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Activity summary:
This worksheet will be used as evidence regarding your work within the following competencies:
1. Describe the fundamental points about cooling systems and related basic components.
2. Identify cooling components.
3. Explain cooling system terminology as used within the automotive industry.
Reference material:
Automotive Mechanics: 10e, Chapter 20.
Safety precautions:
1. Personal protective equipment (PPE) must be worn.
2. Follow all standard operating procedures (SOP) when using workshop tools and equipment.
3. Follow safety precautions with regard to cooling system heat, pressure and moving parts.
Teacher/Supervisor Comments:
Teacher/Supervisor Signature:
Date:
Unit 16 Worksheet
To accompany May & Simpson Automotive Mechanics 10e
© McGraw-Hill Education Australia 2018
2
Name of Workplace:
Student Name:
Student Signature:
Date:
Unit 16 Worksheet
To accompany May & Simpson Automotive Mechanics 10e
© McGraw-Hill Education Australia 2018
3
1. Cooling system components. Use the diagram below to identify the numbered cooling system
components and then complete the chart:
2. The following table highlights a range of cooling system components. Complete the table by providing
an explanation of the location, function and purpose of each component:
Drive belts are located on water pump Drive belts are used to drive the water
Drive Belts
rotator pump.
The cooling fan is located at the front Fans cool the coolant as it circulates to
Electric Fans
or rear of the radiator the car's engine from the radiator.
Unit 16 Worksheet
To accompany May & Simpson Automotive Mechanics 10e
© McGraw-Hill Education Australia 2018
4
A heater core is a small radiator Hot coolant passing through the heater
Heater core located under the dashboard of the core gives off heat before returning to
vehicle the engine cooling circuit.
Unit 16 Worksheet
To accompany May & Simpson Automotive Mechanics 10e
© McGraw-Hill Education Australia 2018
5
Engine removes waste heat through cool intake air, hot exhaust gases, and explicit engine cooling. Cooling
system is needed because high temperatures damage engine materials and lubricants and becomes even
more important in hot climates.
Also The cooling system is provided because temperature of the burning gases in the engine cylinder
reaches up to 1500 to 2000°C, which is above the melting point of the material of the cylinder body and
head of the engine.
(b) What are the four effects that heat can have on materials?
i. This will usually cause the head gasket to leak compression between adjacent cylinders
ii. Leak of coolant into the cylinders.
iii. Heating can also cause an overhead cam to seize and break.
iv. Heating may also stress old radiator and heater hoses and cause them to burst under the additional
pressure.
(c) Heat can be transferred in three ways in order to dissipate heat from the engine. These are:
i. By Water Cooling
ii. By Air Cooling
iii. By Conduction
In cross flow radiator the radiator cap is located in the area of the lowest pressure. This prevents the high
pressure that is created from other parts of the engine from making coolant go at fast speeds through the
radiator cap, keeping engine and radiator in better condition. This process will help keep car at the
temperature it will need to run properly and will prevent from having to do as much maintenance in the
future.
(e) Explain the process you would follow to check combustion gas leakage into the cooling system.
Combustion gas, when it enters the cooling system through any leak, accumulates in the air cushion above
the radiator coolant level (in sealed coolant systems, this air cushion must be created by lowering the
coolant level about an inch and a half).
The Leak Tester analyzes this air: The blue fluid turns yellow when CO2 gas is detected in gasoline engines
and green in diesel engines. The double-chamber feature of the Leak Tester assures a high level of accuracy.
Conventional detection methods often give incorrect readings because alkaline particles present in the air
cushion can cause false indications of a combustion leak.
Alkaline particles are absorbed by the Leak Tester's first chamber, which acts as a filter, allowing only air
and CO2 to reach the second, upper chamber. If the blue fluid in this upper chamber turns yellow or green,
it is proof positive that there is a combustion gas (CO2) leak into the coolant.
Unit 16 Worksheet
To accompany May & Simpson Automotive Mechanics 10e
© McGraw-Hill Education Australia 2018
6
i. Silicate and phosphate: These green coolants typically use a phosphate/ silicate mix as the main
components in their inhibitor system. Conventional inhibitors like silicates and phosphates work by
forming a protective blanket that actually insulates the metals from the coolant.
ii. Ethylene glycol: It plays a critical role in sustaining engine heat balance by removing heat.
The addition of glycol slightly reduces the heat transfer of the water, but in most climates and
applications, freeze protection is critical. Nearly all engines use coolants with similar base fluids a
50/50 mix of ethylene glycol and water
Unit 16 Worksheet
To accompany May & Simpson Automotive Mechanics 10e
© McGraw-Hill Education Australia 2018