SERVICING HEATING AND ENGINE COOLING SYSTEMS

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1 OBJECTIVE SHEET SERVICING HEATING AND 3 ENGINE COOLING SYSTEMS INTRODUCTION The cooling system regulates the temperature of the engine. The heat from the engine transfers heat to the coolant, then as the coolant travels through the cooling system, heat passes to the radiator. Through the processes of conduction and convection, the heat is released. If the heat is not released, malfunctions can occur in the cooling system. The malfunction can cause a variety of problems; these problems range from overheating to overcooling to poor performance of the engine, air conditioner, heater or internal engine damage. PREREQUISITE Introduction to Automotive Heating and Air Conditioning Systems 1. Study one of these sources: FOCUS ASSIGNMENTS Study the Heating section of CDX Module 13: Light Vehicle Heating and Air-Conditioning Systems. < and study the sections under How Car Cooling Systems Work. 2. Complete one of these reports: Write a three or four paragraph report concerning the major parts of the cooling system. Give an oral report concerning the major parts of the cooling system. UNIT OBJECTIVE After completing this unit, you will show the following competencies by mastering the activities on the Assignment Sheets and Job Sheets and by scoring at least 85% on the Written Test. OBJECTIVE SHEET- CIMC - 3-1

2 SPECIFIC OBJECTIVES CIMC OBJECTIVE ASE/NATEF AUTOMOBILE TASK LIST ITEM 1. Identify materials and components in typical heating and engine cooing systems. 2. Match functions of components and materials in a heating and engine cooling system with their names. 3. List safety and environmental precautions to follow when servicing heating and engine cooling systems. 4. Identify common causes of failure of specific components and materials in automotive heating and cooling systems. 5. Identify tools and equipment used to service automotive heating and cooling systems. 6. Diagnose temperature control problems in the heater/ventilation system; determine necessary action. 7. Determine appropriate action to perform for specific conditions involving the radiator, hoses, and other related components. 8. Perform cooling system, cap, and recovery system tests (pressure, combustion leakage, and temperature); determine necessary action. 9. Inspect engine cooling and heater system hoses and belts; perform necessary action. 10. Inspect, test, and replace thermostat and housing. 11. Determine coolant condition and coolant type for vehicle application; drain and recover coolant. 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 OBJECTIVE SHEET- CIMC - 3-2

3 CIMC OBJECTIVE ASE/NATEF AUTOMOBILE TASK LIST ITEM 12. Flush system; refill system with recommended coolant; bleed system. 13. Determine appropriate action to perform for specific conditions involving the fans and related components. 14. Inspect and test cooling fan, fan clutch, fan shroud and air dams; perform necessary action. 15. Inspect and test electric cooling fan, fan control system and circuits; determine necessary action. 16. Determine appropriate action to perform for specific conditions involving the heater core and valve. 17. Inspect and test heater control valve(s); perform necessary action. 18. Remove and reinstall heater core. 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 SELF-PACED LEARNING PLAN Check the box as you complete each step. 1. Take the pretest provided by your instructor. Have your instructor evaluate your completed test. After your test has been evaluated, follow your instructor s recommendations. 2. Read the introduction, unit objective, and specific objectives. 3. Do the focus assignments. 4. Stop and have your instructor evaluate your work from the focus assignment. After your work has been evaluated, follow your instructor s recommendations. OBJECTIVE SHEET- CIMC - 3-3

4 OBJECTIVE SHEET- CIMC - 3-4

5 INFORMATION SHEET SERVICING HEATING AND 3 ENGINE COOLING SYSTEMS SELF-PACED LEARNING PLAN Check the box as you complete each step. 1. Study the Information Sheet, objectives Ask your instructor to point out the materials and components in a heating and engine cooling system. 3. Study the Information Sheet, objectives Do Assignment Sheet Stop and have your instructor evaluate your work from the Assignment Sheet. Ask your instructor for additional diagnostic problems, if needed. 6. Do Assignment Sheet Stop and have your instructor evaluate your work from the Assignment Sheet. Ask your instructor for additional diagnostic problems, if needed. 8. Do Job Sheet 1. Ask your instructor for assistance as needed. When you have completed all the steps in the Job sheet, ask your instructor to evaluate your work. After your work has been evaluated, follow your instructor s directions. 9. Do Job Sheet 2. Ask our instructor for assistance as needed. When you have completed all the steps in the job sheet, ask our instructor to evaluate your work. After your work has been evaluated, follow your instructor s directions. 10. Do Job Sheet 3. Ask your instructor for assistance as needed. When you have completed all the steps in the job sheet, ask your instructor to evaluate your work. After your work has been evaluated, follow your instructor s directions. 11. Do Job Sheet 4. Ask your instructor for assistance as needed. When you have completed all the steps in the job sheet, ask your instructor to evaluate your work. After your work has been evaluated, follow your instructor s directions. INFORMATION SHEET - CIMC - 3-5

