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 …………………………………….. 3
Self Check 1.1 ………………………………………………. 10
Information Sheet 2 …………………………………….. 11
Self Check 2.1 ………………………………………………. 14
Operation Sheet 1... ……………………………………….. 14
Performance Criteria ………………………………………. 18
Learning Outcome 2 ………………………………………………… 19
Learning Experiences/ Activities ……………………….. 20
Operation Sheet 1... ……………………………………….. 20
Operation Sheet 2... ……………………………………….. 23
Performance Criteria ………………………………………. 26
Learning Outcome 3 ………………………………………………… 27
Learning Experiences/ Activities ……………………….. 28
Operation Sheet 1... ……………………………………….. 28
Performance Criteria ………………………………………. 34
Operation Sheet 2 ……………………………………...….. 35
Performance Criteria ………………………………………. 38
Learning Outcome 4 ………………………………………………… 39
Learning Experiences/ Activities ……………………….. 40
Operation Sheet 1 ……………………………………...….. 40
Performance Criteria ………………………………………. 42
Learning Outcome 5 ………………………………………………… 43
Learning Experiences/ Activities ……………………….. 44
Operation Sheet 1 ……………………………………...….. 44
Performance Criteria ………………………………………. 46
Learning Outcome 6 ………………………………………………… 47
Learning Experiences/ Activities ……………………….. 48
Information Sheet 1 ………………………………………. 48
Operation Sheet 1... ……………………………………….. 49
Performance Criteria ………………………………………. 51
Learning Outcome 7 ………………………………………………… 52
Learning Experiences/ Activities ……………………….. 52
Information Sheet 1 …………………………………….. 53
Operation Sheet 1.. ……………………………………….. 56
Self Check 1.1 ………………………………………………. 57
Performance Criteria ………………………………………. 58
Learning Outcome 8 ………………………………………………… 59
Learning Experiences/ Activities ……………………….. 60
Information Sheet 1 …………………………………….. 61
Self Check 1.1 ………………………………………………. 62
Answer key ………………………………………………….. 63
 HOW TO USE THIS MODULE

Welcome to the Module “Perform Gas Engine Tune Up”. This module
contains training materials and activities for you to complete.
The unit of competency “Perform Gas Engine Tune Up” 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.
 Program/Course AUTOMOTIVE SERVICING

Unit of Competency Perform Gas Engine Tune Up

Module Performing Gas Engine Tune Up

INTRODUCTION:

This module contains information and suggested learning

activities on Performing Gas Engine Tune Up. It includes instructions and
procedure on how module on Applying appropriate sealant/adhesive.

Completion of this module will help you better understand the

succeeding module Perform Diesel Engine Tune Up.

This module consists of eight (8) learning outcomes. Each learning

outcome contains learning activities supported by instruction sheets. Before
you perform the instructions, read the information sheets and answer the self-
check and activities provided to ascertain to yourself and your instructor that
you have acquired the knowledge necessary to perform the skill portion of the
particular learning outcome.

Upon completing this module, report to your instructor for assessment

to check your achievement of knowledge and skills requirements of this
module. If you pass the assessment, you will be given a certificate of
completion.

SUMMARY OF LEARNING OUTCOMES:

Upon completion of the module the trainees/students should be able to:

LO1 Check/adjust valve clearance

LO2 Inspect/test spark plug
LO3 Check/Replace Fuel Filter and Air Cleaner
LO4 Inspect/replace contact points/condenser
LO5 Adjust engine idle speed and mixture
LO6 Test/adjust dwell angle and ignition setting
LO7 Check advance mechanism and adjust ignition timing
LO8 Conduct compression test

ASSESSMENT CRITERIA:
 Refer to assessment criteria of learning outcomes # 1-8 of this module.
Terms and Definitions

Accumulator - A gas filled pressure Electrical load - The working device

chamber that provides hydraulic of the circuit.
pressure for ABS operation. Electromagnetism - A form of
Ammeter - A test meter used to magnetism that occurs when
measure current draw. current flows through a conductor.
Analog - A voltage signal that is Field current draw test - Diagnostic
infinitely variable or can be test that determines if there is a
changed within a given range. current available to the field
Battery terminal test - Checks for windings.
poor electrical connections Floor jack - A portable hydraulic tool
between the battery cables and used to raise and lower a vehicle.
terminals. Use a voltmeter to Fuse - A replaceable circuit protection
measure voltage drop across the device that will melt should the
cables and terminals. current passing through it exceeds
Bench test - A term used to indicate its rating.
that the unit is to be removed from Fusible link - A wire made of meltable
the vehicle and tested. material with a special heat-
Brushes - Electrically conductive resistant insulation. When there is
sliding contacts, usually made of an overload in the circuit, the link
copper and carbon. melts and opens the circuit.
Circuit - The path of electron flow Ground - The common negative
consisting of the voltage source, connection of the electrical system
conductors, load component, and that is the point of the lowest
return path to the voltage source. voltage.
Commutator - A series of conducting Grounded circuit - An electrical
segments located around one end defect that allows current to return
of the armature. to ground before it has reached the
Conductor - A substance that is intended load component.
capable of supporting the flow of Ground side - The portion of the
electricity through it. circuit that is from the load
Continuity - Refers to the circuit component to the negative side of
being continuous with no opens. the source.
Current - The aggregate flow of Growler - Test equipment used to test
electrons through a wire. One starter armatures for shorts and
ampere represents the movement grounds. It produces a very strong
of 6.25 billion electrons (or one magnetic field that is capable of
coulomb) past one point in a inducing a current flow and
conductor in one second. magnetism in a conductor.
Current draw test - Diagnostic test Hydrometer - A test instrument used
used to measure the amount of to check the specific gravity of the
current that the starter draws electrolyte to determine the
when actuated. It determines the battery's state of charge.
electrical and mechanical Insulator - A substance that is not
condition of the starting system. capable of supporting the flow of
Magnetism - An energy form electricity.
resulting from atoms aligning Jack stands - Support devices used to
within certain materials, giving the hold the vehicle off the floor after it
materials the ability to attract has been raised by the floor jack.
other metals. Lamp - A device that produces light as
Ohm - Unit of measure for resistance. a result of current flow through a
One ohm is the resistance of the filament. The filament is enclosed
conductor such that a constant within a glass envelope and is a
current of one ampere in it type of resistance wire that is
produces a voltage of one volt generally made from tungsten.
between its ends. Series-parallel circuit - A circuit that
Ohmmeter - A test meter used to have some loads in series and some
measure resistance and continuity in parallel.
in a circuit. Short - An electrical fault that allows
Ohm's law - Defines the relationship for electrical current to bypass its
between current, voltage and normal path.
resistance. Solenoid - An electromagnetic device
Open circuit - A term used to that uses movement of a plunger to
indicate that current flow is exert a pulling or holding force.
stopped. By opening the circuit, Splice - The joining of single wire
the path for electron flow is ends or the joining of two or more
broken. electrical conductors at a single
Overload - Excess current flow in a point.
circuit. State of charge - The condition of a
Parallel circuit - A circuit that battery's electrolyte and plate
provides two or more paths for materials at any given time.
electricity to flow. Valve clearance - The measured gap
Relay - A device that uses low between the end of the valve stem
current to control a high current and the rocker arm, cam lobe or
circuit. Low current is used to follower that activates the valve.
energize the electromagnetic coil, Voltage - The difference or potential
while high current is able to pass that indicates an excess of
over the relay contacts. electrons at the end of the circuit
Resistance - Opposition to current the farthest from the electromotive
flow. force. It is the electrical pressure
that causes electrons to move
through a circuit. One volt is the
amount of pressure required to
move one amp of current through
one ohm of resistance.
Program/Course : Automotive Servicing NC I

Unit of Competency : Perform Gas Engine Tune Up

Module title : Performing Gas Engine Tune Up

Learning outcome 1 : Check/adjust tappet valve clearance

ASSESSMENT CRITERIA:

1. Valve tappet clearance is set.

2. Checking and adjustment is performed.

REFERENCE:

1. Auto Mechanics, Theory and Service

by: de Kryger, Kobacik. Bono

2. Corolla, Service and Repair Manual

2 by: Gregory’s Scientific Publication
3
3. Lancer, Service and Repair Manual
by: Gregory’s Scientific Publication

4. Toyota Training Manual

by: Toyota

5. VHS/CD

6. Corolla, Owners Manual

by: Toyota
LEARNING EXPERIENCES/ACTIVITIES

Learning Outcome # 1: Adjust Valve Clearance

Learning Activities Special Instructions

1. Perform engine operation and  Check your answer to answer key

test equipment and answer self
check.

