UNDERHOOD MAINTENANCE

163C

ENGINE OIL
What does engine oil do?
Lubricates Cools Seals Cleans

Viscosity Oil Types

168C

OIL FILTERS
Cleans oil Paper Element Inlet and Outlet Passages Bypass Valve Filter Identification

168C

OIL FILTER FLOW

Oil Filter Inlets are on outside Oil Filter Outlet is in center Sealing surface must be correct Application must be correct

167C

LUBRICATION SYSTEM
Oil Pan Pick Up Screen Oil Pump Oil Galleries Pressure Relief Valve

170C

COOLANT
Raises Boiling Point Lowers Freezing Point Two Types of Anti-Freeze
Ethylene glycol Propylene glycol

Mixture best at 50/50 Protects to -34 F Acts as Lubricant for Water Pump Remove 70% of Engine heat

What color COOLANT see the whole chart at peak antifreeze

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.

insite - fan/eng block

172C

RADIATOR
Two Types
Crossflow Downflow

Construction
Copper Aluminum

Hoses
Molded Flexible

171C

WATER PUMP
Inlet Outlet Impeller Hub Weep Hole

175C & 176C

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

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

HOSE CLAMPS
Clamp Crevice

Wrong

Correct

Four Types of Clamps Must install on hose correctly Do not over tighten Worm Drive easiest and does good job of clamping hose

Types of hose clamps

Twin wire

Single Wire

Worm Drive

Constant Band

RADIATOR CAP
Cap controls controls pressure and vacuum
Each pound of pressure can raise temperature 3 degrees

Rating printed on top of cap Pressure valve is connected to overflow reservoir

RADIATOR CAP

COOLING SYSTEM MAINTENANCE

COOLING SYSTEM MAINTENANCE

COMMON SERVICES AND REPAIRS of COOLING SYSTEM
Visual Inspection for external leaks Replace radiator and heater hoses Pressure Test Cooling System & Cap Replace Thermostat and Gasket Replace Anti-freeze and Test 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

COOLING SYSTEM MAINTENANCE

Inspect and maintain coolant system hoses. 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. Check clamp connections for leakage. Tighten clamps and replace as needed. Physically check coolant hoses by conducting the following squeeze test. 1) Make sure the engine is cool.

COOLING SYSTEM MAINTENANCE

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. 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.

COOLING SYSTEM MAINTENANCE

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. Many times a hose cracks from the inside from ECD you cannot see it.

COOLING SYSTEM MAINTENANCE

COOLING SYSTEM MAINTENANCE

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.

Types of Engine Heaters

Thanks NAPA

DRIVE BELTS

Pg... 233& 234C

PULLEYS AND BELTS

Make sure you have the right size belt Pitch and Width must be correct Tension belt in foot pounds Some water pumps turn in opposite direction

Belt & Pulley Problems

Belt not aligned Pulley worn

Belt Adjustment
Most new cars have automatic tensioners on them so no adjustment is needed. But the old belts must be checked and tightened.

Belt Adjustment
Find the Drive Belt Picture like this one from All Data if you do not know how to adjust it.
Thanks All Data for use of the picture.

DRIVE BELTS PROBLEMS Thanks Dayco

DRIVE BELTS PROBLEMS Thanks Dayco

DRIVE BELTS PROBLEMS

DRIVE BELTS PROBLEMS

Thanks to Gates for picture and info

APPEARANCE: Each side of belt appears shiny or glazed. In advanced stages, fabric becomes exposed. CAUSE: When in motion, the belt makes contact with an object in its path such as a flange or bolt. This may be caused by improper belt tension or pulley bearing size. SOLUTION: Replace belt and remove the foreign object or, if it cant be removed, ensure that contact is voided. Check the automatic belt tensioner and ensure proper belt tension.

DRIVE BELTS PROBLEMS

Thanks to Gates for picture and info

APPEARANCE: Pieces or chunks of rubber material have broken off from the belt. When chunk-out has occurred, a belt can fail at any moment. CAUSE: Chunk-out can happen when several cracks in one area move parallel to the cord line. Heat, age and stress are the primary contributors.

SOLUTION: Replace the belt immediately.

DRIVE BELTS PROBLEMS

Thanks to Gates for picture and info

APPEARANCE: CAUSE:

Belt material is sheared off from the ribs and builds up in the belt grooves. There are a number of causes, including lack of tension, misalignment, worn pulleys or a combination of these factors. Pilling is found most frequently in diesel engines, but is not isolated to them.

SOLUTION:

When pilling leads to belt noise or excess vibration, the belt should be replaced. Accessory brake pulleys should be checked for material buildup between groves. Replace if necessary.

