COMPETENCY-BASED LEARNING MATERIALS

SECTOR:
AUTOMOTIVE AND LAND TRANSPORT SECTOR
QUALIFICATION:
MOTORCYCLE AND SMALL ENGINE SERVICING
UNIT OF COMPETENCY:
SERVICE COOLING SYSTEM
MODULE TITLE:
SERVICING COOLING SYSTEM
PREPARED BY:

(put your school logo (school name)

here) (school address)
 (Qualification Title)
COMPETENCY-BASED LEARNING MATERIALS

List of Competencies

No. Unit of Competency Module Title Code

Perform Periodic Performing Periodic ALT723335
1. Maintenance Maintenance
Service Fuel System Servicing Fuel System ALT723336
2.
Service Lubrication Servicing Lubrication ALT723337
3. System System
Service Ignition System Servicing Ignition System ALT723338
4.
Service Exhaust System ALT723339
Servicing Exhaust
5.
System
Service Suspension ALT723340
System Servicing Suspension
6.
System
Service Brake System ALT723341
Servicing Brake System
Service Wheels and Tires ALT723342
Servicing Wheels and
Tires
Service Clutch System ALT723343
Servicing Clutch System
Service Electrical System ALT723344
Servicing Electrical
System
Service Final Drive ALT723345
Servicing Final Drive
Service Cooling ALT723346
System Servicing Cooling
System

Overhaul Overhauling
Motorcycle/Small Motorcycle/Small ALT723347
Engine Engine

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 HOW TO USE THIS COMPETENCY- BASED LEARNING
MATERIALS

Welcome!
The unit of competency, "_Service Cooling System_________________________
(Unit of Competency)", is one of the competencies of Motorcycle and Small
Engine Servicing______________________________ (Qualification), a course
which comprises the knowledge, skills and attitudes required for a TVET
trainer to possess. The module, _______________________ (Module Title),
contains training materials and activities related to identifying learners
requirements, preparing session plan, preparing basic instructional
materials and organizing learning and teaching activities for you to
complete. In this module, you are required to go through a series of learning
activities in order to complete each learning outcome. In each learning
outcome are Information Sheets, Self-Checks, Task Sheets and Job Sheets.
Follow and perform the activities on your own. If you have questions, do not
hesitate to ask for assistance from your facilitator.

Remember to:

Read information sheets and complete the self-checks. Suggested

references are included to supplement the materials provided in this
module.

Perform the Task Sheets and Job Sheets until you are confident that your
outputs conform to the Performance Criteria Checklist that follows the
sheets.

Submit outputs of the Task Sheets and Job Sheets to your facilitator for
evaluation and recording in the Accomplishment Chart. Outputs shall
serve as your portfolio during the Institutional Competency Evaluation.
When you feel confident that you have had sufficient practice, ask your
trainer to evaluate you. The results of your assessment will be recorded in
your Progress Chart and Accomplishment Chart. You must pass the
Institutional Competency Evaluation for this competency before moving to
another competency. A Certificate of Achievement will be awarded to you
after passing the evaluation. You need to complete this module before you
can perform the module on ____________________________(Next Module Title)

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 MODULE CONTENT

UNIT OF COMPETENCY SERVICE COOLING SYSTEM

MODULE TITLE: SERVICING COOLING SYSTEM

MODULE DESCRIPTOR: This unit covers the competence required to

service the cooling system. It includes checking the system cooling
components and ensures smooth operation of the system,

NOMINAL DURATION: 16 HOURS

LEARNING OUTCOMES:
At the end of this module you MUST be able to:
Inspect, check and service cooling system components.
Diagnose faults from symptoms and decide preferred action
Repair cooling system components

ASSESSMENT CRITERIA:
: REPAIR COOLING SYSTEM COMPONENTS

ASSESSMENT CRITERIA:

1. Cooling system repaired without causing damage to any of the other

components
2. Repairs carried out according to manufacturers current specification
3. Appropriate guards and cover are used

CONTENTS:

1. Cooling system component repair, removal and replacement procedure

2. Safety precautions
3. Use of manufacturers specification manual

CONDITIONS:

