COMPETENCY BASED LEARNING MATERIAL

Sector:

AUTOMOTIVE
Qualification:

Automotive Servicing NC II
Unit of Competency:

Service Engine Mechanical System

Module Title:

SERVICING COOLING SYSTEM

Technical Education and Skills Development Authority
East Service Road, South Superhighway, Taguig, Metro Manila
 NATIONAL CERTIFICATE LEVEL 2
QUALIFICATION LEVEL

COMPETENCY-BASED LEARNING MATERIALS

No. Unit of Competency Module Title Code

1. Service Starting System  Servicing Starting System ALT723307
2. Service Charging System  Servicing Charging System ALT723308
3. Service Engine Mechanical  Servicing Cooling ALT723309a
System System
 Servicing Lubricating System ALT723309b
 Servicing Gasoline Fuel System ALT723309c
 Servicing Air Induction System ALT723309d
 Servicing Diesel Fuel Injector ALT723309e
4. Service Clutch System  Servicing Clutch System ALT723310
5. Service Differential and Front  Servicing Differential and Front ALT723311
Axle Axle
6. Service Manual Steering System  Servicing Manual Steering ALT723312
System
7. Overhaul Manual Transmission  Pulling-out, Disassembling and ALT723313a
Checking Manual Transmission
 Assembling and Testing ALT723313b
Manual Transmission
8. Service Brake System  Identifying and Explaining ALT723314a
Hydraulic Brake System
Operations and Functions
 Servicing Brakes ALT723314b
 Overhauling Brake Systems ALT723314c
9. Service Suspension System  Servicing Suspension System ALT723315

Code No. Date Developed Date Revised Page #

Servicing Lubricating System
Nov. 28, 2003 April 28, 2005 2
 HOW TO USE THIS COMPETENCY BASED LEARNING MATERIAL

Welcome to the module Servicing Cooling System. This learning material contains
training materials and activities for you to complete.

The unit of competency “Service Engine Mechanical System” contains the knowledge,
skills and attitudes required for Automotive Servicing. It is one of the modules in the Core
Competencies at National Certificate Level (NC 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,
Performance Standards and Operation Sheets for further reading to help you better understand
the required activities. Follow these activities on your own and answer the summative test at the
end of each learning outcome.

Recognition of Prior Learning (RPL)

You may have some or most of the knowledge and skills covered in this learner’s guide
because you have:

 Been working for some time

 Already completed training in this area

If you can demonstrate to your trainer that you are competent in a particular skill, you
don’t have to do the same training again.

If you feel you have some of the skills, talk to your trainer about having them formally
recognized. If you have qualification or a Certificate of Competence from previous training,
show it to your trainer. If the skills you acquired are still relevant to the module, they may
become part of the evidence you can present for RPL.

At the end of each learning outcome is a learner’s diary. Use this diary to record
important dates, jobs undertaken and other workplace events that will assist you in providing
further details to your trainer or assessors. A Record of Achievement is also provided for the
trainer to complete once you completed the module.

This module was prepared to help you achieve the required competency in servicing
engine cooling system. This will be the source of information for you to acquire knowledge and
skills in this particular trade, with minimum supervision or help from your trainer. With the aid of
the materials, you will acquire the competency independently and at your own pace.

 Talk to your trainer and agree on how you will both organize the training of this unit.
Read through the Competency Based Learning Material carefully. It is divided into
learning activities which cover all the skills and knowledge you need to successfully
complete this module.
 Most probably your trainer will also be your supervisor or manager. He/She is there
to support you and show you the correct way to do things. Ask for help.
 Your trainer will tell you about the important things you need to consider when you
are completing activities and it is important that you listen and take notes.
 You will be given plenty of opportunities to ask questions and practice on the job.
Make sure you practice your new skills during regular work shifts. This way you will
improve both your speed and memory and also your confidence.
 Talk to more experienced workmates and ask for their guidance.
 Use self-check questions in each learning activity to test at the end of each section to
test your own progress.
 When you are ready, ask your trainer to watch you perform the activities outlined in
the module.
 As you work through the activities, ask for written feedback on your progress.
Your trainer keeps feedback/pre-assessment reports for this reason. When you
have successfully completed each module, ask your trainer to mark on the reports
that you are ready for assessment.
 When you have completed this module and feel confident that you have had sufficient
practice, your trainer will arrange an appointment with the registered assessor to
assess you. The results of your assessment will be recorded in your competency
Achievement Record.
QUALIFICATION : Automotive Servicing NC II

UNIT OF COMPETENCY : Service Engine Mechanical System

MODULE TITLE # 1 : SERVICING COOLING SYSTEM

INTRODUCTION:

This module covers explaining coolant circulation, checking thermostat condition,

performing leakage test, repairing/replacing water pump and applying coolant additives.

This consists of five learning outcomes; each outcome contains learning activities for the
competency, supported with information sheets, self-check and job/operation sheets, gathered
from different sources. Before performing the manual exercises, read the information/operation
sheets and answer the self-check provided to confirm to yourself and to your trainer that you
are equipped with the knowledge necessary to perform the skill portion of the particular learning
outcome.

Upon completion of this module, you have to subject yourself to your trainer for
assessment. You will be given a Certificate of Achievement as a proof that you met the
standard requirements (knowledge and skills) for the competency “Service Engine Mechanical
System” upon completion of the five modules for this competency. The assessment could be
made in different methods, as prescribed in the competency standards.

LEARNING OUTCOMES:

Upon completion of this module, you must be able to:

1. Explain coolant circulation within the cooling system.

2. Check thermostat condition.
3. Perform leakage test on cooling system.
4. Repair/replace water pump.
5. Apply coolant additives.

ASSESSMENT CRITERIA:

1.1 Parts of cooling system identified

1.2 Function of cooling system parts explained
1.3 Coolant circulation within cooling system explained in accordance with
manufacturer’s specifications.
2.1 Standard condition of thermostat determined in accordance with manufacturer’s
specifications
2.2 Thermostat location determined
2.3 Thermostat condition checked in accordance with service manual/industry
procedure
2.4 Inspection results recorded and reported

Code No. Date: Developed Date: Revised Page #

Servicing Cooling System
ALT723309a Sept. 5, 2004 1
 3.1 Technical data pertaining to engine cooling system obtained, in conformity with
service manual
3.2 Appropriate tools and equipment/materials prepared and used
3.3 Leakage test performed in accordance with industry procedure
3.4 Test results recorded and preferred actions determined
3.5 Coolant heated in accordance with manual specifications
4.1 Technical data of engine water pump obtained using service manual
4.2 Water pump checked/inspected and faults determined
4.3 Water pump/parts replacement determined
4.4 Water pump/parts dismantled in accordance with service manual
4.5 Water pump/parts installed/replaced per manufacturer’s specifications
5.1 Technical specifications of coolant additives obtained
5.2 Coolant additives selected in accordance with manufacturer’s specifications
5.3 Coolant additives applied per manufacturer’s specifications.

PRE-REQUISITE:

Code No. Date: Developed Date: Revised Page #

Servicing Cooling System
ALT723309a Sept. 5, 2004 2
Qualification : Automotive Servicing NC II

Module Title #1 : Servicing Cooling System

Learning Outcome #1 : Explain Coolant Circulation within the Cooling System

Assessment Criteria :

1. Parts of coolant system identified

2. Function of cooling system parts explained
3. Coolant circulation within cooling system explained in accordance with
manufacturer’s specifications

Resources :
th
1. Automotive Engines-Maintenance & Repair, 4 edition, Billiet, Walter
2. Automotive Technology-A System Approach, Erjavec, J., et al.
rd
3. Automotive Tune-up & Engine Performance, 3 edition, Crouse, W. and Anglin, D.
4. Webster’s Dictionary
5. Encyclopedia
6. Chemistry, Santos, G. & Lebron, G.
7. Freshman English, (Geared to ESP), Gaduyon, M.L. A.
8. Engine Cooling System
9. Engine Cooling System Chart (Water Cooling and Air Cooling)

Code No. Date: Developed Date: Revised Page #

ALT723309a Servicing Cooling System Sept. 5, 2004 3
LEARNING EXPERIENCES

Learning Outcome #1: Explain Coolant Circulation within the Cooling System
Learning Activities LO1-1 Resources

1. Read the information on types of cooling  Information Sheet LO1-1, “Types of

systems and their functions. Engine Cooling System”

2. View a short video on automobile.  VHS- How Automobile Works

3. Answer the self-check.  Self Check

4. Check your answers with the answer key.  Answer Key

If your answers are all correct, proceed to the

next learning activity for this learning outcome. If
you did not get all the answers, go back to
learning steps 1-4.

Code No. Date: Developed Date: Revised Page #

Servicing Cooling System
ALT723309a Sept. 5, 2004 4
 INFORMATION SHEET LO1-1
Introduction

The cooling system keeps the engine at its most efficient temperature at all speeds and
operating conditions. Burning fuel in the engine produces heat. Some of this heat must be
taken away before it damages engine parts. This is one of the three jobs performed by the
cooling system. It also helps bring the engine to normal operating temperature as quickly as
possible. In addition, the cooling system provides a source of heat for the passenger
compartment heater.

1.1 Types of Engine Cooling System

Engines use either of two types of cooling systems: air cooling and liquid cooling.

1. Liquid-Cooled System

The most popular and efficient method of engine cooling is the liquid-cooled system. In
this system, heat is removed from around the combustion chambers by a heat-absorbing
liquid (Coolant) circulating inside the engine. This liquid is pumped through the engine
and, after absorbing the heat of combustion, flows into the radiator where the heat is
transferred to the atmosphere. The cooled-liquid is then returned to the engine to repeat
the cycle. Excessive cooling capacity can decrease engine efficiency. Therefore, systems
are designed to keep engine temperatures within a range where they provide peak
performance.

Major components of a typical liquid-cooling system. Arrows indicate the coolant flow.

Code No. Date: Developed Date: Revised Page #

Servicing Cooling System
ALT723309a Sept. 5, 2004 5
 2. Air-Cooled System

Few engines use a coolant system that employs air rather than liquid as the medium to
transfer heat from the engine components to the atmosphere. Cylinders and heads have
fins and are enclosed in a surface area to airflow for better dissipation. Ducts and shrouds
direct the overflow over the engine components, especially over the hotter cylinder head
area. A belt-driven or electric blower provides the means for airflow. Fresh air is taken in
and heated air expelled into the atmosphere. A thermostat connected to a control valve or
door regulates airflow to control engine temperature.

1.2 Cooling-System Components and their Functions

1. Water Jacket – space between the inner and outer shells of the cylinder block or
cylinder head, through which coolant circulates

2. Water Pump – an engine-driven centrifugal pump that circulates coolant between the
engine water jacket and the radiator.

3. Engine Fan or Cooling Fan – pulls or pushes the additional air through the radiator. It
maybe either a mechanical fan or an electric fan.
4. Drive Belt – a continuous loop of reinforced rubber used to transmit power between to
shafts.

5. Radiator – heat exchanger that removes heat from coolant passing through it;
receives hot coolant from the engine and returns the coolant to the engine at a lower
temperature.