DRIVE BELTS PROBLEMS

Thanks to Gates for picture and info

APPEARANCE: Belt shows damage to the side with the possibility of breaks in the tensile cord or jagged edged ribs. A thumping or grinding noise may also be heard when running. CAUSE: A foreign objectsuch as a small pebblein the pulley can cause uneven wear and cut into the belt. SOLUTION: Replace belt and inspect pulley for foreign objects or damage. Replace pulley if necessary

DRIVE BELTS PROBLEMS

Thanks to Gates for picture and info

APPEARANCE: A belt rib begins separating from the joined strands. If left unattended, the cover will often separate, causing the belt to unravel. CAUSE: Improper belt installation is a common cause of premature failure. One of the outer-most belt ribs is placed outside the pulley groove, causing a belt rib to run without a supporting or aligning pulley groove. SOLUTION: The belts life has been severely limited and should be replaced immediately. Ensure all ribs of the replacement belt fit into the pulley grooves. Run the engine. Then, with the engine off and battery disconnected, inspect the belt for proper installation.

DRIVE BELTS PROBLEMS

Thanks to Gates for picture and info

APPEARANCE: Small, yet visible cracks along the length of a rib or ribs. CAUSE: With continuous exposure to high temperatures, the stress of bending around the pulley leads to cracking. Cracks begin on the ribs and grow into the cord line. As a rule, if three or more cracks appear in a three-inch section of a belt, eighty percent of the life is gone and the belt should be replaced. SOLUTION: Replace & Check tensioner pulley and idler pulley for bearing wear. Replace if necessary.

DRIVE BELTS PROBLEMS

Thanks to Gates for picture and info

APPEARANCE: Sidewalls of the belt may appear glazed or the edge-cord may become frayed and ribs removed. A noticeable noise may result. In severe cases, the belt can jump off the pulley. CAUSE: Pulley misalignment can be caused by two conditions (see below). Misalignment forces the belt to kink or twist while running, causing premature wear. SOLUTION: Replace the belt and make sure to realign the pulleys. Also check to make sure the pulleys, pulley brackets and shafts are not bent or broken.

DRIVE BELTS PROBLEMS

Thanks to Gates for picture and info

APPEARANCE: Small pinholes are visible on the backside of the belt. Bumps may be visible and fabric around the holes can be frayed. CAUSE: Rock, gravel or sand is wedged between the belt grooves and pulley ridges. SOLUTION: The belt needs to be replaced to avoid tensile cord separation and possible roadside failure.

DRIVE BELTS PROBLEMS

If You have a squeak and it sounds like a belt try squirting water on it if it goes away you probably need a new belt.

DRIVE BELTS

DRIVE BELTS
Make sure you know how to route the serpentine belt around the pulleys.

DRIVE BELT TENSIONER

.

DRIVE BELT TENSIONER

Thanks to Goodyear for the picture & info
1. SPRING: Maintains belt tension at a constant value throughout the operating range. 2. ARM: Connects spring to idler pulley while maintaining proper alignment. 3. INSERT BEARING: Provides angular alignment needed for proper belt tracking. 4. DAMPING ELEMENT (SPRING SUPPORT): Provides additional tensioner damping and load balancing. 5. SPRING HOUSING/SPINDLE: Anchors spring. Arm pivots around the spindle. 6. IDLER PULLEY: Pulley surface is grooved, flat or crowned. 7. PULLEY BOLT: Allows service replacement of pulley & means for lifting arm. 8. DUST SHIELD: Prevents high-pressure spray, foreign material or installation tools from damaging the bearing seal. *Note: Sometimes integrated with pulley bolt. 9. FRONT PLATE: Holds tensioner together. 10. THRUST WASHER: Provides thrust wear surface.
http://www.goodyearbeltsandhose.ca/replacement/carsandlt/tensioners.html

DRIVE BELT TENSIONER

Make sure the tensioner is in good shape.

Idler Pulleys

Dont forget the Idler Pulley. We change out the belt and the tensioner but forget the other pulleys. Are they whining, check the nylon ones for wear across the surface. All can wear but nylon ones need to be replaced more often. (see picture on previous page)

182C

AIR INDUCTION SYSTEM

Air Filter traps abrasive particles Must be changed regularly System can control inlet air temperature Housings usually plastic

AIR INDUCTION SYSTEM

Air filter Service indicator
This reading shows normal indication when the filter element is clean. (Readings vary with system design.)
As the filter element slowly fills with dust and soot, the indicator moves up the calibrated gauge to show the exact percentage of filter life remaining.

Here the reading shows the filter is no longer allowing sufficient air into the engine and should be changed.
http://www.cat.com/cda/layout?m=37503&x=7

Air Filter Service Indicator

FUEL SYSTEM
Tank, Pump, inlet sock,sender Lines Fuel Filter Fuel pressure tap

185C - 187C

UNDERHOOD FLUIDS
Power Steering Fluid Brake Fluid
Reservoir Ratings (DOT 3,4,5) Must not use lesser rating Do not mix!

Electrolyte
Water/acid mix in the battery

Window Washer Fluid

187C - 195C

BATTERY
Safety is very important! Chemical Action
Lead Peroxide Sponge lead

Battery Construction Battery Types Battery size and ratings

Thanks to Dayco, Cat, Auto Insite, Gates And AllData For the Pictures

DUH, Thats all folks!!!

http://www.gates.com/brochure.cfm?brochure=2837&location_id=3373