Cooling and Heating MV

MOTOR VEHICLE
E R EDUCA
TH T MODULE A7/A8/A9
IO
R
FU
Element 2
N
Underpinning Knowledge
N AT I
M
TIU
Cooling and Heating

O
N
R
AL S O
CON NVQ 2
NAME
EQUAL OPPORTUNITIES STATEMENT
The Further Education National Consortium believes that discrimination and prejudice on the
grounds of ethnicity, gender, religion, marital status, sexual orientation and social class is
incompatible with the principle of Equal Opportunities.
COPYRIGHT STATEMENT
No part of this publication may be reproduced or transmitted without the prior written consent of
the Board of Trustees for the Further Education National Consortium except as authorised by
the terms and conditions of membership of the Further Education National Consortium.
WARNING: THE UNAUTHORISED REPRODUCTION OR TRANSMISSION OF THIS PUBLICATION IS AN

INFRINGEMENT OF COPYRIGHT AND MAY RESULT IN CIVIL PROCEEDINGS AND A CRIMINAL PROSECUTION.
Written by Martin Hutchinson

for the National Consortium
Issued October 1996

UNDERPINNING KNOWLEDGE COOLING AND HEATING MODULE A7/A8/A9 ELEMENT 2
CONTENTS
Introduction 2
Objectives 3
Why a Cooling System? 4
Types of Cooling Systems 4
Fault Finding Guide 8
Heating 10
Fault Finding Guide Air Cooling 12
Fault Finding Guide Liquid Cooling 34
Summary 38
1996 Further Education National Consortium Version 01
MOTOR VEHICLE LEVEL 2 MODULE A7/A8/A9 ELEMENT 2 1

INTRODUCTION
Before you begin you need to have worked through the module
Introduction/Basic Skills which explains how to use the modules and how
they help you gain your National Vocational Qualification. Also it will
help you gain the skills and knowledge you need before working in a
vehicle repair workshop.
You also need to have completed the Safety learning module.
To study this module you will need the following:
somewhere to study with as few distractions as possible
easy access to a well equipped workshop
at least 3 different vehicle models (and their workshop

manuals)
a qualified Tutor
To help you fully understand the content of the modules it would also be
useful to have access to text books such as:
Fundamentals of Motor Technology by VA Hillier
Automate: How to Understand your Car by VA Hillier
Vehicle and Engine Technology: Vol 1 by Heinz Heisler


OBJECTIVES
On completion of this module you will know the construction and

operation of vehicle cooling/heating systems sufficiently to enable you to:
identify faults
replace units
service those systems
This will assist you in completion of the NVQ Modules A7, A8 and A9.
You will need approximately 10 hours to work through this module, this is
only a guide and you should work at your own pace. It is more important
that you have a good understanding of the content. Do not hesitate to
ask for help from your Tutor.

WHY A COOLING SYSTEM?

When the fuel/air mixture is compressed and burned in an engine's
cylinder less than 25% of the energy released can be converted into
mechanical energy to drive the vehicle.
Most of the energy goes out of the exhaust. About 20% has to be got rid
of by the cooling system which protects the main engine components,
such as pistons and cylinders. If these become too hot the oil film which
lubricates them is burnt away resulting in seizure.
The cooling system also keeps the engine at a temperature high enough
for efficient operation. If an engine runs too cool, unvapourised fuel
dilutes the oil film on the cylinder walls so it doesn't do its' job properly
and excessive wear of the cylinders will be the long term result.
So you can see it is important to have a cooling system that will keep the
engine at a stable temperature. Cooling systems are designed to
maintain a cylinder head temperature of about 200C, hot enough to
badly burn your fingers so be careful !
TYPES OF COOLING SYSTEMS

OIL COOLING
Construction/Operation
CROSS SECTION OF AN
As well as lubricating the moving parts of the
ENGINE
engine oil transfers heat away from the hottest
areas as it circulates through the engine.
Heat is conducted through the oil film between

the pistons and cylinders to the cylinder block

and on to the air or liquid cooling system.
Oil film between piston

and cylinder wall.