6. Thermostat – a heat-operated valve that regulates the flow of liquid-coolant between

the engine and the radiator, thereby controlling coolant temperature; a control device
containing a temperature-sensitive element that automatically reacts to temperature
changes by bending and straightening, or expanding or contracting.

Go Back to Learning Activity Sheet

Code No. Date: Developed Date: Revised Page #

Servicing Cooling System
ALT723309a Sept. 5, 2004 6
 SELF-CHECK LO1-1
A. Directions: Answer the following as indicated. Write your answers on the answer sheet
provided by your instructor.

1. What are the two types of cooling system?

2. What type of cooling system is that wherein heat is removed from around the
combustion chambers by a heat-absorbing liquid (coolant) circulating inside the engine?

3. What is the type of cooling system which employs air rather than liquid as the medium to
transfer heat from the engine components to the atmosphere?

4. Enumerate at least 5 components/parts of the cooling system.

B. Directions: Give the functions of the following cooling system components/parts. Answer in
complete sentences. Write your answers on the answer sheet provided.

1. Radiator

2. Cooling fan

3. Water pump

4. Water jacket

5. Thermostat

6. Drive belt

Go Back to Learning Activity Sheet

Code No. Date: Developed Date: Revised Page #

Servicing Cooling System
ALT723309a Sept. 5, 2004 7
 ANSWER KEY LO1-1
A. 1. Liquid-cooling system
Air-cooling system

2. Liquid- cooling system

3. Air- cooling system

4. Radiator
Water pump
Water jacket
Drive belt
Thermostat

B. 1. The radiator functions as heat exchanger that removes heat from coolant passing
through it.

2. The cooling fan pulls or pushes the additional air through the radiator.

3. Water pump is an engine-driven centrifugal pump that circulates coolant between the
engine water jacket and the radiator.

4. The water jacket serves as passageway through which coolant circulates.

5. The thermostat regulates the flow of liquid coolant between the engine and the radiator.

6. Drive belt transmits power between two shafts.

Go Back to Learning Activity Sheet

Code No. Date: Developed Date: Revised Page #

Servicing Cooling System
ALT723309a Sept. 5, 2004 8
LEARNING EXPERIENCES

Learning Outcome #1: Explain Coolant Circulation within the Cooling System
Learning Activities LO1-2 Resources

1. Read the information on types of cooling  Information Sheet LO1-2, “The Cooling
systems. Process”

2. Answer the self-check.  Self Check

3. Check your answers with the answer key.  Answer Key

If your answers are all correct, proceed to the

next learning activity of the next learning
outcome. If you did not get all the answers, go
back to learning steps 1-3.

Code No. Date: Developed Date: Revised Page #

Servicing Cooling System
ALT723309a Sept. 5, 2004 9
 INFORMATION SHEET LO1-2

1.2.1 The Cooling Process

Coolant is a liquid mixture of about 50 percent antifreeze and 50 percent water used to
carry heat out of the engine.

Engine coolant is forced from the water pump into the engine block. The coolant flows
around the outside of the cylinder walls. Coolant continues to flow from the engine block
through passages in the head gaskets into the cylinder head. The coolant flow through the
cylinder head provides cooling for the valves, combustion chambers and spark plugs. After
flowing through the cylinder head, the coolant flows through the thermostat housing and top
radiator hose to the right-hand radiator tank. (The right-and-left hand sides of the car
determined from the driver’s seat.) As the coolant flows through the radiator, heat is transferred
to the air flowing through the radiator. A cross-flow radiator is used in this type of cooling
system. Coolant returns from the left radiator tank and lower hose to the water pump.

When the coolant is cold, the thermostat will be closed and the coolant will flow through
the intake manifold and heater core. Under this condition, there is no coolant flow through the
radiator. Once the engine reaches normal operating temperature, the thermostat will open,
coolant will continue to flow through the intake manifold passage and the heater core. The
coolant flow through the intake manifold provides improved fuel vaporization.

1.2.2 The Cooling System and Its Effects to the Engine

The cooling system is often neglected. A customer will spend a great deal of money on
an overhaul but will not get a complete repair if the cooling system is not put in good order.
Radiators often become plugged or rotten. If the radiator cannot conduct enough heat away,
the engine will overheat.

The following may cause overheating to the engine and have to be checked:

1. low coolant level

2. loose belt (belt-driven water pump)
3. defective pressure cap
4. defective thermostat
5. idle speed too low
6. defective thermal control fan
7. defective electric fan circuit
8. plugged radiator coolant passages
9. Plugged air passages in the radiator
10. defective water pump
11. defective cylinder heated gasket

Code No. Date: Developed Date: Revised Page #

Servicing Cooling System
ALT723309a Sept. 5, 2004 10
1.2.3 Cooling by Expansion

Where there is fire (combustion), there is heat. Burning the air-fuel mixture raises the
temperature inside the engine cylinder several thousands of degrees. Some of this heat
produces the high pressure that causes the piston to move.

Substances with high critical temperatures are easy to liquefy; substances with low
critical temperatures must be cooled before they can be liquefied.

For example, oxygen cannot be liquefied at room temperature (298k or so). It must be
0
cooled below 154k (-119 C) before liquefaction can occur. This cooling would be quite difficult
were it not for the gases that sometimes cool themselves on expansion.

The cause of cooling by unrestrained expansion can be seen by considering the

experiment shown below:

Sudden Expansion of Gas

The box shown is perfectly isolated from its surroundings, so that no heat can get in from
the outside. It is divided into two compartments by a diaphragm. The left hand compartment
contains compressed gas; the right hand compartment is originally empty. If a hole is now
punched in a diaphragm, the gas streams into the vacuum. A thermometer in the path of the
streaming gas would show a drop in temperature. As the gas streams into the empty space,
molecules work against the attractive force of their neighbors. This requires kinetic energy; and
since no outside forces between molecules, there would be no cooling effect. Indeed, the fact
that cooling is observed indicates that there are attractive forces between gas molecules.

The commercial liquefaction of gases makes use of cooling by expansion. In order to

liquefy air, for example, it is first compressed to high pressure, cooled with refrigerant to remove
the heat that accompanies compression, and then allowed to expand. Some of the air liquefies
as a result of cooling on expansion; the rest is passed over the incoming pipes to compressed
air to cool it further.

Go Back to Learning Activity Sheet

Code No. Date: Developed Date: Revised Page #

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ALT723309a Sept. 5, 2004 11
 Self-Check LO1-2
Instructions:

A. True or False. Write true if the statement is true; if false, write false. Get your
answer sheet from your trainer.

____ 1. From the water pump, the coolant goes into the engine block.
____ 2. Coolant returns from the left radiator tank and lower hose to the cylinder
head.
____ 3. When the coolant is cold, the thermostat closes and the coolant continues
to flow.
____ 4. When the engine reaches normal operating temperature, the thermostat
closes and the coolant stops to flow.
____ 5. Low temperature causes lubricating oil to break down.

B. Enumerate 6 causes of engine overheating (in any order)

1. __________________________________________________________
2. __________________________________________________________
3. __________________________________________________________
4. __________________________________________________________
5. __________________________________________________________
6. __________________________________________________________

C. Answer these questions:

1. In the case of heat engines, how do you state the first law of Thermodynamics?
2. How do you state the second law of Thermodynamics in the case of heat
engines?

Go Back to Learning Activity Sheet

Code No. Date: Developed Date: Revised Page #

Servicing Cooling System
ALT723309a Sept. 5, 2004 12
 Answer Key LO1-2
A.
1. True
2. False
3. True
4. False
5. False

B.
1. low coolant level
2. loose belt
3. defective thermostat
4. defective thermal control fan
5. defective water pump
6. defective cylinder head gasket

C.
1. Heat absorbed from a source at a high temperature is equal to the mechanical work
done plus the heat given off at a lower temperature.
2. It is impossible for an engine to transfer heat from one body to another at higher
temperature unless work is done on the engine.

Go Back to Learning Activity Sheet

Code No. Date: Developed Date: Revised Page #

Servicing Cooling System
ALT723309a Sept. 5, 2004 13
QUALIFICATION : Automotive Servicing NC II

MODULE TITLE # 1 : Servicing Cooling System

LEARNING OUTCOME #2 : Check Thermostat Condition

Assessment Criteria:

1. Standard condition of thermostat determined in accordance with manufacturer's

specifications
2. Thermostat location determined
3. Thermostat condition checked in accordance with service manual/industry procedure
4. Inspection results recorded and reported

Resources:
th
1. Automotive Engines-Maintenance & Repair, 4 edition, Billiet, Walter
2. Automotive Technology-A System Approach, E rjavec, J., et al.
rd
3. Automotive Tune-up & Engine Performance, 3 edition, Crouse, W. and Anglin, D.
th
4. Automotive Mechanics, 10 edition, Crouse, W. and Anglin, D.
rd
5. Fundamentals of Chemistry, 3 edition, Wood, J., et al.
6. Fundamentals of Chemistry, Special Philippine Edition, Redmore, F.
7. Technical English, Gaduyon, M.L.A.
8. Running Engine equipped with thermostat
9. Thermostat tester
10. Burner
11. Pot
12. Set of open wrench
13. Set of box wrench

Code No. Date: Developed Date: Revised Page #

 Servicing Cooling System Sept. 5, 2004 14
ALT723309a
LEARNING EXPERIENCES

Learning Outcome #2: Check Thermostat Condition

Learning Activities LO2-1 Resources

1. Read the information on types of cooling  Information Sheet LO2-1, “Thermostat

systems. Location and Parts”

2. Answer the self-check.  Self Check

3. Check your answers with the answer key.  Answer Key

If your answers are all correct, proceed to the

next learning activity of the next learning
outcome. If you did not get all the answers, go
back to learning steps 1-3.

Code No. Date: Developed Date: Revised Page #

Servicing Cooling System
ALT723309a Sept. 5, 2004 15
 INFORMATION SHEET 2.1
Thermostat Location and Parts

2.1.1 Thermostat

The automotive thermostat functions somewhat like a typical home thermostat. It

attempts to control the engine’s operating temperature by routing the coolant either to the
radiator or through by-pass or sometimes by a combination of both.

2.1.2 Location of a Thermostat

While a thermostat might be situated in several locations, the most common spot is at
the front of the engine on top of the engine block. The heat element fits into a recess in the
block where it will be exposed to hot coolant. The top of the thermostat is then covered by the
water outlet housing, which holds it in place and provides a connection to the upper radiator
hose.

2.1.3 Parts of a Thermostat

Go Back to Learning Activity Sheet

Code No. Date: Developed Date: Revised Page #

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ALT723309a Sept. 5, 2004 16
 SELF-CHECK LO2-1
Instruction: Answer the following questions:

1. What is the function of a thermostat?

2. - 4. Give 3 parts of a thermostat.

5. Where is the most common location of a thermostat in an engine?

Go Back to Learning Activity Sheet

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ALT723309a Sept. 5, 2004 17
 Answer Key LO2-1

1. A thermostat controls the engine’s operating temperature through a coolant.

2. Thermostat Housing
3. Thermostat
4. Gasket
5. In front of the engine

Go Back to Learning Activity Sheet

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LEARNING EXPERIENCES

Learning Outcome #2: Check Thermostat Condition

Learning Activities LO2-1 Resources

1. Read the information on types of cooling  Information Sheet LO2-2, “The

systems. Thermostat”

2. Answer the self-check.  Self Check LO2-2

3. Check your answers with the answer key.  Answer Key LO2-2

If you answered all items in the self-check

correctly, proceed to learning step 5. If you failed
to do so, repeat steps 1-3.