 See your teacher for guidance

2. Perform, check and adjust valve  Complete the task
clearance.
 INFORMATION SHEET 1

Engine Test Equipment

TOPIC 1

Quick and accurate diagnosis and service of the engine require the use
of various test instruments and gauges. These will show if the battery, starting,
charging, fuel ignition and emissions systems are operating properly. They
would also indicate the mechanical condition of the engine.

1. Tachometer – Electric or optical

tachometers are used in the shop. The
electric tachometer connects to the
engine primary circuit. The tach counts
the number of times per second the
primary circuit opens and closes. The
optical tachometer has a light beam
focused on a rotating part such as the
engine crankshaft pulley. The tach
counts how many times per second a
mark on the pulley passes by. (A) INSTRUMENT-PANEL
TACHOMETER

2. Dwellmeter – The dwellmeter

electrically measures how long the
contact points remains closed during
each ignition cycle of a contact-point
ignition system. The average for all
cylinders is then displayed in degrees of
distributor-cam rotation. The technican
can also use the dwellmeter to set
contact-point gap and to check for (B) SHOP TACHOMETER
unwanted dwell variation as engine (DWELL-TACH)
speed increases. Excessive variation
indicates mechanical trouble in the Figure 1. Instrument-panel and
distributor. shop tachometers that measures
crankshaft speed or engine rpm.
 In electronic ignition systems, the ECM
controls dwell. It is not adjustable. The
dwellmeter is used to check the duty
cycle of the mixture-control solenoid in a
feedback carburetor.

A dwell-tachometer is a single meter

that serves as both a dwellmeter and a
tachometer. This is possible because
both meters have two leads and require
the same connections. Pushing a button
or turning a knob on the meter switches Figure 2. Dwellmeter showing the
the reading from rpm to dwell. scales for eight, six and four
cylinder engines (Sun Electric
Corporation).

3. Cylinder Compression Tester – The

cylinder compression tester measures
the ability of the cylinders to hold
compression while the starting motor
cranks the engine. The compression
tester is a pressure gauge that measures
the amount of pressure or compression,
built-up in the cylinder during the
compression stroke. How well a cylinder
holds compression is an indication of Figure 3. Using a cylinder
the condition of the piston, piston rings, compression tester. (Toyota
cylinder wall, valves and head gasket. Motor Sales, USA, Inc.)

4. Cylinder Leakage Tester – The

cylinder leakage tester checks
compression but in a different way.
It applies air pressure to the
cylinder with the piston at TDC on
the compression stroke. In this
position, the engine valves are
closed. Very little air should escape
from the cylinder if the engine is in
good condition.

Figure 5. Cylinder leakage tester. The

whistle is used to locate TDC in
number 1 cylinder. (Sun Electric
Corporation)
5. Engine Vacuum Gauge – The
engine vacuum gauge measures
intake-manifold vacuum. The
intake-manifold vacuum changes
with the load on engine defects.
The way the vacuum varies from
normal indicates what could be
wrong inside the engine. Before
making the test, check that all
vacuum hoses are properly
connected and not leaking. Make
a backpressure test if a restricted
exhaust system is indicated.

Connect the vacuum gauge to the

intake manifold. Start the engine
and run it until it reaches normal
operating temperature. Then note
the vacuum reading at idle and
other speeds, as described below.
Figure 8 shows the meaning of Figure 6. The cylinder-leakage tester
various vacuum-gauge readings. applies air pressure to the cylinder
Common vacuum-gauge readings through the spark-plug hole with the
are described below. piston at TDC and the valves-closed.
Places where air is leaking can then be
located. (Sun Electric Corporation)
6. Exhaust Gas Analyzer – The
exhaust gas analyzer measures the
amount of various gases in the
exhaust. There are two main types:
a. Two-gas analyzer that measures
HC and CO.
b. Four-gas analyzer that measures
HC, CO, O2 and CO2

Figure 9. Four-gas type of exhaust-

gas analyzer connected to tailpipe to
test the exhaust gas. (ATW)

Figure 10. Two-gas type of exhaust-

gas analyzer, which measures only
hydrocarbons (HC) and carbon
monoxide (CO). (Chrysler Corporation)

Note: An exhaust gas analyzer can also be used to check for exhaust-gas
leakage into the cooling system. Figure 11 shows the exhaust-gas analyzer
being used to locate fuel or fuel-vapor leaks.
7. Four-Gas Analysis – Combustion
at the stoichiometric ratio of
14.7:1 provides maximum
conversion efficiency. This results
in minimum tail pipe emissions of
HC and CO. Figure 12 shows the
relationship among the four gases Figure 11. Suggested test specifications
measured by the four-gas for testing exhaust emissions.
analyzer. Each gas and its
readings are described below.

Figure 12. Relationship among the four

gases measured by the four-gas
analyzer. (Sun ElectricCorporation)
8. Cylinder-Balance Test – The
cylinder –balance test determines if
each cylinder in a running engine
produces the same amount of
power. Disabling a cylinder should
cause a change in engine speed.
The change should be about the
same for all cylinders.
Connect a tachometer to the
engine. Then disable the cylinder.
This is done by shorting the spark
plug or disconnecting each fuel
injector in a port-injected engine.
Note the tach reading. Repeat the
test on each cylinder. All cylinders Figure 13. All cylinders are
are contributing the same amount contributing to the same amount of
of power if the rpm drops are the power if the tachometer shows that
same. Weaker cylinders show less all rpm drops are the same as each
of rpm change. Shorting or cylinder is disabled. (Sun Electric
disabling a dead cylinder causes no Corporation)
change in rpm.
9. Engine Analyzer – An engine
analyzer combines several testers,
meters and gauges into a single
piece of portable shop equipment.
When connected to the vehicle, the
analyzer provides quick and
accurate testing and diagnosis of
various engine and vehicle systems.
Most shop engine analyzers include
an oscilloscope. It displays voltage
patterns of the ignition system and
electronic fuel injectors. Some
computerized analyzers include a
second screen. This displays
information needed by the
technician, such as steps in a test
procedure or the test results. The
analyzer may have a printer to
provide a written report.

Figure 14. Engine analyzer that

includes an oscilloscope for displaying
ignition voltages. (Sun Electric
Corporation)

10. Service-Bay Diagnostic Computer – Some new-car dealerships and

other service-bay diagnostic computer in Figure 15. This is a computerized
engine-and-exhaust gas analyzer with additional capabilities. Ideally, the
system enables the vehicle to tell the computer what is wrong. Then the
system instructs the technician on how to make the needed repairs.
Many of these computers have a touch-sensitive screen. The technician first
enters the vehicle identification number then the technician answers a
series of yes-no questions about how the vehicle is equipped. The
technician connects the computer to the diagnostic connector on the
vehicle.

11. Dynamometer – the chassis dynamometer measures engine power and

vehicle speed under various operating conditions. The vehicle is driven onto
two rollers so the drive wheels can spin the rollers. The rollers drive a power
absorber which is usually under the floor. The vehicle remains stationary,
but the engine and other components operate the same as on a road test.
Meters on a console report wheel speed and torque or power.
 SELF-CHECK No. 1

Multiple-Choice Test

Select the correct answer to each question. Write the letter in your test
notebook.

