servicing heating and engine cooling systems 3 filestudent workbook - heating and air conditioning...

The cooling system regulates the temperature of the engine. Theheat from the engine transfers heat to the coolant, then as thecoolant travels through the cooling system, heat passes to theradiator. Through the processes of conduction and convection,the heat is released.

If the heat is not released, malfunctions can occur in the coolingsystem. The malfunction can cause a variety of problems; theseproblems range from overheating to overcooling to poorperformance of the engine, air conditioner, heater or internalengine damage.

Introduction to Automotive Heating and Air Conditioning Systems

After completing this unit, you will show the following competenciesby mastering the activities on the Assignment Sheets and JobSheets and by scoring at least 85% on the Written Test.

UNITOBJECTIVE

FOCUS ASSIGNMENTS

1. Study one of these sources:

• Study the “Heating” section of CDX Module 13: Light Vehicle Heating andAir-Conditioning Systems.

• <http://auto.howstuffworks.com/cooling-system.htm> and study thesections under “How Car Cooling Systems Work.

2. Complete one of these reports:

• Write a three or four paragraph report concerning the major parts of thecooling system.

• Give an oral report concerning the major parts of the cooling system.

PREREQUISITE

INTRODUCTION

STUDENT WORKBOOK - Heating and Air Conditioning SpecialistOBJECTIVE SHEET- CIMC - 3 - 1

OBJECTIVESHEET

SERVICING HEATING ANDENGINE COOLING SYSTEMS 3

SPECIFICOBJECTIVES


CIMC OBJECTIVE

1. Identify materials and components intypical heating and engine cooing systems.

2. Match functions of components andmaterials in a heating and engine coolingsystem with their names.

3. List safety and environmental precautionsto follow when servicing heating andengine cooling systems.

4. Identify common causes of failure ofspecific components and materials inautomotive heating and cooling systems.

5. Identify tools and equipment used toservice automotive heating and coolingsystems.

6. Diagnose temperature control problems inthe heater/ventilation system; determinenecessary action.

7. Determine appropriate action to performfor specific conditions involving theradiator, hoses, and other relatedcomponents.

8. Perform cooling system, cap, and recoverysystem tests (pressure, combustionleakage, and temperature); determinenecessary action.

9. Inspect engine cooling and heater systemhoses and belts; perform necessary action.

10. Inspect, test, and replace thermostat andhousing.

11. Determine coolant condition and coolanttype for vehicle application; drain andrecover coolant.

ASE/NATEF AUTOMOBILETASK LIST ITEM

1. ASE A7: A

2. ASE A7: A

3. ASE A7: A

4. ASE A7: A, B, C, D

5. ASE A7: A

6. ASE A7: A

7. ASE A7: C

8. ASE A7: E

9. ASE A7: B, D

10. ASE A7: C

11. ASE A7: A


Check the box as you complete each step.

1. Take the pretest provided by your instructor. Have yourinstructor evaluate your completed test. After your testhas been evaluated, follow your instructor’srecommendations.

2. Read the introduction, unit objective, and specificobjectives.

3. Do the focus assignments.

4. Stop and have your instructor evaluate your work fromthe focus assignment. After your work has beenevaluated, follow your instructor’s recommendations.

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SELF-PACEDLEARNINGPLAN

ASE/NATEF AUTOMOBILETASK LIST ITEM

12. ASE A7: C

13. ASE A7: C

14. ASE A7: C

15. ASE A7: C

16. ASE A7: C

17. ASE A7: C

18. ASE A7: C

CIMC OBJECTIVE

12. Flush system; refill system withrecommended coolant; bleed system.

13. Determine appropriate action to performfor specific conditions involving the fansand related components.

14. Inspect and test cooling fan, fan clutch,fan shroud and air dams; performnecessary action.

15. Inspect and test electric cooling fan, fancontrol system and circuits; determinenecessary action.

16. Determine appropriate action to performfor specific conditions involving the heatercore and valve.

17. Inspect and test heater control valve(s);perform necessary action.

18. Remove and reinstall heater core.

Check the box as you complete each step.

1. Study the Information Sheet, objectives 1-3.

2. Ask your instructor to point out the materials andcomponents in a heating and engine cooling system.

3. Study the Information Sheet, objectives 4-5.

4. Do Assignment Sheet 1.

5. Stop and have your instructor evaluate your work fromthe Assignment Sheet. Ask your instructor for additionaldiagnostic problems, if needed.


7. Stop and have your instructor evaluate your work fromthe Assignment Sheet. Ask your instructor for additionaldiagnostic problems, if needed.

8. Do Job Sheet 1. Ask your instructor for assistance asneeded. When you have completed all the steps in theJob sheet, ask your instructor to evaluate your work.After your work has been evaluated, follow yourinstructor’s directions.

9. Do Job Sheet 2. Ask our instructor for assistance asneeded. When you have completed all the steps in thejob sheet, ask our instructor to evaluate your work.After your work has been evaluated, follow yourinstructor’s directions.