4. Review your performance based on the  Performance Standard LO2-1

performance standard.

5. Perform the activity in the operation sheet.  Operation Sheet LO2-1

If you performed satisfactorily, proceed to step 6.

Repeat steps 5-6 if you performed
unsatisfactorily

6. Review your performance based on the  Performance Standard LO2-2

performance standard.

7. Perform the activity in the operation sheet.  Operation Sheet LO2-2

8. Record results on the worksheet provided.

If you performed satisfactorily, proceed to step 9

and repeat steps 8-10 if you performed
unsatisfactorily.
 Performance Standard LO2-3
9. Review your performance based on the
performance standard.
 Operation Sheet LO2-3
10.Perform the activity in the operation sheet.

If your trainer approves your performance, move

on to the next learning outcome, if he
disapproves, repeat steps 9-10.

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 INFORMATION SHEET LO2-2
Thermostat Function and Operation

The Thermostat

A thermostat is a control device containing a temperature-sensitive element. It

automatically responds to temperature changes by bending, or by expanding and contracting.
This opens and closes electric switch contacts, or a valve regulated fluid.

In the engine cooling system, the thermostat is a heat operated flow-control valve. It
uses the coolant temperature to control coolant flow between the engine and the radiator.
When the engine is cold, the thermostat closes to prevent coolant circulation between engine
and radiator. As the coolant warms up, the thermostat opens. This allows coolant flow through
the radiator.

The thermostat opens at a specific temperature rating. This number is usually stamped
0 0 0 0
on the thermostat. Two common ratings are 185 F (85 C) and 195 F (91 C). Most thermostats
0 0
begin to open at their rated temperature. They are fully opened at about 20 F (11 C) higher.

Removal of the thermostat would have an adverse effect, causing a lowering of cooling
efficiency. Do not remove the thermostat, even if the engine tends to overheat.

When replacing the thermostat also replace the gasket that seals the thermostat in place
and is positioned between the water outlet casting and the engine block. These gaskets are
die-cut to match the thermostat opening and mounting bolt configuration of the water outlet.
Thermostat gaskets generally come with or without an adhesive backing. The adhesive
backing of gaskets holds the thermostat securely centered in the mounting flange to align and
bolt the thermostat securely in place. With the adhesive-backed gasket holding the thermostat
in place, it will not drop out or become misaligned. This provides for a tight seal and also
prevents breaking the mounting flange of the water outlet during installation.

A thermostat is rated according to the engine operating temperature that it is supposed

to maintain. A thermostat can be checked while it is out of the engine.

Several types of commercial testers are available. When using such a tester, be sure to
follow the manufacturer’s instructions.

If a thermostat is more than two years old, or if there is any doubt about its operation,
replace it.

Go Back to Learning Activity Sheet

Code No. Date: Developed Date: Revised Page #

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ALT723309a Sept. 5, 2004 20
 SELF-CHECK LO2-2

A. Direction: Write T if the statement is true; F if it is false on the space provided before each
number.
_____ 1. As the coolant warms up, the thermostat opens and allows coolant to flow through the
radiator.

_____ 2. As temperature of a sample of gas increases at constant pressure, the volume

decreases.

_____ 3. Temperature and volume are directly proportional for a given sample of gas at
constant pressure.

_____ 4. A thermostat expands automatically to temperature changes by expanding only.

_____ 5. Not all gases increase in volume when their temperature is raise.

B. Direction: Answer these questions:

1. The thermostat opens at a specific temperature or thermostat rating. Most

º º
thermostats start to open at 91 C. What is the equivalent in F?

___________________________________________________________

º º
2. Most thermostats are fully open about 20 F. What would this be in C and K?

___________________________________________________________

Go Back to Learning Activity Sheet

Code No. Date: Developed Date: Revised Page #

ALT723309a Servicing Cooling System Sept. 5, 2004 21
 Answer Key LO2-2

A.
1. T
2. F
3. T
4. F
5. F

B.
º º
1. F = 9/5 C + 32
= 9/5 (91) + 32
= 819/5 + 32
= 163.8 + 32
o
= 195.8 F

º º
2. C = 5/9 ( F – 32)
= 5/9 (20 – 32)
= 5/9 (-12)
o
= -6.67 C

º
K = C + 273
= -6.67 + 273
= 266.33 K

Go Back to Learning Activity Sheet

Code No. Date: Developed Date: Revised Page #

 Servicing Cooling System Sept. 5, 2004 22
ALT723309a
 PERFORMANCE STANDARD LO2-1

PERFORMANCE
PERFORMANCE CRITERIA LEVEL
YES NO
1. Were tools and materials prepared?

2. Were protective clothing and goggles worn?

3. Was the coolant drained before the removal of the radiator?

4. Was the thermostat removed from the cooling system in

accordance to industry standard?

5. Was the job accomplished without causing damages to other

parts of the engine?

Satisfactory
Overall Performance
Unsatisfactory

Code No. Date: Developed Date: Revised Page #

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ALT723309a Sept. 5, 2004 23
 Operation Sheet LO2-1
Title: Procedure in Removing the Thermostat

Objective: Given an engine, set of sockets, screwdrivers, mechanical pliers and container,
you will remove the thermostat from the engine and observe Occupational Health
and Safety practices.

Instructions:

1. Prepare tools and materials needed.

2. Wear protective clothing and goggles.

3. Place a container under the radiator to

avoid spillage.

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ALT723309a Sept. 5, 2004 24
4. Open the radiator drain plug

5. Loosen the screw of the radiator hose

clip

6. Remove the hose from the radiator and

turn it aside.

7. Loosen the nuts and bolts in the water

outlet connection and remove them.

Code No. Date: Developed Date: Revised Page #

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ALT723309a Sept. 5, 2004 25
8. Remove the thermostat.

Go Back to Learning Activity Sheet

Code No. Date: Developed Date: Revised Page #

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ALT723309a Sept. 5, 2004 26
 PERFORMANCE STANDARD LO2-2

PERFORMANCE
PERFORMANCE CRITERIA LEVEL
YES NO NA
1. Were tools and materials needed for testing thermostat and
recording/interpreting results prepared?

2. Was the thermostat suspended in a solution of coolant?

º
3. Was the coolant heated 25 F above the temperature stamped on
the thermostat?

4. Were the data recorded as to temperature of the coolant before

the thermostat opens and the temperature at which it closes?

5. Were the data gathered interpreted and the preferred repair

actions indicated?

Satisfactory
Overall Performance
Unsatisfactory

Code No. Date: Developed Date: Revised Page #

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 WORKSHEET IN CHECKING THERMOSTAT CONDITION

Thermostat Reading in Temperature Gauge Remarks

Specification when the Thermostat Opens in
º º
(Thermostat Rating) C/ F

Code No. Date: Developed Date: Revised Page #

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 Operation Sheet LO2-2
Title: Testing the Thermostat

Objective: Given the instrument and materials needed, you will test the condition of a
thermostat. Observe Occupational Health and Safety practices while this.

Instructions:

If the thermostat is removed from the engine after the coolant has been drained, suspend
the thermostat completely submerged in a small container of water so that it so does not touch
the bottom. Place a thermometer in the water so that it does not touch the container and only
measures water temperature. Heat the water. When the thermostat valve barely begins to
open, read the thermometer. This is the opening temperature of this particular thermostat. If
the valve stays open after the thermostat is removed from the water, the thermostat is defective
and must be replaced.

Code No. Date: Developed Date: Revised Page #

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 PERFORMANCE STANDARD LO2-3

PERFORMANCE
PERFORMANCE CRITERIA LEVEL
YES NO NA
1. Were tools and materials appropriate for the job?

2. Was the thermostat installed correctly in the cooling system?

3. Was the cooling system leak-free after the installation of

thermostat?

4. Were the tools, equipment and work area cleaned after

accomplishing the job?

Satisfactory
Overall Performance
Unsatisfactory

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 Operation Sheet LO2-3
Title: Procedure on the Installation of the Thermostat

Objective: Given an engine, set of socket wrench, flat head screwdriver, mechanical pliers,
vellunoid gasket, gasket maker, thermostat, container and gasket scraper, you will
install thermostat in the cooling system and observe Occupational Health and
Safety practices.

Instructions:

1. Prepare tools and materials needed

2. Wear protective clothing and goggles.

3. Scrape the worn-out gasket on the water

outlet connection surfaces.

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Servicing Cooling System
ALT723309a Sept. 5, 2004 31
4. Install the thermostat in the water outlet
connection.

5. Apply gasket maker in the water outlet

connection surfaces

6. Mount the water outlet connection and

tighten the nuts and bolts.

7. Install the radiator hose and tighten the

clip.

Code No. Date: Developed Date: Revised Page #

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ALT723309a Sept. 5, 2004 32
8. Close the radiator drain plug.

9. Pour water into the radiator.

10. Test-run the engine.

Go Back to Learning Activity Sheet

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ALT723309a Sept. 5, 2004 33
QUALIFICATION : Automotive Servicing NC II

MODULE TITLE #1 : Servicing Cooling System

LEARNING OUTCOME #3: Perform Leakage Test on Cooling System

Assessment Criteria:

1. Technical data pertaining to engine cooling system obtained in conformity with service
manual
2. Appropriate tools and equipment/materials prepared and used
3. Leakage test performed in accordance with industry procedure
4. Test results recorded and preferred actions determined
5. Coolant heated in accordance with service manual specifications

Resources:
th
1. Automotive Engines-Maintenance & Repair, 4 edition, Billiet, Walter
2. Automotive Technology-A System Approach, Erjavec, j., et al.
rd
3. Automotive Tune-up & Engine Performance, 3 edition, Crouse, W. and Anglin, D.
th
4. Automotive Mechanics, 10 edition, Crouse, W. and Anglin D.
rd
5. Automotive Engines, 3 edition, Gillies, T.
6. Automotive Excellence, Glencoe/McGraw Hill, Academic Applications Volume I
7. Technical English, Gaduyon, M.L.A.
8. Introductory Mathematics, McKeague, C.

Code No. Date: Developed Date: Revised Page #

 Servicing Cooling System Sept. 5, 2004 34
ALT723309a
LEARNING EXPERIENCES

Learning Outcome #3: Perform Leakage Test on Cooling System

Learning Activities LO3-1 Resources

1. Read the information on cooling system  Information Sheet LO3-1, “Internal and
leakage. External Cooling System Leakage”

2. Answer the self-check.  Self Check

3. Check your answers with the answer key.  Answer Key

If your answers are all correct, proceed to the

next learning activity of the next learning
outcome. If you did not get all the answers, go
back to learning steps 1-3.

Code No. Date: Developed Date: Revised Page #

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 INFORMATION SHEET LO3-1

3.1.1 Internal and External Cooling System Leakage

The cooling system is often neglected. A customer will spend a great deal of money on
an overhaul but will not get a complete repair if the cooling system is not put in good order.

