Solution Manual for Automotive Technology A

Systems Approach, 6th Edition

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Solution Manual for Automotive Technology A Systems Approach, 6th Edition

14

LUBRICATING AND COOLING SYSTEMS

CHAPTER OVERVIEW

This chapter describes the functions of the components of a typical lubricating and cooling

system. Also explained are service requirements such as oil types, oil pump inspection and

installation, and cooling system inspection and service.

CHAPTER OBJECTIVES

▪ Name and describe the components of a typical lubricating system.

▪ Inspect an oil pump

▪ Install an oil pump

▪ Describe the purpose of a crankcase ventilation system.

▪ Describe the operation of the cooling system.

▪ List and describe the major components of the cooling system.

▪ Describe the purpose of the water pump, radiator, radiator cap, and thermostat.

▪ Diagnose the cause of engine overheating.

▪ Explain why operating temperatures are critical in today’s engines.

▪ Test and service the cooling system.

Erjavec/Thompson 14 – 1

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INSTRUCTIONAL OUTLINE WITH TEACHING HINTS

I. Lubrication System

A. Engine Oil

B. Oil Pump

1. Types of Oil Pumps

2. Pressure Regulation

C. Oil Pan or Sump

1. Pan Baffles

2. Dry Sump

D. Oil Filter

E. Oil Coolers

F. Engine Oil Passages or Galleries

G. Dipstick

H. Oil Pressure Indicator

II. Oil Pump Service

A. Inspection

Hint: Provide a demonstration of the proper way to inspect the oil pump.

1. Pickup Unit

III. Installing the Oil Pump

A. Crankshaft-Driven Pump

B. Can-Driven Pumps

1. Distributor-Driven Pump

Erjavec/Thompson 14 – 2
 C. Basic Lubrication System Diagnosis and Service

D. Oil Passages, Galleries, and Lines

E. Oil Consumption

1. Oil Usage

F. Sludge

Hint: Bring in parts with different levels of sludge buildup to indicate normal or

excessive levels of sludge.

IV. Flushing the System

A. Oil Cooler

V. Cooling Systems

A. Coolant

B. Thermostat

C. Water Pump

1. Electric Water Pumps

D. Radiator

1. Transmission Cooler

E. Radiator Pressure Cap

1. Expansion Tank

F. Hoses

1. Water Outlet

2. Water Jackets

G. Hose Clamps

Erjavec/Thompson 14 – 3
 H. Belt Drives

I. Heater Systems

J. Cooling Fans

1. Electric Cooling Fans

K. Hydraulic Cooling Fans

1. Temperature Sensors

L. Temperature Indicators

VI. Cooling System Diagnosis

A. Testing for Electrolysis in Cooling Systems

VII. Inspection of Cooling System

A. Effects of Overheating

B. Temperature Test

C. Radiator Checks

D. Checking Hoses

E. Belt Drives

F. Checking Fans and Fan Clutches

1. Electric Cooling Fans

G. Testing the Thermostat

H. Water Pump Checks

Hint: Provide a presentation about the potential dangers of checking various parts of the

cooling system before the engine has cooled down.

Erjavec/Thompson 14 – 4
VIII. Testing for Leaks

A. Pressure Testing

1. Leak Detection with Dye

2. Combustion Leak Check

B. Testing the Radiator Pressure Cap

C. Water Outlet

IX. Cooling System Service

A. Hoses

1. Hose Clamps

B. Thermostat

1. Replacement

C. Repairing Radiators

D. Replacing the Water Pump

E. Draining the Coolant

1. Coolant Recovery and Recycle System

F. Flushing Cooling Systems

1. Flushing Chemicals

G. Refilling and Bleeding

H. Special Precautions for Hybrid Vehicles

I. Coolant Exchangers

Erjavec/Thompson 14 – 5
ANSWERS TO TEXTBOOK REVIEW QUESTIONS

1. Increase the difference between the temperature of the coolant and the outside air flowing

through it. The efficiency is also dependent on its basic design, the area and thickness of

the core and the amount of coolant going through the radiator.

2. False. Oil pressure is dependent upon oil clearances, the pump’s pressure regulator valve,

and oil viscosity. The type of pump determines oil volume not pressure. A rotor type

pump produces greater flow than a gear pump.

3. To determine whether the water pump is creating good circulation, warm up the engine

and run it at idle speed. Squeeze the upper radiator hose with one hand and accelerate the

engine with the other. If a surge of coolant is felt at the hose, the pump is circulating

coolant.

4. d. All of the above

5. Electrochemical degradation (ECD) is the primary cause of hose failures. It occurs

because the hose, engine coolant, and the engine/radiator fittings form a galvanic (battery)

cell. This chemical reaction causes very small cracks in the hose, allowing the coolant to

attack and weaken the reinforcement in the hose.

6. False. The fan clutch operates only when the engine and radiator are heated up and not as

stated.