6 12. Do Job Sheet 5. Ask your instructor for assistance as needed. When you have completed all the steps in the job sheet, ask your instructor to evaluate your work. After your work has been evaluated, follow your instructor s directions. 13. Do Assignment Sheet Stop and have your instructor evaluate your work from the Assignment Sheet. Ask your instructor for additional diagnostic problems, if needed. 15. Do Job Sheet 6. Ask your instructor for assistance as needed. When you have completed all the steps in the job sheet, ask your instructor to evaluate your work. After your work has been evaluated, follow your instructor s directions. 16. Do Job Sheet 7. Ask your instructor for assistance as needed. When you have completed all the steps in the job sheet, ask your instructor to evaluate your work. After your work has been evaluated, follow your instructor s directions. 17. Do Assignment Sheet Do Job Sheet 8. Ask your instructor for assistance as needed. When you have completed all the steps in the job sheet, ask your instructor to evaluate your work. After your work has been evaluated, follow your instructor s directions. 19. Do Job Sheet 9. Ask your instructor for assistance as needed. When you have completed all the steps in the job sheet, ask your instructor to evaluate your work. After your work has been evaluated, follow your instructor s directions. 20. Take the written test. When you have completed the test, ask your instructor to evaluate it. After your test has been evaluated, follow your instructor s directions. INFORMATION SHEET - CIMC - 3-6

7 OBJECTIVE 1 Identify materials and components in typical heating and engine cooling systems. (ASE A7: A) FIGURE 1 Coolant reservoir Upper hose Thermostat Heater core Heater hoses Condenser Radiator Radiator fan Lower radiator hose Water pump INFORMATION SHEET - CIMC - 3-7

8 FIGURE 2 Thermostat Water pump Water pump pulley and belts Overflow tank or coolant reservoir Pressure radiator cap OBJECTIVE 2 Match functions of components and materials in a heating and engine cooling system with their names. (ASE A7: A) coolant reservoir (overflow tank) non-pressurized or pressurized tank used to hold coolant; allows for expansion of coolant as it heats in the engine coolant substance that acts as a rust inhibitor, a lubrication for the water pump, protects against freezing, as well as removes heat from the engine EXAMPLES: EG/based antifreeze (ethylene glycol), PG/based antifreeze (propyplene glycol) heater core transfers heat from engine to the interior of the vehicle INFORMATION SHEET - CIMC - 3-8

9 hoses device used to transport coolant from radiator to engine and heater core pressure or radiator cap regulates the pressure of the coolant radiator fan device used to push or pull air across radiator fins radiator a system of coils or tubes and fins used to remove heat from the coolant thermostat regulates temperature of the coolant water pump circulates coolant through the engine cooling system OBJECTIVE 3 List safety and environmental precautions to follow when servicing heating and engine cooling systems. (ASE A7: A) WORDS YOU SHOULD KNOW material safety data sheet (MSDS) resistant dispose lethal product information that must be provided by manufacturers and importers of chemicals as required by the Occupational Safety and Health Act (OSHA). the ability to oppose to get rid of an item having the ability to cause death Coolant system can be under pressure, and personal injury may result from improper removal of radiator cap. CAUTION: Do not remove radiator cap on hot or operating engine - servere burns may occur Coolant is extremely hot in an operating engine. The radiator fan on an operating engine can inflict severe injuries if it is touched or if components, tools, or other materials strike the rotating blades. The belts and pulleys on an operating engine can inflict severe injuries if part of the person s body or clothing becomes caught in or between belts and pulleys. INFORMATION SHEET - CIMC - 3-9

10 Request a Material Safety Data Sheet (MSDS) from the coolant manufacturer CAUTION: Wear chemical resistant gloves when removing radiator cap on an operating engine, as pressure is released from the system. Hot coolant will spray in all directions, so exercise caution. Follow the manufacturer s directions on the label when adding coolant. Dispose of coolant in compliance with local laws and regulations. If engine coolant recycling is available, coolant should be recycled and reused. It is best to add water or coolant to an operating engine through the overflow tank. Even a small amount of coolant is poisonous to humans and animals when ingested. Care must be taken in storage, handling and disposing of engine cooling. Propylene glycol is less toxic than ethylene glycol, but it is still considered a hazardous material. Label any container with engine coolant; never use a food/drink container for storing coolant. INFORMATION SHEET - CIMC

11 OBJECTIVE 4 Identify causes of failure of specific components and materials in heating and cooling systems. (ASE A: 7, A, B, C, D) water pumps leaks (most frequently caused by worn bearings) radiator restriction caused by rust and debris, leaks radiator cap defective cap pressure valve, defective vacuum valve, or gasket thermostat thermostat sticks in open position, thermostat sticks 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 OBJECTIVE 5 Identify tools and equipment used to service automotive heating and cooling systems. (ASE A7:A) Pressure tester (Figure 3) FIGURE INFORMATION SHEET - CIMC

12 40 60 Thermometer (Figure 4) FIGURE Jumper wire (Figure 5) FIGURE 5 Alligator clip Probe tip Pin terminal Spade terminal Test lamp (Figure 6) FIGURE 6 INFORMATION SHEET - CIMC

13 Temperature probe (Figure 7) FIGURE 7 Infared thermometer (Figure 8) FIGURE 8 OBJECTIVE 6 Complete Assignment Sheet 1. OBJECTIVE 7 Complete Assignment Sheet 2. OBJECTIVE 8 Complete Job Sheet 1. OBJECTIVE 9 Complete Job Sheet 2. INFORMATION SHEET - CIMC