The following is a list of places to check for a suspected leak in the cooling system:

External Leakage
- Radiator leak
- Loose hose clamp
- Hose leak
- Faulty radiator cap
- Dented radiator inlet of outlet tube
- Cracked or porous water pump housing
- Water core leak
- Loose core hole plug in cylinder block
- Cracked thermostat housing
- Leak at water temperature sending unit
- Cylinder head bolts loosened or tightened unevenly
- Warped or cracked cylinder head
- Cracked cylinder block
- Damaged gasket or dry gasket if engine has been stored
- Coolant reservoir or hose leak

Internal Leakage
- Faulty head gasket
- Cracked head
- Cracked block
- Transmission fluid cooler leak

3.1.2 Diagnosing Leaks in the Cooling System

We use the five senses of smell, taste, touch, sight, and hearing to pick up messages
about what is going on around. For example, our sense of sight allows us to find our way
around the school. Touch mat helps us estimate temperature when we step out of the work
place.

Automotive technicians also use their senses. When automotive technicians put
together a diagnostic strategy, they rely on their senses. You learn how observing the color
exhaust can help you diagnose some engine problems. Listening to engine can help
technicians detect worn engine parts such as bearing and rocker arms. Some engine problems
can be detected by fluid leaks.

When there is a coolant leak into a combustion chamber, this can be spotted easily
during engine disassembly. A small amount of carbon is normal in a combustion chamber. The
cylinder with the leak will not have any carbon in it.

Internal leaks are diagnosed using the block tester, pressure tester, or infrared analyzer.
Fluorescent dye can also reveal cooling system leaks.

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3.1.3 Inspecting Cooling System for Leaks

1. Fill the radiator and engine with coolant, and attach a radiator cap tester to the water
outlet.

2. Warm up the engine.

3. Pump it to 118 kPa (1.2 kgf/cm2, 17.1 psi), and check that the pressure does not
drop.

If the pressure drops, check the hoses, radiator or water pump for leaks. If no external
leaks are found, check the heater core, cylinder block and head.

Go Back to Learning Activity Sheet

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 SELF-CHECK LO3-1
A. Direction: Answer the following. Write your answers on the answer sheet provided.

1. What are the four ways of leakage testing of the cooling system?
2. What are the equipment used in leak testing of the cooling system?
3. What are the two equipment used to check for exhaust-gas leakage into the
cooling system?
4. What device is used to identify leakage due to cracked cylinder head,
cracked cylinder block or worn-out gasket?
5. What leak testing instrument is used to locate external leakage of coolant?

B. Direction: Select the best answer inside the parenthesis and write the letter only on the
space provided before each number.

______ 1. If the cylinder head is defective, which of the following will leak into
the cooling system?
(a. air-fuel mixture b. fuel c. combustion gases d. exhaust gases)

______ 2. Leakage of gases into the cooling system may form

(a. oil sludge b. carbon deposits c. strong acids d. scales)

______ 3. The acids that form in the cooling system may corrode the
(a. radiator b. temperature gauge c. thermostat d. water pumping)

______ 4. Combustion leaks in the valve areas can cause cracks in the
(a. cylinder and piston b. valve seats and cylinder heads
c. crank shaft and camshaft d. oil pan and timing cover)

______ 5. Combustion leak in the valve area can be stopped by

(a. replacing cylinder head gasket b. grinding the valve face and
valve seat c. replacing the piston ring d. none of the above)

Go Back to Learning Activity Sheet

Code No. Date: Developed Date: Revised Page #

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 Answer Key LO3-1
1. a) Pressure testing the cooling system
b) Checking for exhaust gas leakage into the cooling system
c) Pressure testing the cooling system
d) Leak testing with ultraviolet light

2. a) Exhaust gas analyzer

b) Combustion leakage tester
c) Cooling system pressure tester
d) Ultraviolet light

3. a) exhaust gas analyzer

b) combustion leakage tester

4. Cooling system pressure tester

5. Ultraviolet light

B.
1. d
2. c
3. a
4. b
5. b

Go Back to Learning Activity Sheet

Code No. Date: Developed Date: Revised Page #

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ALT723309a Sept. 5, 2004 39
LEARNING EXPERIENCES

Learning Outcome #3: Perform Leakage Test on Cooling System

Learning Activities LO3-2 Resources

1. Read and study the performance standard.  Performance Standard LO3-1

2. Perform the procedures in the operation  Operation Sheet LO3-1 “Preparing

sheet. Tools and Working Area”

If your trainer approves your performance, move

on to learning activity 3.3 for this learning
outcome, if he disapproves it, go back to steps 1-
2.

Code No. Date: Developed Date: Revised Page #

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 PERFORMANCE STANDARD LO3-1

PERFORMANCE
PERFORMANCE CRITERIA LEVEL
YES NO NA
1. Was the working table prepared?

2. Were the tools and materials prepared and available on the

working table?

3. Was the workplace clean and free from unnecessary objects?

4. Was the work area conducive to working and OH & S?

Satisfactory
Overall Performance
Unsatisfactory

Code No. Date: Developed Date: Revised Page #

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 Operation Sheet LO3-1
Title: Preparing Tools and Working Area

Objective: Given a set of open-end wrench, close-end wrench, screwdrivers, bearing puller,
vellunoid gaskets, ball peen hammer and rugs, you will prepare tools and working area
observing OH & S practices.

Instructions:

1. Prepare working table

2. Gather the following tools and put them in

the working tables:

1 – set close-end wrench (metric)

1 – set open-end wrench (metric)

2 – pcs. Screwdriver

Code No. Date: Developed Date: Revised Page #

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ALT723309a Sept. 5, 2004 42
 1 – set bearing puller

1 – pc. ball peen hammer

1 – sheet vellumoid gasket

1 – pc. Rug

3. Remove all unnecessary objects/

obstructions in the workplace.

Go Back to Learning Activity Sheet

Code No. Date: Developed Date: Revised Page #

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ALT723309a Sept. 5, 2004 43
LEARNING EXPERIENCES

Learning Outcome #3: Perform Leakage Test on Cooling System

Learning Activities LO3-3 Resources

1. Read the information on recording information  Information Sheet LO3-3, “Recording

and identifying fluid leaks. Information” and “Identifying Auto Fluid
Leaks”.

2. Read and study the performance standard.  Performance Standard LO3-2

3. Perform the procedures in the operation  Operation Sheet LO3-2

sheet.

4. Have your performance standard sheet

evaluated by your instructor.

If you performed step 3 unsatisfactorily, repeat

steps 1 - 4; if satisfactorily, you can proceed to
learning activity 3 - 4.

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 INFORMATION SHEET LO3-3

3.3.1 Recording Information

Note taking is an informal method used to record information. You can write in a form
you can easily understand. You don’t need to use complete sentences. However, you should
write neatly and spell words correctly so you can share your notes with others if necessary.
Taking notes as a form of communication can be especially helpful in diagnosing a vehicle’s
problem.

You should take notes during a discussion with a customer about a vehicle’s problem.
Listen carefully. Write down what you believe are the customer’s important observations.
Include observations of your own.

Using these notes and your knowledge, you can start eliminate unlikely causes. You can
also jot down ideas for testing to diagnose the problem.

3.3.2 Identifying Auto Fluid Leaks

We use the five senses of smell, taste, touch, sight, and hearing to pick up messages
about what is going on around. For example, our sense of sight allows us to find our way
around the school. Touch may help us estimate temperature when we step out of the work
place.

Automotive technicians also use their senses. In this, you will learn about diagnostic
strategy. When automotive technicians put together a diagnostic strategy, they rely on their
senses. You learn how observing the color exhaust can help you diagnose some engine
problems. Listening to engine can help technician detect worn engine parts such as bearing and
rocker arms. You are told that some obvious engine problems can be detected by fluid leaks.
Let’s see how you might do this:

Fluid leaks are often one of these clues that a technician has in identifying a possible
engine problem. With just a little practice, you can “fine tune” your senses to help you identify
fluid leaks from an engine.

Go Back to Learning Activity Sheet

Code No. Date: Developed Date: Revised Page #

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ALT723309a Sept. 5, 2004 45
 PERFORMANCE STANDARD LO3-2

PERFORMANCE
PERFORMANCE CRITERIA LEVEL
YES NO NA
1. Were tools, equipment and materials appropriate for the job?

2. Was the specified amount of special dye added to the coolant?

3. Were the leakages in the cooling system identified?

4. Were the leaking parts recorded and the preferred corrective

actions accurately indicated?
Satisfactory
Overall Performance
Unsatisfactory

Code No. Date: Developed Date: Revised Page #

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 Operation Sheet LO3-2
Title: Performing Leakage Test, Recording, Analyzing Results and Prescribing Action

Objectives: Given an engine, ultraviolet light, special dye, paper and pencil and clean rags, you
will perform leak test, record, analyze results and prescribe action.

Instructions:
1. Prepare tools/equipment needed.
2. Wear protective clothing and goggles.
3. Add the specified amount of special dye to the coolant.
4. With the heater on, run the engine until the upper radiator tank hose is warm.
5. Aim the ultraviolet light at the suspected heating area. (Note: the dye in the
coolant will cause any leaking coolant to glow bright green)
6. Identify and record the part of the engine where the leakage occurs.
7. Analyze if the leakage is caused by worn-out gaskets, broken parts, loose
fasteners, etc.
8. Indicate preferred corrective actions. (Note: For the data in numbers 4,5 and 6,
use the attached worksheet)

Go Back to Learning Activity Sheet

Code No. Date: Developed Date: Revised Page #

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ALT723309a Sept. 5, 2004 47
 WORKSHEET IN PERFORMING LEAKAGE TEST, RECORDING AND
ANALYZING RESULTS

Part of the Engine

Cause of the Preferred Corrective
where the Leakage Findings
Leakage Actions
Occurs

Code No. Date: Developed Date: Revised Page #

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ALT723309a Sept. 5, 2004 48
LEARNING EXPERIENCES

Learning Outcome #3: Perform Leakage Test on Cooling System

Learning Activities LO3-4 Resources

1. Read the information on recording information  Information Sheet LO3-4, “Reading

and identifying fluid leaks. Feeler Gauge”.

2. Answer the self-check.  Self-check LO3-1

3. Check your answers with the answer key.  Answer Key LO3-1

If you got perfect score, move on to step 4. If

your score is not perfect, repeat steps 1 - 3

4. Read and study the performance standard.  Performance Standard LO3-3

5. Perform the procedures in the operation  Operation Sheet LO3-3 “Running the
sheet. Engine to Operating Temperature”

If your trainer approves your performance, move

on to the first learning activity of the next learning
outcome. If he disapproves, repeat steps 4 - 5.

Code No. Date: Developed Date: Revised Page #

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 INFORMATION SHEET LO3-4

Reading Feeler Gauge

The feeler gauge is a thin strip of metal

of known and closely controlled thickness.
Several of these metal strips are often
combined into a multiple measuring instrument
that pivots in a manner similar to a pocket
knife. The desired thickness gauge can be
pivoted away from others for convenient use.
A steel feeler gauge pack usually contains
leaves of 0.002 to 0.010 (in steps of 0.001
inch) inch thickness and leaves of 0.012 to
0.024 inch thickness (in steps of 0.002).