On some engines the hot oil is circulated

through a separate small radiator (oil
cooler) to get rid of the heat.
Cooler oil out
Hot oil in
Some oil coolers use the liquid cooling system to cool the oil.
Oil Cooler
Oil Filter

ACTIVITY 1
Examine the oil coolers on several vehicles and fill in the table below.
You would be advised to check their workshop manuals first so that you
know what to look for and where.
Vehicle model? Where is Oil Cooler Cooling fins clear

fitted? or blocked?
Vehicle 1
Vehicle 2
Vehicle 3
Ask your Tutor to check your answers
COMPLETED TO MY SATISFACTION.
TUTOR SIGNATURE DATE
High performance and turbo-charged engines also often have oil

spraying the underside of the pistons from small jets in the conrods or at
the bottom of the cylinder walls assisting the cooling of the pistons.
Oil spray jet
CROSS SECTION SHOWING OIL SPRAYING CYLINDER WALL

Under extreme load automatic transmission oil can get too hot, so for
towing or high performance, automatic vehicles have an oil cooler
usually cooled by the engine's liquid cooling system.
MAINTENANCE OF THE OIL COOLING SYSTEM
1 Check oil level and possible leaks.
2 Oil and filter changes as per manufacturer recommendations.
3 Visual inspection of oil cooler fins for leaks or blockage by debris,

repair or clean as necessary.
TESTING THE OIL SYSTEM
The Oil Pressure Test
Usually done because of excessive mechanical noise or an oil warning

light. However, low oil pressure can also give overheating problems
especially on some motorbike engines. Take the following steps.
1 Check quality and level of oil.
2 Remove warning light switch and insert gauge.
3 Take readings at engine speeds specified in workshop manual.
4 Compare with manufacturer's specifications.


FAULT FINDING GUIDE

FAULT POSSIBLE CAUSE RECTIFICATION
Overheating 1 Oil quantity/type Renew/top up
2 System blockage Run with flushing oil

change filter or dismantle
and clean
3 Oil cooler fins blocked Clean carefully
4 Low oil pressure Test oil pump/pressure
5 Pressure valve Replace unit check

defective bearings
You will gain more knowledge on the lubricants system in another

module, but you now know how important it is to engine cooling.
SELF ASSESSMENT 1
1 What is the first check you should make before doing an oil
pressure test?
2 What happens to the oil film between the piston and cylinder if an
engine gets too hot?
3 What would be the most likely cause of low engine oil pressure?
Check your answers with your Tutor

AIR COOLING
To get rid of the excess heat from

the combustion process the cylinder
is made with fins on the outside
which are exposed to air flow. The
large surface area of the fins conduct
heat away from the cylinder and
transfer it into the cool air flow. Fins Air Flow
at the top of the cylinder and cylinder
head are usually larger to dissipate
heat from the hottest area.
CROSS SECTION OF AN AIR COOLED

ENGINE
This is usually enough for lawnmower and other small engines. Modern
air cooled motor cycles rely on additional efficient oil cooling and the air
flow created by moving at speed.
Air cooled car engines need additional air flow to keep the engine cool
especially when in slow moving traffic.
AIR COOLED ENGINE SHOWING COOLING FAN
Cooling fan
A large fan, belt driven by the crankshaft, circulates air around the
cylinders at all times. Thermostatically controlled flaps control the air
flow, to ensure a rapid warm up and maintain the correct engine
operating temperature.

HEATING
Some of the air which has passed over the hot cylinders is diverted
through ducting to the interior of the car to provide heat. The amount is
controlled by a driver operated cable moving a flap.
Cooling fan
Warm air
Engine
Cable
operated flap
MAINTENANCE OF AN AIR COOLING SYSTEM
The fan itself requires no maintenance other than occasionally giving the
spindle a shake to make sure the bearings are in good order.
As with other drive belts this will require regular checking for cracking/
wear and adjustment. For drive belt adjustment check the workshop
manual, methods and tensions.
Thermostatically controlled air flaps should be checked at service

intervals making sure parts are lubricated and free from corrosion.
Access can be difficult. If faults develop here the engine will run either
too hot or too cold depending on what position the flaps are stuck in.
Heater control cables and flaps need regular lubrication.


ACTIVITY 2
Examine the workshop manual of an air cooled car, read the section on
cooling fan, belt adjustment. List the steps you would follow to carry out
the job, in as simple a way as you can.