14 OBJECTIVE 10 Complete Job Sheet 3. OBJECTIVE 11 Complete Job Sheet 4. OBJECTIVE 12 Complete Job Sheet 5. OBJECTIVE 13 Complete Assignment Sheet 3. OBJECTIVE 14 Complete Job Sheet 6. OBJECTIVE 15 Complete Job Sheet 7. OBJECTIVE 16 Complete Assignment Sheet 4. OBJECTIVE 17 Complete Job Sheet 8. OBJECTIVE 18 Complete Job Sheet 9. INFORMATION SHEET - CIMC

15 ASSIGNMENT SHEET 1 SERVICING HEATING AND 3 ENGINE COOLING SYSTEMS Name Score OBJECTIVE 6 Diagnose temperature control problems in the heater/ventilation system; determine necessary action (ASE A7:A) BASIC SKILLS Reading Employability Critical Thinking INTRODUCTION Maintaining a comfortable temperature is important. This assignment sheet will provide situations that will better prepare individuals to diagnose temperature control problems. EQUIPMENT AND SUPPLIES Pen or Pencil INSTRUCTIONS NOTICE: As you complete this assignment, review the diagnostic information that may apply to each situation. Look for manufacturers images, diagrams, tables, diagnostic flowcharts, and wiring diagrams as needed. You can find diagnostic information in manufacturers service manuals and related publications, technical service bulletins, and online service support products such as ShopKey from Snap-On, ALLDATA, and others. (Ask your instructor which products are available.) After reading each scenario, circle the best answer. ASSIGNMENT SHEET 1 - CIMC

16 1. A customer says that the heater is not warming the car adequately. In checking the vehicle, it is discovered that the engine is running/operating cold. Technician A says a defective thermostat could be causing the problem. Technician B says a defective temperature sending unit could be causing the problem. Who is correct? A. Technician A B. Technician B C. Both Technician A & B D. Neither Technician A or B 2. A customer says there is very little heat output from the heater. In checking the coolant level in the radiator, it is found to be low. Technician A says adding coolant may solve the problem. Technician B says the radiator needs to be repaired or replaced. Who is correct? A. Technician A B. Technician B C. Both Technician A & B D. Neither Technician A or B 3. There is not enough heat to warm the car on a cold day. The coolant level was checked and found to be normal. The engine was operated until it reached normal operating temperature. The hose was then held and was found to be cool. Technician A says the problem could be an open thermostat that should be replaced. Technician B says the problem could be a leaking heater hose. Who is correct? A. Technician A B. Technician B C. Both Technician A & B D. Neither Technician A or B 4. A customer says that the air conditioner is not cooling. The temperature gauge indicates that the car s engine is running hot. Technician A says the problem could be a defective water pump. Technician B says the engine could be out of tune and should be serviced. Who is correct? A. Technician A B. Technician B C. Both Technician A & B D. Neither Technician A or B ASSIGNMENT SHEET 1 - CIMC

17 5. A vehicle is brought into the shop that does not have bleeder valves on the hoses. Air has not escaped as the system is filled. Technician A says loosen the heater outlet hose temporarily. This will allow the excess air to be bled from the system. Technician B says replace the heater outlet hose, as it cannot be repaired. Who is correct? A. Technician A B. Technician B C. Both Technician A & B D. Neither Technician A or B 6. The vehicle s engine is not reaching normal operating temperature. Technician A says replace the hose. Technician B says replace the thermostat. Who is correct? A. Technician A B. Technician B C. Both Technician A & B D. Neither Technician A or B 7. The vehicle s engine is slow to warm up. Technician A says the radiator cap could be faulty and needs to be replaced. Technician B says the thermostat could be faulty and needs to be replaced. Who is correct? A. Technician A B. Technician B C. Both Technician A & B D. Neither Technician A or B ASSIGNMENT SHEET 1 - CIMC

18 ASSIGNMENT SHEET 1 - CIMC

19 ASSIGNMENT SHEET 2 SERVICING HEATING AND 3 ENGINE COOLING SYSTEMS Name Score OBJECTIVE 7 Determine appropriate action to perform for specific conditions involving the radiator, hoses, and other related components. (ASE A7:C) BASIC SKILLS Reading Employability Critical Thinking INTRODUCTION Replacing the hoses every few years and periodically maintaining the radiator can prevent a problem from occurring. Neglect and defective parts can create situations that an automotive technician must handle. This assignment sheet will provide you with situations to help you determine what action should be taken when working with radiators, hoses, and other related parts. EQUIPMENT AND SUPPLIES Pen or Pencil INSTRUCTIONS NOTICE: Procedures vary with the vehicle. Always check the procedure before starting any service or repair. Use manufacturers service manuals and publications to verify the proper procedure. Look for any technical service bulletins (TSBs) that might apply. Check with online service support products such as shopkey from Snap-On, ALL DATA, and others. They usually include frequent online updates of TSBs and recall notices. (Ask your instructor which products are available.) ASSIGNMENT SHEET 2 - CIMC

