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AURTTC103 Diagnose and repair cooling systems
Student Assessment Agreement
Make sure you read through the assessments in this booklet before you fill out and sign the
agreement below. If there is anything that you are unsure of, consult your assessor prior to
signing this agreement.
Have you read the assessment requirements for this unit?
Yes
□ No Do you understand the requirements of the assessments for this unit?
Yes
□ No Do you agree to the way in which you are being assessed?
Yes
□ No Do you have any specific needs that should be considered?
Yes □
No
If so, explain these in the space below.
Do you understand your rights to re-assessment? Yes
□
No
Do you understand your right to appeal the decisions made in an assessment? Yes
□ No
Student name
ANUP RAJ NEUPANE
Student number
20230047
Student signature
Anup
Date
9/3/2024
Qualification Code and Title
AUR30616: Certificate III in Light Vehicle Mechanical Technology
Unit Code and Title
AURTTC003 Diagnose and repair cooling systems
Assessor name
Document Name:
Student Written Knowledge Assessment – AURTTC103
Created Date:
13
th
July 2020
Document No:
Trinity Institute (Australia) – AURTTC103
Version No:
3
.
0
Last Modified Date:
14/5/22
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AURTTC103 Diagnose and repair cooling systems
Assessor signature
Date
Assessment Task 1 Cover Sheet
Student Declaration
To be filled out and submitted with assessment responses
□ I declare that this task is all my own work and I have not cheated or plagiarised the work or colluded with any other student(s).
þ I understand that if I If I am found to have plagiarised, cheated or colluded, action will be taken against me according to the process explained to me.
þ I have correctly referenced all resources and reference texts throughout these assessment tasks.
Assessor declaration
□
I hereby certify that this student has been assessed by me and that the assessment has been carried out according to the required assessment procedures.
Assessor name
Assessor signature
Date
Document Name:
Student Written Knowledge Assessment – AURTTC103
Created Date:
13
th
July 2020
Document No:
Trinity Institute (Australia) – AURTTC103
Version No:
3
.
0
Last Modified Date:
14/5/22
© Trinity Institute (Australia) | RTO Code: 41310 | CRICOS Code: 03556F
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AURTTC103 Diagnose and repair cooling systems
Assessment outcome
S
N
S
DNS
Resubmission Y
N
Student name
ANUP RAJ NEUPANE
Student ID number
20230047
Student signature
Anup
Date
9/3/2024
Feedback
Student result response
□
My performance in this assessment task has been discussed and explained to me.
□
I would like to appeal this assessment decision.
A copy of this page must be supplied to the office and kept in the student’s file with the evidence
Assessment 1 – Questioning – Written
Assessment
Student Name
ANUP RAJ NEUPANE
Student ID Number
20230047
Unit Start Date
Unit End Date
Assessment Due Date
Date Submitted
9/3/2024
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This cover sheet is to be completed by the student and assessor and used as a record to determine student competency in this assessment task
The assessment process and tasks were fully explained.
Yes I am aware of which evidence will be collected and how.
Yes I am aware of my right to appeal an assessment decision.
Yes I am aware that I can locate The RTO Complaints and Appeals Policy and Procedure on their website at (Insert Website Link)
Yes Document Name:
Student Written Knowledge Assessment – AURTTC103
Created Date:
13
th
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Document No:
Trinity Institute (Australia) – AURTTC103
Version No:
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Student signature
ANUP RAJ NEUPANE
Date
9/3/2024
Document Name:
Student Written Knowledge Assessment – AURTTC103
Created Date:
13
th
July 2020
Document No:
Trinity Institute (Australia) – AURTTC103
Version No:
3
.
0
Last Modified Date:
14/5/22
© Trinity Institute (Australia) | RTO Code: 41310 | CRICOS Code: 03556F
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AURTTC103 Diagnose and repair cooling systems
I have discussed any additional educational support or reasonable adjustments I require in order to undertake this assessment with the Student Support Services Officer and Trainer / Assessor, (if applicable). e.g. Student Handbook and Access and Equity Policy (Insert Website Link)
Yes / No
I have access to all required resources?