TESTING AN AIR COOLING SYSTEM
The air thermostat flaps can be tested by making sure the flaps are
closed when the engine is cold, run the engine until hot and checking
that the flaps are then open. If dismantled the air thermostat can be
checked with a hot air gun.
FAULT FINDING GUIDE AIR COOLING
FAULT POSSIBLE CAUSE RECTIFICATION
Overheating 1 Fan belt faults Renew or adjust
2 Flaps stuck closed Lubricate or renew

thermostat or flap
3 Cooling fins blocked Clean
4 Cowling or ducting out Secure in correct place

of position
Heater not 1 Cable/flap stuck open Lubricate or renew

operating
2 Thermostat flaps Lubricate or renew
stuck thermostat or flap
3 Faulty heat exchanger Renew
Screeching 1 Fan belt slipping Renew/adjust belt

noise check fan turning freely
Rattling 1 Fan, cowling, flaps Check all are secure

noises vibrating loose

UNIT REPLACEMENT SOME GENERAL POINTS
1 Ducting/cowlings and covers must be fitted in correct positions and

well secured as they are subjected to a lot of vibration.
2 Belt adjustment is critical, so always refer to workshop manual.
3 Usually awkward to work on, requires patience and skill.
AIR COOLING COMPARED TO LIQUID COOLING
The advantages are:
simpler, lightweight construction
very little maintenance
quick warm up from cold
can withstand very high and very low temperatures
generally considered more reliable
The disadvantages are:
relatively noisy
bulky cylinders to allow for cooling fins
difficult to keep cylinders at a steady even temperature
cooling fan absorbs a large amount of engine power

more prone to overheating in extreme load conditions

SELF ASSESSMENT 2
1 What is the most important service check on an air cooled system

fitted with a fan?
2 On an air cooled engine why are the fins at the top of the cylinder
longer?
3 What is likely to be the most obvious effect of a fan belt being too
slack?
4 Give 2 advantages of an air cooling system.


LIQUID (WATER) COOLING
A coolant liquid (mostly water) circulates around the cylinders absorbing

waste heat, then, through the radiator, loses this heat. A pump helps the
coolant circulate. The thermostat helps control the flow to allow the
engine to warm up quickly and maintain a stable temperature. A fan
assists air flow through the radiator to help keep the engine temperature
steady.
CROSS SECTION OF A WATER COOLED ENGINE SHOWING MAIN COMPONENTS
Radiator
fins Cap Thermostat Valves Fan Heater
Pipes Fan Water

pump
Coolant circulates down the pipes in the radiator, air flow around the
pipes cools it before being drawn back into the engine.

THE MAIN COMPONENTS AND WHAT THEY DO
Cylinder Block and Head
These are usually made of cast iron or aluminium alloy and have
passages around the cylinders (water jacket) which contain the
circulating coolant.
If the engine is overheated the cylinder head can become warped,

causing the 'head gasket to blow'. This results in further overheating
problems. The repair involves removing the head and having it
machined ('skimmed') or renewed.
There are round steel inserts in the side of the cylinder block, and
sometimes in the cylinder head as well, these are core plugs. These can
leak and will then need to be replaced, either due to corrosion, usually
caused by using inadequate coolant, or freezing. If the coolant freezes
in cold weather it expands (10% increase in volume), this can crack the
cylinder block or push out the core plugs.
ENGINE WITH CORE PLUGS
Cylinder head
Core plugs
Cylinder block

ACTIVITY 3
1 Examine three different engines, preferably on stands, and

complete the table below.
What is the What is the How many core

cylinder block cylinder head plugs are there?
made of? made of?
Engine 1
Engine 2
Engine 3
2 Look up, in a workshop manual, the method for checking a cylinder

head for 'flatness', simplify and list the steps below.

3 Now check a cylinder head by this method.
VEHICLE MODEL MEASUREMENT SPECIFICATION
Is the cylinder head within specification? Yes No
COOLANT (ANTI-FREEZE)
The coolant is usually a mixture of water and an additive commonly

called anti-freeze.
It has three jobs to do.
1 Prevent the system freezing when parked in cold weather.

2 Raise the boiling point of the coolant, important in modern engines

which run at high temperatures.
3 Reduce internal corrosion of the engine, especially core plugs.
There are different types and qualities of coolant which you can put in an
engine. Check what type and quality the car manufacture recommends
before you possibly use the wrong type and cause long term damage.
What percentage concentration is needed depends on the worst weather

conditions the vehicle is likely to be left out in, don't forget the wind chill
factor, and the manufacturers recommendations.