The feeler gauge can be used by itself to measure piston ring side clearance, piston ring
end gap, connecting rod side clearance, crankshaft end play, and other similar procedures. The
feeler gauge can also be used with a precision straight edge to measure main bearing bore
alignment and cylinder head/block warpage.

Thickness gauges are commonly called feeler gauges. They can be either the flat or wire
type. Feeler gauges are commonly used to measure such things as valve clearance and the
gaps of spark plugs, piston rings, and ignition points.

Plastigauge is a product used to measure oil clearance in bearings and oil pumps. It is a
strip of plastic that deforms when crushed. The deformed plastic gives an idea of the amount of
clearance present.

The metric system has been established as the international system of measurement
and is known as System International or simply S.I. It is more convenient to use than the
English system because its units are expressed in multiples of 10. Prefixes are used to indicate
larger or smaller units and to show place value position.

Prefixes Meaning English-Metric System Equivalents

12
Tera trillions (10 ) 1 meter = 3.3 feet
9
Giga billions (10 ) = 39.37 inches
6
Mega millions (10 ) 1 yard = 3 feet
3
Kilo thousands (10 ) = 36 inches
2
Hecto hundreds (10 ) = 91.44 cm.
1
deka tens (10 ) 1 foot = 12 inches
-1
deci tenths(10 ) = 30.48 cm.
-2
centi hundredths (10 ) 1 inch = 2.54 cm.
-3
milli thousandths (10 )
micro -6
millionths (10 )
nano -9
billionths (10 )
pico trillionths (10 )
-12

Code No. Date: Developed Date: Revised Page #

ALT723309a Servicing Cooling System Sept. 5, 2004 50
 Large units are used to measure distance, for example, the distance between two cities
are measured in kilometers or miles, not in meters or feet.

In the metric system, meter is the basic unit of length. However, units can be converted
from one system to another or from one unit to another using conversion factor.

The Relationship between Is To convert from one to the other

multiply by
millimeters (mm) 1,000 mm = 1 m 1000 mm or 1m
and meters (m) 1m 1000mm

centimeters (cm) 100 cm = 1 m 100 cm or 1m

and meters (m) 1m 100 cm

decimeters (dm) 10 dm = 1 m 10 dm or 1m
and meters (m) 1m 10 dm

decameters (dam) 1 dam = 10 m 10 m or 1 dam

and meters (m) 1 dam 10 m

hectometers (hm) 1 hm = 100 m 100 m or 1 hm

meters (m) 1 hm 100 m

kilometers (km) 1 km = 1000 m 1000 m or 1 km

and meters (m) 1 km 1000 m

Go Back to Learning Activity Sheet

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 SELF-CHECK LO3-1
A. Direction: Make the following conversions in the metric system.

1. Convert 25 millimeters to meters

2. Convert 36.5 centimeters to decimeters

3. Convert 18 meters to millimeters

4. Convert 3,498 centimeters to meters

5. Convert 4.58 meters to decimeters

6. Convert 5.75 feet to centimeters

Go Back to Learning Activity Sheet

Code No. Date: Developed Date: Revised Page #

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 Answer Key LO3-1

A.

1) 25 mm = 25 mm x 1m = 25 m = 0.025 m
1000 mm
1000
= 36.5x10 dm = 3.65 dm
2) 36.5 cm = 36.5 cm x 1m x 10 dm 100
100 cm 1m

3) 18 m = 18 m x 1000 mm = 18000 mm
1m

4) 3498 cm = 3498 cm x 1m = 3498 m = 34.98 m

100 cm 100

5) 4.58 m = 4.58 m x 1 dam = 4.58 dam = 0.458 dam

10 m 10

6) 5.75 ft = 5.75 ft. x 30.48 cm = 175.26 cm

1 ft.

Go Back to Learning Activity Sheet

Code No. Date: Developed Date: Revised Page #

 Servicing Cooling System Sept. 5, 2004 53
ALT723309a
 PERFORMANCE STANDARD LO3-3

PERFORMANCE
PERFORMANCE CRITERIA LEVEL
YES NO NA
1. Was the engine/vehicle prepared?

2. Was the engine started in accordance with manufacturer’s

specifications?

3. Was the engine speed adjusted to low speed operation?

º
4. Had the engine reached the temperature of 160 F?
Satisfactory
Overall Performance
Unsatisfactory

Code No. Date: Developed Date: Revised Page #

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 Operation Sheet LO3-3
Title: Running Engine until Operating Temperature is Obtained

Objective: Given an engine/running vehicle, you will run the engine until operating temperature
is obtained. Observe Occupational Health and Safety practices while performing
this.

Instructions:

1. Prepare the vehicle needed

2. Wear protective clothing and goggles.

3. Start the engine

Code No. Date: Developed Date: Revised Page #

Servicing Cooling System
ALT723309a Sept. 5, 2004 55
4. With the engine running, adjust the idle
speed adjusting screw until the engine is
set at low speed operation.

5. Observe until engine temperature

0
reaches 160 F.

6. Readjust engine to idle speed as soon as

temperature is obtained.

Go Back to Learning Activity Sheet

Code No. Date: Developed Date: Revised Page #

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ALT723309a Sept. 5, 2004 56
QUALIFICATION : Automotive Servicing NC II
MODULE TITLE #1 : Servicing Cooling System
LEARNING OUTCOME #4 : Repair/Replace Water Pump

Assessment Criteria:

1. Technical data pertaining to engine water pump obtained using service manual
2. Water pump checked/inspected and faults determined
3. Water pump/ parts replacement determined
4. Water pump/parts dismantled in accordance with service manual
5. Water pump/parts installed/replaced per manufacturer’s specifications

Resources:
th
1. Automotive Engines-Maintenance & Repair, 4 edition, Billiet, Walter
2. Automotive Technology-A System Approach, Erjavec, et al.
rd
3. Automotive Tuneup & Engine Performance, 3 edition, Crouse, W. and Anglin, D.
th
4. Automotive Mechanics, 10 edition, Crouse, W. and Anglin, D.
rd
5. Automotive Engines, 3 edition, Gillies, T.
6. Water Pump
7. Set of wrenches
8. Set of box wrench
9. Water pump repair kit
10. Puller/Installer
11. Gasket maker/cement

Code No. Date: Developed Date: Revised Page #

 Servicing Cooling System Sept. 5, 2004 57
ALT723309a
LEARNING EXPERIENCES

Learning Outcome #4: Repair/Replace Water Pump

Learning Activities LO4-1 Resources

1. Read the information on recording information  Information Sheet LO4-1, “Water

and identifying fluid leaks. Pump”.

2. Read the service manual  Service Manual for Components

Specifications

3. Answer the self-check.  Self-Check LO4-1

3. Check your answers with the answer key.  Answer Key LO4-1

If you answered all items in the self-check

correctly, proceed to step 6. If not, repeat steps 1
- 3.

4. Read and study the performance standard.  Performance Standard LO4-1

5. Perform the procedures in the operation  Operation Sheet LO4-1

sheet. “Inspecting/Checking Water Pump and
Determining Preferred Repair Action”
If your trainer rated you as competent, go to the
next learning activity for this learning outcome. If
incompetent, repeat steps 4 - 5.

Code No. Date: Developed Date: Revised Page #

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 INFORMATION SHEET LO4-1

4.1.1 Water Pump

The heart of the cooling system is the water pump. Its job is to move the coolant
efficiently through the system. Water pumps are centrifugal pumps that use an impeller to
move the coolant.

The water pump is sometimes called upon to circulate as much as 7500 gallons of
coolant in one hour. It is mounted on the front of the engine and is belt-driven by the
crankshaft. Usually, the alternator uses the same belt and has a provision for adjusting the belt
tension.

It has a spring loaded permanent seal to keep water from leaking out.

4.1.2 Water Pump Parts and their Functions

An Impeller Type Water Pump

Code No. Date: Developed Date: Revised Page #

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4.1.3 Checking the Water Pump

The water pump housing is either aluminum or cast iron. Cast iron is more popular in
rebuilt pumps because aluminum is subject to erosion. As the aluminum erodes, the pump
cavity becomes larger. The reduce pump efficiency can cause air pockets.

Pump impellers are made either of steel or plastic. Carefully inspect the impeller for
erosion, looseness, or breakage. If pieces break off the impeller, they will go into the block and,
possibly, the radiator. It may be necessary to disassemble the radiator to be sure that all pieces
are removed.

A water pump often has a steel plate bolted to its back. The plate casket sometimes
dries out and leaks during shipping. It is a good idea to remove the bolts in this kind of pump
and cement both sides of the plate gasket before installing it.

Water pumps can fail because of a failure in the bearing, seal or impeller. They become
evident when water leaks from a water pump vent hole.

4.1.4 Causes of Water Pump Failure

 When a vehicle has been allowed to sit with a dry or dirty cooling system, the water
pump seal will sometimes stick to the shaft. When the engine is started, it breaks, loose,
resulting in a leak.
 A pump seal can also fail because of bearing failure, corrosion of the shaft, or dirt.
 An out of balance fan assembly can lead to water pump shaft and bearing failure.
 A leaking fan clutch, bent or broken fan, or a cocked or cracked aluminum fan spacer are
all possible causes of pump failure. Be sure to tighten the fan bolts evenly to avoid
causing a cocked assembly.

Go Back to Learning Activity Sheet

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 SELF-CHECK LO4-1
A. Direction: Enumerate the component parts of the water pump.

1.

2.

3.

4.

5.

6.

B. What is the purpose of the cooling system?

C. Where is the water pump mounted?

D. Give three causes of water pump failure

Go Back to Learning Activity Sheet

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 Model Answer

A. (in any order)

1. gasket

2. impeller

3. seal

4. slinger

5. shaft

6. bearing

B. Its work is to move the coolant efficiently through the system.

C. It is mounted on the front of the engine and is belt-driven by the crankshaft.

D. 1. Cracked or loose water pump seal

2. Bearing failure
3. Leaking fan clutch, bent or broken fan

Go Back to Learning Activity Sheet

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 PERFORMANCE STANDARD LO4-1

PERFORMANCE
PERFORMANCE CRITERIA LEVEL
YES NO NA
1. Was the coolant drained and collected in containers?

2. Was the volume of cooling system capacity determined?

3. Were the water additive mixtures in accordance with

manufacturer’s specifications?
Satisfactory
Overall Performance
Unsatisfactory

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 Operation Sheet LO4-1
Title: Inspecting/Checking Water Pump and Determining Preferred Repair Action

Objective: Given disassembled water pump parts, clean rugs and magnifying glass, you
should inspect/check water pump and determine preferred repair action.

Instructions:

1. Check the impeller. In normal operation,

impeller blades may wear due to the
abrasive action of sand in the coolant.

2. Check the water pump shaft bearing for

lack of lubricant or wear.

3. Check water pump shaft for wears or

cracks

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4. Check water pump seal for leakage due
to cracks

5. Check water pump gasket.

Note: Any worn-out, cracked or loose parts

should be replaced.

