Republic of the Philippines

Department of Education
N a t i o n a l C a pi t a l Re g i o n
Sc h o o l s D i v i s i o n O f f i c e o f La s Pi ñ a s C i t y

WEEK 1-WEEK4
 Republic of the Philippines
Department of Education
N a t i o n a l C a pi t a l Re g i o n
Sc h o o l s D i v i s i o n O f f i c e o f La s Pi ñ a s C i t y

NAME: ___________________________________________ Date: ______________

GRADE & SECTION ____________________________ Teacher: _____________

AUTOMOTIVE SERVICING NC II
GRADE 12
Third Quarter
Week 1

MOST ESSENTIAL LEARNING COMPETENCY

• SERVICING CHARGING SYSTEM (SCH)
o Test charging system component and identify faults

PRE-TEST – Multiple Choice

Direction: write the letter of the correct answer in a separate paper.

1. Technician A says that the alternator is a device for changing electrical

energy into mechanical energy. Technician B says the alternator is a device for
changing mechanical energy into electrical energy. Who is right?
Who is right?
A. Technician A Only
B. Technician B Only
C. Both Technician A and B
D. Neither Technician A nor B

2. Technician A believes that once an engine starts running, the engine

crankshaft pulley powers the alternator to supply electricity to a car’s electrical
systems. Technician B feels a battery is a car’s sole electrical supplier. Who is
right?
A. Technician A Only
B. Technician B Only
C. Both Technician A and B
D. Neither Technician A nor B

2
3. Technician A says alternator rear bearings are frequently held in place with a
small plate and screws. Technician B says alternator front bearings are usually
press-fit. Who is right?
A. Technician A Only
B. Technician B Only
C. Both Technician A and B
D. Neither Technician A nor B

4. Which of the following is not a component of a typical 12-volt charging

system?
A. voltage regulator
B. drive belt
C. battery
D. ignition switch

5. What component that is turned by the alternator drive belt and creates a
rotating magnetic field?
A. pulley
B. rotor
C. stator
D. diode trio

6. Which of the following is not a type of alternator belt?

A. V.
B. Ribbed
C. Cogged V.
D. Integrated.

7. Technician A says some overcharging is okay. Technician B says overcharging

can result in battery overheating. Who is right?
A. Technician A Only
B. Technician B Only
C. Both Technician A and B
D. Neither Technician A nor B

8. Which of the following below is not considered a charging system problem?

A. A bad timing belt
B. A bad alternator
C. A bad voltage regulator
D. A worn or slipping drive belt

3
9. Technician A says that charge indicator is an ammeter, voltmeter, or warning
light that informs the driver of charging system condition. Student B says that
Tachometer is the instrument for giving the correct information about the status
of the battery. Who is riht?
A. Technician A Only
B. Technician B Only
C. Both Technician A and B
D. Neither Technician A nor B

10. One common problem of charging system is when the headlights shine
brighter when accelerating. Would be the possible cause?
A. The battery may be undercharged
B. There are problems in the alternator
C. There are problems in the regulator
D. All of the above

COMPONENTS AND FUNCTIONS

In general, the components of the charging system are composed of
alternators and regulators. However, the charging system needs to add some
additional components so that the electricity generated can be supplied to the
battery and to all electrical loads safely and precisely. The component,
consisting of;

1. Battery
The function of the battery is as a storage of electrical energy. Like a
warehouse, the battery will store all the electrical energy generated by the
alternator and then this stored electricity is removed when necessary.

2. Fuse and Fusible links

Fuse and fusible links have different functions even though have the same
shape. Fusible link can be called as main fuse which is placed near the battery
positive terminal. The function of this fuse is to protect the entire electrical system
of the car from excessive currents. Generally the fusible link has a capacity of up
to more than 60 Ampere.

3. CHG Lights

CHG lamp or commonly also called “charging warning light” is an

indicator light to indicate the presence failure of charging system. When the
ignition key ON then this light will light up normally, as well as when the engine
life of this lamp should turn on, if it is dead then it could mean the charging
system failure.
4
4. Ignition key

The ignition key works as a switch. The charging system will be activated
automatically when the engine is running, but to generate a magnetic field on
the rotor coil must be done by a switch.

5. Regulator

The function of the regulator is to regulate the voltage generated by the

alternator. Why should it be there? Because the voltage generated by the
alternator depends on the engine’s RPM. This means that if the engine RPM is
low, the alternator voltage is also low, but if the engine RPM is high then the
altenator voltage is also high.

6. Alternator

The function of the alternator is to convert a partial engine’s rotating

energy into electricity. The alternator input comes from the engine pulley
connected through a V belt, the rotation of the rotor will cause the intersection
of the magnetic force line with the stator coil so that the electrons flow on the
stator coil.

