1. UNDERHOOD MAINTENANCE Cooling

2. COOLANT Raises Boiling Point Raises Boiling Point Lowers Freezing Point Lowers Freezing Point Two Types of Anti-Freeze Two Types of Anti-Freeze – Ethylene glycol – Propylene glycol Mixture best at 50/50 Protects to -34 F Mixture best at 50/50 Protects to -34 F Acts as Lubricant for Water Pump Acts as Lubricant for Water Pump Remove 70% of Engine heat Remove 70% of Engine heat 170C

3. What color COOLANT?

4. What color COOLANT Original Green AntiFreeze Original Green AntiFreeze Needs to be change every other year Needs to be change every other year GM DEX-COOL GM vehicles beginning in 1996 Protection for up to 5 years / 150,000 miles GM DEX-COOL GM vehicles beginning in 1996 Protection for up to 5 years / 150,000 miles G-05 Yellow Approved by Ford and DaimlerChrysler G-05 Yellow Approved by Ford and DaimlerChrysler Protection for up to 5 years / 150,000 miles Protection for up to 5 years / 150,000 miles Video from ZEREX

5. COOLANT info thanks to Kevin McCartney iatn G05 - Hybrid/low silicate/OAT/phosphate free/8.0 pH/Gold, orange,"kinda clear"or green. Chrysler (orange), Ford/ Mazda (Gold), MB (clear), Mazda (Gold), MTU marine (green). G48 - Hybrid/low silicate/OAT/phosphate free/8.1 pH/blue or green. BMW (blue), Volkswagon(G11) (blue), Audi (blue), Volvo (green), Saab (blue), Jaguar? (blue), Scania (blue), Man (blue). G34 - Carboxylate OAT/silicate free/phosphate free/8.6 pH/pink, red, etc. Porsche (Kinda red/brown/orange), Volkswagon(G12) (red), Audi (red), Saab (red), Dexcool - Carboxylate OAT/silicate free/phosphate free/8.6 pH/pink, red, orange,etc. very similar to G34 GM 1994 and later. G30 - Carboxylate OAT/silicate free/phosphate free/8.6 pH/red. High silicate light duty/phosphates/10.6 pH/green. Low silicate light duty/phosphates/1.6 pH/green. Partially formulated HD/low silicate/phosphates/10.6 pH/green. Fully formulated HD/low silicate/phosphates/10.6 pH/green. "OAT" stands for Organic Acid Technology.

6. insite - fan/eng block

7. RADIATOR Two Types Two Types – Crossflow – Downflow Construction Construction – Copper – Aluminum Hoses Hoses – Molded – Flexible 172C

8. WATER PUMP Inlet Inlet Outlet Outlet Impeller Impeller Hub Hub Weep Hole Weep Hole 171C

9. THERMOSTAT Engine Temp must be regulated 180 to 210 degrees Engine Temp must be regulated 180 to 210 degrees Located in upper passage Located in upper passage Engine has bypass hose for flow when stat is closed Engine has bypass hose for flow when stat is closed 175C & 176C Stant thermostats Cutaway

10. COOLING FANS Engine only needs air flow at low speeds and idle Engine only needs air flow at low speeds and idle Types of Fans Types of Fans – Mechanical – Electric – Viscous clutch

11. HOSE CLAMPS Four Types of Clamps Four Types of Clamps Must install on hose correctly Must install on hose correctly Do not over tighten Do not over tighten Worm Drive easiest and does good job of clamping hose Worm Drive easiest and does good job of clamping hose Crevice WrongCorrect Clamp

12. Types of hose clamps Twin wire Single Wire Constant Band Worm Drive

13. RADIATOR CAP Cap controls controls pressure and vacuum Cap controls controls pressure and vacuum – Each pound of pressure can raise temperature 3 degrees Rating printed on top of cap Rating printed on top of cap Pressure valve is connected to overflow reservoir Pressure valve is connected to overflow reservoir

14. RADIATOR CAP

15. COOLING SYSTEM MAINTENANCE

16. COMMON SERVICES AND REPAIRS of COOLING SYSTEM COMMON SERVICES AND REPAIRS of COOLING SYSTEM Visual Inspection for external leaks Visual Inspection for external leaks Replace radiator and heater hoses Replace radiator and heater hoses Pressure Test Cooling System & Cap Pressure Test Cooling System & Cap Replace Thermostat and Gasket Replace Thermostat and Gasket Replace Anti-freeze and Test Replace Anti-freeze and Test Flush Cooling System Flush Cooling System For more information about cooling hoses go to gates web site. http://www.gates.com/brochure.cfm?brochure=2833&location_id=3369

17. COOLING SYSTEM MAINTENANCE Inspect and maintain coolant system hoses.Inspect and maintain coolant system hoses. Look for kinks and ensure that hoses don't touch hot or moving parts or sharp edges. Look for kinks and ensure that hoses don't touch hot or moving parts or sharp edges. Oil may damage hoses; look for swollen, soft, mushy or sticky sections of hose. Oil may damage hoses; look for swollen, soft, mushy or sticky sections of hose. Check clamp connections for leakage. Tighten clamps and replace as needed. Check clamp connections for leakage. Tighten clamps and replace as needed. Physically check coolant hoses by conducting the following squeeze test. Physically check coolant hoses by conducting the following squeeze test. 1) Make sure the engine is cool.1) Make sure the engine is cool.