20 After reading each scenario, circle the best answer. 1. A customer recently had a radiator cap replaced. After two weeks, the customer is frequently needing to add water. Technician A says it could be a defective radiator cap and should be tested. Technician B says an incorrect radiator cap may have been installed. Who is correct? A. Technician A B. Technician B C. Both Technician A & B D. Neither Technician A or B 2. A customer inherits a vehicle and finds that it frequently needs water. Upon inspection you find there is rust in the coolant system. Technician A says inspect the system for leaks, flush the system, and add coolant. Technician B says add coolant as necessary. Who is correct? A. Technician A B. Technician B C. Both Technician A & B D. Neither Technician A or B 3. An overheating issue is being discussed. The customer mentions that the air conditioning also doesn t seem to cool as well as it used to. Technician A says the overheating can be due to a radiator hose collapsing and the hose should be replaced. Technician B says the problem can be due to the exterior of the radiator being dirty and the radiator should be cleaned. Who is correct? A. Technician A B. Technician B C. Both Technician A & B D. Neither Technician A or B ASSIGNMENT SHEET 2 - CIMC

21 4. The customer is considering buying a used vehicle and brings it in to be inspected. The vehicle s current owner says the engine tends to overheat. Technician A says it could be a radiator hose leak, a heater hose leak, or a sticking thermostat. Technician B says the engine is low on coolant, probably caused by a radiator hose or heater hose leak or a loose hose clamp. Who is correct? A. Technician A B. Technician B C. Both Technician A & B D. Neither Technician A or B 5. The heater hose is being replaced. The technician working on the vehicle slides the heater hose onto the heater core with ease. Technician A says it is better to use a slightly larger hose than the fitting, then use the hose clamp to secure the hose. Technician B says the hose and fitting should be the same size. Who is correct? A. Technician A B. Technician B C. Both Technician A & B D. Neither Technician A or B 6. A radiator hose is found to be leaking. Technician A says it is best to replace the hose and clamp. Technician B says only the hose should be replaced. Who is correct? A. Technician A B. Technician B C. Both Technician A & B D. Neither Technician A or B 7. Upon examining the radiator hose, it is found to be cracked and is causing a leak. Technician A says replace the hose. Technician B says there is enough slack in the hose and it is pliable, so the end can be cut off and the hose reattached to the radiator. Who is correct? A. Technician A B. Technician B C. Both Technician A & B D. Neither Technician A or B ASSIGNMENT SHEET 2 - CIMC

22 ASSIGNMENT SHEET 2 - CIMC

23 JOB SHEET 1 SERVICING HEATING AND 3 ENGINE COOLING SYSTEMS Name OBJECTIVE 8 Perform cooling system, cap, and recovery system tests (pressure, combustion leakage and temperature); determine necessary action (ASE A7: E) BASIC SKILLS Reading Employability Critical Thinking INTRODUCTION Since the cooling system is very important to the vehicle operation, it is essential to keep each part in working order. A technician will find that leaks are the most common problem in a cooling system. This job sheet will help you check for leaks and other potential problems. EQUIPMENT AND SUPPLIES Appropriate safety equipment Equipment and Supplies Gloves Shop rag Pressure tester Adapter Assorted hand tools NOTICE: Procedures vary with the vehicle. Always check the procedure before starting any service or repair. Use manufacturers service manuals and publications to verify the proper procedure. Look for any technical service bulletins (TSBs) that might apply. Check with online service support products such as shopkey from Snap-On, ALL DATA, and others. They usually include frequent online updates of TSBs and recall notices. (Ask your instructor which products are available.) CAUTION: Service procedures can be hazardous! Hazards include personal injury, damage to tools and equipment, and contamination of the environment. Follow all rules, practices, and laws that apply to the procedure, to the tools you will use, and to any chemicals or hazardous materials involved! Examples include wearing personal JOB SHEET 1 - CIMC

24 protective equipment, using the right hand tools and power tools properly; using power equipment properly, maintaining proper ventilation; and handling, storing, and disposing of chemicals/materials properly. Follow local, state, and federal safety and environmental regulations. Manufacturers service information may include additional cautions, warnings and guidelines for a procedure. PROCEDURE Yes No Cooling System Test 1. Let the engine and coolant cool. 2. Remove pressure cap. Record pressure range on the cap. 3. Adjust coolant level to a level just below the bottom of the fill neck of the radiator. 4. Fasten the pressure tester to the radiator neck. 5. Monitor the gauge as you pump the tester until the pressure 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 the service manual or marked on the radiator cap. JOB SHEET 1 - CIMC

25 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 radiator cap. 6. Does the radiator cap discharge pressure? If yes, the cap is working correctly. If no, replace the cap. SKILL TEST RECORD PRODUCT EVALUATION Evaluator note: Rate the student on the following criteria by circling the appropriate numbers. Each criterion must receive a rating of 3 or higher to demonstrate student mastery. (See Key below.) A student who is unable to demonstrate mastery should review the material and submit another product for evaluation. Criteria: Product meets manufacturer s installation specifications Product meets manufacturer s adjustment specifications Product includes proper components/materials Product meets performance requirements Product appearance meets industry standards AVERAGE RATING Evaluator note: To obtain an average rating for the Profile of Training Mastery, total the points in Product Evaluation and divide by the total number of criteria. Circle the rating on the Key. JOB SHEET 1 - CIMC