Yes / No
Cheating & Plagiarism Declaration
Student Declaration: In accordance with The RTO Plagiarism Policy, I hereby acknowledge by signing this declaration that I have not cheated or plagiarised any work regarding the assessment
tasks undertaken in this unit of competency except where the work has been correctly acknowledged.
NOTE: Student must sign this prior to submitting their assessments to the assessor
Signature
RUPINDER SINGH
Dat
e
:
/
/ 20
Assessment Results
Satisfactory
or
Not Yet Satisfactory
(Please circle the assessment result for this task)
Feedback to Student - Please provide general feedback on the Student’s performance
Student Declaration: - I verify that the work completed is my own and that I was adequately informed of the assessment process prior to commencing this assessment task.
Assessor Declaration: - I verify that I have
adequately explained and negotiated the
assessment tasks with the student prior to
commencing assessment.
Student Name: RUPINDER SINGH
Assessor’s Name:
Student Signature RUPINDER SINGH
Date
Assessor Signature
Date
Student Guide for Written Knowledge Assessment
Overview of Assessm
ent
This is a written assessment task you will be assess on your knowledge of diagnosing and repairing cooling systems.
The topics that will be covered in the assessment are:
1.
Prepare to diagnose and repair cooling systems
2.
Diagnose cooling systems
AURTTC103 Diagnose and repair cooling
systems
3.
Repair cooling systems
4.
Complete work processes
This assessment will ensure that the elements, performance criteria,
performance evidence and knowledge evidence required, and conditions are
adhered to demonstrate competency in this unit assessment task.
•
Read the assessment carefully before commencing.
•
Your Assessor will use the assessment criteria in this document and will provide feedback / comment.
•
You MUST
answer all the questions in the assessment tasks in your own words and own handwriting.
•
This is an “Open Book” assessment, and students can use the resources listed in the “Resources Required” section below.
Task/s to be assessed
To complete this written assessment, you will need to answer the 76
questions comprising of Multiple Choice, True and False, Fill-in the Gap and Short Answer questions.
Time allowed
On average, the Assessment should take 2 – 4 hours to complete.
Location
This theory assessment will be completed in a classroom under the supervision of a trainer/assessor.
Decision making rules
To receive a ‘satisfactory’ outcome for this assessment students MUST
successfully answer all questions. If a student achieves less than 100%, they can reattempt the assessment after further study has taken place. Students who cannot achieve a minimum of 100% you will not have satisfactorily completed this assessment
Your assessor will be looking for the following in this assessment task: -
•
Work health and safety (WHS) and occupational health and safety (OHS) requirements relating to diagnosing and repairing cooling systems, including procedures for handling hot pressurised cooling systems
•
Environmental requirements, including procedures for trapping, storing and disposing of fluids released from cooling systems
•
Operating principles of cooling systems and associated components, including:
o
Effects of heat, including changes of temperature, colour, state and volume of substances
o
Heat transfer, including conduction, convection and radiation
o
Air cooled systems
o
Liquid cooled systems
•
Application, purpose and operation of the following components of cooling systems and components, including:
o
Engine coolant types and composition
o
Water pumps
o
Thermostats and bypass systems
o
Mechanical, hydraulic, pneumatic and electric cooling fan systems
o
Radiators and radiator caps
o
Heat exchangers
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AURTTC103 Diagnose and repair cooling
systems
o
Expansion tanks
o
Hoses
o
Drive belts
o
Temperature sensors and gauges
•
Diagnostic testing procedures for cooling systems, including testing procedures for:
o
Effects of corrosion, cavitation and electrolysis
o
Transient voltage
o
Engine coolant
o
Cooling system pressure
o
Combustion leak
o
Cooling fan system
o
Thermostat
o
Infra-red thermal devices
o
Cooling system hose
o
Water pump
•
Repair procedures for cooling systems, including procedures for bleeding coolant systems
•
Post-repair testing procedures for cooling systems, including:
o
Fan system operation
o
Thermostat operation.