7. b. Each pound of pressure on engine coolant raises the boiling point about 3°F (–1.6°C).

8. c. Automotive water pumps are usually belt driven by the crankshaft or an electric

motor.

9. c. The use of a dye and black light is only effective for external leaks.

10. Since the oil pump is a positive displacement pump, an oil pressure relief valve is used to

prevent excessively high system pressures from occurring as engine speed is increased.

Erjavec/Thompson 14 – 6
11. Engine overheating can cause the following problems: detonation, preignition, blown

head gasket, OHC cam seizure and breakage, blown hoses, radiator leaks, cylinder

damage due to swelling pistons, sticky exhaust valve stems, and engine bearing damage.

12. d.

13. False.

14. a. Air in the system could not be caused by a faulty thermostat.

15. To use the air bleeds, make sure the engine is warm and the heater is fully on. Connect a

hose to the end of the valves and place the open end in a catch can. Open all bleed valves.

Slowly put the required amount of coolant into the radiator until the coolant begins to

leak out of the valves. Then close the valves and top off the system.

ANSWERS TO ASE-STYLE REVIEW QUESTIONS

1. c. Both technicians are correct. A straightedge and feeler gauges are used to determine

pump cover flatness, and an outside micrometer is used to measure the diameter and

thickness of an oil pump outer rotor.

2. b. Excessive oil consumption can result from external and internal leaks, or worn piston

rings, valve seals, or valve guides. If the valve guides are worn, oil will be drawn into the

cylinder during the intake stroke.

3. a. To check for the conditions prone to electrolysis set a voltmeter so it can read in

tenths of a volt. Attach the negative meter lead to a good ground. Place the positive lead

into the coolant. Look at the meter while the engine is cranked with the starter and record

the readings. Take another reading with the engine running and all accessories turned on.

4. b. When installing an oil pump in an engine, the pump should be submerged in clean oil

and the pump shaft rotated to fill the pump body. Filling the pump with anything other

than oil will make it very difficult for the oil to move oil.

Erjavec/Thompson 14 – 7
5. c. Both are correct.

6. c. Both are correct.

7. a. If the cooling fan didn’t work correctly, the engine would tend to overheat in heavy

traffic and during idle speeds.

8. c. Both are correct.

9. c. Both are correct. The leaking radiator could cause an overheating problem.

10. c. Both are correct.

ADDITIONAL TEACHING HINTS

▪ Examine and discuss an oil pump pressure valve.

▪ Examine an oil pressure system, pointing out the location of sending units, oil lines, and

gauges.

▪ Completely inspect several types of oil pumps according to manufacturer’s

recommendations.

▪ Examine the various types of radiator core constructions.

▪ Pressure test the cooling system for leaks.

ANSWERS TO TECH MANUAL REVIEW QUESTIONS

1. Worn main bearings, worn rod bearings, worn oil pump, restricted oil pick up

2. An engine may run too cold, increasing fuel use and emissions.

3. The radiator cap allows pressure to build in the system as the coolant expands as it gets

hot. The increase in pressure raises the boiling point of the coolant.

4. Electrolysis occurs when a current flows through the cooling system components. This

can cause damage as the outer layers of cooling system materials are removed.

Erjavec/Thompson 14 – 8
5. A hybrid may have a coolant tank that keeps hot coolant for several days to aid in quick

engine warm up. Also, hybrids have two cooling systems, one for the ICE and one for the

hybrid drive system. The two systems are separate and use different coolants.

ANSWERS TO TECH MANUAL CONTENT QUESTIONS

CA 14–1

11. Oil that is too thin will not provide enough lubrication within bearing clearances. Oil that

is too thick may not be able to form an oil film in very small bearing clearances

12. excessive oil consumption, rapid wear on cold starts

CA 14–2

2. water molecules bond together, oil molecules which are made of long chains of

hydrocarbons and have a differing charge repel against the water and separate

CA 14–3

12. both need room for expansion, if filled to the top the coolant would overflow when hot

13. radiator cap

14. A leak will allow coolant out and air back in.

CA 14–4

1. Oil allows heat to move from engine components into the oil which is then dissipated into

the air circulation through the crankcase and by an oil cooler if present.

2. Heat is removed from engine components and absorbed by the coolant which then

transfers the heat to the surrounding air of the surface of cooling system components.

3. Radiator fins provide a large surface area over which air moves and removes heat. If the

fins are damaged air will not be able to flow across them.

Erjavec/Thompson 14 – 9
Solution Manual for Automotive Technology A Systems Approach, 6th Edition

4. Answers will vary but may include: oil and coolant type and condition, surface area of

components, air flow across radiators and oil coolers, oil and coolant flow rates.

SECTION 2

Answers to ASE Prep Test Questions

1. c

2. c

3. a

4. c

5. a

6. a

7. c

8. b

9. c

10. a

11. c

12. b

13. b

14. b

15. b

16. a

17. c

18. c

19. b

20. b

Erjavec/Thompson 14 – 10

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