Go Back to Learning Activity Sheet

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LEARNING EXPERIENCES

Learning Outcome #4: Repair/Replace Water Pump

Learning Activities LO4-2 Resources

1. Read and study the performance standard.  Performance Standard LO4-2

2. Perform the procedures in the operation  Operation Sheet LO4-2 “Preparing

sheet. Tools and Work Area”

If you are competent in performing the Operation

Sheet, move on to learning step 4. If
incompetent, go back to steps 1 – 2.

4. Read and study the performance standard.

 Performance Standard LO4-3
5. Perform the procedures in the operation
sheet.  Operation Sheet LO4-3 “Dismounting
Water Pump”
If your trainer approves your performance to be
satisfactory, move on to learning activity 4-3. If he
disapproves, go back to steps 5-6.

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 PERFORMANCE STANDARD LO4-2

PERFORMANCE
PERFORMANCE CRITERIA LEVEL
YES NO NA
1. Was the working table prepared?

2. Were the tools and materials prepared and available on the

working table?

3. Was the workplace clean and free from unnecessary objects?

4. Was the work area conducive to working and OH & S?

Satisfactory
Overall Performance
Unsatisfactory

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 Operation Sheet LO4-2
Title: Preparing Tools and Work Area

Objective: Given a set of open-end wrench, close-end wrench, screwdrivers, bearing puller,
vellunoid gaskets, ball peen hammer and rugs, you will prepare tools and working
area in preparation for water pump servicing.

Instructions:

1. Prepare and clean the working tables

2. Gather the following tools and put them in

the working tables.

1 set – close-end wrench (Metric)

1 set – open-end wrench (Metric)

2 pcs – screwdriver

1 set – bearing puller

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 1 pc – ball peen hammer

1 sheet – vellunoid gasket

1 pc – rug

3. Remove all unnecessary objects/

obstructions in the work place.

Go Back to Learning Activity Sheet

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 PERFORMANCE STANDARD LO4-3

PERFORMANCE
PERFORMANCE CRITERIA LEVEL
YES NO NA
1. Were the tools and materials gathered appropriate for
dismounting water pump?

2. Were the hoses and radiator removed without causing

damage?

3. Were the fan belt, cooling fan and pulley removed in

accordance with job requirements?

4. Was the water pump removed properly?

Satisfactory
Overall Performance
Unsatisfactory

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 Operation Sheet LO4-3
Title: Dismounting Water Pump

Objective: Given an engine/vehicle, 1 set open-end wrench, 1 set close-end wrench, flat head
screwdriver, pliers, engine and rugs, you will dismount water pump from the engine
and observe Occupational Health and Safety practices.

Instructions:

1. Prepare tools and materials needed

2. Wear protective clothing and goggles.

3. Drain coolant in the radiator and engine

using the following steps:

a. Place a container under the radiator

to avoid spillage.

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 b. Open the radiator drain plug

4. Remove the radiator hose when coolant

is completely drained.

5. Remove the radiator.

6. Dismount fan belt, cooling fan and pulley

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7. Loosen water pump bolts

8. Dismount water pump assembly

Go Back to Learning Activity Sheet

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LEARNING EXPERIENCES

Learning Outcome #4: Repair/Replace Water Pump

Learning Activities LO4-3 Resources

1. Read and study the performance standard.  Performance Standard LO4-4

2. Perform the procedures in the operation  Operation Sheet LO4-4 “Dismantling

sheet. Water Pump”

If your trainer rated your performance

satisfactory, move on to learning step 4. If
unsatisfactory, repeat steps 1 - 2.

4. Read and study the performance standard.  Performance Standard LO4-5

5. Perform the procedures in the operation  Operation Sheet LO4-5 “Repairing/

sheet. Replacing Water Pump”

Proceed to learning activity 4-4 if you performed

step 5 satisfactorily. If not, repeat steps 4 - 5.

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 PERFORMANCE STANDARD LO4-4

PERFORMANCE
PERFORMANCE CRITERIA LEVEL
YES NO NA
1. Were tools and materials gathered appropriate for the job?

2. Was the impeller cover removed?

3. Was the impeller removed with the use of the bearing puller?

4. Were the impeller shaft, bearing and seal removed with the use
of the hydraulic press?

5. Were all parts dismantled without any damage?

Satisfactory
Overall Performance
Unsatisfactory

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 Operation Sheet LO4-4
Title: Dismantling Water Pump

Objective: Given a water pump, bearing puller, ball peen hammer, flat screwdriver and
hydraulic press, you will dismantle water pump and observe Occupational Health
and Safety practices at the satisfaction of your trainer.

Instructions:

1. Prepare tools and materials needed.

2. Wear protective clothing and goggles.

3. Loosen screws of the impeller cover and remove.

4. Remove impeller with bearing puller.

5. Remove impeller shaft and bearing with hydraulic press.

Go Back to Learning Activity Sheet

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 PERFORMANCE STANDARD LO4-5

PERFORMANCE
PERFORMANCE CRITERIA LEVEL
YES NO NA
1. Were appropriate tools, materials, equipment for the job
prepared?

2. Were the defective parts of the water pump determined?

3. Were the defective parts replaced/repaired?

4. Was the whole water pump assembly replaced or some of the

parts only?
Satisfactory
Overall Performance
Unsatisfactory

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 Operation Sheet LO4-5
Title: Repairing/Replacing Water Pump

Objective: Given a set of close-end wrench, screwdriver, bearing puller, rugs, gasket materials
and grease, you will dismantle/repair/replace defective water pump parts properly.

Instructions:
1. Prepare tools and materials needed.

2. Determine the defective parts of the water pump through visual inspection.
Note: Common defects of the water pump are the following:

 Worn-out shafts, bearing, seal shaft and gasket.

3. Replace defective parts as the case may be.

Note: If most of the parts are beyond economical repair, replace the whole
water pump.

Go Back to Learning Activity Sheet

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LEARNING EXPERIENCES

Learning Outcome #4: Repair/Replace Water Pump

Learning Activities LO4-4 Resources

1. Read and study the performance standard.  Performance Standard LO4-6

2. Perform the procedures in the operation  Operation Sheet LO4-6 “Assembling

sheet. and Installing Water Pump”

If you performed step 2 satisfactorily, you can

proceed to the first learning activity of the next
learning outcome. If unsatisfactorily, repeat steps
1 - 2.

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 PERFORMANCE STANDARD

PERFORMANCE LEVEL
PERFORMANCE CRITERIA
YES NO NA
1. Were appropriate tools and materials
needed for the job prepared?

2. Was the bearing applied with grease before

installation?

3. Was the impeller shaft installed in the pump

body in accordance with industry standard?

4. Were all parts installed according to job

requirements?
Satisfactory
Overall Performance
Unsatisfactory

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 Operation Sheet
Title: Assembling and Installing Water Pump

Objective: Given disassembled parts of the water pump, ball peen hammer, flat screwdriver,
gasket, gasket maker and grease oil, you will assemble water pump parts and
install them to the engine.

Instructions:
1. Prepare tools and materials needed.
2. Apply slight grease oil on the bearing surface and install the bearing in water
pump body.
3. Assemble the impeller shaft with the use of hydraulic press.
4. Apply gasket maker on the gasket surface of the impeller cover.
5. Assemble the impeller cover and tighten the screw.
6. Install the water pump assembly to the engine.

Go Back to Learning Activity Sheet

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QUALIFICATION : Automotive Servicing NC II
MODULE TITLE #1 : Servicing Cooling System
LEARNING OUTCOME #5 : Apply Coolant Additives

Assessment Criteria:

1. Technical specifications of coolant additives obtained

2. Coolant additives selected in accordance with manufacturer's specifications
3. Coolant additives applied per manufacturer's specifications

Resources:
th
1. Automotive Engines-Maintenance & Repair, 4 edition, Billiet, Walter
2. Automotive Technology-A System Approach, Erjavec, et al.
rd
3. Automotive Tuneup & Engine Performance, 3 edition, Crouse, W. and Anglin, D.
th
4. Automotive Mechanics, 10 edition, Crouse, W. and Anglin, D.
rd
5. Automotive Engines, 3 edition, Gillies, T.
rd
6. Fundamentals of Chemistry, 3 Edition, Wood, J., et al.
7. Owner's Manual, Mitsubishi Adventure
8. Antifreeze solution
9. Antirust/corrosion solution
10. Antifoam

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 Servicing Cooling System Sept. 5, 2004 82
ALT723309a
LEARNING EXPERIENCES

Learning Outcome #5: Apply Coolant Additives

Learning Activities LO5-1 Resources

1. Read Information on coolant additives.  Information Sheet LO5-1 “Coolant

Additives”
2. Answer the self-check.
 Self-Checks LO5-1 and LO5-2
3. Check your answers with the answer key.
 Answer Keys LO5-1 and LO5-2
If you have answered all items correctly, go to the
next learning activity for this learning outcome. If
there is/are incorrect answers, repeat steps 1 - 3.

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 INFORMATION SHEET LO5-1
Coolant Additives
5.1.1 Anti-freeze

The engine coolant contains ethylene glycol anti-corrosion agent. The cylinder head and
water pump housing are cast aluminum alloy, and periodic changing of the engine coolant is
necessary to prevent corrosion of these parts.

Because of the necessity of this anti-corrosion agent, the coolant must not be replaced
with plain water even in summer. The required concentration of anti-freeze defers depending
on the expected ambient temperature.

º -15 -20 -25 -30 -35- -50

Ambient Temperature C
(minimum)
Anti-freeze concentration % 30 35 40 45 50 60

The effective anti-corrosion and anti-freeze performance keeps the anti-freeze

concentration within the range of 30-60%. Concentrations exceeding 60% will result in a
reduction of both the anti-freeze and cooling performance, thus adversely affect the engine.

5.1.2 Engine Coolant

A translucent coolant reserved tank is located in the engine compartment. The coolant
level in this tank should be kept the “LOW” and “FULL” marks when measured while the engine
is warm and idling.

The cooling system is a close system and normally the loss of coolant should be very
slight. A noticeable drop in the coolant level will indicate leakage. If this occurs, have the
system checked as soon as possible. If the level should drop below the ”LOW” level on the
reserve tank, open the lid and add coolant. Also if the reserve tank is completely empty,
remove the radiator cap and add coolant until the level reaches the filter neck.

5.1.3 Types of Coolant Additives and their Uses

There are Three Types of Coolant Additives Commonly Used in Automotive Vehicle

1. Antifreeze solution
2. Anti rust/corrosion solution
3. Antifoam

Uses:

1. Antifreeze solution – a chemical, usually ethylene glycol, added to the engine coolant
to raise its boiling temperature and lower its freezing temperature. Mixing the proper
amount of antifreeze with water produces a coolant mixture that is not likely to freeze.

2. Anti rust/corrosion solution – removes and prevents rust and corrosion in the engine
cooling system particularly in the water jackets and radiator. Corrosion and rust can
shorten the life of metal parts. It also forms an insulating layer which reduces heat
transfer from the metal to the coolant.
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 3. Antifoam solution – helps prevent the coolant from foaming as it passes through the
water pump. Foam contains air bubbles which do not conduct heat as well as the
liquid coolant. If the coolant foams excessively, the cooling system becomes less
effective. The engine could overheat.