Students/ trainees must be provided with the following:

1. Motorcycle
2. Combination wrench

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3. Socket wrench
4. Pliers
5. Screw drivers
6. Hammer
7. Parts replacements
8. Manufacturers Specification manual
9. Shop uniform
10. Learning module

METHODOLOGIES:

1. Self paced learning

2. Discussion
3. Demonstration
4. Individual practice

ASSESSMENT METHODS:

1. Observation
2. Demonstration
3. Interview/ Questioning
4. Written test

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 LEARNING OUTCOME NO.3

Contents:

1. Cooling system component repair, removal and replacement procedure

2. Safety precautions on removal and replacement of cooling system
component;
3. Use of manufacturers specification manual

Assessment Criteria

1. Cooling system repaired without causing damage to any of the other

components
2. Repairs carried out according to manufacturers current specification
3. Appropriate guards and cover are used
Conditions

Students/ trainees must be provided with the following:

1. Motorcycle
2. Combination wrench
3. Socket wrench
4. Pliers
5. Screw drivers
6. Hammer
7. Parts replacements
8. Manufacturers Specification manual
9. Shop uniform
10. Learning module

Assessment Method:

1. Self paced learning

2. Discussion
3. Demonstration
4. Individual practice
5.
6.
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 Learning Experiences

Learning Outcome

Learning Activities Special Instructions

Read information sheet 12.3-1 on
safety precautions in replacing and
removing component of cooling
system
Answer Self Check12.3-1 on safety
precautions in replacing and
removing components of cooling
system
Compare answers to Answer Key12.3-1
Remember on safety precautions
in replacing and removing
components of cooling system
Try to answer with out looking at
the answer key
Ask your trainer the available
video and power point presentation

Multimedia presentation on Ask your trainer the available

Procedures in repairing cooling video and power point presentation
system component
Read information sheet 12.3-2 on Try to memorize the terms listed in
using manufacturer;s specification manufacturers specification
manual manuals
Answer Self Check12.3-2 on using Remember on how to use
manufacturers specification and manufcturers specification
manual manual
Compare answers to Answer Key12.3- Double check the answer in case
2 you forgot to answer correctly
using self-check
Tasksheet 12.3-2 on Perform Always wear PPE when performing
Component Repair, Removal and the task

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 Information Sheet 12.3-1
Safety Precautions in replacing and Removing Component of
Cooling System Based on Manufactures Specification

Learning Objectives:
After reading this information sheet, you must be able to:
1. understand the safety precautions in removing and replacing
cooling system components without causing damage to any of the other
components;
2. explain the steps in removing component parts of cooling system;
3. follow the manufactures specification manual in replacing parts of
cooling system.

(Introductory Paragraph
This information sheet covers the safety standards and proper steps in
replacing parts of cooling system with reference to the manufacturers
service manual. Proper maintenance service procedure in safe efficient
operation of all motor vehicles, as well as to the safety of the person
performing the work.

COOLING SYSTEM MAINTENANCE AND SAFETY

PROCEDURE
Why maintain your cooling system?
At least every two years, your vehicle's cooling system should be drained,
flushed and refilled to redamage to the engine.
These instructions will help you drain, flush and refill most popular
vehicles. Although replacing coolant isn't difficult, be sure to READ these
instructions completely before you begin working.
Make sure you get the correct coolant for your car. Check with your local
NAPA Auto Parts store for the specific coolant your vehicle requires.

TOOLS AND EQUIPMENT

TO FLUSH YOUR COOLING SYSTEM YOU WILL NEED:
A container large enough to catch the old coolant as it drains out of the
radiator.
A garden hose or large bucket for flushing the system.
A jug of new coolantA bottle of radiator flush
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 SAFETY PROCEDURE WHILE WORKING THE COOLING
SYSTEM OF A VEHICLE
Proper maintenance and service procedures are vital to the safe,
efficient operation of all motor vehicles, as well as to the safety of the person
performing the workyou.
Whenever you are working on your vehicle, we recommend that you
follow these important safety rules:
1. Do have a first-aid kit handy.
2. Do be careful when working around hot or sharp objects.
3. Do follow the manufacturer's instructions for all products.
4. Do use safety stands under the frame or drive-on ramps if you
must raise your vehicle.
5. Don't run the engine without proper ventilation.
6. Don't smoke when working around the engine.

