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TVET-BUREAU,SNNPR STATE FDR OF ETHIOPIA

Unit of Competence: Apply Lubricants and Coolants

Module Title: Appling Lubricants and Coolants
LG Code: AUM AES 1 M08L01- 03
TTLM Code: AUM AES1 M08L0 01-L0 03 0114V1

L0-1- prepare for work

 Instruction Sheet Learning Guide ___AUM AES 2 M08L01- 03

This learning guide is developed to provide you the necessary information

regarding the following content coverage and topics –
 Plan & prepare work/ prepare for work
 Request materials tools & equipment
 Direct & Apply Lubricants and Coolants
This guide will also assist you to attain the learning outcome stated in the cover
page. Specifically, upon completion of this Learning Guide, you will be able to –
 Drown /diagrams are read & interpret
 Select of tools, equipment with establishes procedures

Learning Activities
1. Read the specific objectives of this Learning Guide.
2. Read the information written in the “Information Sheet __”. Try to
understand what are being discussed. Ask you teacher for assistance if you
have hard time understanding them.
3. Accomplish the “Self-check” in page __.
4. Submit your accomplished Self-check. This will form part of your training
portfolio.
5. If you earned a satisfactory evaluation proceed to “Operation Sheet” in page.
However, if your rating is unsatisfactory, see your teacher for further
instructions or go back to Learning Activity #2.
6. Read the “Operation Sheet” and try to understand the procedures discussed.
7. Do the “LAP test” in page __ (if you are ready) and show your output to your
teacher. Your teacher will evaluate your output either satisfactory or
unsatisfactory. If unsatisfactory, your teacher shall advice you on additional
work. But if satisfactory you can proceed to Learning
Working Safely on the Cooling System
1.) Keep your hands away from the moving fan. The spinning fan blades can mangle
your hand and even cut off fingers.
2.) Never stand in a direct line with the fan. A fan blade could break off and fly out of
the engine compartment. Anyone standing in line with the fan could be seriously
injured. Before starting an engine, examine the fan for cracked or loose blades. If
you find damage, replace the fan.
3.) Electric fans can turn on unexpectedly, especially if the engine is warm. Always
disconnect the fan before working in the fan area.
4.) Keep your fingers away from the moving belt and pulleys. Your fingers could be
pitched and cut off if they are caught between the belt and a pulley.
5.) Never attempt to remove the radiator cap from an engine that is near or above its
normal operating temperature. Releasing the pressure cap may cause instant boiling
of the coolant. You may be scalded and burned by boiling coolant and steam spurting
from the radiator filler neck. Allow the engine to cool before removing the radiator
cap.
6.) Coolant is poisonous. It can cause serious illness or even death if swallowed. Always
wash your hands if you get coolant on them.
7.) A puddle of drained coolant will poison any pet drinking from it. Coolant is a
hazardous material. Dispose of it in a safe and legal manner.
8.) Under some conditions, the ethylene glycol in antifreeze is combustible. Do not spill
antifreeze on the exhaust manifold or other hot engine parts.
9.) If the engine overheats, turn off the engine as soon as it is safe to do so. Continued
operation of an overheated engine may cause fire, the possibility of personal injury,
and severe vehicle damage.
10.) Never disconnect a hose or attempt to replace any cooling system part until after the
engine cools. Pressure in the system may cause hot coolant to spray out, burning or
scalding the person.
 Information Sheet-__

ENGINE LUBRICATING SYSTEM

The engine has many moving parts. All the moving parts are operating at high temperatures
and at high speeds and most of these components are subjected to very high pressures. If the
parts rub against one another, they will wear out quickly due to friction. It becomes essential to
reduce this friction. The purpose of the engine lubricating system is to minimize friction and
wear. Thereby reducing power loss. The lubricating system performs this job by supplying oil to
prevent metal-to-metal contact.
The lubricating system supplies lubricating oil to all moving parts in the engine. It also
control of friction and wear by the introduction of a friction–reducing film between moving
surfaces in contact.
The internal combustion engine consists of many moving parts that rub against each other. The
principal friction surfaces in an engine are piston, cylinder, crankshaft, camshaft, main bearings, valves
and valve operating mechanism. Friction between moving surfaces can be reduced by interposing a
lubricant between them. The lubricant actually replaces dry friction with a fluid frictionIn the lubrication
system, oil is delivered to the various parts of the engine by the oil pump and after performing its
functions, returns to the oil pan. Oil circulates through the systems as follows:

Friction; friction can be

defined as a resistances to
movement b/n any two surface
in contact with each other. e.g.
– Friction b/n ship and water. -
Friction b/n sole of shoes &
ground surface.
- Friction b/n tyres & road surface
- Friction b/n brake lining & brake
drum.

Friction can classify

in to three basic
types
1, Dry friction 2, Greasy friction
3, Viscose friction
1, Dry friction: A friction b/n
two materials with any lubrication, e.g. desirable b/n brake lining & brake drum, clutch plate &
fly wheel so on. But on this friction a lot of heat will be greeted.
2, Greasy friction: A friction b/n two materials with very little lubrication, e.g. present in
door hinges, gear shift linkage to joint.
3, Viscose friction/Fluid friction/ ; A film of fluid prevents contact b/n two solid
materials , e.g. rotating b/n the crank shaft journal and the bearing. A film of oil under pressure
ensures that the two metal surfaces slide over one another. The only friction that occurs is b/n the
oil particles themselves.