10. Do Job Sheet 3. Ask your instructor for assistance asneeded. When you have completed all the steps in thejob sheet, ask your instructor to evaluate your work.After your work has been evaluated, follow yourinstructor’s directions.


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SELF-PACEDLEARNING PLAN

STUDENT WORKBOOK - Heating and Air Conditioning SpecialistINFORMATION SHEET - CIMC - 3 - 5

INFORMATIONSHEET




14. Stop and have your instructor evaluate your work fromthe Assignment Sheet. Ask your instructor foradditional diagnostic problems, if needed.






20. Take the written test. When you have completed thetest, ask your instructor to evaluate it. After your testhas been evaluated, follow your instructor’s directions.

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Identify materials and components in typical heating andengine cooling systems. (ASE A7: A)

FIGURE 1

Condenser

Upper hose

Radiator fan

Coolant reservoir

Lowerradiator hose

Water pump

Heatercore

Heater hoses

Thermostat

Radiator

OBJECTIVE 1


FIGURE 2

Match functions of components and materials in a heatingand engine cooling system with their names. (ASE A7: A)

• coolant reservoir (overflow tank) — non-pressurized orpressurized tank used to hold coolant; allows for expansion ofcoolant as it heats in the engine

• coolant — substance that acts as a rust inhibitor, alubrication for the water pump, protects against freezing, aswell as removes heat from the engine

EXAMPLES: EG/based antifreeze (ethylene glycol), PG/basedantifreeze (propyplene glycol)

• heater core — transfers heat from engine to the interior ofthe vehicle

OBJECTIVE 2

Thermostat

Water pump

Water pumppulley and belts

Pressure radiator cap

Overflow tank orcoolant reservoir

• hoses — device used to transport coolant from radiator toengine and heater core

• pressure or radiator cap — regulates the pressure of thecoolant

• radiator fan — device used to push or pull air across radiatorfins

• radiator — a system of coils or tubes and fins used to removeheat from the coolant

• thermostat — regulates temperature of the coolant

• water pump — circulates coolant through the engine coolingsystem

List safety and environmental precautions to follow whenservicing heating and engine cooling systems. (ASE A7: A)

• Coolant system can be under pressure, and personal injurymay result from improper removal of radiator cap.

CAUTION: Do not remove radiator cap on hot or operatingengine - servere burns may occur

• Coolant is extremely hot in an operating engine.

• The radiator fan on an operating engine can inflict severeinjuries if it is touched or if components, tools, or othermaterials strike the rotating blades.

• The belts and pulleys on an operating engine can inflictsevere injuries if part of the person’s body or clothingbecomes caught in or between belts and pulleys.

WORDS YOU SHOULD KNOW

material safety product information that must be data sheet provided by manufacturers and(MSDS) importers of chemicals as required by the

Occupational Safety and Health Act(OSHA).

resistant the ability to oppose

dispose to get rid of an item

lethal having the ability to cause death

OBJECTIVE 3


• Request a Material Safety Data Sheet (MSDS) from thecoolant manufacturer

CAUTION: Wear chemical resistant gloves when removingradiator cap on an operating engine, as pressure isreleased from the system. Hot coolant will spray in alldirections, so exercise caution.

• Follow the manufacturer’s directions on the label whenadding coolant.

• Dispose of coolant in compliance with local laws andregulations.

• If engine coolant recycling is available, coolant should berecycled and reused.

• It is best to add water or coolant to an operating enginethrough the overflow tank.

• Even a small amount of coolant is poisonous to humans andanimals when ingested.

• Care must be taken in storage, handling and disposing ofengine cooling.

• Propylene glycol is less toxic than ethylene glycol, but it isstill considered a hazardous material.

• Label any container with engine coolant; never use afood/drink container for storing coolant.


Identify causes of failure of specific components andmaterials in heating and cooling systems. (ASE A: 7, A, B, C,D)

• water pumps — leaks (most frequently caused by wornbearings)

• radiator — restriction caused by rust and debris, leaks

• radiator cap — defective cap pressure valve, defective vacuumvalve, or gasket

• thermostat — thermostat sticks in open position, thermostatsticks in closed position

• coolant reservoir — clog in hose, kink in hoses or leaks,stress cracks in tank

• heater core — leaks in the core or hoses

• hoses — leaks and cracks, internal damage from electrolysis

• coolant — additive breakdown

• belts — broken, loose, or cracked

Identify tools and equipment used to service automotiveheating and cooling systems. (ASE A7:A)

• Pressure tester (Figure 3)

FIGURE 3

0

10

20

30

4050 60

70

80

90

100

3030

OBJECTIVE 5

OBJECTIVE 4


• Thermometer (Figure 4)

FIGURE 4

• Jumper wire (Figure 5)

FIGURE 5

• Test lamp (Figure 6)

FIGURE 6

Alligator clip Probe tip Pin terminal Spade terminal

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• Temperature probe (Figure 7)

FIGURE 7

• Infared thermometer (Figure 8)

FIGURE 8

Complete Assignment Sheet 1.


Complete Job Sheet 1.