Assessm
ent condition
s
Assessors MUST
satisfy NVR/AQTF assessor requirements.
Competency is to be assessed in the workplace or a simulated environment that accurately reflects performance in a real workplace setting.
Assessment MUST
include direct observation of tasks.
Where assessment of competency includes third-party evidence, individuals MUST
provide evidence that links them to the cooling systems that they have worked on, e.g. repair orders.
Assessors MUST
verify performance evidence through questioning on skills and knowledge to ensure correct interpretation and application.
The following resources MUST
be made available:
•
Automotive repair workplace or simulated workplace
•
Workplace instructions
•
Manufacturer cooling system specifications
•
Two [2] different vehicles or machinery with cooling system faults
•
Diagnostic equipment for cooling systems
•
Tools, equipment and materials appropriate for repairing cooling systems.
Resources required
Learning Resources available to students include:
•
Automotive Technology (A System Approach) 6
th
Edition – Chapters 5, 6,
7, 8 & 14
•
Websites – http://what-when-how.com/automobile/air-cooling-system-
automobile/
•
Trainer Handouts
AURTTC103 Diagnose and repair cooling
systems
Results/
Re- assessm
ent
•
The Assessor will grade the assessment and record the result on the front page of this document (S) – Satisfactory if all observable behaviours are correct and (NS) not satisfactory if any areas are left incorrect
•
Feedback will be provided on either result
•
Where a student receives a ‘NS – Not Satisfactory’ result, the assessor
will discuss the area of the non-compliant observable behaviour and an opportunity given for re-
assessment. This may be through direct observation or a different method of assessment e.g. verbal/oral questioning, problem solving exercise.
•
If the outcome is again not satisfactory the student result will be deemed (NYC) not
yet competent. Additional feedback will be given, and a time agreed upon for further assessment after additional training and skills practice
has taken place, this information will be recorded, dated and signed in the re-assessment area on the last page of this document
•
Where all the assessment tasks have been graded (S) Satisfactory, the student will
be deemed C – Competent for the practical component and the result recorded and signed in the area indicated on the last page of this document
Reasona
ble Adjustme
nt
If the participant is unable to undertake the written assessment as designed, an interview (verbal questioning) may be used as an alternate approach.
AURTTC103 Diagnose and repair cooling systems
Assessment 1 – Questioning
Written Assessment
1.
Identify five (5) important items of personal safety when diagnosing and repairing cooling systems?
1
Safety shoes
2
Safety vest
3
Eye protector
4
Glove
5
Hearing protection
2.
Describe the safety precaution that must be observed before removing the radiator cap or disconnecting any component of a hot cooling system?
•Do not remove the radiator cap when the engine is hot and running.
•Be aware of the rotating components before topping up the coolant.
•
Adhere to safe work practices and wear protective clothing and eyewear
3.
Why should the radiator cap NEVER be removed when the engine is hot?
4.
What are the potential danger of working near electric thematically operated cooling fans?
There a risk of injury when in contact with rotating blades. Rotating fan may also blow dust and hot particles into mechanic eyes.
Document Name:
Student Written Knowledge Assessment – AURTTC103
Created Date:
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th
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Document No:
Trinity Institute (Australia) – AURTTC103
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Last Modified Date:
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coolant would be under high pressure and may spray out and lead to serious burns.
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AURTTC103 Diagnose and repair cooling systems
5.
When handling, trapping, storing and disposing of new or waste coolants, which document should you use to find this information?
Fuels and Lubricants Handbook
6.
How should waste coolant be stored and disposed?
Make sure tainted and merely old antifreeze are separated and stored separately. They require different disposal treatments — tainted antifreeze may contain heavy metals and is considered hazardous waste, so only that kind of facility will take it.
Drive the substance to the appropriate disposal facility or hire a commercial waste hauler to pick up the antifreeze for you.
Some locations will have coolant recycling machines that remove glycol from the old coolant and,
with an additive, can make it reusable. However, this process requires the antifreeze to be untainted with oils or other materials, otherwise, it will not work.