26 KEY 4 Skilled Can perform job with no additional training 3 Moderately Skilled Has performed job during training program; limited additional training may be required 2 Limited Skill Has performed job during training program; additional training is required to develop skill 1 Unskilled Is familiar with process, but is unable to perform job EVALUATOR S COMMENTS JOB SHEET 1 - CIMC

27 JOB SHEET 2 SERVICING HEATING AND 3 ENGINE COOLING SYSTEMS Name OBJECTIVE9 Inspect engine cooling and heater system hoses and belts; perform necessary action (ASE A7: B, D) BASIC SKILLS Reading Employability Critical Thinking INTRODUCTION Hoses should be replaced every couple of years. This regular maintenance will prevent a more expensive repair in the future. This job sheet will assist you in checking the hoses and belts. EQUIPMENT AND SUPPLIES Appropriate safety equipment Hoses Hose removal tool Assorted hand tools NOTICE: Procedures vary with the vehicle. Always check the procedure before starting any service or repair. Use manufacturers service manuals and publications to verify the proper procedure. Look for any technical service bulletins (TSBs) that might apply. Check with online service support products such as shopkey from Snap-On, ALL DATA, and others. They usually include frequent online updates of TSBs and recall notices. (Ask your instructor which products are available.) CAUTION: Service procedures can be hazardous! Hazards include personal injury, damage to tools and equipment, and contamination of the environment. Follow all rules, practices, and laws that apply to the procedure, to the tools you will use, and to any chemicals or hazardous materials involved! Examples include wearing personal protective equipment, using the right hand tools and power tools properly; using power equipment properly, maintaining proper ventilation; and handling, storing, and disposing of chemicals/materials properly. Follow local, JOB SHEET 2 - CIMC

28 state, and federal safety and environmental regulations. Manufacturers service information may include additional cautions, warnings and guidelines for a procedure. 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 when the hose is compressed. 8. Check if the reinforced wiring is missing when the lower radiator hose is compressed. 9. If any of the above problems are noted, the hose should be replaced. Replace Hose CAUTION: Hoses can adhere to engine parts and can be very difficult to remove. Remove with extreme caution to prevent damage to radiator, heater core, etc. 1. Check coolant level. Remove coolant to a level that is lower than that of the hose that is being replaced. 2. Release the hose clamp on each end of the hose. 3. Remove the hose without using undue force. JOB SHEET 2 - CIMC

29 Inspect Belts 1. Check belt for presence of more than 4 cracks per inch (a small amount of cracking is normal on a serpentine 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 belt should be replaced. 5. Inspect pulleys/tensioner for wear, damage, and alignment SKILL TEST RECORD PRODUCT EVALUATION Evaluator note: Rate the student on the following criteria by circling the appropriate numbers. Each criterion must receive a rating of 3 or higher to demonstrate student mastery. (See Key below.) A student who is unable to demonstrate mastery should review the material and submit another product for evaluation. Criteria: Product meets manufacturer s installation specifications Product meets manufacturer s adjustment specifications Product includes proper components/materials Product meets performance requirements Product appearance meets industry standards AVERAGE RATING Evaluator note: To obtain an average rating for the Profile of Training Mastery, total the points in Product Evaluation and divide by the total number of criteria. Circle the rating on the Key. JOB SHEET 2 - CIMC

30 KEY 4 Skilled Can perform job with no additional training 3 Moderately Skilled Has performed job during training program; limited additional training may be required 2 Limited Skill Has performed job during training program; additional training is required to develop skill 1 Unskilled Is familiar with process, but is unable to perform job EVALUATOR S COMMENTS JOB SHEET 2 - CIMC

31 JOB SHEET 3 SERVICING HEATING AND 3 ENGINE COOLING SYSTEMS Name OBJECTIVE 10 Inspect, test, and replace thermostat and housing (ASE A7: C) BASIC SKILLS Reading Employability Critical Thinking Science INTRODUCTION The thermostat regulates the temperature of the coolant. Problems arise when the thermostat is stuck open or closed. This job sheet will provide the steps to take in testing the thermostat or housing. EQUIPMENT AND SUPPLIES Appropriate safety equipment Heatproof glass container Thermometer Range top Hot plate Assorted hand tools NOTICE: Procedures vary with the vehicle. Always check the procedure before starting any service or repair. Use manufacturers service manuals and publications to verify the proper procedure. Look for any technical service bulletins (TSBs) that might apply. Check with online service support products such as shopkey from Snap-On, ALL DATA, and others. They usually include frequent online updates of TSBs and recall notices. (Ask your instructor which products are available.) CAUTION: Service procedures can be hazardous! Hazards include personal injury, damage to tools and equipment, and contamination of the environment. Follow all rules, practices, and laws that apply to the procedure, to the tools you will use, and to any chemicals or hazardous materials involved! Examples include wearing personal protective equipment, using the right hand tools and JOB SHEET 3 - CIMC