Ethylene Glycol, which has a boiling point of 195C is the basic

ingredient in most coolant mixtures. The chart shows how much
protection it gives.
% COOLANT ADDITIVE PROTECTION DOWN TO (APPROXIMATELY)
25% 10C
33% 15C
40% 20C
50% 30C
ACTIVITY 4
Look up, in a workshop manual, the steps you would follow to drain, flush
and refill the cooling system.

If possible do this job on a vehicle.
VEHICLE MODEL COOLING SYSTEM TYPE OF COOLANT % MIXTURE

CAPACITY RECOMMENDED
THE RADIATOR
Operation and Construction
The coolant which has absorbed waste heat from the engine is circulated
down through the radiator core, a matrix of flattened tubes made of
copper, plastic or brass. The thin metal strips, made of aluminium or
copper between the tubes help transfer the heat from the coolant into the
air flow through the radiator. The cooled coolant is drawn out of the
bottom of the radiator and back into the engine.
A cross flow radiator is not so tall,

it allows for a lower bonnet
A CROSS FLOW RADIATOR

a
Hot coolant in
Coolant flows down

through radiator
Cooler coolant out

a
UNDERPINNING KNOWLEDGE COOLING AND HEATING
A RADIATOR
EXPANSION TANK (used in a sealed system)

MODULE A7/A8/A9 ELEMENT 2
Most modern cooling systems have an expansion tank separate from the
radiator. As the coolant gets hot it expands and flows into the expansion
tank, as it cools it is drawn back into the system.
With this type of sealed system the pressure cap is usually fitted to the
expansion tank.
Take care not to overfill the system or it will overflow.
AN EXPANSION TANK
MOTOR VEHICLE LEVEL 2 MODULE A7/A8/A9 ELEMENT 2

HOT AND COLD
21
PRESSURE CAP
WARNING
TAKE GREAT CARE REMOVING CAP.

THERE IS A DANGER OF BEING SCALDED BY BOILING WATER AS THE PRESSURE IN
THE SYSTEM IS REDUCED WHEN THE CAP IS REMOVED.
MAKE SURE THE ENGINE HAS COOLED BEFORE REMOVING CAP AND LOOSEN
SLOWLY.
WARNING SYMBOLS SEEN ON PRESSURE CAPS
A sealed cooling system stops coolant evaporation. It allows pressure to

build up as the coolant is heated by the engine and tries to boil, under
pressure it can't and so the whole system can operate at the high
temperatures required by modern engines for better efficiency.
Take care to fit the cap properly, if you don't the engine may overheat
and cause serious damage.
Outlet to expansion tank

Vapour builds up
pressure as coolant
tries to boil until
pressure overcomes
spring and lifts main
valve. A second valve
allows air/coolant to
return from expansion
tank as system cools.
Coolant level
CROSS SECTION OF A PRESSURE CAP

HOSES
These reinforced rubber pipes connect together the cooling system

components allowing the hot coolant to circulate. Hoses in the upper
area of the engine compartment may have air bleed valves fitted. These
are needed to remove air trapped in the system when refilling, check the
workshop manual for the method of clearing trapped air.
ACTIVITY 5
Examine several vehicles and their workshop manuals and fill in the
table below.
VEHICLE 1 VEHICLE 2 VEHICLE 3
Vehicle model
Expansion tank
Fill where?
Bleed valves in system?
Hoses in good condition?

WATER PUMP
Mounted on the cylinder block the water pump derives coolant around
the engine. It is a vane pump on a shaft rotating on waterproof bearings
and driven by either a V belt or toothed belt from the crankshaft.
A leak here can be difficult to spot as the spinning drive pulley tends to
throw the coolant away from the source of the leak.
Leaks are usually through the waterproof bearings and so the whole
pump must be replaced as it is a sealed unit and cannot be repaired.
Some vehicles have an additional thermostatically controlled electric

pump fitted in the cooling system. This will continue to circulate coolant,
even after the vehicle is switched off, until the engine is cooled.
THERMOSTAT
Usually mounted in a housing on the outlet from the engine to the

radiator. The thermostat is closed when cold preventing the flow of
coolant to the radiator until the engine is warm when the thermostat
opens.
The thermostat is the main component which gives the engine a stable
temperature by controlling coolant flow through the radiator.
Thermostat shut: water circulates in Thermostat open: water flows through

cylinder block. radiator to be cooled.
FLOW OF COOLANT AROUND AN ENGINE HOT AND COLD