Multiple Choice question. Select the correct answer.
7.
When changing the coolant in the cooling system, what should you use to catch the waste fluid?
A.
Drain pan.
B.
Mop bucket.
C.
Storm water drain.
D.
Funnel.
8.
What is the difference between heat and temperature?
Heat is a measure of change, never a property possessed by an object or system. Therefore, it is classified as a process variable. Temperature describes the average kinetic energy of molecules within
a material or system and is measured in Celsius (°C), Kelvin(K), Fahrenheit (°F), or Rankine (R).
9.
What are the four (4) possible effects when heat is applied to a substance?
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AURTTC103 Diagnose and repair cooling
systems
1
Changes state
2
Brings about chemical action
3
Kinetic energy of the particles increases
4
Raises the temperature
10. What is the unusual effect that occurs with water when its temperature is reduced?
A decrease in temperature caused the water molecules to lose energy and slowdown, which results in water molecules that are closer together and a decrease in water volume.
11. Heat can be transferred in three (3) different ways. What are these?
1
Conduction
2
Convention
3
Radiation
12. What is meant by radiation?
Thermal radiation is electromagnetic radiation generated by the thermal motion of particles in matter. Thermal radiation is generated when heat from the movement of charges in the material is converted to electromagnetic radiation. All matter with a temperature greater than absolute zero emits thermal radiation
Fill in the Gaps
13. Complete the following statement about air cooled systems using the following words. http://what-
when
- how.com/automobile/air-cooling-system-automobile/
Words: , , , ,
An air-cooled
Engines
is simpler to design then the water-cooled engine because the heat is
_Transferred
from the cylinder and head Directly
to the air. There is no need for water jackets,
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AURTTC103 Diagnose and repair cooling systems
Hoses
, water pump, radiator, etc. But the engine design uses many
Fins
on the cylinder and head for effective heat transfer to the surrounding air.
14.
How is heat removed from the engine?
There are two types of coolants used to remove the heat from the engine block and head: air, and
water. With air as a coolant, the heat is removed through the use of fins attached to the cylinder wall. With water as a coolant, the heat is removed through the use of fluid filled internal cooling passage
15.
Why is it necessary to remove heat from the engine?
If this heat is not removed, engine internal temperatures would soon reach a point of component damage and engine failure. That is why, it is necessary to remove heat from the engin
Multiple Choice question. Select the correct answer.
16. Ethylene glycol antifreeze is
.
A.
The most commonly used antifreeze.
B.
Green in colour.
C.
Poisonous.
D.
All answers are correct.
Multiple Choice question. Select the correct answer.
17. The minimum concentration of antifreeze is .
A.
20% antifreeze, 80% water.
B.
33% antifreeze, 66% water.
C.
44% antifreeze, 56% water.
D.
50% antifreeze, 50% water.
18. List three (3) different types of antifreeze.
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AURTTC103 Diagnose and repair cooling
systems
1
Ethylene glycol Ethylene glycol
2
Organic acid technology (OAT)
3
Hybrid OAT
Multiple Choice question. Select the correct answer.
19. In most automotive applications, the water pump is driven by the
.
A.
Flywheel.
B.
Camshaft.
C.
Crankshaft
.
D.
Impeller.
Multiple Choice question. Select the correct answer.
20. Water pumps are
type pumps.
A.
Positive displacement.
B.
Negative displacement.
C.
Centrifugal
.
D.
Reciprocating.
True or False question
21. The heart of the cooling system is the water pump. Its job is to move the coolant through the system.
☒ True
or
☐ False
22. What is the function of the thermostat?
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The thermostat is basically a valve between the engine and the radiator. It is connected to the cylinder head and enclosed by a small housing with a coolant outlet and a thermo switch.
AURTTC103 Diagnose and repair cooling systems
Multiple Choice question. Select the correct answer.
23. During engine warm-up, when the thermostat is closed,
.
A.
Coolant flows through the radiator.