Types of Lubricating System

1.) Splash Type – it refers to the system in which the oil is being splashed from the oil
pan into the lower part of the crankcase. Usually, the connecting rod has a dipper that dips into
the crankcase oil each time the piston reaches BDC. Likewise, usually used in a smaller like a
single cylinder engine.
2.) Pressure Feed Type – this type of lubricating system connotes that the engine parts
are lubricated by oil fed under pressure from the oil pump.
Component Parts of the Lubricating System
 Crankcase/Oil pan/
 Oil Pump
 Relief(or)Regulator Valve
 Oil Filter
 Oil Gallery
 Crankshaft Main Bearings
 Connecting Rod Bearings
 Oil Jet
 Oil cap
 Dipstick
 Oil Pressure Gauge
1, Crankcase / oil pan / – it is an iron or aluminum casting enclosing the
crankshaft; it is usually considered as the storage of oil in the engine.
2, Oil Pump: - The pump is driven by the engine and takes oil from the oil pan
through the strainer and pickup pipe. The strainer is provided to prevent any
foreign matter present in the oil from reaching the pump. Oil leaving the pump is
directed to the filter
Types of oil pumps

1. Rotor –TypePump– it has the inner rotor meshes internally with the outer one, which has one
more lobe, so the spaces vary in size, causing oil to be drawn in and forced out.
2 - Gear Type Pump - this contains a pair of meshing gears revolving in a closely fitting

housing. Oil fed in at one side is carried round the edge and out at the other side.

3, Crescent Type Oil Pump

The crescent pump is a modern variant of the gear type pump. It has an external toothed gear
meshed with an internal toothed gear. Some of the teeth of the gears are in mesh, the others are
separated by a crescent shaped part. The pump is mounted on the front of the cylinder block with
the inner gear on the end of the crankshaft, so that the pump is driven directly from the
crankshaft. When the pump is operating, oil is taken in through the intake port and is carried
around between the gears and the crescent to the outlet port. The main advantage of the crescent
pump compared with the conventional gear type pump is its higher output, particularly at low
engine speeds. It is also easier to manufacture.

3, Relief(or) Regulator Valve: This valve regulates pressure in the system. As the engine speed
increases, pump output increases and this must be controlled to prevent excessive pressure in the
system. When the specified pressure for the engine is reached, the relief valve opens to regulate
the pressure. Excess oil from the relief valve is then bypassed to the intake side of the pump.
4, Oil Filter: – it is usually embodying an element of impregnated paper, fitted to an engine to
prevent dirt, metal particles and other impurities from circulating in the engine’s lubrication
system

Two types of oil Filter

1. Full-flow filters
2. Bypass filters

Oil Pump Filter By-pass

Valve
 Engine parts
that needs
lubrication

Pressure Relief
Valve

Oil Pump

1. Full-flow filters
All the oil delivered from the pump passes through the filter on its way to the bearings and other
engine parts, so that only filtered oil is used for lubrication, provided the filter is in good condition. A
relief valve is located in the filter so that if the filter becomes clogged, the relief valve will open and
continue to supply oil to the system. Full-flow filter operate at a higher pressure than bypass filters, and
attention should be paid to renewing seals and applying correct torque to the bolt or filter during
servicing, so that oil leaks do not occur.

2. Bypass filters
These filters only a portion of the oil delivered from the pump to the oil ways of the engine. An
oil line is tapped into the oil gallery and a restricted amount of oil (5-10%) is allowed to flow to the filter
and then back to the oil pan. This oil is not delivered into the engine oil ways as clean oil, but it bypasses
the engine, to be returned as clean oil to the oil pan, again ready for the pump. In this way some oil is
always being filtered though not directly on its way to the engine parts.
5, Oil Gallery: The main oil gallery is a passage that runs full length of the crankcase. A number of
drillings and passages from the gallery to other parts of the lubrication system. Figure shows two
passages from the gallery, one to the crankshaft and its associated parts, and the other to the camshaft
and its associated parts.
6, Crankshaft Main Bearings: Each of the crankshaft main bearings is supplied with oil through a
separate drilling from the main oil gallery.
 7, Connecting Rod Bearings: Oil from the drillings in the crankshaft lubricates the connecting rod
bearings.
 8, Oil Jet: An oil jet is used to lubricate the cylinder walls and pistons. A small hole in the side
of the connecting rod is arranged to line up with the oil drilling in the crankpin journal. As this occurs, a stream of
oil is directed onto the cylinder walls as a mist to provide lubrication. This happens once in each crankshaft
revolution.9, Dipstick – connotes to a graduated rod for measuring the amount of oil in the engine sump
or gearbox.
10, Oil Pressure Gauge – use to measure the amount of oil pressure
11, Dipstick ;-connotes to a graduated rod for measuring the amount of oil in the engine sump
or gearbox.

Function of Lubricants Or Uses of Lubricants

1; Minimize Friction – the oil must form a film between highly loaded moving
parts.
2; Prevent Wear – the must protect highly loaded parts which can wear out when
the fluid film is very thin (boundary lubrication).
3; Act as a coolant – the oil must remove heat generated both inside and outside
the equipment.
4; Act as a seal and prevent leakage between the parts such as pistons, rings and
cylinders. 5; Remove the heat generated by friction. This
keeps down the temperature of the moving parts and thus prevents seizure.
6; Act as a cleaning agent. Wash away dirt, carbon particles and abrasive metal
worn from the friction surfaces.
7; Absorbs shock between bearings and other engine parts, thus reducing engine
noise and extended engine life.
8; Prevent Corrosion– The oil must protect precision parts made of various metals,
which are vulnerable to rust and corrosion.

Properties of Lubricating Oil

 Viscosity: is the tendency of the oil to resist flowing. OR
1.) Proper Viscosity– means to measure the oil’s resistance to flow. Low-viscosity oil is
thin and flows easily. High-viscosity oil is thicker. It flows more slowly.
2.) Viscosity Index– this is a measure of how much the viscosity of an oil changes with
temperature.
3.) Viscosity Numbers – lubricating oils either in single or multi-viscosity oils is rated
according to its numbers. SAE 5W – 20Ware examples of a single-viscosity oil and SAE20W -
50 is also an example of multi-viscosity oil. The letter W indicated in multi-viscosity oil stands
for Winter Grade and the word SAE means Society of Automotive Engineers.
Viscosity of an oil is expressed by a number called the viscosity index. The lower the index, the
thinner the oil.The higher the index, the thicker the oil.