Flushing the System

1. Retighten the drain plug or petcock at the bottom of the
radiator. If the lower radiator hose was disconnected to facilitate
the draining of the cooling system, reconnect it.
2. Add water until the radiator is almost full.
3. Add one bottle (12 fl. oz.) of flushing product to the radiator.
Flushing the radiator
4. Replace the radiator cap, start the engine and run at idle with
the heater control on HOT for 10 to 20 minutes.
5. Stop the engine, open the drain plug or petcock, catch the fluid
in a large container and dispose of it properly. WARNING: THE
FLUID WILL BE HOT! TAKE SPECIAL CARE TO AVOID
BURNING YOURSELF.
6. After the coolant has completely drained out of the radiator,
place a garden hose in the radiator filler neck and flush out the
system.
7. Flush the radiator until the water coming out of the drain hole,
petcock or lower radiator hose opening is clear. If a garden hose
is not available, use a clean bucket to pour fresh water into the
radiator filler neck.
8. Inspect the rubber gasket and seal on the inside of the radiator
cap for cracks or deterioration. If you replace the cap, make
sure the new one has the same pressure rating as the old one.
The pressure rating is stamped on the top of the cap.
9. Inspect all the radiator hoses for cracks or deterioration and
replace them if necessary.
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 SAFETY CHECK BEFORE DOING REPAIR AND REPLACEMENT OF PARTS OF
COOLING SYSTEM OF A VEHICLE

1. Never try to assess the serviceability of a coolant hose while the engine is
hot. Let it to cool down so that you can handle the hoses comfortably and
safely.
2. Always ensure the engine is turned 'off' before attempting to check the
radiator hoses.
3. Always make sure that you wear the appropriate personal protection
equipment before starting the job. It is very easy to hurt yourself even when
the most exhaustive protection measures are taken.
4. Always make sure that your work area/environment is as safe as you can
make it of not use damaged, broken or worn out workshop equipment.
5. Always follow any manufacturer's personal safety instructions to prevent
damage the vehicle you are servicing.
6. Make sure that you understand and observe all legislative and personal
safety procedures when carrying out the following tasks. If you are unsure of
what these are, ask your supervisor.

RADIATOR MAINTENANCE

1. Most all water cooled engines have a radiator, thermostat, fan, pump, and the
connecting hoses and pipes. The fans are usually controlled by a heat activated,
thermostatic switch located in the radiator. For the most part they are trouble free,
but there are a few things you need to know.

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2. Always run antifreeze, in a 50/50
mix, in the radiator. If you use water
and forget to put antifreeze in and
things freeze... it could crack your
engine block/cylinder and ruin your
engine. Always use a motorcycle type
antifreeze or a car type without
silicates. Some car types contain
silicates that can accelerate wear on
your water pump. This probably doesn't
matter for dirt bikes because they just don't put on that many miles, but in a street
bike it's important. Use an antifreeze designed for an aluminum engine without
silicates. There are several brands on the market, just read the label. Always use
distilled water, if possible. This cuts down on the buildup of mineral salts that can
coat the inside of the radiator, cutting down it's efficiency. It's also a good idea to
replace the hoses every couple of years they tell me but I don't think very many
people do. It's still a good idea. Same with the antifreeze fluid too.

3.If things start running hot and the fluid level is ok, check the thermostat. You
can check it by suspending the thermostat in a pan of water with a
thermometer.Then heat the water and see if it opens at the temperature that's
marked on the thermostat. If it does, check to see if the pump is pumping. Take the
radiator cap off and look down the fill tube. Not the overflow (coolant reservoir) tank
cap, but the pressure cap on the radiator. Do this with the thermostat out and you
should be able to see the fluid flow through the radiator. You could do it with the
thermostat in but you have to let everything heat up so the thermostat will open.
Could be fun! If there is flow, then the pump is working, check for a plugged
radiator. Some you can fix and others you have to replace and they're not cheap.