5.1.4 Technical Specifications of Coolant Additives

o o
Water freezes at 32 F (0 C). If only water were used as the coolant, it would freeze each
o o
time the temperature dropped below 32 F (0 C). This would stop coolant circulation and the
engine would overheat. Mixing the proper amount of anti-freeze with water produces a coolant
mixture that is not likely to freeze.

Table below shows freeze temperature of coolant containing various percentage of

ethylene glycol anti-freeze.

Percentage of Anti-freeze by
Freezing Point Volume
º º
F C
+32 0 0
+20 -7 15
+10 -12 25
0 -18 33
-10 -23 40
-20 -29 45
-30 -34 48
-35 -37 50
-40 -40 53
-50 -46 56
-60 -51 59
-70 -57 62
-80 -62 65
-90 -69 67
-92 -69 68

5.1.5 Ratio and Proportion

Coolant – the liquid mixture of about 50% antifreeze and 50% water used to carry heat
out of the engine. Antifreeze which is a chemical usually ethylene glycol, is added to the engine
coolant to raise its boiling temperature and lower its freezing temperature.

The most commonly used antifreeze is ethylene glycol. A mixture of half water and half
ethylene is the recommended coolant for year-round use in most automobile engines. The
o o o
mixture will not freeze about –34 F(-37 C). That is 34 F below zero. A solution of 70%
o o
antifreeze will prevent freezing of the coolant at temperatures as low as –84 F(-64 C).
However, any mixture of ethylene glycol and water is less effective than only water in
transferring heat from the engine.

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 Antifreeze contains several additives. These include a corrosion inhibitor and a foam
inhibitor. Corrosion or rust can shorten the life of metal parts. It also forms an insulating layer
which reduces heat transfer from the metal to the coolant. In engines with severe corrosion, the
coolant may be at normal temperature while the cylinders and heads are overheating. One
reason for having 50% antifreeze is to ensure the cooling system contains an adequate amount
of corrosion inhibitors. Antifreeze is colored with a dye for identification. The color is usually
green or blue-green. The dye allows the antifreeze to serve as a leak detector. The distinctive
color makes it easier to locate and identify a leak.

Foam and corrosion inhibitors gradually lose their effectiveness. If corrosion occurs, the
coolant may become rust colored. Vehicle manufacturers usually recommend changing the
coolant every two years. This restores the inhibitors and removes the contaminants in the
coolant.

When the engine is shut off and begins to cool, the coolant contracts. Cold coolant takes
less space than hot coolant.

The ratio of two numbers is a way of comparing them. It can be expressed as a fraction.
A statement that two ratios are equal is called proportion. The first and fourth terms of a
proportion are called extremes, and the second and third terms of the proportion are called the
means. In any proportion, the product of the means is equal to the product of the extremes.

Go Back to Learning Activity Sheet

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 SELF-CHECK LO5-1
A. Directions: Answer the following questions in complete sentences. (Please refer to the
information sheet “Interpreting Information”). Write your answers in the answer sheet
provided.

1. What does the engine coolant contain?

2. Why is periodic changing of the engine coolant necessary?

3. Given an anti-freeze concentration of 40%, what should be the minimum ambient

temperature?
º
4. With a minimum ambient temperature of -35 C, how many percent should be the anti-
freeze concentration?

5. What happens when the anti-freeze concentration exceeds 60%?

B. Directions. (For information sheet “Technical Specifications of Coolant Additives”).

Select the best answer. Write the number of your answer in the answer sheet provided.

6. The water inside the cooling system would freeze inside the cooling system each time
the temperature dropped below:
1) 32ºF 2) 42ºF 3) 52ºF 4) 62ºF

7. Frozen water in the cooling system would cause:

1) engine overheating 3) loose compression
2) lack of water 4) backfires

8. To prevent freezing of coolant in the cooling system, which of the following should be
done?
1) Mix proper amount of anti-rust/corrosion solution.
2) Mix anti-freeze solution.
3) Do not put water in the cooling system.
4) All of the above

9. If 33 percent of anti-freeze solution by volume is mixed with the coolant, it is likely to

freeze at:
o o o o
1) -18 C 2) -23 C 3) -29 C 4) -34 C

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 SELF-CHECK LO5-2

A. Direction: Answer the following questions to test your knowledge pertaining to types of
coolant additives and their uses.

1. What are the three types of coolant additives:

a. ______________________
b. ______________________
c. ______________________

2. ______________ a chemical added to the engine coolant to raise its boiling temperature
and lower its freezing temperature.
3. ______________ a solution that removes and prevents rust and corrosion in the engine
cooling system.

4. ______________ a solution that prevents the coolant from foaming as it passes through
the water pump.

B. Direction: Solve the following problems on ratio and proportion.

1. A solution contains 25 ml of ethylene glycol and 25 ml of water. If another solution is to

have the same ratio of ml of ethylene glycol to ml of water and must contain 75 ml of
water, how much ethylene glycol should it contain?

2. If a 500 ml coolant costs P 55.00, how much would 1500 ml cost?

3. A gasoline station had sold the following items for the day: super coolant – 15 liters, 2-
stroke engine oil – 45 liters, gasoline – 78 liters, diesoline – 132 liters, kerosene – 27
liters. Find the following:

a. Ratio of super coolant to 2-stroke engine oil

b. Ratio of gasoline to kerosene
c. Ratio of kerosene to diesoline
d. Ratio of 2-stroke engine oil to gasoline
e. Ratio of kerosene to super coolant

Go Back to Learning Activity Sheet

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 Answer Key LO5-2
A.

1. The engine coolant contains an ethylene glycol anti-corrosion agent.

2. The periodic changing of the engine coolant is necessary to prevent corrosion of the
cylinder head and water pump housing.
º
3. The minimum ambient temperature should be -25 C.

4. The anti-freeze concentration should be 50%.

5. When the anti-freeze concentration exceeds 60%, this results in a reduction of the anti-
freeze and cooling performance; thus, adversely affecting the engine.

B.

6. 1

7. 1

8. 2

9. 1

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ALT723309a Servicing Cooling System Sept. 5, 2004 89
 Answer Key LO5-2
A.
1. a. Antifreeze solution
b. Antirust solution
c. Antifoam solution
2. Antifreeze solution
3. Antirust solution
4. Antifoam solution
B.
1. Solution: We let X represent the number of ml of ml of ethylene glycol in the
second solution. The problem translates to x ml is to 75 ml as 25 ml is to 25 ml.
X = 25
75 25
X(25) = 75(25)
X(25) = 1875
X(25) = 1875
25 25
X = 75 ml of ethylene glycol

2. Solution: We let X represent the cost of the 1500 ml coolant. The problem
translates to
500 ml is to P55.00 as 1500 ml is to X
500:55 = 1500:X
500(X) = 1500(55)
500(X) = 82500
500(X) = 82500
500 500
X = P165.00 cost of 1500 ml coolant
3. Solution:
super coolant ------------ 15 liters a. 15 or 15:45
2-stroke engine oil ----- 45 liters 45
gasoline ------------------- 78 liters
diesoline ------------------ 132 liters b. 78 or 28:27
kerosene ----------------- 27 liters 27

c. 27 or 27:132
132

d. 45 or 45:78
78

e. 27 or 27:15
15

Go Back to Learning Activity Sheet

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LEARNING EXPERIENCES

Learning Outcome #5: Apply Coolant Additives

Learning Activities LO5-2 Resources

1. Read Information on antifreeze.  Information Sheet LO5-2 “OH & S

Practices in Handling Coolant
Additives”

2. Answer the self-check.  Self-Checks LO5-3

3. Check your answers with the answer key.  Answer Keys LO5-3

If you have all items correct, go to learning step

5. If error/s is/are made, repeat steps 1 - 3.

4. Read and study the performance standard.  Performance Standard LO5-1

5. Perform the procedures in the operation  Operation Sheet LO5-1

sheet.

If your trainer rates you as competent in doing

step 6, you can take the summative assessment
for this module. If not, repeat steps 4 – 5

Proceed to the next module for this unit of

competency, if you passed the assessment. If
you failed, you will undergo retraining in all the
learning outcomes for this module.

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 INFORMATION SHEET LO5-2

5.2.1 Occupational Health & Safety Practices in Handling Coolant Additives

Coolant Safety Notes

 Ethylene glycol is a poison. Ingestion of 4 ounces is sufficient to kill a human being.

Because ethylene glycol has a sweet taste, it is especially dangerous to animals.
Drained coolant left on the floor in a drain pan can poison a dog. Do not leave used
coolant around the shop.

 Ethylene glycol can freeze-burn skin if left in the trunk during cold weather. Be
careful when handling extremely cold coolant.
o
Ethylene glycol will ignite in the presence of flame at about 474 F. Research by GM has
shown that an explosion can actually occur if a mist of pressurized ethylene glycol coolant
mixture is sprayed on an open flame.

5.2.2 What are the Effects of Coolant Additives to Engine Performance?

The cooling system is often neglected, especially in frost-free areas of the country. Many
people in more temperate areas use tap water to fill their radiators. This can lead to plugged
radiators, rusted radiator cap springs, rusted core plugs, plugged heater cores, rusted radiator
hose reinforcement springs, and a host of other problems. Most of these problems could be
avoided simply by using a coolant/water mixture instead of pure water.

All manufacturers recommend the use of coolant in the radiator. Coolant contains ethylene
glycol. A good antifreeze will protect against rust and aluminum corrosion and provide
lubrication for the water pump. It will also raise the boiling point of the water and lower its
freezing point. Corrosion cannot be completely prevented, but it can be retarded. To prevent
aluminum corrosion, coolant must contain corrosion inhibitor. Be sure the antifreeze container
specially states that it may be used with aluminum.

Go Back to Learning Activity Sheet

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 SELF-CHECK LO5-3

A. Direction: Check your knowledge on the OH & S practices in handling coolant additives.

1. Ethylene glycol is (a. edible b. poisonous when swallowed c. hazardous to health if

inhaled d. none of the above).
2. The taste of ethylene glycol is (a. sour b. sweet c. bitter d. salty).
3. How many ounces of ethylene glycol if swallowed could potentially kill a human being?
(a. 4 b. 6 c. 8 d. 10)
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4. At 474 F, ethylene glycol becomes (a. flammable b. poisonous c. sweet smell d.
none of the above).

B. Direction: Complete the following sentences by filling the blanks with the correct answers.
1. Many people in temperate areas used _________ to fill their radiators.
2. Coolant contains _________.
3. A good anti-freeze will protect against _________ and corrosion.
4. To prevent aluminum corrosion, coolant must contain ___________.

C. Using tap water to fill radiators can lead to:

1. _________________________________.
2. _________________________________.
3. _________________________________.
4. _________________________________.
5. _________________________________.

Go Back to Learning Activity Sheet

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 Answer Key LO5-3
A. 1. b
2. b
3. a
4. a

B. 1. tap water
2. ethylene glycol
3. rust
4. corrosion inhibitor

C. 1. Plugged radiators
2. Rusted radiators cap springs
3. Rusted core plugs
4. Plugged heater cores
5. Rusted radiators hose reinforcement springs

Go Back to Learning Activity Sheet

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 PERFORMANCE STANDARD

PERFORMANCE
PERFORMANCE CRITERIA LEVEL
YES NO NA
1. Was the coolant drained and collected in containers?