32 power tools properly; using power equipment properly, maintaining proper ventilation; and handling, storing, and disposing of chemicals/materials properly. Follow local, state, and federal safety and environmental regulations. Manufacturers service information may include additional cautions, warnings and guidelines for a procedure. PROCEDURE Yes No Remove Thermostat 1. Lower the engine coolant to a level below the level of the thermostat. 2. Loosen and remove the bolts that hold the thermostat housing onto the engine. NOTE: Removal of the radiator hose is usually not required. 3. Remove the thermostat housing. Note position of the thermostat for correct installation. 4. Remove the thermostat. NOTE: to reinstall the thermostat, reverse this process. 5. Clean the thermostat housing and engine mating surfaces. Inspect and Test Thermostat 1. Inspect condition of thermostat is it corroded or open? If yes, replace the thermostat. If no, proceed to next step. 2. Note the temperature rating stamped on the thermostat and verify that the rating is the correct one for the vehicle. 3. Fill the heatproof glass receptacle with water and insert the thermostat and thermometer, making sure they do not touch the receptacle or each other. JOB SHEET 3 - CIMC

33 4. Place the receptacle on a range burner and observe the thermometer as you heat the water. Does the thermostat open at about 20 F (11 C) below its rating? If no, replace the thermostat. If yes, proceed to the next step. 5. Is the thermostat fully open at its listed or marked temperature? If no, replace the thermostat. If yes, the thermostat is working properly. 6. Install thermostat according to manufacturer s instructions. SKILL TEST RECORD PRODUCT EVALUATION Evaluator note: Rate the student on the following criteria by circling the appropriate numbers. Each criterion must receive a rating of 3 or higher to demonstrate student mastery. (See Key below.) A student who is unable to demonstrate mastery should review the material and submit another product for evaluation. Criteria: Product meets manufacturer s installation specifications Product meets manufacturer s adjustment specifications Product includes proper components/materials Product meets performance requirements Product appearance meets industry standards AVERAGE RATING Evaluator note: To obtain an average rating for the Profile of Training Mastery, total the points in Product Evaluation and divide by the total number of criteria. Circle the rating on the Key. JOB SHEET 3 - CIMC

34 KEY 4 Skilled Can perform job with no additional training 3 Moderately Skilled Has performed job during training program; limited additional training may be required 2 Limited Skill Has performed job during training program; additional training is required to develop skill 1 Unskilled Is familiar with process, but is unable to perform job EVALUATOR S COMMENTS JOB SHEET 3 - CIMC

35 JOB SHEET 4 SERVICING HEATING AND 3 ENGINE COOLING SYSTEMS Name OBJECTIVE 11 Determine coolant condition and coolant type for vehicle application; drain and recover coolant (ASE A7: A) BASIC SKILLS Reading Employability Critical Thinking INTRODUCTION Draining the coolant is one of the most important things a technician can do to prevent engine-related problems. Determining the condition and type of coolant for the vehicle can help prevent freezing, rust, and corrosion. This job sheet presents the steps needed to prevent these type of problems from occurring. EQUIPMENT AND SUPPLIES Appropriate safety equipment Owner s manual Gloves Drain pans Drain hose/tube Wrench EPA recycle/disposal container NOTICE: Procedures vary with the vehicle. Always check the procedure before starting any service or repair. Use manufacturers service manuals and publications to verify the proper procedure. Look for any technical service bulletins (TSBs) that might apply. Check with online service support products such as shopkey from Snap-On, ALL DATA, and others. They usually include frequent online updates of TSBs and recall notices. (Ask your instructor which products are available.) CAUTION: Service procedures can be hazardous! Hazards include personal injury, damage to tools and equipment, and contamination of the environment. Follow all rules, practices, and laws that apply to the procedure, to the tools you will use, and to any chemicals or hazardous JOB SHEET 4 - CIMC

36 materials involved! Examples include wearing personal protective equipment, using the right hand tools and power tools properly; using power equipment properly, maintaining proper ventilation; and handling, storing, and disposing of chemicals/materials properly. Follow local, state, and federal safety and environmental regulations. Manufacturers service information may include additional cautions, warnings and guidelines for a procedure. PROCEDURE Yes No Determine Coolant Condition and Coolant Type 1. Check owner s manual for coolant specifications before draining the vehicle s coolant. 2. Check to make sure the engine and radiator are cool to the touch; then slowly remove the radiator cap. CAUTION: PERSONAL INJURY MAY RESULT FROM IMPROPER 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 the other 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 local regulations. CAUTION: Label antifreeze container. Never put antifreeze in beverage/food containers. Keep containers away from children and animals. Dispose of empty antifreeze containers properly. JOB SHEET 4 - CIMC

37 SKILL TEST RECORD PRODUCT EVALUATION Evaluator note: Rate the student on the following criteria by circling the appropriate numbers. Each criterion must receive a rating of 3 or higher to demonstrate student mastery. (See Key below.) A student who is unable to demonstrate mastery should review the material and submit another product for evaluation. Criteria: Product meets manufacturer s installation specifications Product meets manufacturer s adjustment specifications Product includes proper components/materials Product meets performance requirements Product appearance meets industry standards AVERAGE RATING Evaluator note: To obtain an average rating for the Profile of Training Mastery, total the points in Product Evaluation and divide by the total number of criteria. Circle the rating on the Key. KEY 4 Skilled Can perform job with no additional training 3 Moderately Skilled Has performed job during training program; limited additional training may be required 2 Limited Skill Has performed job during training program; additional training is required to develop skill 1 Unskilled Is familiar with process, but is unable to perform job EVALUATOR S COMMENTS JOB SHEET 4 - CIMC