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4.If the temperature goes up just when you are idling at a stop light and the fluidL
level l is OK, check it see if the fan works. Sometimes you can just ground the
wire going to the fan thermostat switch, or pull the wires at the fan and connect
them directly to the battery. If the fan works, replace the sending unit.

You can run without a thermostat but it's not a good idea because the thermostat
controls the flow of water from the radiator to the engine. Some old line mechanics
theorize that if the flow is too fast, the water doesn't stay in the radiator long
enough to cool off so your engine could end up running too hot. Others disagree
and feel the engine will run too cold and never reach operating temperature. It may
depend on how efficient the system is to begin with. Also, when starting from cold,

it would keep the engine too cold, as the engine would have to heat up all the
coolant in the radiator as well as the engine coolant. Take your pick, but all agree
you need a thermostat to keep the engine temperature right.

COOLING SYSTEM PARTS AND FUNCTIONS

Coolant Reservoir

Most Cooling Systems have a Coolant Reservoir Tank, also called a Recovery or
Overflow Tank. This tank catches coolant that overflows from the radiator when it
is hot then, as the engine cools, the coolant is sucked back into the radiator.
Radiators operate under pressure. The Radiator Cap holds the pressure in until it
reaches whatever pressure the cap is set for, usually ten to twenty pounds. When
the engine gets hot from running, the internal pressure of the Radiator goes over
the pressure of the Radiator Cap. The cap then releases that pressure into the

Coolant Over Flow Tank.

When the radiator is full of Anti-Freeze the Anti-Freeze is vented into the overflow
tank. When the engine is turned off and everything cools down the Anti-Freeze is
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sucked back into the Radiator. The Over Flow Tank
should have just a bit of Anti-Freeze in it when cold.
There is usually a line on the tank. Keep the coolant
level at this line. That way it has room for the over
flow when hot but still has all the Anti-freeze the
Radiator needs when it is cold.

When you refill your radiator with new coolant

remember to recheck the coolant level in the radiator again after you have run the
engine up to operating temperature and then allowed it to cool off. Also recheck the
fluid in the overflow tank too.

Radiator Parts Engines run usually best with a 190 degree thermostat. Most bike
thermostats only come in one temperature... the one they give you! I just mention
this because some people think that running a cooler thermostat helps the engine
cool better, but it doesn't really matter. Combustion runs a lot hotter than that
water. 10-15 degrees doesn't mean a thing to that engine, but where I live it's
cold... I really like a nice HOT heater! But, as bikes don't have heaters (I guess they
could though.) this whole paragraph doesn't really matter! Anyway...

If you start your engine and water starts coming out the radiator cap you might
have a blown head gasket or a cracked head. Somehow combustion pressure is
getting into the cooling system. Of course, not always... people tell me all the time
I've got a cracked head, but I ride an air cooled BMW, and I've checked. Its head is
not cracked... I wonder what they mean?

Water Pump Impeller

Weep HoleSome Water Pumps, mostly on single

cylinder dirt bikes, are cast into the side of the
crankcase. Others
areseparateunitsthatboltonlikecarwaterpumps.Some
water pumpmps have a "Weep Hole",also known as
a"TatleTale"or "Telltale" hole, in the side of the pump
itse lfor in the pump housing.Ithere is any leakage
of coolant from this "Weep Hole" the pump sealsnd
bearings are failing. The pump will need to be
replaced, and soon!

Radiator

You may have more that one radiator. Many dirt bikes have
two.

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One Radiator Two Radiator

Cylinder Coolant Passages Coolant Fouled Spark Plug Always run the engine
easy till the engine and coolant warm up. If you push things hard with a cold
engine you could get what some call "Cold Seizure". Some think the piston expands
faster than the cool cylinder, others think the problem is poor lubrication. Doesn't
make much difference what you think causes it if you end up walking, so warm the
engine up before you push it OK? Good idea even with an air cooled engine.

If your head gasket is leaking a bit it can foul out your spark plug.