The electricity in the stator coil is not directly connected to the battery,
but it must pass through the diode bridge to rectify the current. This is done
because the current in the stator coil is AC (Alternate Current).

7. Charging Wires

The function of charging wires are to connect every component of the

charging system, there are at least two types of wires: standard wire and B +
wire. The standard wire has a small diameter like the car’s electrical wiring in
general, the function of this wire is connecting each terminal on the entire
charging system.

5
 Troubleshooting Charging System Problems

Charging system problems may come from one or more troubled system
components:

• A bad battery
• A bad alternator
• A bad voltage regulator
• A worn or slipping drive belt
• Circuit problems
• A misaligned pulley
• A bad bearing
• Computer or control module issues

Problems with one or more of these components can manifest under different
symptoms:

• An undercharged battery
• An overcharged battery
• A battery, alternator or engine light indicator that illuminates when the engine is
running
• An ammeter or voltmeter showing troubling readings
• Grinding or whining noises coming from the alternator or drive belt

Remember, a charging system still must do two basic functions:

• Meet the electrical needs of the different electrical systems.

6
• Recharge the battery after the engine has started or while the engine is running,
if necessary.

Charging System Symptoms

It's easy to confuse problems in other areas, like the starting system, with
problems in the charging system. The following list of symptoms, and their
possible causes, can help you not only to confirm you have a charging system
problem but to focus your diagnostic efforts in specific system components.

Common charging system problems and their potential causes:

1. The indicator light stays on after the engine has started

2. The alternator light stays off when the ignition switch is turned to the On
position
3. The headlights shine brighter when accelerating
4. The alternator light comes on intermittently when the engine is running
5. Light bulbs frequently blow out
6. The voltmeter or ammeter gauge reading indicates charging problems
7. The battery loses its charge
8. The battery is getting overcharged
9. The battery is not being properly charged
10. The battery is not getting charged
11. The alternator is producing a higher-than-normal rate of charge
12. The alternator is producing a lower-than-normal rate of charge

A worn or loose drive belt is a common issue in the chagrining system.

II. Make a Visual Inspection of the Charging System

7
 Many common charging system problems can be diagnosed by making a
simple visual inspection. So before you start removing or replacing components,
pop the hood open and search for these signs of trouble that can lead you to
the source of the problem.

1. Check the charging system for warning indicators:

2. Check the alternator drive belt or serpentine belt

3. Check your battery and battery terminals:

4. Now check the wires:

5. Check the alternator for unusual noises

If you haven't found anything unusual so far and you think your battery is not
being properly charged, do a battery drain test to make sure the problem is not
somewhere else. Usually, any current draw above 50 milliamps (.05 amps), with
the engine and all accessories turned off, is considered a harmful drain on the
battery. If necessary, consult your car owner's manual.

To check if the alternator is causing a parasitic draw on the battery, connect

your ammeter in series with the battery.

• Disconnect the negative battery cable and connect one of the meter probes
to the battery post and the other probe to the battery cable terminal.
• If current draw exceeds 50 mA, unplug the electrical connector from the back
of the alternator.
• If current draw drops to acceptable levels, there is a problem with the
alternator.

Charging System Warning

Whenever you need to disconnect or remove a component in the charging

system, disconnect the negative battery terminal to prevent shorting out the
circuit and damaging sensitive components in your vehicle.

8
 Use your digital multimeter to do charging system tests.

III. Simple Charging System Tests

Before you start your test, make sure your battery is in good condition and
properly charged. If possible, do a hydrometer test on your battery (those with
removable caps) or take it to a shop for a diagnostic. Many charging problems
come from an apparently good battery.

An ideal test tool for the charging system is a load tester, which can measure
voltage and current while applying a load to the system at the same time. Still,
you can use a digital multimeter to get an indication of the condition of the
charging system by testing for charging output and an overall charging system
condition.

1. Checking Base Voltage

• Turn on the high beams for ten seconds to remove any surface charge.
• Turn them off and wait for 2 minutes without turning any electrical accessory on.
• Then, with engine off and all accessories off, connect your voltmeter across the
terminals of your battery.
• Your battery voltage should be between 12.4 and 12.6 volts.

Here are some battery voltage values you can use as reference to check the
charge percentage on your battery:
• 12.6 volts or higher - 100% charged
• 12.4 volts or higher - 75% charged
• 12.2 volts or higher - 50% charged
• 12.0 volts or higher - 25% charged
• less than 12.0 volts - discharged

9
 These values may not apply to a modern charging system equipped with a
modern battery.

2. Measuring Charging System No-Load Voltage

Next, measure system voltage output without current draw (all accessories
turned off).