38 JOB SHEET 4 - CIMC

39 JOB SHEET 5 SERVICING HEATING AND 3 ENGINE COOLING SYSTEMS Name OBJECTIVE 12 Flush system; refill system with recommended coolant; bleed system. (ASE A7: C) BASIC SKILLS Reading Employability Critical Thinking Science INTRODUCTION When replacing coolant with an extended-life coolant, it is important to flush the system so the full benefit of the longer lasting coolant is not lost. This job sheet provides the steps to flush the system. EQUIPMENT AND SUPPLIES 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 NOTICE: Procedures vary with the vehicle. Always check the procedure before starting any service or repair. Use manufacturers service manuals and publications to verify the proper procedure. Look for any technical service bulletins (TSBs) that might apply. Check with online service support products such as shopkey from Snap-On, ALL DATA, and others. They usually include frequent online updates of TSBs and recall notices. (Ask your instructor which products are available.) JOB SHEET 5 - CIMC

40 CAUTION: Service procedures can be hazardous! Hazards include personal injury, damage to tools and equipment, and contamination of the environment. Follow all rules, practices, and laws that apply to the procedure, to the tools you will use, and to any chemicals or hazardous materials involved! Examples include wearing personal protective equipment, using the right hand tools and power tools properly; using power equipment properly, maintaining proper ventilation; and handling, storing, and disposing of chemicals/materials properly. Follow local, state, and federal safety and environmental regulations. Manufacturers service information may include additional cautions, warnings and guidelines for a procedure. PROCEDURE Yes No Flushing and refilling the system 1. Refer to appropriate service manual. 2. Check that engine and radiator cap are cool to the touch, then slowly remove the radiator cap. CAUTION: Personal injury may result from improper removal of the radiator cap. 3. Arrange one drain pan under the radiator drain cock. Fasten a hose/tube on the drain cock and place the other end of the hose/tube in the drain pan. 4. Open the drain cock and drain the radiator. 5. Secure the radiator drain cock. 6. Dispose of coolant according to EPA or local regulations. CAUTION: Label antifreeze container. Never put antifreeze in beverage/food containers. Keep containers away from children and animals. Dispose of empty antifreeze containers properly. 7. Flush the cooling system to clean the engine block by removing the radiator cap and filling with flushing agent (cleaner and/or water). JOB SHEET 5 - CIMC

41 8. Operate engine with heater on high and with a temperature gauge reading of normal operating temperature for the time stated by the coolant flush label. NOTE: An infrared thermometer will assist in reading normal cooling temperature. 9. Turn off engine and allow to cool. 10. Open drain valve and drain cooling system of flushing agent. 11. Properly dispose of flushing agent according to EPA or local regulations. 12. Close drain valve and refill radiator with water. 13. Operate engine for 15 minutes at normal operating temperature. 14. Turn off engine and let it cool, then open the drain valve and redrain the cooling system. 15. Properly dispose of flushing agent according to EPA or local regulations. 16. Close drain valve and refill system, following refill steps 10 and If required, add sealant pellets. 18. Refer to vehicle manual for type of antifreeze and combination of fluids to use in vehicle (some manufacturers recommend distilled water). Always add the same type of antifreeze that has been used in the cooling system. When the antifreeze type is unknown or if it is to be replaced by a different type of antifreeze/coolant, follow the drain, flush and refill procedure. 19. Using a large funnel, slowly poor coolant mixture into the radiator opening. Fill to about 1 inch (25.4 mm) below the fill hole, unless otherwise specified by the vehicle manual. 20. Start engine and warm up cooling system on high for 15 minutes. NOTE: lower. When thermostat opens, coolant level may JOB SHEET 5 - CIMC

42 21. If coolant level lowers, add coolant until level with fill hole. 22. Replace cap. 23. Check coolant level in recovery reservoir. Add coolant if needed. SKILL TEST RECORD PRODUCT EVALUATION Evaluator note: Rate the student on the following criteria by circling the appropriate numbers. Each criterion must receive a rating of 3 or higher to demonstrate student mastery. (See Key below.) A student who is unable to demonstrate mastery should review the material and submit another product for evaluation. Criteria: Product meets manufacturer s installation specifications Product meets manufacturer s adjustment specifications Product includes proper components/materials Product meets performance requirements Product appearance meets industry standards AVERAGE RATING Evaluator note: To obtain an average rating for the Profile of Training Mastery, total the points in Product Evaluation and divide by the total number of criteria. Circle the rating on the Key. JOB SHEET 5 - CIMC

43 KEY 4 Skilled Can perform job with no additional training 3 Moderately Skilled Has performed job during training program; limited additional training may be required 2 Limited Skill Has performed job during training program; additional training is required to develop skill 1 Unskilled Is familiar with process, but is unable to perform job EVALUATOR S COMMENTS JOB SHEET 5 - CIMC