Heads and Cylinders are cooled with water through passages in the cylinder.
Sometimes they have O-Rings for head gaskets.

Most Fans are electric and a sensor on the radiator tells the Fan when to turn on or
off. Some Fans are mounted on an engine driven shaft and can break like this one
from a CX500 Honda.

Do not get the anti-freeze on painted surfaces. It could harm the paint. Also
remember that anti-freeze is very poisonous. Do not leave pans of it sitting around
where unauthorized personal (Like pet dogs) could get into it.

soda to completely neutralize the acid to a PH of 7.0. Now dispose of it in

accordance with EPA regulations! Remember, this is acid even if it is diluted... don't
get any on you. If you do, rinse with plenty of water and baking soda.

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Self- Check 12.3-1

TRUE OR FALSE : Write T if the statement is correct and F if the statement is

wrong.

___________1. To check the radiator hose, we should assure that the ignition switch
is turned off.
__________2. To prevent damage we should always observe personal safety tips;
___________3. It is necessary to check regularly the coolant level and radiator hose
for leaks ?
___________4. An example of hand protection equipment is earplugs.
_________5. In the product design process, the main purpose of visualization
is to present detailed drawing from which the client ca select.

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 ANSWER KEY (code no.)

1. T
2. T
3. T
4. F
5. T

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 TASK SHEET (code no.)
Title:

Performance Objective: Given required supplies and materials you

should be able to:
1.
2.
3.

Supplies/Materials :

Equipment :

Steps/Procedure:
1.
2.
3.
4.

Assessment Method:

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 INFORMATION SHEET 12.3-2

Motorcycle Service Specifications

Manufacturers Included
Arctic Cat, Harley-Davidson, Honda, Kawasaki, KTM, KYMCO, Polaris, Suzuki,
Victory and Yamaha

Specifications Included
Here are just a few of the specifications available to you:

Brakes Front Disc Deflection Limit

Brakes Front Disc Thickness Limit

Brakes Front Pad Lining Thickness

Brakes Rear Disc Deflection Limit

Brakes Rear Disc Thickness Limit

Brakes Rear Pad Lining Thickness

Capacities Brake Fluid

Capacities Coolant

Capacities Coolant Type

Capacities Engine Oil

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Capacities Engine Oil Classification

Capacities Engine Oil Grade

Capacities Final Drive Grease

Capacities Final Drive Grease Type

Capacities Final Drive Oil

Capacities Final Drive Oil Classification

Capacities Final Drive Oil Grade

Capacities Fork Oil Classification

Capacities Fork Oil Grade

Capacities Fork Oil Level

Capacities Fork Oil Volume

Capacities Primary Drive Oil

Capacities Primary Drive Oil Classification

Capacities Transmission Oil

Capacities Transmission Oil Classification

Capacities Transmission Oil Grade

Capacities Wheel Hub Fluid

Capacities Wheel Hub Fluid Classification

Electrical Battery Type

Electrical Fuse Size

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Electrical Ignition Coil Peak Voltage

Electrical Ignition Coil Resistance

Electrical Pickup Coil Peak Voltage

Electrical Pickup Coil Resistance

Electrical Regulated Voltage

Electrical Spark Plug Gap

Electrical Spark Plug Type NGK

Electrical Starter Motor Brush Length

Electrical Starter Relay Resistance

Electrical Stator Output

Electrical Stator Peak Voltage

Electrical Stator Resistance

Electrical TPS Resistance

Electrical Wiring Diagrams

Engine Cam End Play

Engine Camshaft Lobe Height Exhaust

Engine Camshaft Lobe Height Intake

Engine Camshaft Runout

Engine Clutch Friction Plate Thickness

Engine Clutch Spring Free Length

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Engine Clutch Steel Disc Warp

Engine Con. Rod Bearing Clearance

Engine Con. Rod Big End Bore Diameter

Engine Con. Rod Small End Free Play

Engine Con. Rod Small End I.D.

Engine Countershaft O.D.