Complete Job Sheet 2.OBJECTIVE 9

OBJECTIVE 8

OBJECTIVE 7

OBJECTIVE 6










Complete Job Sheet 9.OBJECTIVE 18

OBJECTIVE 17

OBJECTIVE 16

OBJECTIVE 15

OBJECTIVE 14

OBJECTIVE 13

OBJECTIVE 12

OBJECTIVE 11

OBJECTIVE 10


Name ____________________________________________Score_________

Diagnose temperature control problems in theheater/ventilation system; determine necessary action (ASE A7:A)

Maintaining a comfortable temperature is important. Thisassignment sheet will provide situations that will better prepareindividuals to diagnose temperature control problems.

• Pen or Pencil

NOTICE: As you complete this assignment, review thediagnostic information that may apply to each situation.Look for manufacturers’ images, diagrams, tables,diagnostic flowcharts, and wiring diagrams as needed. Youcan find diagnostic information in manufacturers’ servicemanuals and related publications, technical servicebulletins, and online service support products such asShopKey from Snap-On, ALLDATA, and others. (Ask yourinstructor which products are available.)

After reading each scenario, circle the best answer.

INSTRUCTIONS

EQUIPMENTAND SUPPLIES

INTRODUCTION

CriticalThinking

EmployabilityReading

BASIC SKILLS

OBJECTIVE 6

STUDENT WORKBOOK - Heating and Air Conditioning SpecialistASSIGNMENT SHEET 1 - CIMC - 3 - 15

ASSIGNMENTSHEET 1



1. A customer says that the heater is not warming the caradequately. In checking the vehicle, it is discovered that theengine is running/operating cold. Technician A says adefective thermostat could be causing the problem.Technician B says a defective temperature sending unit couldbe causing the problem. Who is correct?

A. Technician AB. Technician BC. Both Technician A & BD. Neither Technician A or B

2. A customer says there is very little heat output from theheater. In checking the coolant level in the radiator, it isfound to be low. Technician A says adding coolant may solvethe problem. Technician B says the radiator needs to berepaired or replaced. Who is correct?


3. There is not enough heat to warm the car on a cold day. Thecoolant level was checked and found to be normal. The enginewas operated until it reached normal operating temperature.The hose was then held and was found to be cool. TechnicianA says the problem could be an open thermostat that shouldbe replaced. Technician B says the problem could be aleaking heater hose. Who is correct?


4. A customer says that the air conditioner is not cooling. Thetemperature gauge indicates that the car’s engine is runninghot. Technician A says the problem could be a defective waterpump. Technician B says the engine could be out of tune andshould be serviced. Who is correct?



5. A vehicle is brought into the shop that does not have bleedervalves on the hoses. Air has not escaped as the system isfilled. Technician A says loosen the heater outlet hosetemporarily. This will allow the excess air to be bled from thesystem. Technician B says replace the heater outlet hose, asit cannot be repaired. Who is correct?


6. The vehicle’s engine is not reaching normal operatingtemperature. Technician A says replace the hose. TechnicianB says replace the thermostat. Who is correct?


7. The vehicle’s engine is slow to warm up. Technician A saysthe radiator cap could be faulty and needs to be replaced.Technician B says the thermostat could be faulty and needsto be replaced. Who is correct?


Name ____________________________________________Score_________

Determine appropriate action to perform for specificconditions involving the radiator, hoses, and other relatedcomponents. (ASE A7:C)

Replacing the hoses every few years and periodically maintainingthe radiator can prevent a problem from occurring. Neglect anddefective parts can create situations that an automotivetechnician must handle. This assignment sheet will provide youwith situations to help you determine what action should betaken when working with radiators, hoses, and other relatedparts.

• Pen or Pencil

NOTICE: Procedures vary with the vehicle. Always checkthe procedure before starting any service or repair. Usemanufacturers’ service manuals and publications to verifythe proper procedure. Look for any technical servicebulletins (TSBs) that might apply. Check with onlineservice support products such as shopKey from Snap-On,ALL DATA, and others. They usually include frequentonline updates of TSBs and recall notices. (Ask yourinstructor which products are available.)

INSTRUCTIONS


INTRODUCTION

CriticalThinking


BASIC SKILLS

OBJECTIVE 7


ASSIGNMENTSHEET 2



After reading each scenario, circle the best answer.

1. A customer recently had a radiator cap replaced. After twoweeks, the customer is frequently needing to add water.Technician A says it could be a defective radiator cap andshould be tested. Technician B says an incorrect radiator capmay have been installed. Who is correct?


2. A customer inherits a vehicle and finds that it frequentlyneeds water. Upon inspection you find there is rust in thecoolant system. Technician A says inspect the system forleaks, flush the system, and add coolant. Technician B saysadd coolant as necessary. Who is correct?


3. An overheating issue is being discussed. The customermentions that the air conditioning also doesn’t seem to coolas well as it used to. Technician A says the overheating canbe due to a radiator hose collapsing and the hose should bereplaced. Technician B says the problem can be due to theexterior of the radiator being dirty and the radiator should becleaned. Who is correct?



