1. Score:Difficulty_____ XQuality_____= ______
Part 1: Vehicle Information
Studentname(s):
Eugene Alston
Vehicle year,make,model:
1997 Toyota Camry
Customer’s name &repairordernumber:
TuckerHolyoak
Customer’sconcern(s):
Coolantleakinfrontof engine whenthe engine isrunning.Needstoaddcoolanteveryfew days.
Part 2: Documentation
Documentthe stepsyoutookto diagnose andrepairthe vehicle—inthe orderthatyoudidthem. Write every
step—evenif you made mistakesand nowwishyouwouldhave done itdifferently. Beginwhenyoupickedupthe
keys,endwhenyoureturnedthem. BEDETAILED & INCLUDE PHOTOGRAPHS!
We beganour workon Tucker’scar byverifyingthe leak.Assoonaswe drove the car intothe shopwe couldsee
that there wascoolanton the ground.We poppedthe hoodtosee where the leakwascomingfrom.We couldn’t
tell where itwasleakingsowe liftedthe carinhopesthatit wouldgive usa betterangle tosee where the car was
leaking. We sawwhatwe thoughtwas radiatordamage.It wasactuallyjusta damagedAC coolerthatsitsin frontof
the radiator.
We continuedontothe bottomof the engine blockandfollowedthe leakbackuptothe topof the engine where it
had beenleakingfrom. We foundthe thatthe engine wasleakingfromthe bypasshose.Itistuckedinbehindthe

2. alternatorsowe misseditwhenwe firstlookedfromthe topof the engine. We hadto remove the alternatortoget
access to the leakarea.ProDemand helpedusoutwiththe procedure.
Upon inspectingthe leakarea,we noticedthatthe waterpump(tothe left) lookedverycleanlike itwasanew
waterpump.We askedthe customerif the waterpumphad recentlybeenreplaced.The customerconfirmedthata
monthpriorhe had the waterpumpreplacedandthe coolantleakstartedtwoweeksafterthat.
We lookedthe vehicle upinProDemandtosee whatcomponentswereinthe waterpump/thermostattosee
whatcould be leaking.Where are leakwaslocateditmade the mostsense thatour coolantbypassgasketand/oro-
ringhad to be the cause of the leak.

3. Once we pulledoff the waterbypasshose itbecame veryclearthe cause forthe coolant leak.Whoever
performedthe waterpumprepairre-usedthe existinggasketando-ring.Theyusedaliquidgasketagenttotry to
reseal the gasketandeitherre-usedatorno-ringor tore the o-ringinthe reinstallationprocess.We thoughtthis
was oddbecause everywaterpumpwe searchedforcame withnew seals.

7. We had some trouble gettingthe partswe neededbecausethe gasketisonlyavailable with the entire water
pumpassembly.We spentquite abitof time searchingforit as an individual itemwithnoavail.We wentaheadand
orderedthe cheapestwaterpumpassemblywe couldfindthatcontainednew sealsforourrepair.
Withthe sealsreplacedwe neededtoputeverythingbacktogether.Onourcar the alternatorpulleyalsoserves
as the belttensioner.Incheckingforthe speconthe belttensionwe neededaspecial tool thatchecksthe tension
on the belt.We didn’thave thattool available tousand were toldto gooff of feel.

8. We tightenedthe tensionerdownuntil the beltwastight.All wasfine until we startedthe car.Once there wasstress
on the auxiliarycomponents,the belthadlostitstension.Anothersmall adjustmentwasable tofix thisissue
quickly.
Withthe engine coldtothe engine atnormal operatingtemperature,we watchedthe leaktomake sure thatit
heldthe seal.Thisverifiedourrepair.
The customeralsohad a concernof a jumpytransmissionandfeltthathisengine mountsmayneedtobe
replaced.We verifiedthisconcernbyputtingthe carin drive andreverse several timeswithaloadonthe engine
and the brakesapplied.Thisallowedustowatchto movementof the engine.The customerwascorrectas the front
and rear engine mountsshowedexcessiveplay.

9. Replacingthe engine mountswasafairlystraightforwardprocessthatinvolvedusliftingthe carand placinga
transmissionmountunderthe engine torelieve the stressoff of the mounts.The rear mountrequiredsome
creativitytoextractbecause itslocationisbetweenthe rearexhaustmanifoldandthe frame of the vehicle.
Removingthe frontrightwheel gave usbetteraccessandleverage tobe able toapplyenoughtorque toremove the
bolts.
We verifiedthe repairbydoingthe loadtestprocedure onthe engine mountstoverifythe excessplayhadbeen
takencare of.Once we verifiednomore excessplay,we tookthe carfor a testdrive to ensure there wasnothing
that we missedbefore the carwentbackto the customer.The customerasveryhappy withthe repair,us
communicatingwithhimeachstepof the wayand the timelymannerthatittook to complete the repair.
Part 3: Reflection & Analysis
 What parts of thisprocesswentwell?
Our diagnosisof the leakandthe cause for the “jumpytransmission”wasveryprecise.Didnottake uslongto
accuratelyfigure outthe source of ourproblems.
 Whichstepswere mostcritical inyour diagnosisprocess?

10. Inspectingthe sealsandlearningthatthe waterpumphadrecentlybeenreplacedbysomeone else andthe leak
startedafterthat replacement.
 What keptyoufrom beingaseffectiveasyoucouldhave been?
Notknowingthatthe water bypassgasketwasnot soldseparatelyslowedusdownquite abit.We searchedfor
aboutan hour tryingto finditseparatelytosave the customerthe moneyof havingtopurchase anotherwater
pump.
 Nowthat youcan lookbackon howthisprojectunfolded,whatwouldyouliketo dodifferentlynexttime?
It may have beenagood ideatotightenthe belta little bitmore thanwe didthe firsttime because once the engine
runs the tensiononthe beltbecomesslightlyless.