1. Ask an assistant to start the engine and hold engine speed at about 1500 rpm.
Make sure all accessories are turned off.
2. This time, your voltage reading across the battery should be no more than 2 volts
higher than your base voltage. When you start the engine, if system voltage is
below 13 volts, a charging problem exists. On the other hand, a voltage reading
over 15 indicates an overcharging problem. Overcharging problems usually are
caused by a bad voltage regulator or its control circuit.

If your no-load voltage reading is lower than 13.2 or 13.8 volts or lower than base
voltage, measure no-load voltage at the alternator as follows (no-load voltage
specs may vary according to your alternator or application. If necessary, consult
your vehicle repair manual):

1. With the engine running, connect the meter red probe to terminal B+ on the
back of the alternator and the black meter probe to the alternator case
(ground).
2. If your voltage is still the same, there's a problem with the charging system. The
problem could be with your alternator, or the voltage regulator. Consult your
vehicle repair manual to check the system bypassing the voltage regulator.
3. If alternator voltage is equal to or higher than 13.2 or 13.8 volts, head over to the
Voltage Drop test section.

If your no-load voltage is more than 2 to 3 volts higher than base voltage, there
is an overcharge condition. The problem might be with the voltage regulator or
the wiring. NOTE: For this test, some manufacturers find an output voltage range
between 13 and 15 volts at 2000 rpm as acceptable (this is also true for voltage
at the alternator -- B+ and case). Compare your results to your manufacturer's
specifications in the vehicle repair manual.

3. Measuring Charging System Load Voltage

This test will check if the charging system can service the different electrical
systems in your vehicle while still being able to recharge the battery.

10
1. Ask an assistant to start the engine and hold engine speed at around 2000 rpm.
2. Turn on all the electrical accessories like wipers, air conditioning, blower motor,
headlights, and radio.
3. Measure voltage across the battery terminal with your multimeter.
• Your voltage reading should be about 0.5 volts higher than your base voltage.
• If voltage reading is not about 0.5 volts higher than base voltage, bypass the
voltage regulator to check whether your voltage regulator or alternator is bad.
Consult your vehicle repair manual, if necessary.
• Another reason for an alternator to fail this test is the installation of aftermarket
accessories that surpass the alternator capacity when run along other devices.

NOTE: If you diagnose a bad alternator, make sure to do a charging system

voltage drop test as well. If there's too much resistance in the charging circuit,
most likely it'll force the new alternator to overcharge to compensate the
voltage drop in the circuit. Eventually, the new alternator will overheat and fail.
This also reduces the service life of the battery.

4. Testing for Alternator Current Leak

A charging system should only charge your battery with direct current. However,
if one or more diodes in the rectifier go bad, alternating current (AC) can leak
and cause problems. You can use a DMM to measure for the presence of AC
current from the alternator output terminal. Don't turn on the engine during this
test.

• Temporarily disconnect the negative battery cable.

• Disconnect the wire from the B+ connector on the back of the alternator.
• Set your DMM to milliamps and connect it in series between the alternator B+
(output terminal) and the wire you just disconnected.
• Connect the ground negative battery cable to the battery. Your meter should
read no more than 0.5 milliamps. If so, continue with the next steps; otherwise,
one or more diodes are bad.
• Disconnect the battery negative cable from the battery and reconnect the
output wire to the alternator B+ terminal.
• Set your DMM to AC voltage and connect the meter black probe to chassis
ground and touch the positive meter terminal to the B+ terminal on the
alternator. There should be no more than 0.5 AC volts; otherwise, there are one
or more bad diodes.

5. Charging System Voltage Drop Test

A voltage drop test can help you locate a bad connection or bad wiring
harness in a circuit caused by corrosion, loose, or damaged wires. These tests will
11
 help you check voltage drop on both sides of the charging circuit. Bad
connections introduce unwanted resistance into the circuit and prevent a
charging system from operating properly. For this test you'll need a digital
voltmeter.

Voltage drops test points on the positive side of the circuit.

Author

Positive side voltage drop test:

1. Set your voltmeter to a low setting on the VDC scale.

2. Connect the meter's positive (red) probe to the B+ terminal connector on the
back of the alternator.
3. Connect the meter's ground (black) probe to the battery positive post.
4. Start the engine. Then, increase and hold engine speed to about 2000 rpm's.
5. Turn on the headlights, wipers, radio and blower motor. You need the alternator
to put out at leas 20 amps for this test.
6. Your meter read-out should indicate a voltage drop of 0.2 volts or less;
otherwise, there's unwanted resistance in the circuit you need to clear. NOTE:
some manufacturers may consider a voltage drop of 0.5 volts acceptable for
this test, consult your vehicle repair manual for the specifications for your
particular application.