44 JOB SHEET 5 - CIMC

45 ASSIGNMENT SHEET 3 SERVICING HEATING AND 3 ENGINE COOLING SYSTEMS Name Score OBJECTIVE 13 Determine appropriate action to perform for specific conditions involving the fans and related components (ASE A7: C) BASIC SKILLS Reading Employability Critical Thinking INTRODUCTION The fan and its related parts will occasionally need service. Fans may become damaged in a collision or from a road hazard or metal fatigue. EQUIPMENT AND SUPPLIES Pen or Pencil INSTRUCTIONS NOTICE: As you complete this assignment, review the diagnostic information that may apply to each situation. Look for manufacturers images, diagrams, tables, diagnostic flowcharts, and wiring diagrams as needed. You can find diagnostic information in manufacturers service manuals and related publications, technical service bulletins, and online service support products such as ShopKey from Snap-On, ALLDATA, and others. (Ask your instructor which products are available.) After reading each scenario, circle the best action to perform on the vehicle. ASSIGNMENT SHEET 3 - CIMC

46 1. A customer says that the air coming from the heater vents is very weak. Technician A says the blower motor is broken and should be replaced. Technician B says it is a defective fan clutch and should be replaced. Who is correct? A. Technician A B. Technician B C. Both Technician A & B D. Neither Technician A or B 2. While a car is being inspected, oil is noticed on the fan clutch. Technician A says it is a defective fan clutch that needs to be replaced. Technician B says if the problem is not addressed, the fan clutch can become detached and damage the radiator. Who is correct? A. Technician A B. Technician B C. Both Technician A & B D. Neither Technician A or B 3. A car is brought in with a radiator cooling fan that does not run for engine cooling, yet runs when the air conditioner is in operation. Technician A says the problem is a loose fan belt. Technician B says the radiator fan switch circuit is open and needs to be repaired. Who is correct? A. Technician A B. Technician B C. Both Technician A & B D. Neither Technician A or B 4. A customer says his vehicle has a squeaking sound while idling. Technician A says it has a defective pulley that needs to be replaced, or a loose belt that needs to be tightened. Technician B says the accessory pulleys are misaligned or the belt needs to be replaced. Who is correct? A. Technician A B. Technician B C. Both Technician A & B D. Neither Technician A or B ASSIGNMENT SHEET 3 - CIMC

47 5. A customer says her vehicle makes a rumbling noise under the hood. Technician A says the belt may be too tight and needs to be loosened. Technician B says the belt may be worn and needs to be replaced. Who is correct? A. Technician A B. Technician B C. Both Technician A & B D. Neither Technician A or B 6. A customer says that the fan belt just broke on his car for the second time in three weeks. Technician A says fan belts must be installed with care, and the person installing the belt may have damaged it during installation. Technician B says the belt may have been under excessive tension, and when the belt is replaced, it is important to have the tension correctly adjusted. Who is correct? A. Technician A B. Technician B C. Both Technician A & B D. Neither Technician A or B ASSIGNMENT SHEET 3 - CIMC

48 ASSIGNMENT SHEET 3 - CIMC

49 JOB SHEET 6 SERVICING HEATING AND 3 ENGINE COOLING SYSTEMS Name OBJECTIVE 14 Inspect and test cooling fan, fan clutch, fan shroud, and air dams; perform necessary action. (ASE A7: C) BASIC SKILLS Reading Employability Critical Thinking INTRODUCTION Five- or six-blade cooling fans are found on air-conditioned vehicles. Typically, non-air-conditioned vehicles have fewer fan blades. A balanced fan can prevent numerous problems. NOTICE: Procedures vary with the vehicle. Always check the procedure before starting any service or repair. Use manufacturers service manuals and publications to verify the proper procedure. Look for any technical service bulletins (TSBs) that might apply. Check with online service support products such as shopkey from Snap-On, ALL DATA, and others. They usually include frequent online updates of TSBs and recall notices. (Ask your instructor which products are available.) CAUTION: Service procedures can be hazardous! Hazards include personal injury, damage to tools and equipment, and contamination of the environment. Follow all rules, practices, and laws that apply to the procedure, to the tools you will use, and to any chemicals or hazardous materials involved! Examples include wearing personal protective equipment, using the right hand tools and power tools properly; using power equipment properly, maintaining proper ventilation; and handling, storing, and disposing of chemicals/materials properly. Follow local, state, and federal safety and environmental regulations. Manufacturers service information may include additional cautions, warnings and guidelines for a procedure. JOB SHEET 6 - CIMC

50 PROCEDURE 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-oftrue condition or other damage. 4. Turn the fan by hand quickly and check for out-oftrue 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 hot weather. 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. JOB SHEET 6 - CIMC

51 SKILL TEST RECORD PRODUCT EVALUATION Evaluator note: Rate the student on the following criteria by circling the appropriate numbers. Each criterion must receive a rating of 3 or higher to demonstrate student mastery. (See Key below.) A student who is unable to demonstrate mastery should review the material and submit another product for evaluation. Criteria: Product meets manufacturer s installation specifications Product meets manufacturer s adjustment specifications Product includes proper components/materials Product meets performance requirements Product appearance meets industry standards AVERAGE RATING Evaluator note: To obtain an average rating for the Profile of Training Mastery, total the points in Product Evaluation and divide by the total number of criteria. Circle the rating on the Key. KEY 4 Skilled Can perform job with no additional training 3 Moderately Skilled Has performed job during training program; limited additional training may be required 2 Limited Skill Has performed job during training program; additional training is required to develop skill 1 Unskilled Is familiar with process, but is unable to perform job EVALUATOR S COMMENTS JOB SHEET 6 - CIMC

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