4.) SLUDGE: IS a thicker, creamy, black substance that often forms in the crankcase. It
clogs oil screens and oil lines, preventing normal circulating of the lubricating oil to engine
parts. This can result in engine failure from oil starvation.
If the engine parts are cold the water condenses and drops in to the crankcase. Since the engine
oil mixed with this water by crankshaft, slugging is formed. The black colour comes from dirt
and carbon.
Howslugging forms- If the engine is operated, when cold most of the time, than slugging is
formed.
How preventing slugging- To preventing slugging, the car mast be driven long enough
for the engine to heat up and get rid of the water in crankcase.

Servicing Lubrication Systems

Replacing Engine Oil
1, Draining the oil from the engine
2, Flushing the lubrication system
3, Refilling the system with fresh oil
Replacing oil Filter
1, Removing old oil filter from engine
2, Installing NEW oil filter to the engine
 Oil pumps Servicing
1, Removing oil pump
2, Disassembling oil pump
3, Identifying parts of oil pump
4, Inspecting parts of oil pump
5, Assembling oil pump
6,Inspecting oil pump
7, Testing oil pump
INSPECTION
Check disassembled parts for wear or damage.
 Check the relive valve for wear or scoring and if it slides smoothly
 Measuring oil pump body clearance1.
 Rotor –Type oil Pump
A;-Inspect rotor body clearance
-Using a feeler gauge, measured the body clearance between the driven rotor and body.
Standard body clearance;- 0.144 –0.219 mm (0.0057 – 0.0086 in)
Maximum body clearance;- 0.40 mm (0.0157 in)
If the body clearance is greater than maximum, replace the rotors as a set. If necessary,
replace the oil pump assemble.
B;-Inspect rotor side clearance
-Using a feeler gauge and precision straight edge, measured the clearance between the
precision straight edges.
Standard side clearance;- 0.0110 – 0.024mm (0.0043 – 0.0094)
Maximum side clearance;- 0.30mm (0.0118 in)
If the side clearance is greater than maximum, replace the rotors as a set. If necessary,
replace the oil pump assemble.
C;- Inspect rotor tip clearance
-Using a feeler gauge, measured the clearance between the derive and driven rotors.
Standard tip clearance;- 0.035 – 0.085mm (0.0014 – 0.0033)
Maximum tip clearance;- 0.15mm (0.0059 in)
If the tip clearance is greater than maximum, replace the rotors as a set.

N.BBe careful measure the same to other two types of oil pumps ,with the same measuring
tools, feeler gauge and precision straight edge.
Service Rating Oil
 Oil is rated by viscosity number and by its servicing rating. This designation by
the American Petroleum Institute (API) indicates the service for which the oil is
best suited.
Gasoline Engine oil Diesel Engine oil
SA, SB, SC, SD, SE, SF, and SG. CA, CB, CD, CE, and CF
Engine oil changes procedure
  Due to the contamination of oil, it loses its effectiveness so fresh oil is put in to
the engine. Manufacturers recommend, for normal service, changing oil every
four month or 6400km, which comes first. For sever service , change oil two
months or 3200km.
 Draining the oil from the engine
1, Raise the car on proper position
2, Preparing container
3, Place the oil drain pan position
4, Remove the drain plug from the oil pan
5, After the oil is drained, install the plug and lower the car
 Flushing the lubrication system
1, Drain oil from the system
2, Mix contaminated engine oil with the diesel fuel and fill the system, then run
the engine for 10 min.
3, Drain the oil from the system
 Refilling the system with fresh oil
1, After the oil is drained from the engine and flushed the lubrication system add
the recommended amount of oil to the engine.
2, Start the engine and check for level with dipstick and leaks.

N.B:- Engine oil should be changed before the new filter is

installed A new filter should be always start out with new oil.
NOTE- Always put on a new lubrication sticker with car mileage
and date when the oil was changed.

Engine Cooling System

INTERODACTION;-The burning of fuel in an internal combustion engine produces heat, which
is sufficient to melt the metal of the cylinder. It is the function of the cooling system to prevent
the engine overheating but it must also allow it to operate at a temperature high enough to assist
in effective combustion. If the engine operating temperature were allowed to go unchecked, it
would burn and dry up the lubricating oil film, so that the pistons would seize in their cylinders
and distortion would result from over-expansion of metals.
The engine burns fuel in the cylinder to transform its thermal energy (heat energy) into a driving
power. But the thermal energy of the fuel is not converted into power entirely. It can be stated
that approximately 25 per cent of the energy contained in the fuel is converted into useful work;
30 per cent is absorbed by the engine itself, and the remaining 45 per cent passes away in the hot
exhaust gases or frictional losses & pumping losses. The heat that is absorbed by the engine must
be discharged to the atmosphere because the engine will become overheated and eventually seize
up. Therefore a cooling system is built into the engine to cool it and prevent overheating.
The engine cooling system keeps the engine maintains its normal operating
temperature. Here the follow fig. show how cooling system circulation in the engine.

Types of Cooling System

1 .Direct Cooling System – engines with this type of cooling system are also called air-
coldengines. During operation, air is drawn by a blower leading to air metal fins or shrouds are
the cylinders through air ducts. OR
If the engine is air-cooled, excess heat is radiated
from the cylinder bores and head directly into the
surrounding air. In order to increase the surface
area exposed to the cooling effect of the air, fins
are formed on the external surfaces of the engine. The fins are cast integrally with the cylinder
and cylinder head and act as a means of increasing the amount of radiation surface presented to
the cooling air stream. Heat produced by the combustion process passes through the walls of the
cylinder and cylinder head to the fins, where it is dissipated into the passing air.