Voltage drops test points on the negative side of the circuit.

Author

Negative side voltage drop test:

12
 Repeat the previous test on the negative side of the charging system circuit;
however, meter connections should be as follows:

1. Connect the meter's positive (red) probe to the battery negative (-) post, and
the meter's ground (black) probe to the alternator case.
2. Your meter should read 0.2 volts of voltage drop or less; otherwise, check that
side of the circuit and remove the unwanted resistance.

Check Your Vehicle's Charging System Specifications

Doing a charging system check on your vehicle is not difficult, if you know how
to diagnose common problems that affect most charging systems. Many of
these problems are not difficult to repair either and often require a few tools.
However, depending on your system, the electrical value specifications may
vary among vehicle makes and models. So, make sure to consult your vehicle
repair manual to get the specifications for your particular application.

POST TEST – Multiple Choice

Direction: write the letter of the correct answer in a separate paper

1. How alternator produces an alternating current? It’s because of

A. Rotor field coil
B. Stator windings
C. Regulator
D. Load current

2. What is the purpose of regulator?

A. To prevent the alternator voltage from going too high
B. Allow the alternator to produce high current
C. Keep alternator speed from going too thigh
D. Keep alternator high voltage enough to charge the battery

3. Where is voltage regulator located?

A. In the driver’s compartment
B. On the battery
C. In the engine compartment
D. In the ECM

4. What is meant by ECM?

A. Electrical Computer Module
B. Energy Consumer Management
C. Electronic Computer management
D. Electronic Control Module

13
5 Technician A says that charge indicator is an ammeter, voltmeter, or warning
light that informs the driver of charging system condition. Student B says that
Tachometer is the instrument for giving the correct information about the status
of the battery. Who is right?
A. Technician A Only
B. Technician B Only
C. Both Technician A and B
D. Neither Technician A nor B
6. Technician A says that the alternator is a device for changing electrical
energy into mechanical energy. Technician B says the alternator is a device for
changing mechanical energy into electrical energy. Who is right?
Who is right?
A. Technician A Only
B. Technician B Only
C. Both Technician A and B
D. Neither Technician A nor B
7. Technician A believes that once an engine starts running, the engine
crankshaft pulley powers the alternator to supply electricity to a car’s electrical
systems. Technician B feels a battery is a car’s sole electrical supplier. Who is
right?
A. Technician A Only
B. Technician B Only
C. Both Technician A and B
D. Neither Technician A nor B
8. Technician A says alternator rear bearings are frequently held in place with a
small plate and screws. Technician B says alternator front bearings are usually
press-fit. Who is right?
A. Technician A Only
B. Technician B Only
C. Both Technician A and B
D. Neither Technician A nor B
9. Which of the following is not a component of a typical 12-volt charging
system?
A. voltage regulator
B. drive belt
C. battery
D. ignition switch
10. What component that is turned by the alternator drive belt and creates a
rotating magnetic field?
A. pulley
B. rotor
C. stator
D. Winding

14
 AUTOMOTIVE SERVICING NC II GRADE
NAME: ___________________________________________ 12
Date:______________
Second Quarter
GRADE & SECTION ____________________________ Teacher: _____________
Week 6

AUTOMOTIVE SERVICING NC II
GRADE 12
Third Quarter
Week 2

MOST ESSENTIAL LEARNING COMPETENCY

• SERVICING CHARGING SYSTEM (SCH)
o Disassemble Alternator
PRE-TEST – Multiple Choice
Direction: write the letter of the correct answer in a separate paper
1. How drive is transmitted to alternator from Crankshaft by
A. Camshaft C. Linkages
B. Vee belt D Return springs
2. The process of the rotating rotor inside the windings of the stator produce
A. Delta charge C. Rectification
B. Direct current D. Alternating current
3. A stator has three sets of these
A. Deltas C. Windings
B. Rotors D. Vee belt
4. Stator windings are wired in configurations of either star or
A. Rotor C. Triangle
B. Delta D. Cubic
5. What are the rotating windings within an alternator known as?

A. Stator C. Delta
B. Rotor D. Voltage regulator
6. What is the component of an alternator that switches output from AC to DC

A. Rectifier pack C. Rotor

B. Voltage stabilizer D. Delta

15
7. What component is used in Alternators to make a continuous electrical
connection between Carbon Brushes and Rotor Winding?

