head Lamp Switch- is an on/off switch and rheostat in the dash panel
or on the steering column.
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___________
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
5
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.
6
Fig. 21 (a) off position (b) on position of stoplight switch
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
8
circuit with a voltmeter, or test light, check those components that
can be easily accessed first.
9
SELF CHECK No. 1
_______ 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
CONDITIONS:
• Automotive wires
10
Tools
• Electrical Pliers
• Long nose plier
• Test light
• Screw Driver
Equipment
• Battery 12 volts
• Electrical mock-up/Vehicle
Plan/Working Drawing
PROCEDURE
2. Connect a wire to the lamp specified as the back-up light to the backup
switch found on the transmission.
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.
7. Connect the negative terminal of the battery to the ground a part of the
vehicle.
11
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 EXPERIENCES/ACTIVITIES
12
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.
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.
SELF-CHECK No. 2
13
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.
______ ___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:
• Automotive wires
Tools
• Electrical Pliers
• Long nose plier
• Test light
• Screw Driver
Equipment
• Battery 12 volts
• Electrical mock-up/Vehicle
Plan/Working Drawing
PROCEDURE
2. Connect a wire to the lamp specified as the back-up light to the backup
switch found on the transmission.
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.
7. Connect the negative terminal of the battery to the ground a part of vehicle body.
15
OPERATION SHEET NO. 2
CONDITIONS:
Equipment:
• Battery (12 volts)
• Electrical mock-up/Vehicle
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.
2. This type of replacement usually requires the removal of the bezel.( The
bezel is the retaining trim around a component)
16
3. Remove the retaining ring screws and the retaining trim. Do not turn
the two headlight aiming adjustment screw.
6. Check the wire connector for corrosion or other foreign materials. Clean
as needed.
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.
Workmanship/Performance POINTS
35 – Functional
25 – Not Functional
10 – None Functional
TOTAL SCORE
18
Program/Course: Automotive Servicing
ASSESSMENT CRITERIA:
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.
Resources
19
LEARNING EXPERIENCES/ACTIVITIES
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.
21
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.
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
22
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.
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.
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:
23
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.
24
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.
25
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.
26
7. Remove screw from the cap.
27
9. Remove the end frame.
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.
28
12. Remove snap ring from the shaft.
29
15. Remove bushing with a hammer and a special service tool (SST)
30
Fig. 29 Component parts of starter motor.
BRONZE BUSHING
ARMATURE
31
FIELD COIL ASSEMBLY
PEAR HOUSING
SHIFT LEVER
MAGNETIC SWITCH
32
CARBON BRUSH HOLDER
CARBON BRUSH
THROUGH BOLTS
Commutator Tests
PERFORMANCE CRITERIA
Workmanship/Performance POINTS
34
Quality of Work with application of safety measures
35 – Functional
25 – Not Functional
10 – None Functional
TOTAL SCORE
ASSESSMENT PERFORMANCE
Workmanship/Performance Points
35 – Exemplary
25 – Adequate
10 – Need improvement
35
B. Accuracy of Performance under specified time limit
TOTAL SCORES
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.
36
3. Voltage drops are measured by connecting a voltmeter
Direction: On the blank provided for, write the correct letter of your choice.
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
37
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
Direction: Select the one correct, best or most probable answer to each
question.
38
d. lock switch
4. A solenoid is an electromagnetic switching __________.
a. Device
b. Gadget
c. Tools
d. equipment
Answer Key
LO1
No. 1
1. d – dome light
2. c – dimmer switch
3. b – stoplight
4. a – transmission
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
39
1. a
2. b
3. a
4. c
5. d
1. b
2. d 3. a
4.
ACKNOWLEDGMENT
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
40
Romeo DQ. Ibloguin
E. Rodriguez Vocational HS
Sta. Mesa, Manila
Nelson C. Señedo
Tagum National High School
Tagum, Davao del Norte
English:
Belen L. Tado
Tagum National High School
Tagum, Davao del Norte
Facilitators:
Encoder:
Rowena S. Fonacier
4. Manufacturer’s Manual
By: Toyota Corporation
41
Republic of the Philippines
Department of Education
0
TABLE OF CONTENTS
Page
How to Use this Module ………………………………………….. i
Introduction……………………………………………………………. ii
Technical Terms …………………………………………………….. iii
1
Operation Sheet 1... ……………………………………….. 25
This module contains training materials and activities for you to complete.