2. Indirect Cooling System

Engines with this type of cooling system are also called water-cooled engines. OR
The term ‘indirect air cooling’ refers to the conventional liquid-or water-cooled engine. In
a water-cooled system the heat from the cylinders is transferred to the coolant contained in
jackets surrounding the cylinders. This coolant then passes through a radiator which transfers
heat to the cool air flowing around it.
In the modern internal combustion engine, the rate of coolant circulation must be rapid enough to
ensure that localized pockets of relatively stagnant water are not formed, otherwise local
overheating will take place even though the coolant may be at a comparatively low temperature.
If local overheating does occur, the area affected will rise to a temperature considerably higher
than the general temperature of the surrounding metal and this results in heavy localized ‘heat
stress’ which may eventually cause the metal to crack. It is therefore very important that the rate
of coolant circulation is controlled to ensure adequate cooling throughout the complete system.

Component Parts of the Indirect Cooling System

1. Radiator
2. Expansion Tank
3. Radiator Hose
4. Radiator Pressure Cap
5. Fan
6. Shroud
7. Fan Belt
8. Thermostat
9. Temperature Gauge
10. Water Jackets
 1. Radiator –The function of the radiator is to transfer heat from the coolant to the
surrounding air stream.
The radiator consists of two storage tanks; the top tank which is called a header tank,
and the bottom tank. These two tanks are connected by a series of brass or copper tubes
fitted with finning to increase their surface area and thereby improve the cooling effect.
This group of tubes between the two tanks is known as the radiator core. As the coolant
passes through the radiator core it dissipates its heat through the tubes into the air steam
flowing around the core
The radiator is connected to the engine by means of flexible rubber hoses, which are held
in place by metal clips to form a watertight seal. A removable cap, overflow pipe, and
drain tap or plug must also be fitted to the radiator

Two types of radiators

A, Down flow B, Cross flow

2. Expansion Tank– The expansion tank (or reservoir tank or overflow tank) is connected
to the radiator by the overflow hose.When the coolant volume expands due to a rise in
temperature, the excess coolant is sent to the expansion tank. When the temperature
drops, the coolant in the expansion tank returns to the radiator. This prevents wasteful
discharge of the coolant and eliminates the need for constant replenishment of the
coolant supply.

3. Radiator Hose– it is a rubber or fabric pipe between the radiator and the engine. The
upper house feeds hot coolant to the radiator and the lower hose returns the cooled
coolant to the engine.
4,Radiator Hose Clips

Various Kinds of Radiator Clips

Kinds of Radiator Hose

 4. Radiator Pressure Cap – designed to maintain pressure in the cooling system above that
atmospheric pressure of 101 kPa at sea level.
Radiator Cap

Water Pump – To provide effective cooling in modern engines, it is necessary to incorporate a

water pump to assist and maintain circulation. The water pump is mounted centrally at the front

Downfl Crossflo
of the engine cylinder block and is usually driven by a belt from the crankshaft.

ow w
Cooling Fan
The fan is usually located behind the radiator, and in most cases is mounted on the water
pump drive flange. A v belt may be employed to drive the fan from the crankshaft.
The fan consists of a number of blades constructed from metal or a plastic such as nylon.
In the case of a vehicle travelling at a relatively high speed, a great deal of air flows through the
radiator core, but when the engine is idling or travelling at low speed in heavy traffic on a hot
day, the flow of air would be insufficient to provide effective
cooling. Therefore, the purpose of the cooling fan is to
maintain an adequate flow of air through the radiator,
particularly at low road speeds and under engine idling
conditions. Air flowing through the radiator assists in
dissipating the heat of the coolant flowing through the
radiator core. Care must be taken with the design of the fan,
as the amount of power absorbed in driving the fan increases
with engine speed. Furthermore, by increasing the number of
blades the fan size can be reduced and improvements in
efficiency obtained.

Shroud

Mechanical Belt Driven Fan7.Shroud

-Ensures that the fan pulls air through
the radiator core
Electric Fan
 8. Fan Belt– it is used to drive the fan, water pump, and the generator/alternator from a
pulley of the crankshaft.

Fan
Belt
9. Temperature Gauge– it is an instrument used to indicate the temperature of the engine coolant.
10. Water Jackets – In most designs the water jackets are cast as an integral part of the cylinder block
and cylinder head to provide passages or galleries around the
cylinders, combustion chambers, valve seats, etc., for the circulation of
the coolant. It is essential that theses passages allow an unrestricted
flow of coolant around the cylinders and valves. The majority of
modern engines have full-length water jackets which extend almost to
the bottom of the cylinders. An outlet is formed in the cylinder head to
connect the upper part of the water jacket with the radiator header
tank. The cylinder block water jacket is connected to the radiator
bottom tank via the inlet connection on the water pump. A drain plug or
valve should also be provided in the cylinder block at the lowest point
in the water jacket so that the coolant may be drained from the jackets.
Thermostat
The thermostat is usually located between the cylinder head
(water jacket outlet) and the header tank of the radiator. Its exact
location varies with engine application.
Internal combustion engines are designed to operate most efficiently at
a particular temperature (operating or working temperature) and it is most important that this
temperature should be attained as soon as possible after starting the engine, and then maintained. The
thermostat continues to control the flow of coolant to prevent overheating or overcooling and ensure that
the engine will operate at its most efficient temperature. Therefore the function of a thermostat is to
maintain ideal engine working temperature, which it does by controlling the rate of coolant flow through
the radiator according to engine operating conditions.

Page 19
The opening and closing of the thermostat is controlled by the temperature of the coolant in the system.
When the coolant is cold and during the ‘warm-up’ period, the thermostat remains closed and the water
pump circulates the coolant through the cylinder block and cylinder head only. As the normal operating
temperature is reached, the valve opens to allow the coolant to circulate throughout the entire system.
The thermostat is usually marked with the temperature at which the valve begins to open. A standard
temperature range used in modern engines may be in the region of 80 0C to 900C and the valve should be
fully opened at 930C. However, this range will be recommended by the manufacturers.