A. Slip Rings C. Slip ring

B. Split Pin D. Split pin

8. What are alternator Cooling Fan can be made from the following material?

A. Aluminum C. Steel
B. Plastic D. All of the above

9. How does an alternator work.

A. Convert mechanical energy to chemical energy

B. Convert chemical energy to mechanical energy
C. Convert electrical energy to mechanical energy
D. Convert mechanical energy to electrical energy

10. Which of the following below is the process of converting AC to DC?

A. Rectification C. Phasing
B. Alternation D. Conversion

16
The Alternator

It is a main part of the charging system. The alternator produces electrical

energy while the engine is running to charge the battery. When the engine is off,
the battery can be used as an electrical power source to power the starter
motor and make the engine runs.

There are two main functions of the alternator to the charging system. The first is
to generate electrical power to run all of the car's electrical systems. The second
is to generate currents to recharge the car battery.

1. Pulley
The first alternator part is a pulley. The pulley function is to rotate the rotor
assembly as the engine is running. Yes, the pulley works as a connector between
the rotor assembly and the engine through a drive belt were known as an
alternator belt or serpentine belt.

2. Housing
The second alternator part is housing. The housing function is to protect the inner
parts of an alternator and become a household of them like stator, bearings,
rectifier, etc.

The housings are split into two parts, front housing, and rear housing. Front
housing is located near the pulley, while the rear housing is at the opposite.
Between them, there is a stator assembly body.

17
3. Bearings
The third alternator part is the bearings. The bearings function is to make the
rotor assembly rotate freely. They are attached in front of and at the end of the
rotor shaft. They support the rotor shaft, so the rotation runs smooth and freely.

4. Rotor assembly
The fourth alternator part is rotor assembly. The rotor assembly function
generates a magnetic field by electromagnetic force built up because the
electric current flows from the battery through the rotor coil.

The rotor assembly is built from several parts, such as

• Rotor shaft; the shaft that will rotate the rotor assembly. It is connected to the
bearings and on the rear end shaft.
• North claw poles; the north claw poles changed to be the north pole
electromagnetic when the electric flow through the rotor coil.
• South claw poles; the south claw poles changed to be the south pole
electromagnetic when the electric flow through the rotor coil.
• Rotor coil; A coil rolled between the rotor shaft and the rotor claws (north
and south claws). This coil is connected to the slip rings.
• Slip rings; rounded shapes cooper were connected to the rotor coil. The slip
rings make the electric current flows while the rotor shaft is spinning.
• Cooling fan; the cooling fan function is to cool down the air temperature
inside the alternator.

5. Stator assembly
The fifth alternator part is stator assembly. The stator is a stationary set of
windings that surrounds the rotor. The stator assembly function generates
electric current as the rotor assembly (being electromagnetic) cuts the stator
coil. The coil builds in rounded shapes so the rotor assembly can rotate inside
the stator coil.

Two types of coil connections were used inside the stator coil, Y connection,
and delta connection. In a Y connection type stator, the wire ends from the
stator windings are connected to a neutral junction. The circuit looks like the
letter "Y." A Y-type stator provides a good current output at low engine speeds.

18
In a delta connection type stator, the wires are connected end-to-end so that
the circuit looks like a triangle. Delta-type stators are used in high-output
alternators.

6. Rectifier
The sixth
alternator part is a
rectifier. The rectifier
converts current from alternating current (AC) to direct current (DC) during the
charging process.
Since the stator windings generate an alternating current, they cannot be used
in most car electrical systems. So, to convert the alternating current to be direct
current, an alternator is equipped with a rectifier built from 6 or more diodes.

POST TEST – Multiple Choice

Direction: write the letter of the correct answer in a separate paper
1. Which of the following below is not part of rotor assembly?
A. Cooling fan C. Slip ring
B. Rotor coil D. Rotor bushing
2. A stator has three sets of these
A. Deltas C. Windings
B. Rotors D. Vee belt
3. Stator windings are wired in configurations of either star or
A. Rotor C. Triangle
B. Delta D. Cubic

4. What are the rotating windings within an alternator known as?

A. Stator C. Delta
B Rotor D. Voltage regulator

19
5. What is the component of an alternator that switches output from AC to DC

A. Rectifier pack C. Rotor

B. Voltage stabilizer D. Delta

6. What component is used in Alternators to make a continuous electrical

connection between Carbon Brushes and Rotor Winding?

A. Slip Rings C. Slip pin

B. Split Pin D. Split pin
7. What are alternator Cooling Fan can be made from the following material?

A. Aluminum C. Steel
B. Plastic D. All of the above
8. How does an alternator work.

A. Convert mechanical energy to chemical energy

B. Convert chemical energy to mechanical energy
C. Convert electrical energy to mechanical energy
D. Convert mechanical energy to electrical energy

20
9. Which of the following below is the process of converting AC to DC?