1. When connected to the engine, the tachometer measures

a. engine torque
b. engine rpm
c. engine compression
d. engine vacuum
.
2. After the engine is at normal operating temperature, the first step in
using the compression tester is to:
a. disconnect the battery
b. adjust engine idle speed
c. remove the spark plug
d. shift the transmission into low gear

3.The cylinder leakage tester applies air pressure to the cylinder with the
piston
a. at TDC with both valves closed
b. at BDC with both valves closed
c. starting the compression stroke
e. at TDC with both valves open

4. Technician A says to use tail pipe measurements of HC and CO to check

the operation of the catalytic converter. Technician B says tail pipe
measurements of O2 and CO2 indicate the air-fuel ratio of the mixture
entering the cylinder. Who is right?
f. A only
g. B only
h. both A and B
i. neither A nor B

5. A service-bay diagnostic computer may do the following except

a. automatically perform tests
b. interpret the results
c. show how to correct faults
d. grade the technician’s work
 INFORMATION SHEET No. 2

PRINCIPLE OF ENGINE OPERATION

TOPIC 1. ENGINE CLASSIFICATION BY CYCLES

Piston engine operates on either the two-stroke cycle or the four stroke
cycle. Automotive engines are four-stroke cycle engine. Every fourth piston
stoke is a power stroke, there is power in every two full crankshaft revolution
(720 degrees).

In two-stroke-cycle engine produces twice as many power at the same

crankshaft speed (RPM) as the four-stroke-cycle engine. However, this not
make the two-stroke-cycle engine twice as powerful. In two-stroke-cycle, there
is power in every one full crankshaft revolution 360 degrees.

A. ENGINE OPERATION

The action in the spark-ignition engine can be divided into four parts.
Each part consists of a piston stroke. Piston stroke is the movement of the
piston from BDC to TDC to BDC.

Top Dead Center (TDC) – the highest point reaches by the piston
head.

Bottom Dead Center (BDC) – the lowest point reach by the piston
head.

The complete cycle of events in the cylinder requires four piston strokes.
These are intake, compression, power and exhaust.
CYCLE – means a series of events that repeat themselves.

PISTON PISTON VALVE POSITION DEGREES

STROKE MOVEMENT INTAKE EXHAUST
Intake Downward Open Closed 180
Compression Upward Closed Closed 180
Power Downward Closed Closed 180
Exhaust Upward Closed Open 180

INTAKE – intake value is open, air-fuel mixture flows through

the port and into the cylinder

COMPRESSION – both valve are closed, the upward moving piston

Compresses the air-fuel mixture into a smaller space,
between the top of the piston and cylinder head. This
space is called the Combustion Chamber.

POWER-STROKE- as the piston nears TDC the end of the compression

stroke, an electric spark jumps the gap at the spark
plug. The heat from the spark ignites the compressed
air-fuel mixture, the air-fuel mixture then burns
rapidly, producing high temperature of up to 6000F
(3316C), this high temperatures cause very high
pressure which pushes down on the top of the piston.

EXHAUST STROKE – as the piston approaches BDC on the power-stroke

the exhaust valve opens. After passing through BDC,
the pistons moves up again. The burn gases escape
 through the open exhaust port.

B. VALVE ACTION

In many engines, each cylinder has two valves. One intake valve, the
other is an exhaust valve, some engines have more than two valves; these are
multi-valve engines. They have three, four, five, or six valves for cylinder.

Value train is the series of parts that open and close the valves. The
action starts at the camshaft. The crankshaft drives the camshaft through
gears, sprockets and chain or sprockets and a toothed timing belt, most
camshaft have a cam for each valve in the engine. Each cam is a round collar
with a highest spot or lobe. When the rotating cam brings the cam lobe down
against the top of the bucket tappet, the lobe pushes the tappet down, this
compresses the spring and pushes the value down off its seat. The valve is
open as the cam continues to rotate, the lobe moves away from the tappet.
The spring pushes the tappet and value until the valve seats.
 SELF CHECK No. 2

Fill in the blanks with the appropriate answer.

Direction: Write your answer on your test notebook.

1. The highest point reach by the piston head__________________________.

2. The lowest point reach by the piston head _________________________.

3. Means a series of events that repeat themselves called

_____________________.

4. During intake stroke the piston movement is ____________________ and

the valve is _________________________.

5. During exhaust stroke the piston movement is ______________________

and the valve is _______________________.

OPERATION SHEET 1

ADJUSTING VALVE TAPPET CLEARANCE

Adjust tappet clearance according to specifications. Correct clearance

contributes to quiet engine operation and long valve seat wear. Insufficient
clearance causes the valve to ride open, resulting in lost compression and
burning. Too much clearance retards timing and shortens valve life above seat
preventing maximum intake and exhaust. Check tappet guide clearance.
Sloppy fit permits tappet to strike valve stem off-center, causing side thrust on
valve stem with excessive wear and bad seating.
The valve tappets are removable.
These large, barrel shaped, pressure
lubricated tappets are so designed
that by removing the adjusting
screw, the main body can be lifted
out and replaced from above
through the valve chamber. This
eliminates the costly service
operation of dropping the oil pan
and pulling the camshaft. Locking of
the adjustment is both simple and
effective. Accurate valve tappet
settings materially prolong engine
life and aid performance. In addition
to impairing performance, excessive
clearances are harmful to cams and
tappets as well as to the rest of the
valve mechanism. When clearances Figure LO1-1. Removable Valve Tappet
are too low, the possibility of burned
valves increases.

Check and adjust intake and

exhaust tappets to following
clearances at normal operating
temperature:

Intake - .012"
Exhaust - .020"

Procedures in adjusting valve tappet

clearance:

1. Disconnect and ground the high

tension coil wire to prevent
accidentally starting the engine.

Figure LO1-2. Disconnect high tension

coil wire.
2. Remove the valve tappet cover
from the left side of the
crankcase.

Figure LO1-3. Remove valve tappet

cover.

3. Remove the spark plug from

number one cylinder.

4. Place thumb over the spark plug

opening and slowly crank the
engine until an outward pressure
can be felt. Pressure indicates
number one piston is moving
toward Top Dead Center of the
compression stroke. Continue
cranking until the timing mark
on the flywheel is in center of the Figure LO1-4. Remove #1 spark plug.
flywheel housing timing hole.
Both valves are then closed on
the compression stroke of
number one cylinder.

5. Use two thin wrenches when

adjusting valve clearance. Use
the lower wrench to hold the
tappet and the upper wrench to
raise or lower the tappet
adjusting screw. When the valve Figure LO1-5. Adjusting valve tappet
lash is properly adjusted, the clearance
appropriate feeler gauge should
pass between the tappet and its
corresponding valve stem with a
slight drag
6. Crank the engine one-half
revolution at a time and check
the clearance of each valve;
adjust if necessary. Do this on
each set of cylinder valves in
succession according to the firing
order of the engine, which is 1-3-
4-2.

Figure LO1-6. Checking the valve

clearances.
7. Install new gasket and install
valve tappet cover. Check to see
that the valve cover makes an oil-
tight seal with the crankcase.

Figure LO1-7. New gaskets.

8. Replace the spark plug, spark plug wire and coil wire.
 PERFORMANCE CRITERIA

CHECK /Adjust valve clearance LO 1

SCORING RUBRICS

Assessment Criteria Score

Setting valve tappet 30
 Valve tappet is set with 95-100% accurately 30
 Valve tappet is not set 75% accurately 20
 Valve tappet is not set 10
Checking and adjusting valve clearance 70
 All valve clearance are checked and adjusted with
95% - 100% accurately 70
 Valve clearance are checked and adjusted within
tolerance level 60
 Valve clearances are checked with only 50%
accuracy 50
QUALIFICATION : Automotive Servicing NC I

UNIT OF COMPETENCY : Perform Gas Engine Tune Up

MODULE TITLE : Performing Gas Engine Tune Up

LEARNING OUTCOME 2: Test spark plug

ASSESSMENT CRITERIA:

1. Spark plug clearance is adjusted.

2. Spark plug is tested.

3. Spark plug test result analyzed and appropriate recommendations

are prescribed

REFERENCE:

1. Auto Mechanics, Theory and Service

by: de Kryger, Kobacik. Bono

2. Corolla, Service and Repair Manual

4 by: Gregory’s Scientific Publication
5
3. Lancer, Service and Repair Manual
by: Gregory’s Scientific Publication

4. Toyota Training Manual

by: Toyota

6. VHS/CD

6. Corolla, Owners Manual

by: Toyota

7. Communication Module
LEARNING EXPERIENCES / ACTIVITIES

Learning Outcome # 2: Test spark plug

Learning Activities Special Instructions

1. Perform removing and installing  Read Information Sheet 1

spark plugs.
 Read Operation Sheet 1 “
2. perform gapping the spark plugs.  Follow the procedures in
3. Perform gapping of spark plugs. Operation Sheet 2.
 Complete the task

Operation Sheet No. 1

TEST SPARK PLUG

Supplies and materials

 Sand paper
 Rag
 New set of spark plug

 TOOLS, EQUIPMENT AND MATERIALS:

 Running condition engine

 Vehicle service/repair manual
 Spark plug socket wrench (magnetic) and handle
 Wire gauge, ramp gauge or feeler gauge
 Ignition spark tester
 Spark plug tester
 Removing the Old Spark Plugs

Procedures

1. Pull the hood release lever located under the dashboard.

2. Walk around to the front of the car, reach under the hood, find the latch and
squeeze it. Open the hood.
3. Find the spark plugs, located in a
row along one side of the engine (on
an in-line four-cylinder engine) and
attached to thick wires, called spark
plug wires. Cars with V-shaped
engines (which can have four, six or
eight cylinders) will have spark plugs
and spark plug wires on both sides
of the engine.