4. The customer is considering buying a used vehicle and bringsit in to be inspected. The vehicle’s current owner says theengine tends to overheat. Technician A says it could be aradiator hose leak, a heater hose leak, or a stickingthermostat. Technician B says the engine is low on coolant,probably caused by a radiator hose or heater hose leak or aloose hose clamp. Who is correct?


5. The heater hose is being replaced. The technician working onthe vehicle slides the heater hose onto the heater core withease. Technician A says it is better to use a slightly largerhose than the fitting, then use the hose clamp to secure thehose. Technician B says the hose and fitting should be thesame size. Who is correct?


6. A radiator hose is found to be leaking. Technician A says it isbest to replace the hose and clamp. Technician B says onlythe hose should be replaced. Who is correct?


7. Upon examining the radiator hose, it is found to be crackedand is causing a leak. Technician A says replace the hose.Technician B says there is enough slack in the hose and it ispliable, so the end can be cut off and the hose reattached tothe radiator. Who is correct?


STUDENT WORKBOOK - Heating and Air Conditioning SpecialistJOB SHEET 1 - CIMC - 3 - 23

Name __________________________________________________________

Perform cooling system, cap, and recovery system tests(pressure, combustion leakage and temperature); determinenecessary action (ASE A7: E)

Since the cooling system is very important to the vehicleoperation, it is essential to keep each part in working order. Atechnician will find that leaks are the most common problem in acooling system. This job sheet will help you check for leaks andother potential problems.

• Appropriate safety equipment• Equipment and Supplies• Gloves • Shop rag• Pressure tester• Adapter• Assorted hand tools


CAUTION: Service procedures can be hazardous! Hazardsinclude personal injury, damage to tools and equipment,and contamination of the environment. Follow all rules,practices, and laws that apply to the procedure, to thetools you will use, and to any chemicals or hazardousmaterials involved! Examples include wearing personal


INTRODUCTION

CriticalThinking


BASIC SKILLS

OBJECTIVE 8

JOB SHEET 1



protective equipment, using the right hand tools andpower tools properly; using power equipment properly,maintaining proper ventilation; and handling, storing, anddisposing of chemicals/materials properly. Follow local,state, and federal safety and environmental regulations.Manufacturers’ service information may include additionalcautions, warnings and guidelines for a procedure.

Yes No

Cooling System Test

1. Let the engine and coolant cool.

2. Remove pressure cap. Record pressure range on thecap.

3. Adjust coolant level to a level just below the bottom ofthe fill neck of the radiator.

4. Fasten the pressure tester to the radiator neck.

5. Monitor the gauge as you pump the tester until thepressure is equal to the cap rating.• When the pressure is met, proceed to the next step.• If the pressure cannot be reached, check for leaks.

6. Allow the system to stand for 5 minutes.

7. Recheck the gauge.• If the pressure is the same as in step 5, the system

is working correctly.• If the pressure drops slightly, repressurize the

system to the highest end of the pressure rating and proceed to the radiator cap test.

• If the pressure drops significantly, look for leaks.

8. If a leak is found, repair and recheck the system.

Radiator Cap Test

1. Connect the adapter to the pressure tester.

2. Install the radiator cap to be assessed.

3. Bring the pressure tester to the value stated in theservice manual or marked on the radiator cap.

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PROCEDURE


4. Does the cap hold pressure?• If yes, continue to the next step.• If not, replace the radiator cap.

5. Apply pressure to surpass the rating of the radiatorcap.

6. Does the radiator cap discharge pressure?• If yes, the cap is working correctly.• If no, replace the cap.

SKILL TEST RECORD

Evaluator note: Rate the student on the following criteria bycircling the appropriate numbers. Each criterion must receive arating of “3” or higher to demonstrate student mastery. (See Keybelow.) A student who is unable to demonstrate mastery shouldreview the material and submit another product for evaluation.

Criteria:

Product meets manufacturer’sinstallation specifications 4 3 2 1

Product meets manufacturer’sadjustment specifications 4 3 2 1

Product includes proper com-ponents/materials 4 3 2 1

Product meets performancerequirements 4 3 2 1

Product appearance meetsindustry standards 4 3 2 1

Evaluator note: To obtain an average rating for the Profile ofTraining Mastery, total the points in Product Evaluation anddivide by the total number of criteria. Circle the rating on the Key.

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PRODUCTEVALUATION

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4 Skilled — Can perform job with no additional training3 Moderately Skilled — Has performed job during training

program; limited additional training may be required2 Limited Skill — Has performed job during training program;

additional training is required to develop skill1 Unskilled — Is familiar with process, but is unable to

perform job

EVALUATOR’SCOMMENTS

KEY


Name __________________________________________________________

Inspect engine cooling and heater system hoses and belts;perform necessary action (ASE A7: B, D)

Hoses should be replaced every couple of years. This regularmaintenance will prevent a more expensive repair in the future.This job sheet will assist you in checking the hoses and belts.