A. Rectification C. Phasing
B. Alternation D. Conversion

10. How drive is transmitted to alternator from Crankshaft by

A. Camshaft C. Linkages
B. Vee belt D Return springs

21
 NAME: ___________________________________________ Score:______________
GRADE & SECTION ____________________________ Teacher: _____________

AUTOMOTIVE SERVICING NC II
GRADE 12 Third Quarter
Week 3

MOST ESSENTIAL LEARNING COMPETENCY

SERVICING MECHANICAL SYSTEM - COOLING SYSTEM (SMS)

PRE-TEST(multiple choice)
Direction: Write the letter of your answer in a separate sheet of paper

1. Which of the following statements are true about coolant?

A. coolant and antifreeze are the same thing
B. the ideal mixture for most climates is 50/50
C. only ethylene glycol-based coolant requires specific disposal
requirements
D. coolant can only be tested by specific gravity
2. Which of the following is NOT correct about antifreeze?

A. antifreeze lowers the freeze point of coolant

B. antifreeze raises the boiling point of coolant
C. pure antifreeze has a really low freeze point
D. antifreeze is only a portion of coolant
3, Nitrite is added to diesel coolant to protect from _________?
A. cavitation erosion
B. oxidation
C. scale generation
D. electrolysis
4. The number one cause of damage to wet liners is _________?
A. cavitation erosion
B. cold weather freezes up
C. electrolysis from poor electrical grounds
D. poor heat transfer through two metal components
5. During rapid acceleration, water pumps on diesel engines can momentarily
produce as much as __________ psi.

A. 40 B. 60 C. 20 D.10
6. All of the following are true of scale build up in the diesel cooling system
EXCEPT?

A. scale deposits reduce heat transfer

B. scale deposits cause freeze plug failure
C. scale deposits are more prevalent in wet liner engines
D. scale deposits can be reduced by using a water filter
22
7. Diesel engine coolant contains all the following EXCEPT?
A. distilled water
B. corrosion inhibitor additives
C. nitrite
D. nitrile
8. Cooling system vent lines ______________?
A. assist in air removal
B. assist in returning coolant to surge tank
C. assist in steam removal
D. return coolant from the thermostat to radiator overflow tan
9. Propylene glycol can be all the following EXCEPT?
A. orange in color
B. red in color
C. blue in color
D. green in color
10. All of the following are true of glycerin-based coolants EXCEPT?
A. close to neutral on the PH scale
B. non-toxic
C. more expensive
D. issue free when mixed with other coolants

Automotive Cooing System

How Does a Cooling System Work?

Actually, there are two types of cooling systems found on motor vehicles: liquid
cooled and air cooled.

Air cooled engines are found on a few older cars, like the original Volkswagen
Beetle, the Chevrolet Corsair, and a few others. Many modern motorcycles still

23
use air cooling, but for the most part, automobiles and trucks use liquid cooled
systems and that is what this article will concentrate on.
The cooling system is made up of:
• passages inside the engine block and heads

o water galleries

• a water pump to circulate the coolant

• a thermostat to control the temperature of the coolant

• a radiator to cool the coolant

• a radiator cap to control the pressure in the system

• interconnecting hoses to transfer the coolant from engine to radiator (and

also to the car’s heater system where hot coolant is used to warm up the
vehicle’s interior)

A cooling system works by sending a liquid coolant through passages in the

engine block and heads. As the coolant flows through these passages, it picks
up heat from the engine. The heated fluid then makes its way through a rubber
hose to the radiator in the front of the car. As it flows through the thin tubes in

24
the radiator, the hot liquid is cooled by the air stream entering the engine
compartment from the grill in front of the car.

Once the fluid is cooled, it returns to the engine to absorb more heat. The water
pump has the job of keeping the fluid moving through this system of plumbing
and hidden passages.

A thermostat is placed between the engine and the radiator to make sure that
the coolant stays above a certain preset temperature. If the coolant
temperature falls below this temperature, the thermostat blocks the coolant flow
to the radiator, forcing the fluid instead through a bypass directly back to the
engine.

The coolant will continue to circulate like this until it reaches the design
temperature, at which point, the thermostat will open a valve and allow the
coolant back through the radiator.

In order to prevent the coolant from boiling, the cooling system is designed to
be pressurized. Under pressure, the boiling point of the coolant is raised
considerably. However, too much pressure will cause hoses and other parts to
burst, so a system is needed to relieve pressure if it exceeds a certain point.