2
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 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
INTRODUCTION:
TECHNICAL TERMS
5. Ground side the portion of the circuit that is from the load
component to the negative side of the source.
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.
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.
5
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.
6
Program/Course: Automotive Servicing NC I
ASSESSMENT CRITERIA:
Resources
1
Learning Activities Special Instructions
2
INFORMATION SHEET No.1
The ignition system feeds high voltage surge to the spark plugs at
proper time. The three major functions are:
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
B. BREAKERLESS TYPE
4
Topic 3. PARTS AND FUNCTIONS OF THE IGNITION SYSTEM
5
4. Ignition Coil the ignition system component that set as
a transformer to step up(increase) the battery voltage into
many thousands of volts.
6
8. Condenser connected across the contact point to prevent
arcing and burning. It also provides the storage of
electricity when breaker point is open.
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.
9
Topic 7. SERVICING IGNITION SYSTEM COMPONENTS
SELF-CHECK
Direction: Identify and fill-in the blanks with the correct answer. Write your
answers on a separate sheet.
10
_______________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.
ASSESSMENT CRITERIA:
11
2. Spark test is conducted in accordance with standard testing
procedures.
3. Safety measures are applied in accordance with standard testing
procedure.
Resources
12
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.
Conditions:
• Rug cloth
• Sand paper
Tools
• Screw Driver
• Insulated Pliers (special tool)
• Spark Plug wrench
• Feeler Gauge
Equipment
• Engine
• Battery Charger
• Mock – up
Procedure:
13
1. Prepare the supplies, materials, tools and equipment 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.
14
OPERATION SHEET No. 2
Conditions:
• Rug cloth
• Sandpaper
• Soft brush nylon
• Functional battery
• Functional starter motor
Tools:
Equipment
• Functional vehicle
• Functional engine mock –up
• Battery charger
3. Disconnect the spark-plug cable from the spark plug one by one
while the engine is running.
16
OPERATION SHEET No. 3
Conditions:
• Rug cloth
• Sandpaper
• Soft brush nylon
• Functional battery
• Functional starter motor
Tools
Equipment
• Functional vehicle
• Functional engine mock –up
• Battery charger
17
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
the finding of the primary circuit and parts are in good service
condition.
18
SAFETY MEASURES IN SPARK TEST/TRIGGERING TEST.
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.
19
1. Reading the Patterns
ASSESSMENT PERFORMANCE
Workmanship/Performance Points
20
With 95-100% standard of specifications. All spark
plugs are spark tested correctly
ASSESSMENT CRITERIA:
Resources
22
Topic 1. FUNCTIONS OF IGNITION COIL
1. Soft iron core is the center of the Ignition coil, a laminated soft
iron or steel.
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
aircooled, 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).
23
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.
24
Self-check
3. __________It is the center of the ignition coil, a laminated soft iron or steel.
Conditions:
• Ball pen/pencil
• Bond paper
Tools
• Pliers
• VOM
• Multi tester
Equipment
25
• Engine mock-up
26
b. With the 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.
27
Note: If the reading does not meet
within the range of minimum and
maximum in the secondary coil
opened.
Workmanship/Performance Points
50
29
ASSESSMENT CRITERIA:
Resources
1. Check and test the resistance of • See the operation sheet no.5.
ballast resistor.
Conditions:
• Ball-pen/pencil
• Bond paper Tools:
• Box wrench
30
• Screw driver
• VOM tester
• Multi-tester
• Screw drive Equipment:
• Ignition mock-up
• Engine mock-up
31
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
ASSESSMENT PERFORMANCE
Workmanship/Performance Points
32
A. Checked safely the ballast resistor, when it is not
connected from the coil as per requirements. 50
33
Module Title: Servicing Ignition System
ASSESSMENT CRITERIA:
Resources
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
LO 5
2. Perform the adjusting contact point
when the distributor assembly
remove from the engine.