B.
Coolant flows through the bypass passage.
C.
Both “coolant flows through the radiator” and “coolant flows through the bypass passage”.
D.
Neither “coolant flows through the radiator” nor “coolant flows through the bypass passage”.
Fill in the Gaps
24. Complete the following statement about bypass thermostats using the following words.
Words: Bypass, Coolant, Engine, Open, Prevents, Radiator, Secondary, Thermostats, Valve
Bypass Thermostats increase cooling system efficiency. They do this by ensuring that all
Coolant passes through the radiator when the Engine is at correct operating
temperature. This thermostat has two valves: a primary and a Secondary . When the
engine is cold, the primary valve is closed and this Prevents fluid from reaching the
radiator. The secondary valve is
Open , and this allows the coolant to bypass the Radiator
and go back into
the engine. As the engine temperature rises, the primary Valve
opens
and
the
secondary valve closes. This blocks off the Bypass and all the coolant is then directed
through the radiator.
True or False question
25. Electric cooling fans may be controlled by the engine control module (ECM)?
☒ True
or
☐ False
26. What is the function of a fan clutch?
the fan clutch will disengage the engine’s radiator cooling fan to a certain degree (which is
mechanically compelled). This is typically found at the front of the water pump and it is driven by a belt and pulley that is attached to the engine’s crankshaft
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AURTTC103 Diagnose and repair cooling systems
Document Name:
Student Written Knowledge Assessment – AURTTC103
Created Date:
13
th
July 2020
Document No:
Trinity Institute (Australia) – AURTTC103
Version No:
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AURTTC103 Diagnose and repair cooling
systems
Fill in the Gaps
27. Complete the following statement about cooling fans using the following words.
Words: Air, Engine, Cooling, Motor, Removed, Speeds, Steering
The efficiency of the
Cooling
system depends on the amount of heat that can be
Removed
from the system and transferred to the air. At highway
Speeds
, the ram air through the radiator should be sufficient to maintain proper cooling. At low speeds and idle, the system needs additional
Air
. This air is delivered by a fan. The fan may be driven by the
Engine
, via a belt, driven by an electric
Motor , or hydraulically through the power-
Steering
system.
28. Briefly, how does a hydraulic cooling fan operate?
Hydraulic cooling fan are driven by a hydraulic unit. When the temperature of the system is high,
the viscous fluid inside the fan expands and allows a tight bond between fan and coupling which
makes the fan to rotate according to the engine speed
29. Explain how a belt-driven cooling fan operates?
Belt-driven fans pull air through the radiator all the time, regardless of cooling requirements. Hydraulic fan drives determine fan speed based on cooling demands, not engine speed. Hydraulic drives consume less power and maintain engine temperature for the best fuel economy and lowest emissions
Multiple Choice question. Select the correct answer.
30. An engine coolant temperature switch or sensor is used to directly or indirectly energise the.
A.
Blower motor.
B.
Radiator fan motor relay.
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AURTTC103 Diagnose and repair cooling
systems
C.
Compressor clutch.
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D.
Dashboard warning light.
31. Many electric cooling fans are ultimately controlled by what device?
Power train control module
True or False question
32. On some medium/heavy duty trucks, the ECM-controlled variable speed (VS) clutches can be either electromagnetically or pneumatically controlled and can be considered the more advanced of the currently available fan drive technologies.
☒ True
or
☐ False Multiple Choice question. Select the correct answer.
33. In a crossflow radiator, the coolant flow is from.
A.
Top to bottom
.
B.
One side to the other side.
C.
Diagonally.
D.
Bottom to top.
Fill in the Gaps
34. Complete the following statement about radiators using the
following words. Words: Aluminium, Cap, Coolant’s, Exchanger, Hot, Petcocks, Radiator, Top
The radiator is a heat
Exchanger
, transferring heat from the engine to the air passing
through it. The
Radiator
is a series of tubes and fins (collectively called the core) that expose the
Coolant’s
heat to as much surface area as possible. Attached to the sides or
Top
and bottom of the core are plastic or aluminium tanks. One tank holds Hot coolant and the other holds the cooled coolant. Cores are normally comprised of flattened aluminium tubes
surrounded by thin
Aluminium
fins. The fins conduct the heat from the tubes to the air flowing through the radiator.