4. Change one spark plug at a time,

always putting the plug wire back on
before changing the next spark plug
Warning:
Change one spark plug at a time,
putting the wire back on after you're
done. If you pull all the wires off at
once, you may put them back on the
wrong spark plugs; this changes the
firing order, and your car will run
badly or not at all. If you must take
all the wires off at once, label them
with white correction fluid or with
masking tape and a marker.

5. Pull off one spark plug wire where it

attaches to the plug. There is a little
rubber boot at the plug end of the
wire; pull on this part. Pulling higher
up on the wire can damage the spark
plug wire and cause it to separate.
6. Blow or wipe away any dirt or debris
around the spark plug. You do not
want anything to fall into the
cylinder while the spark plug is out.

7. With the spark plug socket and a

ratchet, remove the spark plug by
turning it in a counterclockwise
direction. You may need an
extension for your ratchet if the
spark plugs are deep-set or not
directly accessible. Ratchets with
flexible heads are especially helpful
for hard-to-reach spark plugs.

8. Check the spark plug to make sure it needs replacing. A good spark plug
should be lightly coated with grayish brown deposits. If heavy deposits are
present, if the spark plug is black or if the electrode or core nose is damaged,
the plug needs to be replaced.

Installing spark plugs

Torque is one of the most critical aspects of spark plug installation. Torque
directly affects the spark plugs' ability to transfer heat out of the combustion
chamber. A spark plug that is under-torque will not be fully seated on the
cylinder head, hence heat transfer will be slowed. This will tend to elevate
combustion chamber temperatures to unsafe levels, and pre-ignition and
detonation will usually follow. Serious engine damage is not far behind.

An over-torque spark plug can suffer from severe stress to the Metal Shell
which in turn can distort the spark plug's inner gas seals or even cause a
hairline fracture to the spark plug's insulator...in either case, heat transfer can
again be slowed and the above mentioned conditions can occur.

The spark plug holes must always be cleaned prior to installation, otherwise
you may be torquing against dirt or debris and the spark plug may actually
end up under-torque, even though your torque wrench says otherwise. Of
course, you should only install spark plugs in a cool engine, because metal
expands when its hot and installation may prove difficult. Proper torque specs
for both aluminum and cast iron cylinder heads are listed below.

Cast Iron Aluminum

Spark plug type Thread Diameter Cylinder Head Cylinder Head
(lb-ft.) (lb-ft.)
Flat seat type (with
18 ø mm 25.3~32.5 25.3~32.5
gasket)
" 14 ø mm 18.0~25.3 18.0~21.6
 " 12 ø mm 10.8~18.0 10.8~14.5
" 10 ø mm 7.2~10.8 7.2~8.7
" 8 ø mm -- 5.8~7.2
Conical seat type
18 ø mm 14.5~21.6 14.5~21.6
(without gasket)
Conical seat type
14 ø mm 10.8~18.0 7.2~14.5
(without gasket)

Steps:

1. Hand-tighten each spark plug in place. If you feel any resistance, stop and
start over to prevent cross-threading.
 
2. Tighten the plugs with a socket wrench until snug. Do not over tighten.
 
3. Replace the spark plug wires. Usually, you will hear a soft pop when the
plug wire snaps onto the plug.
 
4. Start the engine. Listen. If the engine runs roughly or doesn't start, make
sure the wires are pushed all the way onto the new plugs.

OPERATION SHEET No. 2

Gapping the Spark Plug

Procedures:

1. Find the chart listing the proper "gap" for your plugs in your car's repair
manual. The spark plug gap may also be on the sticker on the inside of the
car's hood. The parts store can provide you with this specification as well or
read the basics below.
 
2. Insert the spark plug gapping tool
in the gap between the metal
center electrode and the metal side
electrode of the plug's tip.

3. Look at the tool's ruled edge and

find the gap's measurement. If it is
too big, bend the spark plug's end
with the tool to widen the gap. To
make the gap smaller, push the
side electrode (the metal part at
the very top) against a hard
surface.

4. After adjusting, measure again.

Repeat this procedure until the
gap matches the specification
listed in your car's manual.

 
5. Repeat with each plug.

Note: Spark plug gap specifications are listed in inches and/or millimeters.
The gapper will have inches on one side and millimeters on the other.

Spark Plug Gapping Basics

Since the gap size has a direct affect on the spark plug's tip temperature and
on the voltage necessary to ionize (light) the air/fuel mixture, careful attention
is required. While it is a popular misconception that plugs are pre-gapped from
the factory, the fact remains that the gap must be adjusted for the vehicle that
the spark plug is intended for. Those with modified engines must remember
that a modified engine with higher compression or forced induction will
typically require a smaller gap setting (to ensure ignitability in these denser
air/fuel mixtures). As a rule, the more power you are making, the smaller the
gap you will need.

A spark plug's voltage requirement is directly proportionate to the gap size. The
larger the gap, the more voltage is needed to bridge the gap. Most experienced
tuners know that opening gaps up to present a larger spark to the air/fuel
mixture maximizes burn efficiency. It is for this reason that most racers add
high power ignition systems. The added power allows them to open the gap yet
still provide a strong spark.

 Proper gapping of the spark plug is necessary to get maximum spark

energy, lowest RFI release as well as what is best for the longevity of the
secondary ignition components (coil, cap, rotor, wires, plugs).
 When checking plug gaps, the correct way is to use ONLY wire gauges,
though many of us are using the slider style gapping tools. These flat or
 feeler gauge style gauges do not accurately measure true width of spark
plug gap.
 When increasing the gap size for our high performance applications
utilizing advanced ignition systems such as Mallory, Accel, Jacobs, Crane
and Holley ... it is important never to go more than plus or minus .008".
This is to maintain parallel surfaces between ground and the center
electrodes.
 Something many people do not know is that with Higher Compression
ratios and Superchargers as well as Nitrous, in many cases smaller spark
plug gaps must be used as well as the use of a much hotter ignition system
(see above). These higher cylinder pressures require more energy to jump
the spark plug gap.
 The rule of thumb on plug gaps is to open them up in .002" increments at a
time. When the car (race vehicle) begins to lose power or slow down then go
back .001-.002" and this in most cases is the optimum gap.

Remembering that the Ignition Unit, plug brand as well as heat range, cap
and/or rotor styles and in many cases fuel type or brand will change the
optimum spark plug gap settings.