The job of maintaining the pressure in the cooling system belongs to the radiator
cap. It is designed to release pressure if it reaches the specified upper limit that
the system was designed to handle. Prior to the ’70s, the cap would release this
extra pressure to the pavement. Since then, a system was added to capture
any released fluid and store it temporarily in a reserve tank. This fluid would then
return to the cooling system after the engine cooled down.

Circulation
The coolant follows a path that takes it from the water pump through passages
inside the engine block, where it collects the heat produced by the cylinders. It
then flows up to the cylinder head (or heads in the case of a V-type engine)
where it collects more heat from the combustion chambers. It then flows out
past the thermostat (if the thermostat is opened to allow the fluid to pass), then
through the upper radiator hose and into the radiator.

The coolant flows through the thin, flattened tubes that make up the core of the
radiator and is cooled by the air flow through the radiator. From there, it flows
out of the radiator, through the lower radiator hose, and back to the water
pump.

Antifreeze
The coolant that courses through the engine and associated plumbing must be
able to withstand temperatures well below zero without freezing. It must also be
able to handle engine temperatures in excess of 250 degrees without boiling. It’s

25
 a tall order for any fluid, but that’s not all—the fluid must also contain rust
inhibitors and a lubricant.

The coolant in today’s vehicles is a mixture of ethylene glycol (antifreeze) and

water, with a recommended ratio of 1:1. In other words, one part antifreeze and
one part water. This is the minimum recommended for use in automobile
engines. Less antifreeze and the boiling point would be too low. In certain
climates where the temperatures can go well below zero, it is permissible to
have as much as 75% antifreeze and 25% water, but no more than that. Pure
antifreeze will not work properly and can cause a boil-over.

Antifreeze is poisonous and should be kept away from people and animals,
especially dogs and cats, who are attracted by the sweet taste. Ethylene glycol,
if ingested, will form calcium oxalate crystals in the kidneys, which can cause
acute renal failure and death.

Six common reasons for an overheated car.

• Cooling System Failure. An overheated engine is very often caused by cooling

system failure. ...
• Radiator Problems. ...
• Faulty Belts or Hoses. ...
• Low Oil. ...
• Bad Thermostat. ...
• Failing Water Pump.

POST TEST. Multiple choice

Direction: Write the letter of your answer in a separate sheet of paper

1. What is the purpose of the cooling system in the automotive engine?

A. Prevent coolant from boiling

B. Prevent coolant from freezing
C. Keep the engine running as cool as possible
D. Keep the engine running at the most efficient operating temperature

2. Student A says the water cooled and wind cooledare the basic types of
automotive cooling system Student B says the air cooled and liquid are the two
types of cooling system. Who is right?
A. Student A B. Student B
C. Both A & B D. Neither A nor B
3. What makes water in the cooling system circulated?
A. Radiator C. thermostat
B. Water pump D. water jackets

26
4. Which of the following is true about engine coolant?

A. 50% of antifreeze and 50% water

B. 60% of antifreeze and 40% water
C. 70% of antifreeze and 30% water
D. 80% of antifreeze and 20% water

5. Propylene glycol can be all the following EXCEPT?

A. orange in color
B. red in color
C. blue in color
D. green in color

27
 NAME: ___________________________________________ Date:______________
GRADE & SECTION ____________________________ Teacher: _____________

AUTOMOTIVE SERVICING NC II
GRADE 12
Third Quarter
Week 4

MOST ESSENTIAL LEARNING COMPETENCY

• Disassemble starter
• Repair/replace and assemble starter components/parts.

PRE-TEST IDENTIFICATION.
Direction: Identify the following parts of an engine thermostat by selecting the
correct answer from the choices. Write the letter of your choices

A. Bridge B. Piston guide C. Spring.

D. wax pellet E. Poppet valve F. Piston
G. Seal

1. 4.
2. 5.
3. 6.
7.

28
How an engine thermostat works

An engine thermostat regulates the temperature of the coolant in the engine by

regulating the flow rate of the coolant. It’s basically a valve that opens and
closes to keep the engine temperature around 200°F. Here’s how an engine
thermostat works.

The parts of a coolant thermostat

The main component of an engine thermostat is a copper tube filled with a

mixture of wax and copper particles. The copper tube is sealed at the bottom
and has a seal and guide a the top. The bottom portion of a stainless-steel
piston is inserted into a rubber “bag” that is pressed into the wax and the top is
affixed to the bridge. It’s referred to as a wax “pellet” and it’s the “motor” that
opens and closes the poppet valve.

The wax pellet is connected to a circular disc called the poppet valve. The
poppet valve seats against the thermostat frame to close off coolant flow.