2. Was the volume of cooling system capacity determined?

3. Were the water-additive mixtures in accordance with

manufacturer’s specifications?
Satisfactory
Overall Performance
Unsatisfactory

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Operation Sheet

Title: Applying Coolant Additives as per Manufacturer’s Specifications

Objective: Given a coolant additive, coolant hydrometer, empty containers and water, you will
apply coolant additive as per manufacturer’s specifications.

Instructions:

1. Drain and collect the water in the cooling system.

2. Measure the volume of collected water to determine the capacity of the cooling
system.
3. Measure half amount of water from the total capacity.
4. Mix it with the same amount of additive and stir thoroughly.
5. Pour all the mixture into the radiator.

Go Back to Learning Activity Sheet

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 PERFORMANCE TEST

Learner's Name Date

Competency: SERVICE ENGINE MECHANICAL SYSTEM Test Attempt

1st 2nd 3rd

Directions: OVERALL EVALUATION

Level
CALL YOUR INSTRUCTOR, ask Achieved PERFORMANCE LEVELS
your instructor to assess your
4 - Can perform this skill without supervision and with
performance in the following critical initiative and adaptability to problem situations.
task and performance criteria
below. 3 - Can perform this skill satisfactorily without
assistance or supervision.

You will be rated based on the 2 - Can perform this skill satisfactorily but requires
overall evaluation on the right side. some assistance and/or supervision.

1 - Can perform parts of this skill satisfactorily, but

requires considerable assistance and/or supervision.

Instructor will initial level achieved.

PERFORMANCE STANDARDS Yes No N/A

For acceptable achievement, all items should receive a "Yes" or "N/A" response.
1. Identifies parts of the cooling system
2. Explains the functions of the parts of the cooling
3. Explains coolant circulation within the cooling system
4. Determines standard condition of thermostat as per manufacturer’s
specifications.
5. Determines location of the thermostat.
6. Checks thermostat condition in accordance with service manual.
7. Records and reports inspection results.
8. Obtains technical specifications of coolant additives.
9. Selects coolant additives in accordance with manufacturer’s
specifications.
10. Applies coolant additives per specifications.
11. Obtains technical data pertaining to engine cooling system, in
conformity with the service manual.
12. Prepares and uses appropriate tools, equipment and materials
13. Performs leakage test in accordance with industry procedure
14. Records test results and determines preferred actions
15. Heat coolant in accordance to service manual specifications
16. Checks/inspects water pump and determines faults.
17. Determines water pump/parts replacements.
18. Dismantles water pump/parts.
19. Installs replacement of water pump/parts
20. Applies coolant additives in accordance with manufacturer’s specs.

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Learner’s diary
DIARY NOTES
Record important dates, jobs undertaken and other workplace events that will assist you in providing further
details to an Assessor.
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Record of Achievement
Module # 1: Servicing Cooling System
LO 1 : Explain Coolant Circulation within Cooling System

Performance Criteria:
1.1 Parts of coolant system identified

1.2 Function of cooling system parts explained

1.3 Coolant circulation within cooling system explained in accordance with manufacturer’s specifications

Comments:
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Learner has satisfied the above performance criteria.

Learner’s signature: .......................................................................
Trainer’s signature: ........................................................................
Date:...............................................................................................

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Record of Achievement
Module # 1: Servicing Cooling System
LO 2 : Check Thermostat Condition

Performance Criteria:
2.1 Standard condition of thermostat determined in accordance with manufacturer’s specifications

2.2 Thermostat location determined

2.3 Thermostat condition checked in accordance with service manual/industry procedure

2.4 Inspection result recorded and reported

Comments:
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Learner has satisfied the above performance criteria.

Learner’s signature: .......................................................................
Trainer’s signature: ........................................................................
Date:...............................................................................................

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Record of Achievement
Module # 1: Servicing Cooling System
LO 3 : Perform Leakage Test on Cooling System

Performance Criteria:
3.1 Technical data pertaining to engine cooling system obtained in conformity with service manual

3.2 Appropriate tools and equipment/materials prepared and used

3.3 Leakage test performed in accordance with industry procedure

3.4 Test results recorded and preferred actions determined

3.5 Coolant heated in accordance with service manual specifications

Comments:
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Learner has satisfied the above performance criteria.

Learner’s signature: .......................................................................
Trainer’s signature: ........................................................................
Date:...............................................................................................

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Record of Achievement
Module # 1: Servicing Cooling System
LO 4 : Repair/Replace Water Pump

Performance Criteria:
4.1 Technical data pertaining to engine water pump obtained using service manual

4.2 Water pump checked/inspected and faults determined

4.3 Water pump/parts replacement determined

4.4 Water pump/parts dismantled in accordance with service manual

4.5 Water pump/parts installed/replaced per manufacturer specifications

Comments:
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Learner has satisfied the above performance criteria.

Learner’s signature: .......................................................................
Trainer’s signature: ........................................................................
Date:...............................................................................................

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Record of Achievement
Module # 1: Servicing Cooling System
LO 5 : Apply Coolant Additives

Performance Criteria:
5.1 Technical specifications of coolant additives obtained

5.2 Coolant additives selected in accordance with manufacturer’s specifications

5.3 Coolant additives applied per manufacturer’s specifications

Comments:
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Learner has satisfied the above performance criteria.

Learner’s signature: .......................................................................
Trainer’s signature: ........................................................................
Date:...............................................................................................

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 Terms and Definitions
Additive - A substance added to gasoline, oil or water which improves some property of that
fluid.

Ambient Temperature - Temperature of air surrounding an object.

Antifreeze - A chemical, usually ethylene glycol, added to the engine coolant to raise its
boiling temperature and lower its freezing temperature.

Assemble - To put together.

o o
Celsius Scale - The temperature scale using the ice point as 0 and the steam point as 100 ,
with 100 equal divisions , or degrees, between; formerly the centigrade scale.

Charle’s Law - The volume of a dry gas is directly proportional to its Kelvin temperature,
provided the pressure is constant.

Check - To verify the condition of a part, assembly, system, or measurement by visual

inspection, comparison or operation.

Chemical Change - A change in which new substances with new properties are formed.

Circulation - The movement or flow or distribution of something around a path from and to the
starting point.

Combustion - Burning; fire produced by the proper combination of fuel, heat , and oxygen. In
the engine, the rapid burning of air and fuel in the combustion chamber.

Combustion chamber - The space between the top of the piston and the cylinder head, in
which the fuel is burned.

Coolant - The liquid mixture of about 50 percent antifreeze and 50 percent water used to carry
heat out of the engine.

Cooling System - The system that removes heat from the engine by the forced circulation of
air or coolant and thereby prevents engine overheating. In a liquid-cooled engine, the
system includes the coolant, water pump, water jackets, radiator and thermostat.

Cooling System Pressure Tester - A hand-operated air pump with an attached pressure
gauge that usually clamps in the radiator filler neck. After applying the specified
pressure to the cooling system, a rapid pressure drop indicates a leak.

Coolant Temperature Sensor - A thermistor that continuously reports engine coolant

temperature to the PCM (powertrain control module).

Corrosion - Chemical action, usually by an acid, that eats away or decomposes a metal.

Critical temperature - The temperature above which the substance can exist only as a gas.

Dismantle - To take apart the parts, as in machine.

Dismount - To remove something from its mount.

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Engine - A machine that converts heat energy into mechanical energy. A device that burns fuel
to produce mechanical power which moves the vehicle. Sometimes referred to as
power plant.

Equipment - These are furnishings that the technician uses in diagnosis and repair in shops.

Ethylene Glycol - Chemical name of a widely used type of permanent antifreeze.

Fan - A device with rigid blades or vanes that mounts in front or behind the radiator to push or
pull cooling air through the radiator to help control engine temperature. The fan may be
engine-driven (mechanical) or powered by an electric motor (electrical).

Fan belt - A belt (or belts) driven by the crankshaft, whose primary purpose is to drive the
engine fan and water pump.

Freezing Point - The temperature at which a liquid changes to solid.

Fluid - Any substance that can flow, such as a liquid or gas.

Gasket - A layer or combination of soft material clamped between two surfaces to make a tight
seal. It is usually preformed or precut to the desired shape and thickness.

Heat - A form of energy released by the burning fuel. The automobile engine is a heat engine,
which converts the heat energy in fuel into mechanical energy.

Hose - A flexible tube for carrying liquid or vapor.

Idle speed - The speed, or rpm, at which the engine runs when the accelerator pedal is fully
released and there is no load on the engine.

Install - To set up for use any part, accessory, option, or kit which has not previously been part
of or attached to the engine, vehicle, or other assembly.

Kelvin Scale - The scale of temperature having a single fixed point, the temperature of triple
o
point of water, which is assigned the value of 273.16 K.

Kinetic energy - Energy possessed by an object because of its motion.

Leakage - An act of allowing the unwanted entrance or escape of a fluid.

Liquid-Cooled Engine - An engine that is cooled by the circulation of liquid coolant around the
cylinders.

Mixture - Two or more substances, in variable proportions; can be homogeneous (as in a

solution or heterogeneous.

OH and S (Occupational Health and Safety) Practices - The safety practices and regulations
in the workshop to prevent serious personal injury as well as damage of properties.

Overheat - To heat excessively, or become excessively hot.

Precaution - A measure taken beforehand to ward off evil or secure good or success.

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Pressure Test - To use air or fluid pressure to determine the condition or operation of a
component or system.

Proportion - A statement that two ratios are equal.

Radiator - In the engine cooling system, the heat exchanger that removes heat from coolant
passing through it, receives hot coolant from the engine and returns the coolant to the
engine at a lower temperature.

Ratio - A relationship between two numbers or like quantities expressed as a fraction.

Repair - The steps necessary to fix the problem, or both the problem and its cause.

Replace - To remove a part or assembly and then install a new or different part or assembly in
its place. This could include cleaning, lubricating, and adjusting as required.

Safety - Freedom from injury or danger.

Shroud - A hood placed around an engine fan to improve and direct air flow.

Specifications - Information provided by the manufacturer for each major vehicle component
that typically includes operating values, sizes, clearances and capacities of its parts
and assemblies.

System - Two or more parts that work together to perform a specific job. A combination or
grouping of two or more parts or components into a whole, which in operation performs
some functions that cannot be done by the separate parts.

Temperature - The physical quantity that is proportional to the average kinetic energy of
translation of particles in matter.

Thermostat - A control device containing a temperature sensitive element that automatically

reacts to temperature changes by bending and straightening, or by expanding and
contracting. In the engine cooling system, a heat-operated value that regulates the
flow of liquid coolant between the engine and the radiator, thereby controlling coolant
temperature.

Tools - Things when properly used will enable us to do the job with safety, speed and
efficiency.

Water Jacket - The space between the inner and outer shells of the cylinder block or cylinder
head, through which coolant circulates.

Water Pump - In the cooling system, an engine-driven centrifugal pump that circulates coolant
between the engine water jackets and the radiators.

Warpage - Bending.

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