Lastly, NEVER use the porcelain insulator as a fulcrum point when setting
these gaps. This can cause damage to the spark plug.
 PERFORMANCE CRITERIA

INSPECT/TEST SPARK PLUG LO 2

SCORING RUBRICS

Assessment Criteria Score

Adjusting spark plug clearance to specification 40
 4 spark plugs are adjusted to specification 31-40
 3 Spark plugs are adjusted to specification 20-30
 2-1 Spark plugs are adjusted to specification 10
Testing Spark Plug 40
 4 Spark plugs are tested 31-40
 3 Spark plugs are tested 20-30
 2-1 Spark plugs are tested 10
Apply Safely 20
 No accident 15-20
 Minor accident 10-15
 Major accident 5
Program/Course : Automotive Servicing NC I

UNIT OF COMPETENCY : Perform Gas Engine Tune Up

MODULE TITLE : Performing Gas Engine Tune Up

LEARNING OUTCOME 3: Check/replace fuel filter and air cleaner

ASSESSMENT CRITERIA:

1. Fuel filter and air cleaner are replaced.

2. Fuel filter is free of sediments and impurities.

REFERENCE:

1. Auto Mechanics, Theory and Service

by: de Kryger, Kobacik. Bono

2. Corolla, Service and Repair Manual

6 by: Gregory’s Scientific Publication
7
3. Lancer, Service and Repair Manual
by: Gregory’s Scientific Publication

4. Toyota Training Manual

by: Toyota

7. VHS/CD

6. Corolla, Owners Manual

by: Toyota

7. Communication Module
LEARNING EXPERIENCES

Learning Outcome # 3: Check/replace fuel filter and air cleaner

Learning Activities Special Instructions

1. Perform checking/replacing  Follow the procedures in

fuel filter of a gasoline engine with Operation Sheet LO3-1
the presence of your instructor. “Check/Replace Fuel Filter”

 Follow the procedures in

Operation Sheet LO3-2
“Check/Replace Air Filter”

 See your teacher for guidance

 Complete the assessment tasks.

OPERATION SHEET (LO3)

CHECK/REPLACE FUEL FILTER AND AIR CLEANER

Replacing Fuel Filter

Supplies And Materials

 new fuel filter

 new air filter element
 rag

Tools

Screw driver flat and phillip

1 set combination wrench

Equipment

Running condition vehicle/ Engine mock up

Procedure

1. Rest the vehicle for 24 hours to let any remaining fuel pressure bleed off.

Check valves in the fuel lines are meant to maintain pressure to help
prevent vapor lock.

2. Locate the fuel filter.

Note: The fuel filter is located on

the right side of the engine bay
just in front of the power steering
fluid reservoir. To provide room to
work it is highly recommended
you remove the entire air cleaner
housing.

3. Remove the "snorkel tube" from

the front of the air cleaner
housing. This is a friction fit and
if you squeeze the sides you
should be able to easily pop it
out. Undo the two clips holding
the air cleaner housing cover on
and remove the cover and air filter
inside the housing.
4. Use the 3/8" ratchet and 10mm
socket remove the support bolt for
the left half of the air cleaner
housing. Remove the temperature
sensor connector by pushing and
holding down the metal clip and
gently pulling the connector off
the back of the air cleaner
housing.

5. The mass air flow sensor has to

be rotated forward towards the
front of the car to unlock the
bayonet lock that holds the air
cleaner housing and mass air flow
sensor together.
6. Disconnect the electrical
connector to the mass air flow
sensor by turning the plastic
locking ring and then gently
pulling the connector off of the
mass air flow sensor.

7. The mass air flow sensor can now

be rotated forward towards the
front of the car to unlock the
bayonet lock between it and the
air cleaner housing. Rotate the
mass air flow sensor forward
about 1 inch to completely
disengage the lock.

8. The air cleaner housing sits on

two rubber mounts. The housing
can now be lifted up about 3/4"
to clear these mounts and then it
can be separated from the mass
air flow sensor.
9. Now that the air cleaner housing
is out of the way there is plenty of
room in which to work. You'll
need a good supply of rags and a
small can to catch the gas that
will inevitably come out of the
filter. Remove the connection near
the rear of the car first. Used a
19mm open wrench on the filter
side nut to hold the filter steady
and a 19mm flare wrench on the
fuel line nut to break the
connection.

10.First, loosen the fuel filter hose clamp. Then put the 17mm flare wrench on
and braced it against the side of the engine bay to hold the fuel line
steady. Finally, use the 7/8" open wrench on the nut shaped portion of the
fuel filter (side facing rear of car) where the first connection had already
been undone. This allowed a much better leverage angle on the 7/8"
wrench / fuel filter.
11. The fuel line support bracket is
freed up by loosening a 10mm
bolt in the right rear wheel well
that screw into the six-sided
plastic nut on the support
bracket.

All that remain is to put everything back together again pretty much in the
reverse order you took it all apart. The order was:

1. Reattach the fuel line support bracket (note: remember the offset plastic
washer!).

2. Insert new fuel filter and attach to the forward 17mm fuel line nut. Be
careful to get the filter oriented the proper direction. There should be an
arrow on the fuel filter itself (should point to the rear of the car) and the nut
arrangement between the fuel lines and filter are in one direction.

3. Attach the other fuel line to19mm nut.

4. Secure the fuel filter hose clamp. Mark the mileage and date on the filter for
future reference.

5. Attach the rubber hose to the lower left corner of the air cleaner housing.

6. Set the air cleaner housing to the two lower rubber support mounts and
work the mass air flow sensor into the back of the air cleaner housing being
cognizant of the sealing gasket.
7. Rotate the mass air flow sensor to the rear of the car to re-engage the
bayonet lock between the air flow sensor and the air cleaner housing.

8. Secure the 10mm support bolt on the upper left half of the air cleaner
housing.

9. Tighten the mass air flow sensor hose clamp with the 8" #2 Phillips
screwdrivers. Use your right hand to hold the clamp in place while using a
screwdriver in your left hand to tighten the hose clamp.

10. Reattach the mass air flow sensor connector and the air cleaner housing
temperature sensor connector.

11. Replace the air filter, the air cleaner housing cover and the "snorkel tube."

Finally, start the car and check for leaks. It will probably take a couple tries
before the car will start up.

PERFORMANCE CRITERIA

CHECK/REPLACE FUEL FILTER AND AIR CLEANER LO 3

 SCORING RUBRICS

Assessment Criteria Score

Replacing fuel filter and air cleaner 50
 fuel filter and air cleaner are properly replaced and
cleaned with 95%-100% efficiency 50
 fuel filter and air cleaner are properly replaced and
cleaned with 75% efficiency 30
 fuel filter and air cleaner are replaced or cleaned with
50% efficiency. 15

OPERATION SHEET No. 3

Replacing Air Filter

Supplies and Materials

 new air filter element

 rag

Tools

 Screw driver flat and Philip

 wrenches

Equipment
 Air compressor
 Running condition vehicle/ Engine mock up

Procedures:

Follow the procedures in replacing the air filter.

Changing the air filter should be part of any major tune-up, but if you drive on
dirt roads or in other dusty conditions, you will need to replace it more
frequently. On most cars, this is a fairly simple procedure. You should change
your car's air filter every 15,000 miles.

1. Open the hood.

2. Locate your air filter, usually found

on top of the engine. On cars with
carburetors it is in a round piece of
metal about the size of a medium
pizza; fuel-injected cars have square
or rectangular air filter housings
that may be off to the side of the
engine.
3. Unscrew or unclamp the top to the
air filter housing.

4. Lift out the air filter. It should be a

round or rectangular filter made of
paper or plastic, with a rubber rim.

5. Clean the area with a vacuum cleaner or seal the top of the carburetor. This
will keep debris out of the carburetor as you continue to clean the housing.

6. Clean out any dirt or bugs from the

inside of the air filter housing with a
rag.
 
7. Replace the filter with a new filter.
Consult your manual to determine
the proper filter for your car.

Check your old filter element for dirt,

oil or moisture, cracks and proper
sealing at the gasket.

8. Replace the cover and close the

hood.

Warning: Avoid using the wrong size air filter. Your engine will run less
efficiently.
Note: Reusable air filters cost more than disposable filters, but if cared for
correctly, they can last for over 50,000 miles.

Another good way to make your air filter last is to actually use a vacuum
cleaner. Simply take the filter out and with the small attachments from the
vacuum, suck out the dust and dirt. Good as new and it will make your filter
last a littler longer.