Engine Crank Main Journal Bearin Clearance

Engine Crank Main Journal Bearing Clearance

Engine Crankpin Diameter

Engine Crankshaft Big End Side Clearance

Engine Crankshaft Radial Clearance

Engine Crankshaft Runout

Engine Cylinder Compression

Engine Cylinder I.D.

Engine Exhaust Valve Spring Free Length

Engine Exhaust Valve Spring Service Limit

Engine Intake Valve Spring Free Length

Engine Mainshaft O.D.

Engine Oil Pressure

Engine Oil Pump Rotor Clearance

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Engine Piston Ring End Gap 2nd

Engine Piston Ring End Gap Oil Rail

Engine Piston Ring End Gap Top

Engine Piston Ring-to-Groove Clearance 2nd

Engine Piston Ring-to-Groove Clearance Top

Engine Piston-to-Cylinder Clearance

Engine Primary Chain Deflection

Engine Rocker Arm I.D.

Engine Rocker Arm Shaft O.D.

Engine Rocker Arm-to-Shaft Clearance

Engine Shift Fork Claw Thickness

Engine Transmission Shaft Runout

Engine Valve Guide I.D.

Engine Valve Stem O.D.

Engine Valve Stem-to-Guide Clearance

Final Drive Chain Type

Final Drive Links

Final Drive Sprocket Front

Final Drive Sprocket Rear

Fuel Carburetor Clip Position

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Fuel Carburetor Float Height

Fuel Carburetor Fuel Level

Fuel Carburetor Jet Needle

Fuel Carburetor Leak Jet

Fuel Carburetor Main Jet

Fuel Carburetor Manufacturer

Fuel Carburetor Needle Jet

Fuel Carburetor Pilot Jet / Slow Fuel Jet

Fuel Carburetor Pilot Screw Turns Out

Fuel Carburetor Slide Cutaway

Fuel Carburetor Slow Air Jet

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 TASK SHEET 12.3-2
Title: Safety precautions in replacing and removing component of
cooling system following manufacturers specifications

Performance Objective: Given required supplies and materials

you should be able to:
1.Explain safety ruleprodedure while working on removing and replacing
cooling system component;
2. understand the procedure in removing cooling system component
3.follow the manufacturers specification manual in replacing
components in cooling system

Supplies/Materials radiator, radiator hose, coolant

Equipment : Radiator

1.Follow the safety procedure in removing and replacing parts of cooling

system based from manufacturers specification;
2.Prepare the required tools to be used in repairing parts of cooling
syste;
3. follow the manufacturer's instructions for all products.
4 Place a drain pan below the radiator and remove the drain plug;
5. Remove the radiator
6. Inspect the radiator
7.Carry out the visual inspection to ensure that it is suitable for
reinstallation;
8.Replace the radiator;
9..Refill the system

Assessment Method: Oral interview

Demostration

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Performance Criteria Checklist 12.3-2

CRITERIA
YES NO
Did you.
1.Follow the safety procedure in removing and replacing
parts of cooling system based from manufacturers
specification;

2.Prepare the required tools to be used in repairing

parts of cooling systeM
3. Follow the manufacturer's instructions for all
product;
4 Place a drain pan below the radiator and remove the
drain plug;
5. Remove the radiator;
6. Inspect the radiator;
7.Carry out the visual inspection to ensure that it is
suitable for reinstallation;
8.Replace the radiator;
9..Refill the system

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Evidence Plan

Competency Mototcycle and Small Engine Servicing NC-11

standard:
Unit of SERVICE COOLING SYSTEM
competency:
Ways in which evidence will be collected:
[tick the column]

Third party Report

Demonstration &
Observation &
Questioning

Questioning

Portfolio

Written
The evidence must show that the trainee
Cylinder head cooling fins checked for dirt and
cracks
Blower fan blade checked for cracks and dents
Blower fan mounting bolts checked for tightness
Mixing ratio of coolant solution and water
corrected
Radiator cap valve release pressure checked
Radiator hose checked for cracks / leaks
Radiator clamp checked for looseness
Radiator coolant checked for air
Radiator assembly tightness checked by using
radiator tester
Radiator clamp checked for cracks and fins for
damage
Reservoir tank checked for correct coolant level
and leakage
Overflow hose of reservoir tank checked for
cracks
Check water temperature gauge operation and
function
Auxiliary fan motor operation checked
Auxiliary fan motor relay switch checked
Mechanical seal checked for damage