Jiggle pin
Central rod
allows air to
Rubber diaphragm escape when
filling system
Wax pellet
With the engine cold, the wax pellet As the coolant heats up, the wax expands,
inside the thermostat stays contracted forcing the diaphragm to move. This
keeping the thermostat closed. presses on the central rod and opens the
valve.
CROSS SECTION OF A THERMOSTAT HOT AND COLD
MECHANICAL COOLING FANS
Driven off the same shaft as the water pump impellor. Mounted behind
the radiator the fan draws air through the radiator, especially important
when the engine is running and the vehicle is stationary.
Modern vehicles use a viscous coupling which reduces noise and gives a
quicker engine warm up. Some have a temperature sensitive coupling
which means the fan is only driven when the engine is hot.
ELECTRIC COOLING FANS
An electric motor driving a fan mounted on the radiator. Power is sent to

the motor through a temperature switch. The fan only comes on when
the engine is becoming too hot. This design is more energy efficient
than a mechanical fan and allows the radiator to be fitted away from the
engine.
Beware of the fan as it can come on suddenly when the engine is not
running.
AN ELECTRIC COOLING FAN
Radiator
Electric fan

ACTIVITY 6
Examine some vehicles and/or their workshop manuals and answer the
following questions.
How many have:
1 simple mechanical fans
2 viscous mechanical coupling fans
3 electric fans
Also check the workshop manuals and look at where the thermostats are
located.
Are they usually in the same part of the cooling system?
Yes No


THE HEATER
Hot coolant is circulated through a small radiator (heater matrix) in the

bulkhead/dashboard area, flow and therefore temperature is controlled
by a cable operated valve. An electric fan, with speed control, blows air
through the heater matrix into the vehicle interior warming it.
HEATER MATRIX
Heater matrix
(radiator)
Flow from Heater radiator
engine cooling bleed valve
(fitted to some
vehicles)
Heat control
cable
MAINTENANCE OF THE LIQUID COOLING SYSTEM
1 Check coolant level regularly.

2 Check engine, hoses etc for staining/corrosion, early signs of leaks.
3 Squeeze hoses to check they are pliable, replace if brittle or very
soft.
4 Check concentration of coolant (refer to Testing).
5 Drain, flush and refill system with correct type and quantity of
coolant concentrate as recommended by vehicle manufacturer.
6 Visual inspection of radiator for excess dirt in core, blow through
with air or wash, be careful, excessive pressure can damage fins in
core matrix.
7 When replacing a belt check that the water pump operation is not
rough or noisy.
CHECKING A
PUMP BEARING

TESTING THE LIQUID COOLING SYSTEM
The pressure test allows you to test and examine the cooling system for
leaks at operating pressure with the engine stationary and cold, avoiding
the dangers of a hot running engine.
Take the following steps.
1 Remove pressure cap, top up system.
2 Attach pressure test pump.
3 Pump up to a maximum operating pressure of system.
4 If pressure is falling examine for leaks, if none are visible remove

spark plugs, check for coolant in cylinders. This can be caused by
leaking cylinder head gasket.
DO NOT REFIT PLUGS AND ATTEMPT TO START ENGINE IF THERE IS SOME COOLANT
IN A CYLINDER, THIS CAN CAUSE SERIOUS DAMAGE (HYDRAULIC EFFECT ).
DOING A PRESSURE TEST
Radiator Tester
Radiator Cap
Hose
Radiator Tester

ACTIVITY 7
Using the workshop manual, and the instructions for the pressure tester
you are going to use, carry out a cooling system pressure test.
Maximum operating pressure of system
Findings
Pressure cap 'blows' at
Location of any leaks


COOLANT CONCENTRATION TEST
This test is not often done since the coolant should be drained and
refilled regularly. This test uses a Hydrometer which works on the
principle that an additive to water makes it more dense, so an object
floats higher in the mixture the more dense it is.
1 Draw sample of coolant into hydrometer