 
 PERFORMANCE CRITERIA

CHECK/REPLACE FUEL FILTER AND AIR CLEANER LO 3

SCORING RUBRICS

Assessment Criteria Score

Replacing fuel filter and air cleaner 50
 fuel filter and air cleaner are properly replaced and
cleaned with 95%-100% efficiency 50
 fuel filter and air cleaner are properly replaced and
cleaned with 75% efficiency 30
 fuel filter and air cleaner are replaced or cleaned with
50% efficiency. 15
QUALIFICATION : Automotive Servicing NC I

UNIT OF COMPETENCY : Perform Gas Engine Tune Up

MODULE TITLE : Performing Gas Engine Tune Up

LEARNING OUTCOME 4: Test and replace ignition breaker

ASSESSMENT CRITERIA:

1. Ignition breaker is tested and replaced.

2. Condenser is tested and replaced

REFERENCE:

1. Auto Mechanics, Theory and Service

by: de Kryger, Kobacik. Bono

2. Corolla, Service and Repair Manual

8 by: Gregory’s Scientific Publication
9
3. Lancer, Service and Repair Manual
by: Gregory’s Scientific Publication

4. Toyota Training Manual

by: Toyota

8. VHS/CD

6. Corolla, Owners Manual

by: Toyota

7. Communication Module
LEARNING EXPERIENCES / ACTIVITIES

Learning Outcome # 4: Test and replace ignition breaker

Learning Activities Special Instructions

1. Perform checking/replacing  Follow the procedures in

contact point and condenser of a Operation Sheet LO4-1
gasoline engine in the presence of “Inspect/Replace Ignition Breaker
your instructor. and Condenser”
 See your teacher for guidance

 Complete the assessment tasks.

Operation Sheet (LO4)

MATERIALS
 New set of breaker points
 New condenser
 Grease
 Chalk

TOOLS
 Screw drivers: flat and phillip
 Dwell –tach
 Timing light
 Wrench 10mm
 Feeler gauge
 Vehicle service manual

EQUIPMENT
 Running condition vehicle

Procedure

Contact points should be replaced every 10,000 miles. It's good practice to
replace the condenser at the same time. When you replace the points, you then
must check and, if necessary, re-set the timing to specification.
1. Remove the distributor cap. You
will find that there are two spring
clips which hold it on.

2. Insert a screwdriver between each

clip and the distributor case, and
pry them off the cap. The cap
then simply lifts off. Do not
remove the spark plug wires from
the distributor cap.

3. Remove the rotor by pulling it

straight up off the distributor
shaft.
4. Remove the plastic dust cover by
lifting it off the distributor.

5. Remove the old contact points.

You will see that there is a screw
that holds the points unit to a
plate inside the distributor.

6. Loosen and remove this screw.

Unplug the wire from the points
from the black plastic plug that
it's connected to. Just pull it
straight off.

7. Now, withdraw the points and if

they are pitted/excessively worn,
replace them. But if they are still
in good condition keep them as
your spare for an emergency.

8. Remove the condenser. The

condenser is that little metal can
inside or outside of the
distributor. There is one screw
that holds the condenser on itself,
and there is another which holds
the black plastic plug to the
distributor body. Both of these
screws are readily accessible, so
remove them and the little metal
plug clip, and then remove the
condenser and plug from the
distributor.
 PERFORMANCE CRITERIA

INSPECT/REPLACE CONTACT POINT/CONDENSER LO4)

SCORING RUBRICS

Assessment Criteria Score

Checking/Testing or Replacing Contact Point/Condenser 50
 Contact point/condenser is properly checked/tested and
replaced 41-50
 Contact point/condenser is not properly checked/tested
or replaced 30-40
 Contact point/condenser is not checked/tested or
replaced 20
QUALIFICATION : Automotive Servicing NC I

UNIT OF COMPETENCY : Perform Gas Engine Tune Up

MODULE TITLE : Performing Gas Engine Tune Up

LEARNING OUTCOME 5: Adjust engine idle speed

ASSESSMENT CRITERIA:

1. Fuel mixture and idle speed (rpm) is adjusted

2. Advanced timing is checked

REFERENCE:

1. Auto Mechanics, Theory and Service

by: de Kryger, Kobacik. Bono

2. Corolla, Service and Repair Manual

10 by: Gregory’s Scientific Publication
11
3. Lancer, Service and Repair Manual
by: Gregory’s Scientific Publication

4. Toyota Training Manual

by: Toyota

5. VHS/CD

6. Corolla, Owners Manual

by: Toyota

7. Communication Module
LEARNING EXPERIENCES / ACTIVITIES

Learning Outcome # 5: Set fuel mixture and idle rpm

Learning Activities Special Instructions

1. Perform adjust engine idle speed  Follow the procedures in

and mixture of a gasoline engine Operation Sheets LO5 “Adjust
with the presence of your teacher. Engine Idle Speed” and LO5
Adjust Carburetor Air-Fuel
Mixture”
 See your teacher for guidance

 Complete the assessment tasks.

OPERATION SHEET No. 1

SET FUEL MIXTURE AND IDLE RPM

MATERIALS

 Gasoline

TOOLS
 Vehicle service manual
 Screwdrivers flat and Philip
 Carburetor synchronizer
 Wrench 10mm

EQUIPMENT
 Running condition vehicle
Procedures

Adjust Engine Idle Speed and Mixture

An improper air-to-fuel mixture results in bad engine performance and higher gas consumption.
Shown here are the steps in adjusting engine idle speed.

1. Determine if your car has a carburetor by checking your owner’s

manual. Try looking below the air filter to find the carburetor.
2. Be sure the engine is shut off then open the hood.
3. Remove the air filter by
first unscrewing the
wing nut on top.  No
need to disconnect any
hoses connected to the
air filter - just carefully
set it aside.

4. The carburetor is the

part that the air filter
was screwed into. The
air/fuel mixture is
adjusted by two
screws. Typically, these
screws can be found on
the lower-front section
of the carburetor.

5. Using a flat-head screw

driver, turn both
screws to the right
until they stop. Do not
tighten because this
could damage the
needle points.

PERFORMANCE CRITERIA
 INSPECT/REPLACE CONTACT POINT/CONDENSER LO 5

SCORING RUBRICS

Assessment Criteria Score

Checking Engine Speed (RPM) 50
 RPM is properly checked 41-50
 RPM is not properly checked 30-40
 Contact point/condenser is not checked/tested or
replaced 20

QUALIFICATION : Automotive Servicing NC I

UNIT OF COMPETENCY : Perform Gas Engine Tune Up

MODULE TITLE : Performing Gas Engine Tune Up

LEARNING OUTCOME 6: Check/Adjust dwell angle and ignition setting

ASSESSMENT CRITERIA:

1. Ignition distributor is checked

2. Ignition distributor setting is adjusted

REFERENCE:

1. Auto Mechanics, Theory and Service

by: de Kryger, Kobacik. Bono

2. Corolla, Service and Repair Manual

12 by: Gregory’s Scientific Publication
13
3. Lancer, Service and Repair Manual
by: Gregory’s Scientific Publication

4. Toyota Training Manual

by: Toyota

9. VHS/CD

6. Corolla, Owners Manual

by: Toyota

7. Communication Module

LEARNING EXPERIENCES / ACTIVITIES

Learning Outcome # 6: Check/adjust dwell angle and ignition setting

Learning Activities Special Instructions

1. Perform testing/adjusting  Follow the procedures in

dwell angle and ignition setting of Operation Sheet LO6
a gasoline engine with the “Checking/Adjusting Dwell Angle
presence of your instructor. and Ignition Setting”

 Complete the assessment tasks.

Information Sheet

Checking /Adjusting Dwell Angle and Ignition Setting

Dwell* or dwell angle is the number
of degrees the distributor shaft
rotates measured from the point
where the ignition contacts close to
the point where they open again.

Dwell angle is inversely proportional

to point gap, that is, increasing the
gap decreases the dwell, and vice
versa. Insufficient dwell may cause
ignition failure at high speed, while
too much dwell increases the total
average current which the points
must handle, particularly at low
speed. This usually leads to very
short point life.

After a distributor is initially timed

for a given engine, any change in
dwell will result in a change in
timing, requiring re-timing of the
distributor since the rubbing block of
the moving arm will contact the cam
in a different place.

Set the point dwell to the lower limit

for new points to allow for rubbing-
block wear when a dwell specification
is given with a high and low limit.

Parts of a distributor assembly.

OPERATION SHEET
 CHECKING/ADJUSTING FOR PROPER DWELL ANGLE

MATERIALS

 New set of breaker points

 New condenser
 Grease
 chalk

TOOLS

 Screw drivers; Philip and flat

 Dwell tach meter
 Strobe timing light
 Wrench 10mm
 Feeler gauge
 Vehicle service manual

EQUIPMENT

 Running condition vehicle

Procedure

1) Connect the dwell meter as per its manufacturer's instructions: Generally one of two leads is
connected to the positive terminal of the battery and the other lead to the negative terminal
of the coil.