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Most radiators have drain
Petcocks
or plugs near the bottom. Coolant is added at the radiator
cap
or the recovery tank.
35. Name the eight [8] parts of a radiator below?
1
Outlet tank (plastic)
2
Bending tangs
3
Inlet tank (plastic)
4
Draincock
5
O-ring gasket
6
Radiator core (aluminum)
7
O- ring gasket
8
Transmission oil cooler
36. What is the function of the radiator cap?
It keeps the cooling system sealed from outside contaminants.
True or False question
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37. The cooling system pressure is regulated by the radiator cap.
☒ True
or
☐ False
True or False question
38. The transmission cooler is a heat exchanger sealed in the radiator core.
☒ True
or
☐ False
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AURTTC103 Diagnose and repair cooling
systems
True or False question
39. Most cooling systems use an expansion or recovery tank.
☒ True
or
☐ False
Fill in the Gaps
40. Complete the following statement about expansion tanks using the following words.
Words: Coolant, Cooling, Expands, Expansion, Pressure, Shrink
All late-model
Cooling
systems have an expansion or recovery tank. These systems are called closed-cooling systems. They are designed to catch and hold any
Coolant
that passes through the pressure cap. As the engine warms up, the coolant
Expands
. This eventually causes the pressure cap to release and allows some coolant to move into the
Expansion
tank. When the engine is shut down, the coolant begins to
Shrink
. Eventually, the vacuum spring inside the
Pressure
cap opens and the coolant in the expansion tank is drawn back into the cooling system.
True or False question
41. Coolant flows from the engine to the radiator and from the radiator to the engine through radiator hoses.
☒ True
or
☐ False
42. A hose is typically made up of three (3) parts. What are they?
1
An inner rubber tube
2
Some reinforcement mate
3
Outer rubber cover
True or False question
43. Cooling system hoses must be able to endure heavy vibrations and be resistant to oil, heat, abrasion, weathering and pressure.
Document Name:
Student Written Knowledge Assessment – AURTTC103
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Document No:
Trinity Institute (Australia) – AURTTC103
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☒ True
or
☐ False
44. What are drive belts (belt drives) used for in the cooling system?
Drive belts provide power in the cooling system
45. What is the function of the temperature sensor in the cooling system?
They are gauges and sensors to indicate warning in the cooling system. Temperature gauge to indicate any high temperatures and a thermos sensor in the system operates the gauge and the warning light in instrument panel
True or False question
46. The coolant temperature indicator alerts the driver of an overheating condition. These indicators are a temperature gauge and/or a warning light?
☒ True
or
☐ False
47. A voltmeter is used to check the cooling system.
yes
48. Explain how corrosion occurs in the cooling system?
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AURTTC103 Diagnose and repair cooling systems
Corrosion in a vehicle's cooling system can occur due to several factors, including the presence of water, oxygen, and electrolytes (such as dissolved salts) within the system. 49. What is cavitation?
Cavitation is the formation of small vapour bubbles against a metal surface causing erosion of the metal particles. It usually occurs around the water pump impeller. Coolant pressure needs to be monitored regularly to avoid cavitation
Fill in the Gaps
50. Complete the following statement about diagnosing electrolysis using the following words.
Words: Cranked, DMM, Electrolysis, Meter, Negative, Positive, Problem, Running, Voltage
To check for the conditions prone toElectrolysis
, use a voltmeter that is capable of measuring AC and DC voltage. Set the
Meter
so it can read in tenths of a volt DC. Attach
the
Positive
meter lead to a good ground. Place the
Negative
lead into the coolant. Look at the meter while the engine is
Cranked
with the starter and record the readings. Take another reading with the engine
Running
and all accessories turned on. Record that reading.
