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Unit 16 worksheet: Cooling systems

Competency unit: AURTTC003 Diagnose and repair cooling systems

Activity summary:

This worksheet will be used as evidence regarding your work within the following
competencies:

1. Describe the fundamental points about cooling systems and related basic
components.
2. Identify cooling components.
3. Explain cooling system terminology as used within the automotive industry.

Reference material:

Automotive Mechanics: 10e, Chapter 20.

Safety precautions:

1. Personal protective equipment (PPE) must be worn.

2. Follow all standard operating procedures (SOP) when using workshop tools and
equipment.
3. Follow safety precautions with regard to cooling system heat, pressure and
moving parts.

Teacher/supervisor activity record

YES NO
Teacher/ All tasks completed by student □ □
supervisor
to complete Tasks performed to standard as outlined in assessment observation □ □
checklists
Student evidence provided and attached to this file □ □
Teacher/supervisor comments:

Teacher/supervisor signature:

Mr Hemand Kumar

Date: 1-07-2019

Activity result Completed □ Not yet completed □

Unit 16 Worksheet
To accompany May & Simpson Automotive Mechanics 10e
© McGraw-Hill Education Australia 2018
 2

Student self-assessment record

YES NO
Student Did you find these tasks difficult to complete? □ □
to
Did the outcomes of the activity meet your needs? □ □
complete
Were the tasks relevant to the type of work carried out in your workplace? □ □
Did the instruction given to you prior to and during this activity assist you in □ □
completing the tasks?
Additional student comments:

Name of workplace:

Student name: Ajit

Student signature: ajit

Date: 01-07-2019

Unit 16 Worksheet
To accompany May & Simpson Automotive Mechanics 10e
© McGraw-Hill Education Australia 2018
 3

Competency unit: AURTTC003 Diagnose and repair cooling systems

1. Cooling system components. Use the diagram below to identify the numbered cooling
system components and then complete the chart:

1 Water Pump 5 Upper radiator hose

2 Drive Belt 6 Lower Radiator hose
3 Radiator 7 Thermostat

4 radiator cap

2. The following table highlights a range of cooling system components. Complete the
table by providing an explanation of the location, function and purpose of each
component:

Where located in
Component Function and purpose
cooling system
Water jackets Into Cylinder Head Carry and allow flow of Coolent

Water pump Front end of cylinder Circulation of water and coolant is done by
block water pump

Unit 16 Worksheet
To accompany May & Simpson Automotive Mechanics 10e
© McGraw-Hill Education Australia 2018
 4

Where located in
Component Function and purpose
cooling system
Drive belts between water used to drive water pump, alternator, and
pump and engine air conditioning compressor
pulley

Electric fans Front of the radiator Used in vehicles with transverse engines
or behind the allow air circulation
radiator

Fan (belt driven behind the radiator used in engines with driver pulley to allow
where fitted) air circulation

Thermostat Located in a small function is to close off the coolant outlet to

housing attached to the radiator when the engine is cold.
cylinder head.

Temperature
indicator/sender into the radiator this is used to operate the gauge or warning light on instrument panel

Heater core Into Heater transfer heat from cooling system to

passenger compartment

Radiator cap
upper part of used to hold pressure in the radiator
radiator
Header tank at the place of holds the pressure cap into the cooling
pressurized cooled system
reservoir

Radiator behind the car front consists of tank for coolant and electric
bumper fans. supplies the cooled as needed by
engine

Unit 16 Worksheet
To accompany May & Simpson Automotive Mechanics 10e
© McGraw-Hill Education Australia 2018
 5

3. Answer the following questions regarding cooling system operating principles:

a. Why is a cooling system required as part of an internal combustion engine?

Internal combustion engines remove waste heat through cool intake air, hot exhaust g

b. What are the four effects that heat can have on materials?

i.
When heat is supplied to a body its temperature rises

ii. When a material body, solid, liquid or gas, is given heat energy, its temperature inc
iii. On heating, change of state may occur
iv. When heat is supplied to a body it expands

c. Heat can be transferred in three ways in order to dissipate heat from the engine.
These are:

i. conduction
ii. Convection
iii. Radiation

d. Describe the function of a cross flow radiator:

On a cross flow radiator, the fluid is moved across the core from the right side to the

e. Explain the process you would follow to check combustion gas leakage into the
cooling system.

The engine is started and the test bulb is squeezed and then released. This will pull a

f. Why are the following chemicals added to coolant inhibitors?

i. Silicate and phosphate: Conventional inhforming a protective blanket that actually in

ii. Ethylene glycol: used to manage heat in automotive internal combustion engines.

Unit 16 Worksheet
To accompany May & Simpson Automotive Mechanics 10e
© McGraw-Hill Education Australia 2018
 6

4. Cooling system fault diagnosis.

The flow charts below specify common cooling system faults. Using the learning from
this unit, complete each flow chart by providing information as to possible causes and
suggest a range of tests or repairs you would recommend.

Possible causes

Suggested test/repairs

1. Engine
overheating Leakage in cooling system, BadReplacing worn
Thermostat, belts,
Bad getting
Radiator yo
Fan

Suggested test/repairs
Possible causes

2. Loss of
engine coolant cracks in the hoses, small holes in the radiator,
Replacing a blown orhead
issues with
gasket

Unit 16 Worksheet
To accompany May & Simpson Automotive Mechanics 10e
© McGraw-Hill Education Australia 2018
 7

Possible causes Suggested test/repairs

3. Engine slow
to reach
operating A small leak or evaporation mayfixcause your radiator
the thermostat, to slowly
check for le
temperature

Unit 16 Worksheet
To accompany May & Simpson Automotive Mechanics 10e
© McGraw-Hill Education Australia 2018