2) Start the engine and read the

dwell angle (make sure meter is
set on 4 cylinder).

3) If dwell angle is too high (points

closed for too many degree of
rotation), you will have to carefully
reset carefully your points to a
slightly larger gap. If the dwell
angle is too low, the points will
need to be set slightly closer.
Adjust the gap .002" or .003".

4) Restart the engine and re-measure Top view of distributor (cap removed)
dwell angle. Repeat 1-3 until dwell showing contact breaker points.
angle is correct.
SETTING IGNITION TIMING

1. Set the timing by connecting the light (inductive or direct) and then mark
the correct timing position on the crank pulley or damper.

Note: Connect the power lead to the + terminal on the battery or the + side
of the coil and the other wire to ground.
2. Follow your engine manual and make an easy-to-read mark with White-Out
(liquid paper) or chalk.
3. Disconnect the vacuum line from the distributor and stick a pencil or nail
into it to prevent a vacuum leak.
4. Start the engine and get it running about 500-600 rpm to prevent any
action from the centrifugal advance mechanism (if there is one) and then
slowly rotate the distributor until the timing mark lines up with its pointer.
5. Tighten the hold-down on the distributor. If the engine won't run slowly
enough back off on the accelerator linkage at the carburetor. If the engine
runs too slow increase the idle speed.
6. Check the timing again and then put the light away.
 PERFORMANCE CRITERIA

Test/Adjust Dwell Angle and Ignition Setting LO6

SCORING RUBRICS

Assessment Criteria Score

Adjust/Dwell Angle 20
 Dwell angle is properly adjusted 20
 Dwell angle is not properly adjusted 15
 Dwell angle is not adjusted 8
Setting Ignition Timing Safely 20
 Ignition timing is properly set and practice safely 30
 Ignition timing is not properly set and practiced safely 25
 Ignition timing is not set 10
QUALIFICATION : AUTOMOTIVE SERVICING NC1

UNIT OF COMPETENCY : PERFORM GAS ENGINE TUNE-UP

MODULE TITLE : PERFORMING GAS ENGINE TUNE-UP

LEARNING OUTCOME 7: CHECK ADVANCE MECHANISM AND ADJUST

IGNITION TIMING.

ASSESSMENT CRITERIA:
1. Ignition timing procedure is applied per engine requirement.
2. Ignition timing is checked per ignition specifications.
3. Safety measures are applied.

REFERENCE:

1. Modern Automotive Technology

by: James E. Duffy

2. Automotive Mechanics 10th Edition

by: William H. Crouse & Donald L. Anglin

3. Toyota Training Manual

by: Toyota

3. Communication Module

LEARNING EXPERIENCES/ACTIVITIES

Learning Outcome #7: Check advance mechanism and adjust ignition timing

Learning Activities Special Instructions

1. Read the attached information  Ask your instructor for

sheet in LO7, checking advance guidance.
mechanism and adjusting ignition
timing.  For more information refer to
module 9, LO1 & 8

2. Answer Self Check  Refer to answer key

Complete the task

 INFORMATION SHEET

LO 7. CHECK ADVANCE MECHANISM AND ADJUST IGNITION TIMING

Topic 1. IGNITION TIMING

Ignition Timing is also called spark timing, refers to how early or late
the spark plug fires in relation to position of the engine pistons. Ignition
timing must vary with engine speed, load and temperature.

There are two types of timing advance and retard:

1. TIMING ADVANCE
It occurs when the spark plugs fired sooner on the engine’s
compression stokes. The timing is set several degrees before TDC. More
timing advance is needed at higher engine speeds to give combustion enough
time to develop pressure on the power stroke.

2. TIMING RETARD
It occurs when the spark plugs fire later on the compression strokes.
It is the opposite of timing advance; spark retard is needed at lower engine
speeds and under high load conditions. Timing retard prevents the fuel from
burning too much on the compression stroke, causing a spark knock or plug.

There are three basic methods used to control Ignition System

Spark Timing:

Distributor Centrifugal Advance – controlled by engine speed. The

distributor centrifugal makes the ignition coil and spark plugs fire sooner as
engine speed increase. It uses spring-loaded weights, centrifugal force, and
lever action to rotate the distributor cam or trigger wheel against distributor
shaft rotation, spark timing is advanced.

Centrifugal Advance Operation

At low engine speeds, small springs hold the advance weights inward, in
the picture above there is not enough centrifugal force to push the weights
outward, the timing stays as its normal initial setting as long as vacuum
advance is no functioning. As engine speed increase, centrifugal force
overcomes spring tension the weights are thrown outward. The edges of the
weights act on the cam or trigger wheel lever. The lever is rotated on the
distributor shaft. As engine speed keeps increasing, the weights fly out more
and timing is advanced a greater amount, at preset engine RPM, the lever
strikes a stop and centrifugal advance reaches maximum.
 Distributor Vacuum Advance – controlled by engine intake manifold
vacuum and engine load. The distributor vacuum advance provides additional
spark advance when engine load is low at part (medium) throttle position. It is
a method of matching Ignition timing with engine load. The vacuum advance
mechanism increase fuel economy because it helps maintain ideal spark
advance at all times. It consists of a vacuum diaphragm, link, movable
distributor plate, and a vacuum supply hose. Shown below

Dual Advance Operation – at idle, the vacuum port to the distributor

advance is covered. Look at the picture above (left side) vacuum is not applied
to the vacuum diaphragm. Spark timing is NOT advanced, During acceleration
and full throttle, engine vacuum drops-tons, vacuum is not applied to the
distributor diaphragm and the vacuum advance does not operate.

Dual-Diaphragm Distributor – a dual-diaphragm vacuum advance

mechanism, used on some distributors, contains two separate vacuum
chambers: An advance chamber and a retard chamber. Sometimes, a control
switch is used in the distributor vacuum line to alter vacuum diaphragm
action.

Vacuum Delay Valve – a vacuum delay valve restricts the flow of air to
slow down the vacuum action on a vacuum device. Note how the delay valve
has a small orifice (opening) for vacuum. It also has a check valve that allows
flow in only one direction. The vacuum delay valve keeps the vacuum advance
from working too quickly, preventing possible knock or ping. The check valve
allows free release of vacuum from the diaphragm when returning to the retard
position.

Electronic Spark Advance - controlled by various engine sensors, engine

RPM, temperature, intake manifold vacuum, throttle position. An electronic
spark advance system, uses engine sensors and a computer to control ignition
timing. A distributor may be used but it does contain centrifugal or vacuum
advance mechanisms. The engine sensors check various operating condition
and send electrical data to the computer. The computer then changes ignition
timing for maximum engine efficiency.

Ignition System Engine Sensors typically include:

1. Engine Speed Sensor – reports engine RPM to computer.

2. Crankshaft Position Sensor – reports piston position
3. Intake Vacuum Sensor – measure engine vacuum, an indicator of load.
4. Inlet Air Temperature Sensor – check temperature of air entering engine.
5. Engine Coolant Temperature Sensor – measures operating temperature of
engine.
6. Detonation Sensor – allow computer to retard timing when engine pings or
knocks.
7. Throttle Position Switch – notes position of throttle.

The spark control computer receives input signals (different current or

voltage levels) from these sensors. It is programmed to adjust ignition timing
to meet different conditions. The computer may be mounted on the air
cleaner, fender inner panel, under the car dash or under a seat.

Electronic Spark Advance Operation

An example of electronic spark advance, imagine a car traveling down the
highway at 55 mph (88 km/hr). The speed sensor would detect moderate
engine RPM. The throttle position sensor would report Norman operating
temperatures. The intake and coolant temperature sensors would report
normal operating temperatures. The intake manifold pressure sensor would
send high vacuum signals to the computer. The computer could then
calculate that the engine would need maximum spark advance. The timing
would occur several degrees before TDC on the compression stroke. This
would assure that the engine attained high fuel economy on the highway.
Since computer system vary, refer to a service manual for more information.
The manual will detail the operation of the specific system.

Base Timing
Is the ignition timing without computers controlled advance. To make the
engine run on base timing, you might have to disconnect a wire near the
distributor or use a scanner to trigger computer retard.