Voltage
readings of 0 to
0.3 volt are normal for a cast-iron engine; normal readings for a bimetal or aluminium engine are half that amount. Repeat the test with the
DMM
in the AC voltage mode. There
will be AC voltage if the
Problem
is static electricity. Any readings above normal indicate a problem.
True or False question
51. A hydrometer is used to measure the concentration of antifreeze in coolant.
☐
True
or
☒ False
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Student Written Knowledge Assessment – AURTTC103
Created Date:
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Trinity Institute (Australia) – AURTTC103
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AURTTC103 Diagnose and repair cooling
systems
True or False question
52. A refractomer is used to measure the concentration of antifreeze in coolant
☒ True
or
☐ False
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53. How and why are test strips used to evaluate coolant condition?
Coolant Test Strips are disposable test strips for measuring the concentration level and condition of AntiFreeze/AntiBoil coolants used in all types of combustion engines. They effectively test the coolant's concentration as well as the pH level and alkalinity to determine when service of the coolant is necessary
True or False question
54. A cooling system pressure tester is used to test for leaks in the radiator, hoses, water pump, thermostat, and engine assembly.
☒ True
or
☐ False
Multiple Choice question. Select the correct answer.
55. When testing a radiator cap, with the rated pressure applied, the cap should hold that pressure for at least
.
A.
30 seconds.
B.
1 minute.
C.
5 minutes.
D.
20 minutes.
56. What are the requirements when a pressure cap is tested using a cooling system pressure tester?
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AURTTC103 Diagnose and repair cooling systems
check for leaks in the system.
Multiple Choice question. Select the correct answer.
57. When using a combustion gas leak check: the colour of the fluid turns from blue to
if there are combustion gases in the coolant.
A.
Red.
B.
Blue.
C.
Yellow
.
D.
Green.
58. Describe the process to check for combustion gas leakage into the cooling system.
A general test for gas leakage can be made by running the engine with the radiator cap removed. The coolant in the radiator tank is checked for bubbles or any rise in level that may not be due to normal circulation by the water pump. Another method is to check hydrocarbon (HC) in the coolant.
A leaking head gasket will allow small traces of unburnt fuel (HC) into the cooling system. A combustion leak detector being used on the radiator. The test fluid in the detector will change the colour when hydrocarbons are detected
Fill in the Gaps
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AURTTC103 Diagnose and repair cooling
systems
59. Complete the following statement about diagnosing electric cooling fan using the following words.
Words: Blades, Cooling, Motor, Not, Problem, Reaches, Sequence
The action of the electric
Cooling
fan should be observed. However,
before doing so, check the mounting of the fan assembly and the condition of the fan
Blades
. The fan should be energised when the A/C is turned on and when the coolant
Reaches
a specified temperature. If the fan does not turn on when it should, check the
Motor
. Do this by connecting the motor directly to the battery. If the motor runs, the Problem
is in the motor’s control circuit. Diagnosis of this
problem should follow the prescribedSequence
given by the manufacturer. If the jumped motor does
Not
run, the problem is the fan motor.
True or False question
60. The operation of a thermostat can be observed with an infrared thermometer.
☒ True
or
☐ False
61. The thermostat is often the cause of overheating or poor heater performance. What other problems can a faulty thermostat cause?
They can also cause an increase in fuel consumption and poor engine performance
True or False question
62. If the thermostat is stuck closed, because it failed or because there is a steam pocket below the thermostat, coolant will not flow between the engine and the radiator; the engine will, therefore, quickly overheat?
☒ True
or
☐ False
63. You should carefully check all cooling hoses for what type of faults?
Check each hose for signs of cracking, splitting, bulging and chaffing. If any of these conditions exist replace the hose
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64. What is Electrochemical Degradation (ECD), and what effect does it have on rubber hoses?