• Appropriate safety equipment• Hoses• Hose removal tool• Assorted hand tools


CAUTION: Service procedures can be hazardous! Hazardsinclude personal injury, damage to tools and equipment,and contamination of the environment. Follow all rules,practices, and laws that apply to the procedure, to thetools you will use, and to any chemicals or hazardousmaterials involved! Examples include wearing personalprotective equipment, using the right hand tools andpower tools properly; using power equipment properly,maintaining proper ventilation; and handling, storing, anddisposing of chemicals/materials properly. Follow local,


INTRODUCTION

CriticalThinking


BASIC SKILLS

OBJECTIVE9

JOB SHEET 2



state, and federal safety and environmental regulations.Manufacturers’ service information may include additionalcautions, warnings and guidelines for a procedure.

Yes No

Inspect Hose

1. Check for leaks.

2. Check for swelling.

3. Check for chafing.

4. Check for sponginess or bulging.

5. Check for soft or hard spots.

6. Check for brittleness.

7. Check if the hose’s outer layer splits or flakes whenthe hose is compressed.

8. Check if the reinforced wiring is missing when thelower radiator hose is compressed.

9. If any of the above problems are noted, the hoseshould be replaced.

Replace Hose

CAUTION: Hoses can adhere to engine parts and can bevery difficult to remove. Remove with extreme caution toprevent damage to radiator, heater core, etc.

1. Check coolant level. Remove coolant to a level that islower than that of the hose that is being replaced.

2. Release the hose clamp on each end of the hose.

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PROCEDURE


Inspect Belts

1. Check belt for presence of more than 4 cracks perinch (a small amount of cracking is normal on aserpentine belt, v-belts should have no cracking).

2. Check for cuts, nicks or abrasions.

3. Check for missing rib sections.

4. If any of the above problems are noted, the beltshould be replaced.

5. Inspect pulleys/tensioner for wear, damage, andalignment

SKILL TEST RECORD


Criteria:







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perform job


KEY


Name __________________________________________________________

Inspect, test, and replace thermostat and housing (ASE A7: C)

The thermostat regulates the temperature of the coolant.Problems arise when the thermostat is stuck open or closed. Thisjob sheet will provide the steps to take in testing the thermostator housing.

• Appropriate safety equipment• Heatproof glass container• Thermometer• Range top• Hot plate• Assorted hand tools


CAUTION: Service procedures can be hazardous! Hazardsinclude personal injury, damage to tools and equipment,and contamination of the environment. Follow all rules,practices, and laws that apply to the procedure, to thetools you will use, and to any chemicals or hazardousmaterials involved! Examples include wearing personalprotective equipment, using the right hand tools and


INTRODUCTION

ScienceCritical

ThinkingEmployabilityReading

BASIC SKILLS

OBJECTIVE 10

JOB SHEET 3



power tools properly; using power equipment properly,maintaining proper ventilation; and handling, storing, anddisposing of chemicals/materials properly. Follow local,state, and federal safety and environmental regulations.Manufacturers’ service information may include additionalcautions, warnings and guidelines for a procedure.

Yes No

Remove Thermostat

1. Lower the engine coolant to a level below the level ofthe thermostat.

2. Loosen and remove the bolts that hold the thermostathousing onto the engine.

Removal of the radiator hose is usually notrequired.

3. Remove the thermostat housing. Note position of thethermostat for correct installation.

4. Remove the thermostat.

to reinstall the thermostat, reverse thisprocess.

5. Clean the thermostat housing and engine matingsurfaces.

Inspect and Test Thermostat

1. Inspect condition of thermostat – is it corroded oropen?• If yes, replace the thermostat.• If no, proceed to next step.

2. Note the temperature rating stamped on thethermostat and verify that the rating is the correctone for the vehicle.

3. Fill the heatproof glass receptacle with water andinsert the thermostat and thermometer, making surethey do not touch the receptacle or each other.

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PROCEDURE


4. Place the receptacle on a range burner and observethe thermometer as you heat the water. Does thethermostat open at about 20° F (11°C) below itsrating?• If no, replace the thermostat.• If yes, proceed to the next step.

5. Is the thermostat fully open at its listed or markedtemperature?• If no, replace the thermostat.• If yes, the thermostat is working properly.

6. Install thermostat according to manufacturer’sinstructions.

SKILL TEST RECORD


Criteria:







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perform job


KEY


Name __________________________________________________________

Determine coolant condition and coolant type for vehicleapplication; drain and recover coolant (ASE A7: A)

Draining the coolant is one of the most important things atechnician can do to prevent engine-related problems.Determining the condition and type of coolant for the vehicle canhelp prevent freezing, rust, and corrosion. This job sheet presentsthe steps needed to prevent these type of problems fromoccurring.

• Appropriate safety equipment• Owner’s manual• Gloves• Drain pans• Drain hose/tube• Wrench• EPA recycle/disposal container


CAUTION: Service procedures can be hazardous! Hazardsinclude personal injury, damage to tools and equipment,and contamination of the environment. Follow all rules,practices, and laws that apply to the procedure, to thetools you will use, and to any chemicals or hazardous


INTRODUCTION

CriticalThinking


BASIC SKILLS

OBJECTIVE 11

JOB SHEET 4



materials involved! Examples include wearing personalprotective equipment, using the right hand tools andpower tools properly; using power equipment properly,maintaining proper ventilation; and handling, storing, anddisposing of chemicals/materials properly. Follow local,state, and federal safety and environmental regulations.Manufacturers’ service information may include additionalcautions, warnings and guidelines for a procedure.