Servicing Cooling Systems

Different defects of radiator hoses

InstrumentationTwo common types:
 Temperature warning light
 Engine temperature gauge
Flushing a Cooling System
 Cleans rust and scale from the system
 May involve running a cleaning chemical
through the system
 Methods:
 fast flushing
 reverse flushing
 chemical flushing
Fast Flushing

Chemical Flushing
 Used when scale build-up is
causing overheating
 Chemical cleaner is added to the
coolant
 The engine is operated for a specific
amount of time

The system is flushed with water

Page 20
Reverse Flushing
Causes of Overheating
 Low coolant level
 Rust or scale accumulation in water
jacket
 Stuck thermostat
 Retarded ignition
 Loose fan belt
 Bad water pump or collapsed lower
hose
 Missing fan shroud or fan problems
Causes of Overcooling
 Stuck thermostat (open)
 Locked fan clutch
 Shorted fan switch

Water Pump Service

 A bad pump may leak, fail to circulate coolant, or produce a
grinding sound
 Causes:
 Rust in the cooling system
 Lack of coolant over tightened belt
Removing a Water Pump
 Unbolt all brackets and components
 air-conditioning compressor
 power steering pump
 alternator
 Remove the pump
 Scrape off the old gasket or sealer material
 Do not gouge the sealing surfaces
 Installing a Water Pump
 Use sealer where specified
 Fit the pump onto the engine
 Start all bolts by hand
 Torque all fasteners to specifications
 Install the other components

Page 21
Thermostat
N.BThe special O-ring seal should be replaced anytime
the thermostat is removed
Stuck thermostat (open)Causes of Overcooling
Stuck thermostat (closed)Causes of Overheating
 Coolant Leaks
 External leaks
Show up as wet, discolored areas on parts
 Internal leaks
Caused by cracked block, cracked head, or
blown head gasket
Cooling System Leaks Causes
A cracked part or blown gasket can allow coolant
to leak into the engine oil
Cooling System Pressure Test
 Low air pressure is forced into the system
-Causes coolant to pour or drip from any leak
Procedure of cooling system pressure
test
Install a pressure tester on the filler neck
Pump the tester to pressurize system
Maximum 14 psi, (96 kPa) or cap rating

Page 22
 Knowledge test
Name ____________________level________ time allowed1 minute for each
ARBA MINCH POLY TECHNIC COLLEGE DEPARTMENT OF AUTOMOTIVE ENGINE AND
ELECTRICAL / ELECTRONIC SERVICING L-1 APPLY LUBRICATION AND COOLANT THE
LAST EXAM OF 2006 E.C.
I, SAY THE STATEMENT IS TRUE OR FALSE.
1. The lubricating system supplies lubricating oil to all moving parts in the engine by the helps
of oil pump.
2. The water pump consists of number of blades which project one side of a disc called an
impeller.
3. The cooling fan is to maintain an adequate flow of water through the radiator.
4. The thermostat is located b/n the cylinder head and the cylinder block side.
5. Oil pressure gauge use to measure the amount of oil pressure.
II, CHOOSE THE CORRECT ANSWER.
1. One of the following is the correct statement of the function of lubrication system
A, Minimize Friction B, Prevent Wear C, Act as a coolant D, Prevent Corrosion E,
All

2. ______is type of lubrication system which the oil is being splashed from the oil pan into the
lower part of the crankcase.
A, Rotor type oil pump B, Splash type lubrication system
C, Pressure feed pump lubrication system D, none
3, On of the following engine system which prevents cortisone b/n the engine system

Page 23
A, Lubrication system B, Cooling system C, Intake system D, Exhaust system
4. which one of the following causes of engine overheating.
A, Ignition timing retarded B, Thermostat faulty C, water pump faulty D, all
5. Connotes to a graduated rod for measuring the amount of oil in the oil sump or gearbox.
A, Dipstick B, Oil sump C, Sterner D, A and B

III, MATCHING

1. Air cooling A, Thermostat faulty

2. Water cooling B, Direct cooling
3. Removing dirty from lubricant C, Connect by over flow pipe
4. Oil sump D, Indirect cooling
5. Open thermostat E, Oil filter
F, Over cooled
G, Container of lubricant

IV, Explain the exact answer

1.Write the two types of thermostat

2. Explain the function of cooling system

___________________________________________________________________________
________________________________________________________

3. Explain the function of lubrication system

___________________________________________________________________________
_________________________________________________________
4. Oil pump driven by ______________________________________

5. Write the component parts of cooling and lubrication system.

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AUTO ENGINE SERVICE Level I

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Unit of Competence: Apply Lubricants and Coolants
Module Title: Appling Lubricants and Coolants
LG Code: AUM EEE M09 0110
TTLM Code: AUM EEE1M 03 0114 v1

Introduction
This Teacher’s Guide is developed to assist you in delivering the Automotive Engine and
Electrical / Electronic Servicing Itraining program. It is usually designed as a resource to support
the learning activity.

The Automotive Engine and Electrical / Electronic Servicing is developed to equip the trainees
with the required competences in Remove and Replace Electrical/ Electronic Units /
Assemblies, Service and Maintain / Replace Batteries ,Carry Out Repairs of Single Electrical
Circuits, Install, Test & Repair Low Voltage Wiring / Lighting Systems ,Carry Out Soldering of
Electrical Wiring / Circuits, Perform On-Vehicle Minor / Basic Servicing, Use Basic Measuring
Devices, Tools and Equipment , Apply Lubricants and Coolants, Remove and Tag Engine
System Components, Apply Quality Standards, Work with Others, Receive and Respond to
Workplace Communication, Demonstrate Work Values, Develop Understanding of
Entrepreneurship

The Program is consists of fifteen (15) learning modules covering the fifteen (15) units of
competence.