Electrochemical degradation (ECD) is the breakdown of material in thehose wall or tube due to electrical reactions between the fluid (coolant) and the metal parts of the engine. The phenomenon is known as electrochemical degradation, or ECD. It occurs because the hose, liquid coolant and the engine/ radiator fittings form a galvanic cell or “battery”. This chemical reaction causes micro-cracks in the hose tube, allowing the coolant to attack and weaken the hose reinforcement
65. Identify five (5) causes of water pump failure.
1
Improper Use of Seals/Gaskets or Sealant
2
Bearing Overload
3
Bad/wrong coolant
4
Worn/improperly installed belt
5
Dry running
Multiple Choice question. Select the correct answer.
66. Two technicians are discussing a vehicle with an overheating problem. There are no leaks, internal or external. The belts are in good condition, and the radiator has been removed and flow tested. Everything appears to be in good condition. A new thermostat was installed, but it did not cure the problem. What could be the fault?
A.
The impeller could be slipping on the water pump shaft.
B.
The impeller blades could be corroded.
C.
Both “the impeller could be slipping on the water pump shaft” and “the impeller blades could
be corroded”.
D.
Neither “the impeller could be slipping on the water pump shaft” and “the impeller
blades could be corroded”.
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Multiple Choice question. Select the correct answer.
67. If the engine overheats during long periods of idling but runs normally at highway speeds, the problem is most likely
A.
Defective thermostat.
B.
Defective water pump.
C.
Defective cooling fan.
D.
Defective radiator.
68. Two (2) problems with the water pump are normally?
1
Broken belt
2
Broken seal
True or False question
69. When replacing a thermostat, the replacement should always have the same temperature rating as the original.
☒ True
or
☐ False
70. Complete the following statement about replacing the thermostat using the following words.
Words:
Markings on the thermostat normally
which end should face toward the
. Regardless of the markings, the sensor end must always be installed toward the
. When replacing the thermostat, also replace the
that seals the thermostat in place and is positioned between the thermostat housing and the block. Make sure the mating
on the housing and block
are clean and free of old gasket material.
NO ANSWER OPTION, CANNOT BE ANSWERED
True or False
question
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AURTTC103 Diagnose and repair cooling
systems
71. When replacing the water pump, always follow the procedure given by the manufacturer.
☒ True
or
☐ False
72. Describe the procedure to bleed the cooling system using “air bleeds”.
Fill Coolant:When your car is raised, fill the coolant as much as possible. If there are air bleed valves, open them simultaneously while filling the coolant. Close the valves when the coolant starts flowing out. Since coolant is toxic, make sure it is not flowing on the floor, road etc
Bleeding the cooling system removes any air pockets so the cooling system can work effectively. For example, the heat may not be as warm or work at all if too much air is in the heater core, since there will be less hot coolant emitting heat for the blower motor to push into the cabin
73. What is a vacuum fill system, and how does it refill the cooling system?
Vacuum fill system: A vacuum filler is a machine used for filling pasty products. The pasty products are moved with the aid of a vane cell feed system under a vacuum.
- Connect the coolant hose to the vacuum purge and refill tool and submerge in coolant
- Assure that valve No. 3 is in the closed position and that there is coolant in the coolant hose.
- Turn valve No. 6 to the open position to allow the coolant to refill the cooling system.
- The refill is complete when the gauge reads
74. Consider the various post repair checks that you would make during a road test on the cooling system? Check the level of coolant
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Document Name:
Student Written Knowledge Assessment – AURTTC103
Created Date:
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th
July 2020
Document No:
Trinity Institute (Australia) – AURTTC103
Version No:
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Last Modified Date:
14/5/22
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AURTTC103 Diagnose and repair cooling systems
Check the tightness of radiator clamps
Check the radiator mounting bolts
Check the electrical connections
Check for leaks
Multiple Choice question. Select the correct answer.
75. Which source of information will give you the most detail about diagnosing and repairing cooling systems on the vehicle you are working on?
A.
Workshop manual.
B.
Owner’s manual.
C.
Google.
D.
Textbooks.
76. Why is it very important that the Job Card is completed correctly?
The Job Card becomes a legal document. Service records are kept by the workshop to maintain the vehicle’s service history and for legal purposes.
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th
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