Yes No

Determine Coolant Condition and Coolant Type

1. Check owner’s manual for coolant specificationsbefore draining the vehicle’s coolant.

2. Check to make sure the engine and radiator are coolto the touch; then slowly remove the radiator cap.

CAUTION: PERSONAL INJURY MAY RESULT FROMIMPROPER REMOVAL OF THE RADIATOR CAP.

3. Arrange the drain pan under the radiator drain cock.Fasten a hose/tube on the drain cock and place theother end of the hose/tube in the drain pan.

4. Open the drain cock and drain the radiator.

5. Close the radiator drain cock.

6. Dispose of coolant according to EPA or localregulations.

CAUTION: Label antifreeze container. Never put antifreezein beverage/food containers. Keep containers away fromchildren and animals. Dispose of empty antifreezecontainers properly.

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PROCEDURE


SKILL TEST RECORD


Criteria:










perform job


KEY

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Name __________________________________________________________

Flush system; refill system with recommended coolant; bleedsystem. (ASE A7: C)

When replacing coolant with an extended-life coolant, it isimportant to flush the system so the full benefit of the longerlasting coolant is not lost. This job sheet provides the steps toflush the system.

• Appropriate safety equipment• Service manual• Drain pans (2)• Drain hose/tube• EPA recycle/disposal container• Flush kit• Flushing agent• Infrared thermometer• Sealant pellets• Coolant• Water or distilled water• Funnel



INTRODUCTION

ScienceCritical


BASIC SKILLS

OBJECTIVE 12

JOB SHEET 5



CAUTION: Service procedures can be hazardous! Hazardsinclude personal injury, damage to tools and equipment,and contamination of the environment. Follow all rules,practices, and laws that apply to the procedure, to thetools you will use, and to any chemicals or hazardousmaterials involved! Examples include wearing personalprotective equipment, using the right hand tools andpower tools properly; using power equipment properly,maintaining proper ventilation; and handling, storing, anddisposing of chemicals/materials properly. Follow local,state, and federal safety and environmental regulations.Manufacturers’ service information may include additionalcautions, warnings and guidelines for a procedure.

Yes No

Flushing and refilling the system

1. Refer to appropriate service manual.

2. Check that engine and radiator cap are cool to thetouch, then slowly remove the radiator cap.

CAUTION: Personal injury may result from improperremoval of the radiator cap.

3. Arrange one drain pan under the radiator drain cock.Fasten a hose/tube on the drain cock and place theother end of the hose/tube in the drain pan.

4. Open the drain cock and drain the radiator.

5. Secure the radiator drain cock.


CAUTION: Label antifreeze container. Never putantifreeze in beverage/food containers. Keepcontainers away from children and animals. Disposeof empty antifreeze containers properly.

7. Flush the cooling system to clean the engine block byremoving the radiator cap and filling with flushingagent (cleaner and/or water).

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PROCEDURE


8. Operate engine with heater on high and with atemperature gauge reading of normal operatingtemperature for the time stated by the coolant flushlabel.

An infrared thermometer will assist inreading normal cooling temperature.

9. Turn off engine and allow to cool.

10. Open drain valve and drain cooling system of flushingagent.

11. Properly dispose of flushing agent according to EPAor local regulations.

12. Close drain valve and refill radiator with water.

13. Operate engine for 15 minutes at normal operatingtemperature.

14. Turn off engine and let it cool, then open the drainvalve and redrain the cooling system.

15. Properly dispose of flushing agent according to EPAor local regulations.

16. Close drain valve and refill system, following refillsteps 10 and 14.

17. If required, add sealant pellets.

18. Refer to vehicle manual for type of antifreeze andcombination of fluids to use in vehicle (somemanufacturers recommend distilled water). Alwaysadd the same type of antifreeze that has been used inthe cooling system. When the antifreeze type isunknown or if it is to be replaced by a different typeof antifreeze/coolant, follow the drain, flush and refillprocedure.

19. Using a large funnel, slowly poor coolant mixture intothe radiator opening. Fill to about 1 inch (25.4 mm)below the fill hole, unless otherwise specified by thevehicle manual.

20. Start engine and warm up cooling system on high for15 minutes.

When thermostat opens, coolant level maylower.✔ NOTE:

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21. If coolant level lowers, add coolant until level with fillhole.

22. Replace cap.

23. Check coolant level in recovery reservoir. Add coolantif needed.

SKILL TEST RECORD


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PRODUCTEVALUATION

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perform job


KEY

Name ____________________________________________Score_________

Determine appropriate action to perform for specificconditions involving the fans and related components (ASE A7: C)

The fan and its related parts will occasionally need service. Fansmay become damaged in a collision or from a road hazard ormetal fatigue.