This teacher’s guide covers all the fifteen (15) learning modules and it will assist you in
delivering the said program and achieving its learning objectives and outcomes. It also provides
information in the organization of the learning guides and assessment packets. The learning
guides are aid to the trainees by telling them what need to do, when and how to do it and the
expectations once the learning activities are completed. While the assessment packet guide you
in developing the tools or instruments to measure trainee’s overall achievement of the stated
competence. Thus it is important for you to understand the design of this program and the
mechanics in which it shall be delivered.

Your role as the teacher is to provide opportunities aimed at helping the trainees develop and

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improve their competences. You are expected to guide and assist them as they go through the
learning activities and actual work.
Learning Modules
Unit of Competence
AUM EEE1 01 0910 Remove and Replace
Electrical/ Electronic Units /
Assemblies
AUM EEE1 02 0910
Service and Maintain /
Replace Batteries
AUM EEE1 03 0910
Carry Out Repairs of Single
Electrical Circuits
AUM EEE1 04 0910 Install, Test & Repair Low
Voltage Wiring / Lighting
Systems
AUM EEE1 05 0910 Diagnose and Rectify Fault
in Motor Drive System
AUM EEE1 06 0910 Perform On-Vehicle Minor /
Basic Servicing
AUM EES1 07 0910 Use Basic Measuring
Devices, Tools and
Equipment
AUM EES1 08 0910 Read and Interpret
Specifications and Manuals
AUM EES1 09 0910 Apply Lubricants and
Coolants
AUM EES1 10 0910 Remove and Tag Engine
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Learning Modules and Code
AUM EEE1M 01 0114
Removing and Replacing
Electrical/ Electronic Units / Assemblies
AUM EEE1M 02 0114
Servicing and Maintaining / Replacing Batteries
AUM EEE1M 03 0114
Carrying Out Repairs of Single Electrical Circuits
AUM EEE1M 04 0114
Installing, Testing & Repairing Low Voltage Wiring /
Lighting Systems
AUM EEE1M 05 0114
Diagnosing and Rectifying Fault in Motor Drive System
AUM EEE1M 06 0114
Performing On-Vehicle Minor / Basic Servicing
AUM EEE1M 07 0114
Using Basic Measuring Devices, Tools and Equipment
AUM EEE1M 08 0114
Reading and Interpreting Specifications and Manuals
AUM EEE1M 09 0114
Applying Lubricants and Coolants
AUM EEE1M 10 0114
 System Components Removing and Tagging Engine System Components

AUM EES1 11 0910 Apply Quality Standards AUM EEE1M 11 0114

Applying Quality Standards
AUM EEE1 12 0910 Work with Others AUM EEE1M 12 0114
Working with Others

AUM EEE1 13 0910 Receive and Respond to AUM EEE1M 13 0114

Workplace Communication Receiving and Responding to Workplace Communication

AUM EEE1 14 0910 Demonstrate Work Values AUM EEE1M 14 0114

Demonstrating Work Values

AUM EEE1 15 0910 Develop Understanding of AUM EEE1M 15 0114

Entrepreneurship Developing Understanding of Entrepreneurship

Learning Outcomes and Assessment Criteria

Unit of Competence Apply Lubricants and Coolants

AUM EEE M06 0110
Module Title Applying Lubricants and Coolants
LO 1 Prepare for work
Assessment Criteria ► Ready workstation
► Acquire procedures and information
► Implement methods in identifying lubricants and
coolants
► Check identified/selected tools and equipment
► Determine type and quantity of lubricants and coolants
to
► be used
► Determine Lubrication scheduled
► Observe OHS measures and warnings

LO 2 Use lubricants and coolants

Assessment Criteria
► Identify correct procedure for change of lubricant
► Use correct tools and equipment
► Remove and replace existing lubricants
► Use safe procedure
► Check work

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 LO 3 Perform housekeeping
Assessment Criteria ► Dispose used lubricants
► Cleaned and properly store tools and equipment
► Properly store usable excess materials
► Made workplace

Training Mechanics

The Outcome-Based Training is one form of an independent learning approach. This approach
enables trainees to be master of their own environment and in charge of their learning. It is also
characterized by the integration of theory and application as two dimensions of an effective
learning process. In this program, the competence-based system is consists of a combination of
lecture-discussion, individualized learning activities, mentoring, field immersion and feedback.

In this program the trainees will be given individual learning guide to go through and
accomplish. They will be instructed through this learning guide to accomplish learning activities
as part of the mechanism for transfer of learning from the training situation to the job situation.
For each competence area, trainees will formulate a specific learning plan as a guide for
applying their learning to work setting and for their own continuing self-development. At this
point, your role as the teacher/facilitator is to guide the trainee in preparing and accomplishing
their plan.

Lecture and discussion of the topics outlined in the session plan should be performed first before
the trainees are instructed to go to the workshop. You are also required to demonstrate the
correct steps/procedures and techniques to your trainees before you let them practice. Insure that
they are practicing safely.

Most part of the training activities will be conducted in the workshop for better development of
specific skills. Aside from motivating them to relate concepts and skills to their own work
situations, make sure to provide the necessary opportunity for competence practice and better
internalization of such concepts and techniques. The trainees should also be provided the
opportunity to blend with the actual working unit in the industry.

In this system, it is important to develop a sustained relationship with the trainees through a
continued involvement, where you are to offer support, guidance and assistance as the trainee go

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through the learning activities and actual work.

With the mentoring approach, the trainees are grouped in learning teams with one facilitator-
mentor per team. Before learning session or workshop start in the morning, each team and
mentor meets to give feedback regarding their work, or how the group improves, acquire set of
skills for the members to become more effective trainees. You are also to asses them at the end
of each module. However, they have to be ready before the assessment and it should be them to
request for it.

Before the training start you should conduct an orientation session to brief the trainees on how
the training will proceed.