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 Mechanical seal ring and O-ring checked
Bearing and seal condition checked
Water impeller checked for damage
Thermostat pellet inspected for cracks
Thermostat valve opening temperature checked
Function check on sending unit conducted
Radiator shroud unit checked / re-tightened
Radiator shroud checked for crack and dirt
Radiator shroud mounting bolts are checked and re-
tightened
Coolant concentration checked according to specified
ratio
Fault and defective component identified as per
symptoms
No damage done on other components during
diagnosis
Test equipment used are set as per required
specification in the manufacturers manual
Findings and report are forwarded to supervisor and
client is informed
Cooling system repaired without causing damage to
any of the other components
Repairs carried out according to manufacturers
current specification
Appropriate guards and cover are used

NOTE: *Critical aspects of competency

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 TABLE OF SPECIFICATION

Objectives/Content Percentage
Knowledge Comprehension Application
area/Topics of test

Safety precautions
in replacing and
removing 10% 10% 40% 60%
component of
cooling system

Use of
manufacturers
specification manual 15% 15% 10% 40%

TOTAL 100%

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ITEM ANALYSIS

Objectives/Content # of test
Knowledge Comprehension Application
area/Topics item

Safety precautions
in replacing and
removing 2 2 8 12
component of
cooling system

Use of
manufacturers
specification manual 2 2 4 8

TOTAL 20 Items

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Written Test
Name:_Caesar Madridano Date: 11-05-15 Score:___________
Multiple Choice: Using bank sheet of paper write the letter of the best
answer
1.It allows the radiator fan to turn with the belt at low engine speed.
a. radiator
b. fan clutch
c. front whe
2. If the coolant temperature falls below the normal temperature, What
will happen to the thermostat?
a. block the coolant flow
b. coolant will circulate
c.the temperature raise high
3. How do you diagnose a faulty radiator?
a. perform pressure testing
b. perform chemical testing
c.all of the above
4. It is an on/off type switch with a fixed temperature settings
a. sensor
b. thermostat
c.radiator hose
5. what should be the recommended design of a cooling system?
a. pressurized
b. with exhaust vent
c.none of the above
6. How to check the temperature indicator gauge?
a. temperature is in the normal operational range
b. if the radiator has no leaks
c. if the engine has no overheating
7. How many weeks should a coolant hoses be check?
a. a week
b. 2 weeks
c. 3 weeks

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8. What kind of materials constitute the making and production of a
radiator?
a. aluminum
b. carbon
9. How to facilitate the flushing of the cooling system ?
a. disconnect the lower radiator hoses
b. refer the owners manual
c. maintain the level of coolant
10. It is the sytem that maintain the proper engine temperature
a. cooling system
b. fuel system
c. none of the above

True or False: Using blank sheet of paper write true if the statement s
correct and write false if the statement is wrong.
_______1.Can we consider proper maintenance as vital to prolong the
serviceability of the cooling system?
_______2.To avoid accident due to pressurized water vapor from the
radiator, we should tighten the radiator cap
_______3 While working in the shop especially doing repair, are we
required to wear PPE equipment?
_______4.The correct way in removing the radiator is to allow the
coolant to stay inside the radiator.
_______5.If water alone is placed in a radiator without antifreeze would
it bring the engine block to crack.
_______6. When water is coming out the radiator cap. The possible cause
is blown head gasket.
_______7. When the engine is turned off the tendency of the antifreeze
is to solidify.
_______8. Running a cooler thermostat would help the engine to cool
better.
_______9.The meaning of deflection limit is front diameter of the front
Disc
______10. Through observation alone, can be estimate that the standard
specification of the pad lining thickness has change due to worn ou?