18. COOLING SYSTEM MAINTENANCE 2) Use your thumb and fingers to check for weakness, not the whole hand.2) Use your thumb and fingers to check for weakness, not the whole hand. 3) Squeeze near the connectors. A critical form of hose degradation called ECD Electrochemical degradation occurs within two inches of the ends of the hose.3) Squeeze near the connectors. A critical form of hose degradation called ECD Electrochemical degradation occurs within two inches of the ends of the hose. 4) Check for differences in the feel between the middle and ends of the hose.4) Check for differences in the feel between the middle and ends of the hose. 5) If the ends feel soft, the hose should be replaced immediately.5) If the ends feel soft, the hose should be replaced immediately.

19. COOLING SYSTEM MAINTENANCE Hoses showing signs of wear or more than four years old should be replaced immediately. Hoses showing signs of wear or more than four years old should be replaced immediately. Conduct a cooling system pressure test annually or more frequently depending on manufacturer recommendations and working conditions. Conduct a cooling system pressure test annually or more frequently depending on manufacturer recommendations and working conditions. Many times a hose cracks from the inside from ECD you cannot see it. Many times a hose cracks from the inside from ECD you cannot see it.

20. Hose Failures

22. Hose Failures Leakage APPEARANCE: Moisture, seepage or drips form on or around clamps or connectors. PROBLEM: Other than insufficient clamp torque, leakage is usually caused by the deteriorated condition of the hose and/or connector. SOLUTION: Clamp Torque Suggestions – In problem areas, ordinary wormdrive clamps can be less effective at preventing leaks. The use of hose sealants at the connection can help prevent leaks.

23. Hose Failures ECD Damage APPEARANCE:ECD (Electrochemical Degradation) is not obvious by visual inspection. However, by squeezing a cool hose near the end between your thumb and fingers, you can actually feel voids, cracks or weak spots. Also, bulging may occur near clamped connections. PROBLEM:ECD is a primary cause of most coolant hose failures. Modern engine materials react with the coolant to cause an electrical charge. This electrical current creates tiny internal cracks, which weakens the hose. SOLUTION: Replace damaged hoses.

24. Hose Failures Oil Damage APPEARANCE:Damaged hose is soft, gooey, or spongy to the touch. Bulges and swelling are readily apparent. PROBLEM:Oil reacts chemically with hose compounds to weaken the structure of molecular bonds. This causes the hose to soften, swell, and separate by layers, leading to certain failure. Oil can attack both external and internal surfaces of the hose. SOLUTION:For External Damage - Replace the damaged hose and eliminate any source of leaking oil. For Internal Damage - Replace the hose and coolant. Use the recommended type and quantity of coolant for the cooling system. If the vehicle has an automatic transmission, check for oil leakage from the oil cooler into the engine’s cooling system.

25. Hose Failures Heat damage APPEARANCE: As with ECD, heat damage can occur internally and may not be easily detected by physical appearance. Swelling is one sure external sign of internal damage. External heat damage is often easier to detect since it can result in hardened and cracked hose covers. PROBLEM: Overheating can cause reinforcement fibers within a hose to deteriorate. As engine compartments are being designed smaller and more compact, ambient temperatures under the hood increase. Engine heat, low coolant levels and/or temperature spikes all contribute to hose damage. SOLUTION: Buy hoses that are specially designed to resist deterioration from heat. If necessary, shield it or route it away from harmful heat sources.

26. Hose Failures Ozone Damage APPEARANCE:Tiny, parallel cracks show in the hose cover, even though there is no hardening. PROBLEM:Increased ozone, caused by pollution, attacks bonds in certain rubber compounds. Tiny cracks occur primarily where the hose is stressed— at curves, bends and clamping locations. These cracks allow airborne contaminants to invade and weaken the hose. SOLUTION:Install hose’s made of EPDM (ethylene propylene diene) rubber compounds, which is unaffected by ozone.

27. Hose Failures APPEARANCE: Scuffed, gouged or abraded cover. PROBLEM: Abrasion occurs when the hose is cut or punctured by debris that bounces up from the road. A drooping hose can be abraded by coming in contact with a moving motor part, such as a fan blade or spinning belt or pulley. SOLUTION: Replace the damaged hose with high-quality hose and be sure to install one that is factory-molded to curve around potential dangers. If necessary, shield the hose from future abrasion.

28. Engine Heaters Electrically operated heaters are often available as optional equipment on cars and light trucks. The heater may warm coolant with a heating element located in a coolant hose or in the engine block, or the heater may be located in a position that warms the engine oil. They help to provide easier starting in extremely cold temperatures. Electrically operated heaters are often available as optional equipment on cars and light trucks. The heater may warm coolant with a heating element located in a coolant hose or in the engine block, or the heater may be located in a position that warms the engine oil. They help to provide easier starting in extremely cold temperatures.

29. Types of Engine Heaters Thanks NAPA

30. UNDERHOOD FLUIDS Power Steering Fluid Power Steering Fluid Brake Fluid Brake Fluid – Reservoir – Ratings (DOT 3,4,5) – Must not use lesser rating – Do not mix! Electrolyte Electrolyte – Water/acid mix in the battery Window Washer Fluid Window Washer Fluid 185C - 187C

31. DUH, That’s all folks!!! Thanks to Dayco, Cat, Auto Insite, Gates And AllData For the Pictures http://www.gates.com/brochure.cfm?brochure=2837&location_id=3373