• Read the operation sheet no.7.under
3. Follow the safety measures in LO 5
adjusting contact point.
34
Conditions:
• Sand paper
• Rags
• Grease
Tools
Equipment
• Ignition mock-up
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.
Conditions:
• Sand paper
• Rags
• Grease
Tools
36
Equipment
• Ignition mock-up
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.
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)
37
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.
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.
38
ASSESSMENT PERFORMANCE
Workmanship/Performance Points
39
Total=100
ASSESSMENT CRITERIA:
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
40
Learning Outcome 6: Perform Ignition Wiring Installation
41
OPERATION SHEET No. 1
Conditions
Tools:
• Electrical pliers
• Set of screwdriver
• Wire stripper
• Soldering iron Equipment:
• Engine mock-up
• Vehicle
42
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.
43
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.
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)
44
OPERATION SHEET No. 2
Conditions
2. Connect the voltmeter positive lead to the positive terminal of the ignition
coil. Connect the negative lead to engine ground.
45
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.
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).
a. Battery condition
b. Ignition switch resistance
c. Excessive resistance in the ballast resistor circuit.
46
Note: In this ignition circuit the teacher
will demonstrate using voltmeter
Conditions:
47
• 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:
1. Prepare the supplies, materials, tools and equipment needed.
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
48
SAFETY MEASURES IN WIRING INSTALLATION
49
ASSESSMENT PERFORMANCE
Workmanship/Performance Points
50% below.
50% below.
Total=100
50
Program/Course: Automotive Servicing NC I
ASSESSMENT CRITERIA:
Resources
51
• Read the operation sheet no.11
1. Interpret the ignition timing. under LO7.
CONDITION:
• Rags
• White chalk
Tools
• Box wrenches
• Set of screw drivers
Equipment
• Engine mock-up
• Vehicle
• Ignition timing light
• Dwell meter
• Tachometer
52
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
Ignition Timing: Type initial setting in order the spark will reach
spark gap at the right time.
53
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.
CONDITION:
• Rags
54
• White chalk
Tools
• Box wrenches
• Set of screw drivers
Equipment
• Engine mock-up
• Vehicle
• Ignition timing light
• Dwell meter
• Tachometer
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.
56
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.
ASSESSMENT PERFORMANCE
Workmanship/Performance Points
57
Total=100
Total=100
ASSESSMENT CRITERIA:
Resources
Component
CONDITION
• Rags
• Paint brush
• Soldering lead
• Wire
• Fine sand paper
Tools
Equipment
60
IGNITION SYSTEM COMPONENT
ACC
ST
IGN
see manual.
61
TESTING PRIMARY COIL RESITANCE
62
Ohmmeter tester switch to RX100K Ω
TESTING CONDENSER
The hand of the meter will move abrupt then back to infinity.
(∞)
RX1
63
Ohmmeter Tester Switch to RX1. Test Prod
connection as shown.
Distributor Cap
64
Distributor Rotor
Breaker Plate
65
Check the fitting portions of governor weights with support pins for binding.
66
Governor Shaft and Housing
and gear.
67
5. Assemble washers in order as
shown.
68
1. Cracks
or
3. Wear
on
the
electrodes.
69
Check the plug gap with plug
gap gauge. If not to
specified value, adjust by bending the ground
(outer) electrode.
70
Set the octane
selector at standard
line.
71
e. Pre-ignition, due to plugs of wrong heat range, fouled
plugs. Etc.
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.
72
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.
73
Condition is good if none of the following
defects are present.
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.
74
4. Do not bend cords that will
cause the
conductor be broken.
75
Cleaning
ASSESSMENT PERFORMANCE
Workmanship/Performance Points
76
Total=100
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 ACKNOWLEDGMENT
Technology Teachers:
77
TEAM LEADER: GEORGE CALLANTA
JOHN DIEGO
LINO OLIT
ROMEO IBLOGUIN
NELSON SENEDO
Manufacturer’s Manual
Toyota Corporation
79