Session Plan-39 (M0-09-LO1)

Apply Lubricants and Coolants
Unit of Competence

Appling Lubricants and Coolants

Module Title

LO 1 Prepare work station

Session Objectives At the end of this session the trainees shall be able to –
 Ready workstation
 Acquire procedures and information
 Implement methods in identifying lubricants and coolants
 Check identified/selected tools and equipment
 Determine type and quantity of lubricants and coolants to
be used
 Determine Lubrication scheduled
 Observe OHS measures and warnings

Activities Nominal Contents Methods

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 Duration
Sessions 45 mins Introduction to the Module Orientation
55min Ready workstation Lecture-discussion
1hr Acquire procedures and information Lecture-discussion

2hr Implement methods in identifying lubricants Lecture-discussion

and coolants
5hr Check identified/selected tools and equipment Lecture-discussion

5hr Determine type and quantity of lubricants and Lecture-discussion

coolants to be used
1hr Determine Lubrication scheduled Lecture-discussion
1hr Observe OHS measures and warnings Lecture-discussion
Individual
Evaluation 15 mins Accomplishment of LAP Test
Activity
Summary 5 mins Wrap-up and Feedback Discussion
Resources  Learning Guide
 Safety Manual and Guide

Session Plan-40 (M0-09-LO2)

Apply Lubricants and Coolants
Unit of Competence

Appling Lubricants and Coolants

Module Title

LO 2 Use lubricants and coolants

Session Objectives At the end of this session the trainees shall be able to –
 Identify correct procedure for change of lubricant
 Use correct tools and equipment
 Remove and replace existing lubricants
 Use safe procedure
 Check work.

Nominal
Activities Contents Methods
Duration
Sessions 40 mins Introduction to the Module Orientation

2hr Identify correct procedure for change of Lecture-demonstration

lubricant
7hr Use correct tools and equipment Lecture- demonstration

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 7hr Remove and replace existing lubricants Lecture- demonstration

5hr Use safe procedure Lecture- demonstration

4hr Check work Lecture- demonstration

Evaluation 15 mins Accomplishment of LAP Test Individual Activity
Summary 5 mins Wrap-up and Feedback Discussion
Resources  Learning Guide
 Safety Manual and Guide

Session Plan-41 (M0-09-LO3)

Apply Lubricants and Coolants
Unit of Competence

Appling Lubricants and Coolants

Module Title

LO 3 Perform housekeeping
Session Objectives At the end of this session the trainees shall be able to –
 Dispose used lubricants
 Cleaned and properly store tools and equipment
 Properly store usable excess materials

Nominal
Activities Contents Methods
Duration
Sessions 40 mins Introduction to the Module Orientation
3hr Dispose used lubricants Lecture- demonstration

7hr Cleaned and properly store tools and Lecture- demonstration

equipment
6hr Properly store usable excess materials Lecture- demonstration

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Evaluation 15 mins Accomplishment of LAP Test Individual Activity
Summary 5 mins Wrap-up and Feedback Discussion
Resources  Learning Guide
 Safety Manual and Guide

AUTO ENGINE SERVICE Level I

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 TTLM Code: AUM, AES 1 TTLM 080Lo 01-Lo03
0114V1

Assessment Context

There are two types of evaluation used in determining the extent to which learning outcomes are
achieved. The specific learning outcomes are stated in the modules. In assessing them, verifiable
and observable indicators and standards shall be used.

The formative assessment is incorporated in the learning modules and form part of the learning
process. Formative evaluation provides the trainee with feedback regarding success or failure in
attaining learning outcomes. It identifies the specific learning errors that need to be corrected,
and provides reinforcement for successful performance as well. For the trainer/facilitator,
formative evaluation provides information for making instruction and remedial work more
effective.

Summative Evaluation the other form of evaluation is given when all the modules of the program
have been accomplished. It determines the extent to which competence have been achieved.
This will be given in the form of written test for the underpinning knowledge and demonstration
for the attitudes and skills portion. And, the result of the assessment decision shall be expressed
in the term ‘competent or not yet competent’.

These two types of evaluation form part of the training and they are considered as institutional
assessment.
Evaluation Tools

a) Formative Assessment

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  Written test
 LAP test

b) Summative Evaluation
 Comprehensive Written test
► Knowledge Test
 Demonstration with Oral questioning
► Student Test Guide

Evidence Plan
Automotive Engine and Electrical / Electronic Servicing Level-I
TVET Program:

Learning Outcomes LO1 Prepare work station, LO2, Use lubricants and coolants,
covered: LO3 , Perform housekeeping,
2006E.C
Batch Class:
Questioning with OralDemonstration

Ways in which evidence will be collected:

Practical Test
Knowledge Test

The evidence must show that the trainee…

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 Identify & confirm nature and scope of work 
requirements 

 Acquire procedures & information such as work shop manuals,

specifications & tooling & equipment


 Make work station ready and safe for servicing work 

 

 Select and prepare in accordance with methods appropriate 

the circumstances 

 Identify and prepare resource requirements including 

support equipment for servicing 

 Identify and prepare technical requirements for works 

source and support equipment

 Observe throughout the work operation OHS and warning

  
in relation to working with engine
 Implements cooling systems inspection in accordance with
workplace procedures and manufacturer specifications.  


 Compare results with manufacturer specifications to indicate
compliance or non-compliance.
 

 Document results with evidence and supporting information and 

recommendation(s).  

 Process report in accordance with workplace procedures 

 

 Observe OHS requirements, including regional regulatory
requirements and personal protection needs throughout the
 
work.

 Identified Procedures and information required and sourced
 

 Identify resources and support equipment required for servicing
cooling systems and prepare.  

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 Implement Service in accordance with workplace procedures and 
manufacturer specifications  

 Service System without damage to system components.
 

 Make adjustments during the service are in accordance with
manufacturer specifications.  