• Pen or Pencil


After reading each scenario, circle the best action to perform onthe vehicle.

INSTRUCTIONS


INTRODUCTION

CriticalThinking


BASIC SKILLS

OBJECTIVE 13


ASSIGNMENTSHEET 3



1. A customer says that the air coming from the heater vents isvery weak. Technician A says the blower motor is broken andshould be replaced. Technician B says it is a defective fanclutch and should be replaced. Who is correct?


2. While a car is being inspected, oil is noticed on the fanclutch. Technician A says it is a defective fan clutch thatneeds to be replaced. Technician B says if the problem is notaddressed, the fan clutch can become detached and damagethe radiator. Who is correct?


3. A car is brought in with a radiator cooling fan that does notrun for engine cooling, yet runs when the air conditioner is inoperation. Technician A says the problem is a loose fan belt.Technician B says the radiator fan switch circuit is open andneeds to be repaired. Who is correct?


4. A customer says his vehicle has a squeaking sound whileidling. Technician A says it has a defective pulley that needsto be replaced, or a loose belt that needs to be tightened.Technician B says the accessory pulleys are misaligned or thebelt needs to be replaced. Who is correct?



5. A customer says her vehicle makes a rumbling noise underthe hood. Technician A says the belt may be too tight andneeds to be loosened. Technician B says the belt may be wornand needs to be replaced. Who is correct?


6. A customer says that the fan belt just broke on his car for thesecond time in three weeks. Technician A says fan belts mustbe installed with care, and the person installing the belt mayhave damaged it during installation. Technician B says thebelt may have been under excessive tension, and when thebelt is replaced, it is important to have the tension correctlyadjusted. Who is correct?



Name __________________________________________________________

Inspect and test cooling fan, fan clutch, fan shroud, and airdams; perform necessary action. (ASE A7: C)

Five- or six-blade cooling fans are found on air-conditionedvehicles. Typically, non-air-conditioned vehicles have fewer fanblades. A balanced fan can prevent numerous problems.


CAUTION: Service procedures can be hazardous! Hazardsinclude personal injury, damage to tools and equipment,and contamination of the environment. Follow all rules,practices, and laws that apply to the procedure, to thetools you will use, and to any chemicals or hazardousmaterials involved! Examples include wearing personalprotective equipment, using the right hand tools andpower tools properly; using power equipment properly,maintaining proper ventilation; and handling, storing, anddisposing of chemicals/materials properly. Follow local,state, and federal safety and environmental regulations.Manufacturers’ service information may include additionalcautions, warnings and guidelines for a procedure.

INTRODUCTION

CriticalThinking


BASIC SKILLS

OBJECTIVE 14

JOB SHEET 6



Yes No

Inspect and Test Cooling Fan

1. Remove the belt or belts.

2. Visually check the fan for:• Loose blades• Cracks• Breaks• Other damage

3. Turn the fan by hand slowly and check for out-of-true condition or other damage.

4. Turn the fan by hand quickly and check for out-of-true condition.

5. If any of the above are found, replace the fan.

Inspect and Test Fan Clutch

1. Visually inspect the clutch for fluid residue.

2. Check for slight resistance when turning the blades.Note: Slight resistance may be normal during hotweather.

3. Check for looseness in the shaft bearing.

4. If any of the above are found, replace the fan clutch.

Inspect Fan Shroud

1. Visually check the fan shroud for cracks or breaks.

2. If any are found, the fan shroud should be replaced.❏❏

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SKILL TEST RECORD


Criteria:










perform job


KEY

AVERAGERATING

PRODUCTEVALUATION


Name __________________________________________________________

Inspect and test electric cooling fan motor, fan controlsystem and circuits; determine necessary action. (ASE A7: C)

Late model vehicles have electric cooling fans. It is important forthe automotive technician to know how to inspect and test thesefans, as well as the fan control system and circuits.

• Appropriate safety equipment• Assorted hand tools• Jumper wire• Test lamp• Fused jumper wire


CAUTION: Injury possible. An electric engine cooling fanmay start and run even when the ignition switch is in theOFF position.


INTRODUCTION

ScienceCritical


BASIC SKILLS

OBJECTIVE 15

JOB SHEET 7



Yes No

1. Engage the engine.

2. Run the engine until the coolant reaches the specifiedtemperature.

3. Turn on the air conditioner.

4. If fan fails to operate, refer to service manual forappropriate diagnostics and repair.

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SKILL TEST RECORD


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perform job


KEY

AVERAGERATING

PRODUCTEVALUATION

Name ____________________________________________Score_________

Determine appropriate action to perform for specificconditions involving the heater core and valve (ASE A7: C)

The heater core transfers heat to the car’s interior. It plays animportant part in the comfort level of the driver/passenger.

• Pen or Pencil


After reading each scenario, circle the action the technicianshould take to solve the problem.