How a thermostat works

As the engine coolant heats up the heat

causes the wax to melt and expand. The
expansion causes a rise in internal pressure that
pushes the piston out. However, since the top of
the piston is secured to the bridge, the pressure
forces and equal and opposite reaction which
forces the pellet down, which pulls the poppet
valve open, allowing coolant to flow to the
radiator.

As the engine coolant drops in temperature, the wax cools and contracts,
reducing internal pressure. Since there’s now less internal pressure pushing the
pellet and poppet down, the spring force pushes the poppet up, closing off
coolant flow.

A vehicle's water pump is a belt-driven pump that

derives its power from the crankshaft of the engine.
Designed as a centrifuge, the water pump draws
cooled fluid from the radiator in through the pump's
center inlet. It then circulates the fluid outward into
the engine and back into the car's cooling system.

29
WHEN TO REPLACE A CAR WATER PUMP

The average water pump handles 1.7 million litres of coolant in about four years,
or 100,000 km (62,000 miles). A water pump that is failing causes an engine to
overheat. If a water pump does fail, the damage to the engine could be
catastrophic. Therefore, it is important to check the water pump at each service
interval.

The 'standard time' for installing a belt kit usually includes fitment of a water
pump. A decision to change the belt now, but not to replace the water pump
at the same time, assumes that the water pump will last for another complete
duty cycle of the belt. Do the job once!

Gates recommends changing water pumps whenever belt kits are fitted and
recommends the replacement of old gaskets and seals with new ones.

Our water pump kits include everything for a complete drive system
overhaul. Check our online catalogue to see if there is a kit available for the
model that you are working on.

It's essential to check the vehicle manufacturer's recommendations before

attempting to replace any water pump. Each engine design is likely to have its
own belt drive system configuration, so observe any specific instructions. Ensure
that you use the correct tools.

HOW TO INSTALL WATER PUMPS IN 13 EASY STEPS

STEP 1
Safety first
Always wait until the engine is cool before working on any part of the cooling
system.
STEP 2
Remove the belt drive components following the vehicle manufacturer’s
recommended procedures.
STEP 3
Remove the hose attached to the water pump.
Be aware that a considerable amount of coolant can pour out of the hose
when you take it off.
STEP 4
Loosen the bolts and remove the old water pump.
STEP 5
Remove the old seal/gasket or old sealant remains and make sure the mounting
surface is clean.

30
STEP 6
Before installing the new water pump, inspect the other cooling system service
parts: coolant hoses, thermostat and pressure cap(s).
STEP 7
Install the new water pump. Do not force the pump on by striking the pump
shaft.
STEP 8
Tighten the bolts evenly to the manufacturer’s torque specifications.
STEP 9
Re-attach the hose.
STEP 10
Refill the cooling system with the correct vehicle manufacturer’s recommended
coolant.
STEP 11
Manually rotate the pump and make sure it rotates freely.
STEP 12
Make sure the belt drive system that will drive the new water pump is in perfect
condition and installed following the vehicle manufacturer’s recommended
procedures
STEP 13
Do a final visual inspection to ensure there are no leaks after the cooling system
refill.

POST TEST IDENTIFICATION.

Direction: Identify the following parts of an engine thermostat by selecting the
correct answer from the choices. Write the letter of your choices

Choices

A. bearing B. housing C. gasket

D. bolt E. back plate F. impeller

G. seal H. Plugs Fitting I. Hub

1. 6.
2. 7.
3. 8.
4. 9.
5.

31
 KEY ANSWERS

WEEK 1 WEEK 2
PRE-TEST POST-TEST PRE-TEST POST-TEST

1. A 1. D
1. B 1. A 2. A 2. C
2. A 2. A 3. C 3. B
3. D 3. C 4. B
4. D 4. D
4. B
5. B 5. A
5. B 5. A
6. D 6. B 6. A 6. A
7. B 7. A 7. A 7. D
8. A 8. D 8. D 8. D
9. A 9. D 9. D 9. A
10. D 10. B 10. A 10. B

WEEK 3 POST TEST WEEK 4

PRE-TEST PRE-TEST POST-TEST

1. B 1. D 1. A 1. I
2. D 2. B
2. B 2. H
3. A 3. B 3. B
4. A 4. A 3. F
5. A 4. G 4. C
5. C
6. B 6. C 5. E 5. D
7. A 7. C 6. C 6. G
8. C 8. A
7. D 7. F
9. B 9. D 8. E
10. C 10. D
9. J

REFERENCES:
• Automotive Mechanics By Crouse & Anglin 10th edition

32