2 Take reading off float
3 Read concentration percentage off chart
4 Calculate amount of coolant additive to be added
ACTIVITY 8
Using a coolant hydrometer, test the coolant concentration on several

vehicles, refer to the previous table to find out what temperature each
vehicle is protected down to, and the workshop manual to check the
manufacturers recommendations.
VEHICLE MODEL COOLING SYSTEM TYPE OF COOLANT % MIXTURE

CAPACITY RECOMMENDED

TEST OPERATION OF ELECTRIC COOLING FAN
This is one of the first tests you would do on a vehicle reported as

overheating in traffic and the fan not coming on.
1 Disconnect wires from temperature switch. On some vehicle

system designs fan may come on
2 Temporarily connect wires together
3 If fan comes on at step 1 or 2 temperature switch is defective
4 If the fan doesn't come on disconnect it and connect a temporary

live to the motor. Make sure it is earthed to complete the circuit. If
the fan works you will have to do more electrical testing to trace the
fault
TESTING AN ELECTRIC FAN
Bottom of Temp switch

radiator
Temporarily
connect together

ACTIVITY 9
Select 3 different vehicles which are equipped with electric fans, with
reference to their workshop manuals. Carry out the quick test as
described, and answer the following questions.
VEHICLE MODEL WHAT TEMPERATURE SHOULD THE FAN COME ON?
THERMOSTAT TEST
This test is not often done because the thermostat is a relatively

inexpensive item and is time consuming to remove and test.

1 Remove the thermostat.
2 Place in a container of water with a thermometer.
3 Heat water and check thermostat opens at specified temperature.

TESTING A THERMOSTAT
Thermometer
Container of Thermostat
water
Electric heater
ACTIVITY 10
Test several thermostats and fill in the table below.
THERMOSTAT TEMPERATURE IT TEMPERATURE IT THERMOSTAT

OPENED AT SHOULD OPEN AT SERVICEABLE ?
3

FAULT FINDING GUIDE LIQUID COOLING
FAULTS POSSIBLE CAUSES RECTIFICATION
Overheating 1 Coolant loss Pressure test
2 Thermostat fails closed Replace

3 Pressure cap fails Replace
4 Electric fan inoperative Test

5 Radiator blocked Flush or replace
6 Cylinder head gasket Replace
7 Air locks Bleed system

8 Pump not operating Tighten/renew V belt
properly or pump corroded,
replace
Coolant loss 1 Hose leaks Tighten or replace
2 Radiator leak Repair or replace

3 Cylinder block leak Core plug, head
gasket
Electric fan 1 Temperature switch Replace
2 Wiring fault Repair

3 Relay fails Replace
4 Motor fails Replace
Engine runs 1 Thermostat fails open Replace

cold (heater
cool) 2 Fan fails on Replace temperature
switch
Heater cool 1 First signs of engine Refer to overheating

overheating
2 Heat control valve Check cable and

defective valve
3 Engine cold Refer engine runs

cold
4 Air lock in system Bleed system

LIQUID COOLING COMPARED TO AIR COOLING
The advantages are:
more even temperature, less distortion/stress
cooling fan quieter, wastes less power
more compact engine block
system allows more vehicle design flexibility
access better for maintenance and repair
mechanical noise reduced by water jacket
copes better with extreme load conditions
The disadvantages are:
heavier engine assembly
longer warm up time
more complex and liable to leakage so more maintenance
possible engine damage if system freezes
As can be seen by the small percentage of air cooled vehicles still in

production, liquid cooling is much more popular. Even modern motor
cycles commonly use liquid cooled engines.
UNIT REPLACEMENT Some General Points

Hoses can be difficult to remove. Try twisting or levering them gently to

loosen, if this fails, cut off rather than risk damage to radiator or housing
connection. Remember the radiator is made of thin material.
If a hose is tight to fit don't use excessive force, dip in hot water to soften
and use soap to help slip it on. Never use oil or grease as these perish
the rubber.
The thermostat housing can be tight to remove due to corrosion, don't hit
it too hard.

SELF ASSESSMENT 3
1 When an engine is cold would the thermostat be open or closed?
2 What is the main advantage of a cross flow radiator?
3 What are the 3 main reasons for using a coolant additive in a liquid
cooling system?
4 What is the most common fault with 'core' plugs and what is the
main cause?
5 What precaution should you take when removing a pressure cap

and why?
6 What would happen if a cooling system is over filled?