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Answer Key

Multiple Choice:
1.b

2.a

3.c

4. a

5.a

6.b

7.a

8.a

9.a

10.a

True or False
1.T

2.T

3.T

4.F

5.T

6.T

7.F
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8.T

9.F

10.T

Performance Test

Specific Instruction for the Candidate

Qualification MOTORCYCLE AND SMALL

ENGINE SERVICING

Unit of Competency SERVICE COOLING SYSTEM

General Instruction: In servicing cooling system of a motor vehicle you

should follow the procedure and safety tips in repairing and replacing
cooling system components

Specific Instruction:

To avoid damage you should follow the safety procedures in performing

cooling system replacement of parts based from manufacturers
specification manuals.

1.Follow the safety procedure in removing and replacing parts of

cooling system based from manufacturers specification;

2.Prepare the required tools to be used in repairing parts of cooling

system

3. Follow the manufacturer's instructions for all product;

4. Place a drain pan below the radiator and remove the drain plug;

5. Remove the radiator;

6. Inspect the radiator;

7.Carry out the visual inspection to ensure that it is suitable for

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reinstallation;

8.Replace the radiator;

9..Refill the system

List of Tools: Screw Driver, Pliers, wrenches

List of Equipment: Radiator

List of Materials: Radiator hose, radiator clamp, bolts and nuts, coolant

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 Performance Criteria Checklist for Performance Test

Name: Caesar Madridano Date of Assessment: October 05,

2015

CRITERIA
YES NO
Did you.

1.Follow the safety procedure in removing and

replacing parts of cooling system based from
manufacturers specification;

2.Prepare the required tools to be used in repairing

parts of cooling system

3. Follow the manufacturer's instructions for all

product;

4. Place a drain pan below the radiator and remove

the drain plug;

5. Remove the radiator;

6. Inspect the radiator;

7.Carry out the visual inspection to ensure that it is

suitable for reinstallation;

8.Replace the radiator;

9..Refill the system

10.Follow the safety procedure in removing and

replacing parts of cooling system based from
manufacturers specification;

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QUESTIONING TOOL
Satisfactory
Questions to probe the candidates underpinning knowledge
response
Extension/Reflection Questions Yes No
1. What are the components of cooling system that need to be
replaced?

2. What are the safety rules and procedures while working in

cooling system repair?
Safety Questions
3. Why we need to follow safety rules?
4. What will you do if coolant leaks in the radiator hose?
Contingency Questions
5. What will you do if you cant identify the trouble in the
cooling system?
6. What are you going to do if the requested materials are
incomplete?
Job Role/Environment Questions
7. Why we need to follow the procedure in removing cooling
system parts?

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 8. Why we need to use the correct tools for a job being
performed?
Rules and Regulations
9. Use the correct tools for the job assigned to you
10. Follow the rules and procedures in performing repair
The candidates underpinning Satisfactory Not
knowledge was: Satisfactory

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Expected Answer for Questioning Tool
Satisfactory
Questions to probe the candidates underpinning knowledge
response
Extension/Reflection Questions Yes No
1. Are the components of cooling system need to be replaced?
2. Are the safety rules and procedures followed?
Safety Questions
3. Did we follow safety rules?
4. Did you repair the leak radiator?
Contingency Questions
5. Did you identify the trouble in the cooling system?
6 Did your materials complete
Job Role/Environment Questions
7. Did we follow the procedure in removing cooling system
parts?
8. Did we used the correct tools for the job being performed?
Rules and Regulations
7. Did we follow the procedure in removing cooling system
parts?
8. Did we used the correct tools in doing repair?
The candidates underpinning Satisfactory Not
knowledge was: Satisfactory

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Inventory of Training Resources
Qualification Title: ____________________________

Resources for Skills practice of Competency #1

______________________________
Supplies and Materials As per TR As per Remarks
Inventory
Complete
Complete
Complete
Complete
Complete
Complete
Complete
Complete
Complete
Complete
Complete
Complete
Complete
Complete
Complete
Complete
Complete
Tools As per TR As per Remarks
Inventory

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 Equipment As per TR As per Remarks
Inventory

Note: In the remarks section, remarks may include for repair, for
replenishment, for reproduction, for maintenance etc.

Prepared By: ____________________

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WORKSHOP LAYOUT

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