Setting Ignition Timing

The engine requires two types of ignition timing: one is the Basic or Initial
Timing for starting and idling, this timing is determined by the relationship
between piston position and the opening of the primary circuit.
The other timing is Spark Advance, advances and retards the spark from
the base-timing setting, primarily as engine speed and load change. On same
distributors, it is mechanically controlled by centrifugal and vacuum advance
mechanism. Contact point distributors should have the timing checked
periodically. As the contact points and rubbing block wear, ignition timing
and dwell change.
 OPERATION SHEET No. 1(lo1)

PROCEDURE IN SETTING IGNITION TIMING (USING TIMING LIGHT)

Check the timing with the engine at normal operating temperature and
idling at the specified speed, in setting ignition timing follow the procedures.

Supplies and Materials:

 Gasoline

Tools:

 Timing light
 Wrench No. 12mm

Equipment:

 Condition vehicle or engine mock up

Procedures:

1. Connect the red cable (positive) to positive terminal of the battery.

2. Connect the black cable (negative) to negative terminal of the battery.
3. The last cable (usually it is smaller from the two cables) connected to spark
plug No.1.
4. Start the engine at normal operating temperature and idling at specified
speed.
5. Aim the timing light at the timing marks.
6. To adjust timing, slightly loosen the distributor, hold down clamp bolt,
7. Turn the distributor in its mounting, the rotating timing mark will move
ahead or back. Rotating the distributor in the direction opposite to shaft
rotation
ADVANCE TIMING. This opens the primary circuit earlier. Turning the
distributor in the same direction as shaft rotation retards the timing. The
spark occurs later, when the timing is correct the specified timing marks
align.
8. Tighten the distributor clamp bolt.
9. To recheck the timing as timing light pointed to timing marks, to ensure it
did
not change as the clamp was tightened.
10. Off the engine, and
11. Remove the cable from spark plug No.1, disconnect the negative cable
and the positive cable,

CAUTION:

Keep your hands and the timing-light leads away from the fan and drive
belts. Never stand in line with the fan. A blade might fly off and strike you.

Self Check

Identify the following question. Write the answer in your test notebook

1. Ignition timing is also called ______________________.

2. When the spark plugs fired sooner on the engine’s

compression strokes called _______________________.

3. When the spark plugs’ fire later on the compression strokes

called ________.

4. What will you do if the timing is advance or retard ____________.

 PERFORMANCE CRITERIA(LO7)

CHECK ADVANCE MECHANISM

ADJUST IGNITION TIMING

SCORING RUBRICS

Assessment Criteria Score

 Checking and adjusting ignition timing and
advance mechanism 50
 Ignition timing and advance mechanism is
properly checked and adjusted safely 41-50
 Ignition timing and advance mechanism is not
checked and adjusted properly 30-40
 Ignition timing and advance mechanism is not
checked and adjusted 20

Total 50
QUALIFICATION : Automotive Servicing NC I

UNIT OF COMPETENCY : Perform Gas Engine Tune Up

MODULE TITLE : Performing Gas Engine Tune Up

LEARNING OUTCOME 8: Perform compression test

ASSESSMENT CRITERIA:

1. Compression test is performed.

2. Compression test result is interpreted and appropriates
recommendations is prescribed.

REFERENCE:

1. Auto Mechanics, Theory and Service

by: de Kryger, Kobacik. Bono

2. Corolla, Service and Repair Manual

14 by: Gregory’s Scientific Publication
15
3. Lancer, Service and Repair Manual
by: Gregory’s Scientific Publication

4. Toyota Training Manual

by: Toyota

5. VHS/CD

6. Corolla, Owners Manual

by: Toyota

7. Communication Module
LEARNING EXPERIENCES / ACTIVITIES

Learning Outcome # 8: Perform compression test

Learning Activities Special Instructions

1. Perform compression testing of a  Follow the procedures in

gasoline engine with the presence Operation Sheet LO8
of your instructor. “Performing Compression Test”

2. Answer Self- Check  Compare your answer to answer

key
 Complete the assessment tasks.

OPERATION SHEET No. 1 (LO8)

PERFORM COMPRESSION TEST

MATERIALS:
 Gasoline

TOOLS
 Vehicle service manual
 Basic hand tool set
 Compression gauge
 Safety gauge

EQUIPMENT
 Running condition vehicle

Perform Compression Testing

Procedures

The cylinder compression tester measures the ability of the cylinders to hold
compression while the starting motor cranks the engine. The compression
tester is a pressure gauge that measures the amount of pressure or
compression, built-up in the cylinder during the compression stroke. How well
a cylinder holds compression is an indication of the condition of the piston,
piston rings, cylinder wall, valves and head gasket.

1. Warm up the engine to operating temperature.

2. Stop the engine.
3. Remove the injector or injection nozzles.
 4. Connect a pressure gauge to
the cylinder port as shown.

gauge LO7-1.

1. Set the engine speed control to stop position.

2. Turn the engine with the starter until the pressure gauge registers no
further rise in pressure.

Note: It is a good practice to count the number of compression strokes,

indicated by movement of the gauge needle, and check each cylinder
with the same number of strokes. The engine must be at full cranking
speed or as specified in appropriate service manual to get a good
reading.

3. Check the pressure reading against the engine technical manual.

Note: Low pressure indicates leakage through valves, rings or gaskets.

Variations in cylinder pressures of more than 10% usually indicate a
need for cylinder reconditioning.

Information Sheet

Interpreting and Analyzing compression result

Engine compression readings are usually considered normal if the lowest

reading is 75 percent or more of the highest.

For example, if one cylinder in an engine has a compression pressure of

120 psi (828 kPa), then all cylinders should have compression readings of
90 psi (621 kPa) or higher. Typical compression pressures vary among
engines and manufacturers. In many General Motors engines, no cylinder
should have a compression pressure of less than 100 psi (690 kPa). Toyota
specifies a maximum compression pressure of 142 psi (990 kPa) in some
engines. The following section describes interpreting the results of the
compression test.
 The manufacturer’s specification show what the compression pressures
should be. If compression is low, there is leakage past the piston rings,
valves or cylinder-head gasket. If the readings vary, how they vary may
indicate the cause of the problem.

Caution: Never perform a wet compression test on a diesel engine. The heat
of a compression could ignite the oil and damage the compression
tester. Also, since the oil is not compressible, it could fill the
combustion chamber and create a hydrostatic lock. This prevents
the crankshaft from turning and may damage the engine.

Self Check No. 3

Direction: Fill in the blanks.

1. Normal engine compression reading should be ____________________.

2. If the compression is low, there is leakage past on the ______________.
3. Excessive carbon buildup in combustion chamber, the compression
gauge reading is ________________________.
4. It measures the ability of the cylinders to hold compression
__________________________.
 ANSWER KEY

No. 1

1. B
2. C
3. A
4. C
5. D

No. 2

1. TOP DEAD CENTER

2. BOTTOM DEAD CENTER
3. CYCLE
4. DOWNWARD, OPEN
5. UPWARD, OPEN

No. 3

1. 75% and above

2. piston rings

3. 20 psi above

4. compression
 ACKNOWLEDGMENT

Copyright Department of Education 2008

First Published JUNE 2008

This draft was prepared at the Competency-Based Learning Materials

Development Workshop conducted at the Marikina Hotel, Marikina City on
February 18-22, 2008.

This learning instrument was developed by the following personnel:

Technology Teachers:

 LINO OLIT
Calapan, Community V.H.S.

 ROBERT S. DOMINGO
A.F.G.Bernardino Memorial Trade School-Lias, Marilao, Bulacan

 JOHN DIEGO
Isabela SAT

 GEORGE CALLANTA
Don A. Roces, Sr. Science Technology High School-Quezon City

 ROMEO IBLOGUIN
E.Rodriguez V.H.S.

 NELSON SENEDO
Tagum National High School

Contextual Teacher:
 BELEN L. TADO
Tagum National High School

Facilitator:
 Beatrice A. Adriano
E. Rodriguez Vocational HS

Encoder
 Rowena S. Fonacier

This work was produced with funding provided by the Department of

Education.
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
Modern Machining Technology/Richard Baril