7 How would you check the condition of coolant hoses and what do
you not want to find?
8 When replacing a water pump drive belt, what check should you do
on the pump?
9 Where does a water pump usually leak and how would you fix it?


To be or not to be that is the quest

Friends, Romans, Countrymen, le
me your ears, I come to bury Caes
not to praise him.
SUMMARY
* SUMMARY
The evil that men do lives on after
them but the good is oft interred
their bones.
Hark! What light through yonder
window breaks?
Whats in a name? A rose by any
name would smell as sweet.
There was a young man from Cape
Horn who wished hed never been
Now that you have completed this module and the activities, you should
know the construction and operation of vehicle cooling systems
sufficiently to enable you to:
maintain
test
identify faults in
and replace units on those systems
To assist you in completion of the NVQ Modules A7, A8 and A9 ask your
Tutor to set you a test paper on cooling systems.
Your completed test paper marked and verified by your Tutor can be put
in your NVQ Portfolio folder as part of your evidence of underpinning
knowledge.
What next?
We hope you enjoyed learning about cooling systems and will

want to study other modules in the series, ask your Tutor
for the next one

Cooling and Heating MV

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MOTOR VEHICLE

Cooling and Heating

EQUAL OPPORTUNITIES STATEMENT

WARNING: THE UNAUTHORISED REPRODUCTION OR TRANSMISSION OF THIS PUBLICATION IS AN

Written by Martin Hutchinson

Issued October 1996

Why a Cooling System? 4

Types of Cooling Systems 4

Fault Finding Guide 8

Fault Finding Guide Air Cooling 12

Fault Finding Guide Liquid Cooling 34

MOTOR VEHICLE LEVEL 2 MODULE A7/A8/A9 ELEMENT 2 1

You also need to have completed the Safety learning module.

To study this module you will need the following:

somewhere to study with as few distractions as possible

easy access to a well equipped workshop

at least 3 different vehicle models (and their workshop

Fundamentals of Motor Technology by VA Hillier

Automate: How to Understand your Car by VA Hillier

Vehicle and Engine Technology: Vol 1 by Heinz Heisler

MOTOR VEHICLE LEVEL 2 MODULE A7/A8/A9 ELEMENT 2 2

On completion of this module you will know the construction and

service those systems

MOTOR VEHICLE LEVEL 2 MODULE A7/A8/A9 ELEMENT 2 3

WHY A COOLING SYSTEM?

TYPES OF COOLING SYSTEMS

Heat is conducted through the oil film between

the pistons and cylinders to the cylinder block

Oil film between piston

MOTOR VEHICLE LEVEL 2 MODULE A7/A8/A9 ELEMENT 2 4

On some engines the hot oil is circulated

Cooler oil out

MOTOR VEHICLE LEVEL 2 MODULE A7/A8/A9 ELEMENT 2 5

Vehicle model? Where is Oil Cooler Cooling fins clear

Ask your Tutor to check your answers

TUTOR SIGNATURE DATE

High performance and turbo-charged engines also often have oil

Oil spray jet

CROSS SECTION SHOWING OIL SPRAYING CYLINDER WALL

MOTOR VEHICLE LEVEL 2 MODULE A7/A8/A9 ELEMENT 2 6

MAINTENANCE OF THE OIL COOLING SYSTEM

1 Check oil level and possible leaks.

2 Oil and filter changes as per manufacturer recommendations.

3 Visual inspection of oil cooler fins for leaks or blockage by debris,

TESTING THE OIL SYSTEM

The Oil Pressure Test

Usually done because of excessive mechanical noise or an oil warning

1 Check quality and level of oil.

2 Remove warning light switch and insert gauge.

3 Take readings at engine speeds specified in workshop manual.

4 Compare with manufacturer's specifications.

MOTOR VEHICLE LEVEL 2 MODULE A7/A8/A9 ELEMENT 2 7

FAULT FINDING GUIDE

Overheating 1 Oil quantity/type Renew/top up

2 System blockage Run with flushing oil

3 Oil cooler fins blocked Clean carefully

4 Low oil pressure Test oil pump/pressure

5 Pressure valve Replace unit check

You will gain more knowledge on the lubricants system in another

Check your answers with your Tutor

MOTOR VEHICLE LEVEL 2 MODULE A7/A8/A9 ELEMENT 2 8

To get rid of the excess heat from

CROSS SECTION OF AN AIR COOLED