INSTRUCTIONS


INTRODUCTION

CriticalThinking


BASIC SKILLS

OBJECTIVE 16


ASSIGNMENTSHEET 4



1. A customer says that she frequently needs to add water to thevehicle. Upon inspection of the heater control valve, it isdiscovered that the valve is leaking. Technician A says repairthe heater control valve. Technician B says replace the heatercontrol valve. Who is correct?

A. Technician AB. Technician BC. Both Technician A & BD. Neither Technician A nor B is correct

2. A customer says that his heater is performing poorly. Atechnician working on the vehicle notices there is a stickyfilm on the inside of the windshield. Technician A says it isdue to a leak in the heater core, which should be replaced.Technician B says the problem is caused by a low coolantlevel, and that the coolant system should be flushed andreplaced. Who is correct?


3. The cooling system is low on coolant. The technician feels theheater inlet and outlet hoses and checks these hoses as thecar idles. The heater valves are cool to the touch. TechnicianA says the heater control valve needs to be unclogged.Technician B says the coolant needs to be flushed andreplaced. Who is correct?


4. A gurgling noise is coming from the heater core. Technician Asays the heater core needs to be replaced. Technician B saysthe coolant level is low. Who is correct?



5. When the technician feels the inlet hose, it feels hot all theway up to the heater core. The outlet hose is cool. TechnicianA says the heater core is plugged and needs to be replaced.Technician B says the heater core is plugged and should bereverse flushed to open up the blockage. Who is correct?


6. A customer has brought in a vehicle to have a leaky heatercore replaced. He has also asked that an aftermarket airconditioner be installed while the car is in the shop.Technician A says to install the new heater core, aftermarketair conditioner, and a shut off valve in the heater hose.Technician B says to install a new heater core andaftermarket air conditioner. Who is correct?


7. A customer brings in a vehicle she has owned since 1970 andcomplains that the carpet on the front passenger side is wet.Technician A says there could be a leaking seal around thewindshield. Technician B says there could be a leak in theheater core and it should be replaced. Who is correct?



Name __________________________________________________________

Inspect and test heater control valves(s); perform necessaryaction (ASE A7: C)

The heater control valve commonly fails due to a leak, rust, orcorrosion. This job sheet describes the steps needed to inspectand test the heater control valve.

• Appropriate safety equipment• Assorted hand tools• Drain pan• Ratchet or open ended wrenches• Assorted hand tools• Hose clamps


CAUTION: Service procedures can be hazardous! Hazardsinclude personal injury, damage to tools and equipment,and contamination of the environment. Follow all rules,practices, and laws that apply to the procedure, to thetools you will use, and to any chemicals or hazardousmaterials involved! Examples include wearing personalprotective equipment, using the right hand tools andpower tools properly; using power equipment properly,


INTRODUCTION

CriticalThinking


BASIC SKILLS

OBJECTIVE 17

JOB SHEET 8



maintaining proper ventilation; and handling, storing, anddisposing of chemicals/materials properly. Follow local,state, and federal safety and environmental regulations.Manufacturers’ service information may include additionalcautions, warnings and guidelines for a procedure.

Yes No

Inspect heater control valve

1. Are there any leaks?

2. Is there any rust or corrosion?

3. Test heater control valve according to manufacturer’sinstructions.

Valve replacement

1. Drain coolant to a level below the control valve.

2. Remove the cable linkage, vacuum hose(s), and/orelectrical connector from the heater control valve.

3. Release the hose clamps and disconnect the inlethose from the heater control valve.

4. Remove the heater control and disconnect the inlethose from the heater control valve.

5. Disconnect the brackets/fasteners from the heatercontrol valve.

6. Check the hose ends that were disconnected. If theyare hard or split, the hoses should be replaced.

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PROCEDURE


SKILL TEST RECORD


Criteria:










perform job


KEY

AVERAGERATING

PRODUCTEVALUATION


Name __________________________________________________________

Remove and reinstall heater core. (ASE A7: C)

Most heater core problems are due to leaks. When a heater coreneeds to be reinstalled, it can be a difficult task, because theinstallation method varies greatly from vehicle to vehicle.

• Appropriate safety equipment• Service manual• Drain pan• Assorted hand tools• Hose clamp• Heater hose• Coolant


CAUTION: Service procedures can be hazardous! Hazardsinclude personal injury, damage to tools and equipment,and contamination of the environment. Follow all rules,practices, and laws that apply to the procedure, to thetools you will use, and to any chemicals or hazardousmaterials involved! Examples include wearing personalprotective equipment, using the right hand tools andpower tools properly; using power equipment properly,


INTRODUCTION

ScienceCritical


BASIC SKILLS

OBJECTIVE 18

JOB SHEET 9



maintaining proper ventilation; and handling, storing, anddisposing of chemicals/materials properly. Follow local,state, and federal safety and environmental regulations.Manufacturers’ service information may include additionalcautions, warnings and guidelines for a procedure.

Yes No

1. Refer to appropriate service manual.

2. Drain cooling system into a clean container.


4. Follow service manual instructions for removal andreinstallation of heater core.

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PROCEDURE


SKILL TEST RECORD


Criteria:










perform job


KEY

AVERAGERATING

PRODUCTEVALUATION

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