autoLAB

Workshop Jobsheet 04
Module: ACS1 – Heating and Air Conditioning Systems
Practical Task: Vehicle Cooling System Inspection
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Name .......................................................... Date .................................................................

Vehicle make ............................................. Model ..............................................................
License plate ............................................ VIN ..................................................................

Health and Safety

Initial this box to confirm you have received instruction on automotive health and safety
requirements from your instructor.
Initial this box when you have read the section of the Health and Safety Sheet
associated with this task.

Practical Task: Vehicle Cooling System Inspection

Before you start the procedure ensure that the following items are available to you in your
workshop:
• Hand tools.
• Vehicle protection kit.
• Vehicle service manual.
• General wrench, socket and screwdriver set.
• Inspection light.
• Exhaust extraction system.
• Vehicle with a fully operational cooling system and Coolant Recovery system.
• Thermometer.
• DMM (Digital Multimeter).
• Heat resistant gloves.
• Goggles.
• Hydrometer or Refractometer.
• Cooling system hand pressure test equipment.
• Carbon Dioxide engine block tester / sniffer.

Before starting the practical work in this task:

- Read through the section(s) of the service manual that describes the operation of the specific
system(s) and/or components that you are going to work on. Be aware of any service precautions.
- Check the service history of the vehicle for any previous work and/or modifications.
- Use the Internet, CD-ROM’s and TSB’s to research and obtain up-to-date vehicle information.

Warning: Do not remove the radiator or any cooling system caps until the engine has cooled to
an acceptable/safe level. Hot coolant may cause serious burns. Ask your instructor if it is
safe to release the system cap.

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©2007 LJ Technical Systems Page 1 of 4
 autoLAB
Workshop Jobsheet 04
Module: ACS1 – Heating and Air Conditioning Systems
Practical Task: Vehicle Cooling System Inspection
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Depending on the test equipment you have available, some checks may need to be undertaken with
engine coolant at specified temperatures.
Refer to the vehicle service manual for the specified settings and data.
Check the boxes below as you complete the following tasks:
! Ensure the vehicle is on a hard, level surface.
! Apply the vehicle parking (emergency) brake.
! Ensure the vehicle’s gear selector is in the park/neutral position.
! Chock the vehicle’s wheels.
Note:
" Always remove a radiator/cooling system cap slowly.
" Always refer to the vehicle manufacturer data for test levels and coolant data.
" Always wear the appropriate protective clothing and gloves.

Pressure Cap Test

! Fit the cap to the pressure gauge, following the correct procedure.
! Pump the gauge and observe the pressure shown when the cap opens and releases.
! Repeat the test and compare these figures to the manufacturer's specification and replace the
cap if it is not opening within the limits given.
! Inspect the cap for splits or other damage to the rubber pressure seal. Replace the cap if any
damage is found.
! Inspect the vacuum seal fitted in the center of the cap and replace the cap if this is damaged.
! If no faults are found, refit the pressure cap and return the vehicle to service.

Instructor’s Mark: 4.1 /6

Cooling System Pressure Test

! Remove the system pressure cap and fit the adapter and gauge to the system.
! Pump up the pressure to the recommended system pressure (indicated in the service manual).
! Visually observe the system for leaks. Any leaks should be cured by replacement of the faulty part.
! Ensure the system holds its pressure for approximately 2 minutes.
! Observe the pressure gauge fitted to the system for pressure drop.

Instructor’s Mark: 4.2 /5

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©2007 LJ Technical Systems Page 2 of 4
 autoLAB
Workshop Jobsheet 04
Module: ACS1 – Heating and Air Conditioning Systems
Practical Task: Vehicle Cooling System Inspection
____________________________________________________________________________________________

Engine Coolant Temperature Check

! Ensure all items are replaced correctly from the previous checks.
! Start the engine and run until the coolant has achieved normal running temperature.
! Ensure the thermostat has opened.
Note: This can be observed from the dashboard gauge if fitted or can be measured with a
thermistor and gauge.
! To measure coolant temperature, attach the thermistor, thermometer or DMM temperature
probe to the manufacturer’s specified position on the cooling system, with tape.
! Read the temperature on the gauge and compare to the manufacturer’s recommendation.
! Ensure the reading conforms to the tolerance specified in the service manual.
Note: Combustion blow-by, radiator blockage or weak mixture may cause an extremely high
temperature.
! Switch off the engine.

Instructor’s Mark: 4.3 /7

Cylinder Leak Test Using A Leak Detector

! Allow the cooling system to cool to a safe level.
! Using gloves to prevent scalding, remove the system pressure cap.
! Study the instructions supplied with the leak detector.
! Ensure coolant level is appropriate for use with the leak detector – see leak detector instructions.
! Fill the glass tube with the special blue fluid to the marked line.
! Assemble the tester ready for use.
! Ensure the correct amount of fluid is placed in the equipment.
! Start the engine.
! With the engine at normal running temperature, carefully place the leak tester over the reservoir.
! Carry out the leak check by drawing coolant vapor through the dye liquid.
! Note your results.

Observe the color of the liquid in the tester for one minute. If the liquid turns yellow, then carbon
monoxide is present. If this happens discard the test fluid and recommend cylinder head removal
for investigation of combustion leakage.
Instructor’s Mark: 4.4 /11

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©2007 LJ Technical Systems Page 3 of 4
 autoLAB
Workshop Jobsheet 04
Module: ACS1 – Heating and Air Conditioning Systems
Practical Task: Vehicle Cooling System Inspection
____________________________________________________________________________________________

! Inspect CRR hoses. Hoses OK?

! Yes
! No If no, record problem(s):
.................................................................................................................................................

! Inspect for signs of coolant leaks. Any leaks?

! Yes If yes, record problem(s):

! No
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! Check for electrolytic reaction by use of the DMM (0.3V Max). Reading OK?

! Yes
! No If no, record problem(s):
.................................................................................................................................................

! Inspect the surface inside the reservoir for cleanliness and signs of rust deposits. Inside
surface of reservoir OK?

! Yes
! No If no, record problem(s):
.................................................................................................................................................

Instructor’s Mark: 4.5 /4

Instructor’s Signature: .......................................

Date: .......................................................................

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©2007 LJ Technical Systems Page 4 of 4