 Complete servicing schedule documentation.
 

 Make final inspection to ensure protective guards, safety features
and cowlings are in place.  

 Make final inspection to ensure conformance to workplace
standards and expectations.  

 Clean equipment and stored safely and properly.
 

 Process Job card in accordance with workplace procedures.
 
Prepared by: Gelsimo G. Date
Checked by: Date

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General Instructions:
a) The practical test covers the following Learning outcomes
LO1 Prepare work station, LO2, Use lubricants and coolants,
LO3 , Perform housekeeping
3 Prepare to service Lubricant & Coolant process
b) You are to accomplish the tasks provided in the specific instructions.
c) You are given 6 hours to complete them.
d) You will be provided with the following to complete the tasks
For the Coolant For the Lubricant
 Socket wrench box set - Socket wrench box set
 Alenky - Alenky
 ,Hand tools - Benches
 Benches - Oil sump
 Radiator - Oil pump
 Water pump - Oil filter
 Thermostat -Engine
 Expantion tank
 Upper and lower hose
 Fan
 Engine
 And other tools and equipments based on the size and the shape of the material

Your questions and clarifications should be addressed to the teacher only

e) Submit this booklet to your teacher upon completion.

f) After you finish this assessment, you are not allowed to copy anything or tear any
page from this booklet.

Specific Instructions:
You are to accomplish the following and submit to the teacher.
1. Write your full name in block letter
2. Follow the working procedure
3. Ask help if important only from the invigilator
4. Don’t leave the assessment hall until you told to do.

Student Test Guide

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 Rating Sheet for Demonstration (Formative Assessment)
Student’s Name: ----
Teacher’s Name: Gelsimo G.
Learning Module Title: Apply Lubricants and Coolants
LO1 Prepare work station,
LO2, Use lubricants and coolants,
Learning Outcomes covered: LO3 , Perform housekeeping

Batch Class: 2006 E.C

Date of assessment:
Time of assessment:
Instructions for demonstration
a/ You are to accomplish the tasks provided in the specific instructions.
b/ You are given 6 hours to complete them.

Materials and equipment (For the Coolant) Materials and equipment (For the Lubricant)
 socket box set - Socket wrench box set
 Alenky - Alenky
 Hand tools - Benches
 Benches - Oil sump
 Radiator - Oil pump
 Water pump - Oil filter
 Thermosta t - Engine
 Expantion tank
 Upper and lower hose
 Fan
 engine
 And other tools and equipments based on the size and the shape of the material

OBSERVATION
During the demonstration of skills, did the trainee: Yes No N/A

  
Ready Workstation for work activities?

Implement methods in Appling Lubricants and Coolants procedures and   

manufacturer specifications?

Check Identified/selected tools and equipment for functionality and ready   

for use?

Observe OHS measures and warnings in relation to working   

With tools and equipment throughout the work operation?

The trainee’s demonstration was:S

Satisfactory  Not Satisfactory 

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Note: This document serves as the rating sheet of the teacher in evaluating the trainee’s performance. This
must be accomplished for each trainee.

Oral Questions Satisfactory response

The trainee should answer the following questions: Yes No

 
What is the function of the oil pump?
What is the function of the splash type lubrication system?
 
------is removable pressure relief valve and located on the radiator tank.
 
Explain the OHS?
 
The trainee’s underpinning knowledge was:
Satisfactory  Not Satisfactory 
Feedback to trainee:

The trainee’s overall performance was:

Satisfactory  Not Satisfactory 

Student signature: Date:

Teacher signature: Date:

Teacher Evaluation Guide

Key to Corrections

Learning Guide #1-3

Self- check
Multiple choice type True false type
1. E 1, True
2. B 2, True
3, A 3, False
4, D 4, True
5, A 5, True
Matching type Short answer type
1. D 1, Bellow type thermostat and Wax type thermostat
2. B 2, Preventing heat from engine parts
3. E 3, Preventing frication and wear b/n engine parts
4. G 4, Camshaft or Crankshaft
5. F 5,Radiator ,Water pump, Thermostat, Oil pump, Oil
Sump, Oil filter etc.

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TEST ITEM ANSWER MARK

Multiple Choice
1 E

2 B

3 A

4 D

5 A

(Multiple Choice) Total points

Key Answer for Knowledge Test

TEST ITEM ANSWER MARK

Matching Type
1 D
2 B
3 E
4 G
5 F
(Matching Type) Total points

TEST ITEM ANSWER MARK

Short Answer Questions

1 Bellow type thermostat and Wax type thermostat
2 Preventing heat from engine parts
3 Preventing frication and wear b/n engine parts
4 Camshaft or Crankshaft
5  Radiator ,Water pump, Thermostat,
 Oil pump, Oil Sump, Oil filter etc.
(Short Answer Questions) Total points

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 Recommended answers for oral questions

No. Question Recommended Answer

What is the function of the oil pump?
1
What is the function of the splash type
2 lubrication system?
------is removable pressure relief valve
3 and located on the radiator tank.
4 Explain the OHS?
Preventing frication and wear b/n engine
parts
Lubrication system which the oil is being
splashed from the oil pan into the lower part
of the crankcase.
Radiator pressure cap
Occupational health safety

Assessment Summary Results (form part of the Teacher’s Report)

Student’s Name
Teacher’s Name Gelsimo G.
TVET Program Title Automotive Engine and Electrical / Electronic Servicing Level- I
Batch Class 2006E.C
Module Title Apply Lubricants and Coolants
Date of Assessment
The performance of the trainee is – Satisfactory Not Satisfactory

A. Demonstration with Oral questioning

B. Written Test

Did the trainee’s overall performance meet the

 Yes  No
required evidences / standards?

OVERALL EVALUATION  COMPETENT  NOT YET COMPETENT

General Comments [Strengths / Improvements needed]

Student's signature: Date:

Teacher’s signature: Date:

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