CCAS 3382 - Automotive Skills 2

VEHICLE BASIC ELECTRIC

AND
PRACTICAL NOTES
DISTRIBUTOR, SPARK PLUGS, IGNITION CABLES
AND IGNITION COIL

PREPARED by: BR. RETHAUDDIN ABDUL HAMID

Introduction
This basic electrical training gives us a deeper understanding on the electrical system in the cars engine.
It includes knowledge on distributor, ignition coil, spark plug and spark plug cables (wires).
Without the electrical system, whole engine cannot be operated. Electrical system is very essential for
the engine to be turned on. In this case, the ignition coil will generate very high DC voltage of electricity and
distribute by distributor to the each cylinder to burn the fuel mixed thru-by the spark plug. Then the spark will
burned the fuel mixed in each cylinder by following the correct timing then enables the engine to run. The
distributor will distribute the electricity to the determined cylinder (in certain sequence) through the spark plug
cable.
II. Name of Parts with Illustration
1. Distributor

2.
Distributor cap
3. Spark Plug

Rotor

Contact Point

A spark plug by NGK

4. Ignition Coil

A BOSCH ignition coil

5. Spark Plug Wire/ Cable

III. Working System and Function

1. Distributor
The distributor takes on several roles in the car.
One of its jobs is to distribute the high voltage from the coil to the correct cylinder/timing, which is a
rather complex process. The job is completed all based off of a cap and rotor.
The coil is connected to the rotor, which spins inside of the cap. As the rotor spins past a series of
contacts, one contact per cylinder, the tip of the rotor passes each contact. After passing each contact
there is a high-voltage pulse that comes from the coil.
The pulse then arcs across the small gap between the rotor and the contact. The ending result is the
distributor distributing the high voltage from the coil to the correct cylinder.
The distributor contains:
A rotating cam which runs off the engines drive
A set of breaker points
A condenser
A rotor
A distributor cap.
2. Spark Plug
The spark plug is quite simple in theory: It forces electricity to arc across a gap, just like a bolt of
lightning. The electricity must be at a very high voltage in order to travel across the gap and create a
good spark. Voltage at the spark plug can be anywhere from 40,000 to 100,000 volts.
3. Ignition Coil
The ignition coil consist of two transformer windings that share a common magnetic core primary and
secondary windings. For an ignition coil, one end of the windings of both the primary and secondary are
connected together. This point is connected to the battery. The other end of the primary is connected to
the points within the distributor. Then the other end of the secondary is connected, via the distributor cap
and rotor, to the spark plugs.

The sequence of the ignition firing begins with the points (or the contact breaker) closed. A current will
flow from the battery, through the current limiting resistor, then through the coil primary and across the
closed breaker points and the finally back to the battery. This current produces a magnetic field within
the coils core. This magnetic field will form the energy reservoir that will be used to drive the ignition
spark.
4. Spark Plug Cable
Spark plug cable will bring the electricity flow from the distributor to the correct cylinder. The
electricity will be brought to the spark plug to burn the gasoline.
IV. Changing or Replacement Steps
1. Distributor
Here is the procedure to remove the distributor cap, There about 14 steps to remove the distributor:
i.

remove the bolt holding the air intake resonator to the intake manifold

ii.

loosen clamps holding air cleaner cover to air cleaner housing

iii.

remove PCV make-up air hose from air inlet tube

iv.

loosen hose clamp at throttle body

v.

remove air inlet tube, resonator and air cleaner cover

vi.

remove EGR tube

vii.

remove spark plug cable from distributor cap

viii.

loosen distributor cap hold down screws and remove cap

ix.

note and mark (on air intake plenum?) position of rotor and

x.

remove rotor

xi.

remove two harness connectors from distributor

xii.

remove two sets of distributor hold down nuts and washers

xiii.

remove bolt and spark plug cable mounting bracket from top of distributor housing

xiv.

remove bolt and transmission dipstick tube

carefully

xv.

remove distributor from engine

To Replace Contact Point:

i.

Install rotor on shaft

ii.

Position distributor in engine.

iii.

Make certain that the O-ring is properly seated on the distributor. If O-ring is cracked or nicked replace
with a new one.

iv.

Carefully engage distributor drive with slotted end of camshaft. When the distributor is installed
properly the rotor will be in line with previously scribed line on air intake plenum. If engine was
cranked we will have to get TDC on 1st cylinder, etc (write back for further instruction...)

v.

install distributor hold down washers and nuts, tighten to 9 ft-lbs

vi.

install spark plug cable bracket

vii.

install two harness connectors

viii.

install distributor cap

ix.

install spark plug cables onto distributor cap, the cap and the cables are numbered be sure all wires are
firmly in place in the cable tours install transmission dipstick tube install EGR tube to intake manifold
tighten bolts to 8 ft-lbs
2. Spark Plug
We'll need the following tools to replace a spark plug:

ratchet wrench

12-inch socket extension

spark plug socket for our car

1. We need to locate the spark plug.

2. We need to remove the spark plug cable in its order.
3. Put spark plug socket and the extension on the ratchet. If we look inside the spark plug socket, we
should see some black foam or rubber on the inside end. This is important, because it holds onto the
spark plug while we maneuver it in and out of the engine.
4. With our ratchet wrench set to loosen (that's counter-clockwise) slide it over the end of the plug, being
sure to push it on as far as it will go. Now remove the old plug.
5. Install the new spark plug.
6. Repeat the steps in reverse order.

3. Ignition Coil
1. After testing the coil, remove the bracket hold-down bolts or screws and remove the coil and bracket
from the vehicle.
2. Loosen the retaining bolts from the coil bracket and remove the coil.
3. Compare the old and new coil to ensure correct replacement.
4. Install the new coil into the coil bracket.
5. Place the coil and bracket into its mounting position and reinstall the hold-down bolts or screws.
6. Reconnect the primary ignition wires. Place a small amount of dielectric tune-up grease in the coil wire
boot and reinstall it into the coil secondary tour.
7. Remove the tape from the wires.
8. Connect the negative battery cable to the battery. Start the engine and test drive the vehicle to ensure
correct replacement.
4. Spark Plug Cable
Basically we just need to remove the old ones and replace with the new ones according to the cylinder
number.
V. Price and Labor Charge
Price and labor charge for the replacement of distributor, spark plugs, ignition coils and spark plug (ignition)
cables depend on the brand/type of the cars, the type of the engine, the engine configuration itself, the
originality of the parts and the warehouse of garage that we do the replacement. Different brands and places
will give us different figures.
For Proton Cars 1.3 it is about rm300 for the part and rm40 to rm50 for the labor charges.