Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE 18-1 Common cooling system problems; most of these can be located with a visual check.

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE 18-2 Most cooling system problems can be prevented by maintaining good coolant, a mixture of pure water and antifreeze.

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE 18-3 Coolant level in a modern system, using a coolant recovery reservoir, is checked at the reservoir. (Courtesy of Chrysler LLC)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE 18-4 If necessary, follow these methods of removing the cap from a hot system (a). A safety cap has a lever that is raised to release any pressure from the system (b). The inlet hose of this coolant pressure reliever is connected to the radiator overflow hose, and the control lever is operated to safely remove any pressure from a system (c). (b courtesy of Stant Manufacturing; c courtesy of Wynn Oil Company)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE 18-4 (CONTINUED) If necessary, follow these methods of removing the cap from a hot system (a). A safety cap has a lever that is raised to release any pressure from the system (b). The inlet hose of this coolant pressure reliever is connected to the radiator overflow hose, and the control lever is operated to safely remove any pressure from a system (c). (b courtesy of Stant Manufacturing; c courtesy of Wynn Oil Company)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE 18-5 In an older system, the coolant level should be about 2 inches below the seat in the filler neck (a). The coolant level in a coolant recovery system is indicated on the recovery reservoir (b), and the radiator should be filled completely. (a courtesy of Everco Industries)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE 18-6 Coolant is normally a mix of half pure water and half antifreeze, which contains about 3% additives.

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE 18-7 A simple check for cleanliness is to rub a finger around the inside of the filler neck. Any dirt on your finger indicates a dirty system that should be cleaned.

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE 18-8 Ethylene-glycol-based coolant mixtures are commonly tested using a hydrometer or refractometer; test strips are used for propylene glycol mixtures. (Courtesy of Four Seasons)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE 18-9 A test strip is dipped into the coolant (a) and the color change is compared with a chart (b) to determine freeze point, boil point, and acid corrosion protection. (Courtesy of Environmental Test Systems, Inc., Elkhart, IN)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE The plastic pump is used to draw a few drops of coolant and transfer it onto the measuring window. The window is then closed. (Courtesy of Wynn Oil Company)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE Point the refractometer toward a light source and look through the eyepiece. The freeze point is indicated at the dividing line between dark and light (the edge of the shadow). (Courtesy of Wynn Oil Company)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE A hydrometer is read by drawing enough coolant into the unit to lift the float and noting the graduation at the liquid level.

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE Many antifreeze hydrometers include a thermometer and slide. Set the slide to the thermometer reading (a) and read the freeze point on the proper scale (b).

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE Radiator voltage is measured by clipping one voltmeter lead to a good ground or the filler neck of all-metal radiators. Dip the clip on the other lead into the coolant; a reading of 0.3 V or greater indicates a possible problem.

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE Most radiators include a plug or petcock to allow draining the coolant. Be sure to catch the coolant for proper disposal. (Courtesy of Chrysler LLC)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE An inline engine usually has one drain plug (left); a V-type engine usually has a drain plug in each cylinder bank. (Courtesy of Chrysler LLC)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE Some cooling systems include a bleed valve to allow easy removal of air as the water jackets are filled.

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE This plastic drain valve is formed as part of the radiator tank. If the valve should break, the tank or radiator must be replaced.

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE This antifreeze-recycling process adds two chemicals to the used coolant before it is run through the recycling unit. After reclaiming, new antifreeze is added to adjust the coolant concentration. (Courtesy of Wynn Oil Company)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE A coolant exchange unit is used to pull out the old coolant and replace it with a fresh water and antifreeze mixture. (Courtesy of Robinair, SPX Corporation)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE An airlift unit is designed to evacuate the cooling system of all air, check for vacuum leaks, and quickly refill the system completely with new coolant. It attaches to the radiator filler neck with another connection to a shop air hose and then to the coolant container. (Courtesy of UView UltravioletSystems)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE This special funnel attaches with a leak-free connection to the filler neck and holds coolant so it can enter as air leaves the radiator (a). The set contains connectors for various filler necks and a T-shaped stopper so the funnel can be removed without spilling coolant (b). (Courtesy of Lisle Corporation)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE A drive belt should be replaced if it shows any of these faults. (Courtesy of Gates Corporation)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE Drive belt tension can be checked by measuring how far the belt deflects under a light pressure (a), or by using a tension gauge, which is more accurate (b and c).(a and b. Courtesy of Chrysler LLC; c. Courtesy of Gates Corporation)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE Misalignment of the pulleys can cause belt noise and excessive wear of the belt and pulleys. (Courtesy of Gates Corporation)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE As shown here, a small amount of misalignment can increase drive belt temperature and wear. (Courtesy of Gates Corporation)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE (CONTINUED) As shown here, a small amount of misalignment can increase drive belt temperature and wear. (Courtesy of Gates Corporation)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE To remove a drive belt, loosen the adjuster and pivot bolts and pull sharply at the center of the belt. This loosens the adjustment, making installation of the new belt easier.

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE Depending on the installation, you can pry on the adjustable component using a screwdriver or bar, swing it using a wrench, move it using a threaded adjuster (a), or use a pulley jack (b). (a. Courtesy of Chrysler LLC)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE This type of belt tension gauge (a) is hooked onto the belt and quickly released to measure belt tension. Another style (b) is pushed against the belt until the indicator moves out.

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE Moving the automatic tensioner outward allows the serpentine belt to be removed from the pulleys.

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE When a V-ribbed belt is installed, make sure the belt is positioned correctly in the pulley grooves.

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE Oil and abrasion damage are seen during a visual inspection (a). Electrochemical degradation, ECD (b),can be detected by squeezing the hose. ECD is indicated if the hose feels softer at the ends (c). (Courtesy of Gates Corporation)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE (CONTINUED) Oil and abrasion damage are seen during a visual inspection (a). Electrochemical degradation, ECD (b),can be detected by squeezing the hose. ECD is indicated if the hose feels softer at the ends (c). (Courtesy of Gates Corporation)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE The quickest and easiest way to remove a hose is to slit it with a sharp knife (a). If the hose is to be reused, a cotter pin puller or seal remover can be used to aid in removal (b). (a courtesy of Gates Corporation)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE The hose clamp should be located next to the bead on the connector, and the clamp should be tightened to the correct torque.

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE Rubber will be squeezed up into the slots when a screw clamp is properly tightened.

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE A problem-solving guide can be used to help locate the probable () or possible () cause of a cooling system problem. (Courtesy of Wynn Oil Company)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE Many technicians use a checklist during cooling system inspection. The checklist provides a professional display of any problems for the customer and helps ensure that important checks are not skipped. (Courtesy of Wynn Oil Company)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE The most commonly encountered radiator faults. Most of these problems require replacement of the radiator or tanks. (Courtesy of Modine Manufacturing)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE (CONTINUED) The most commonly encountered radiator faults. Most of these problems require replacement of the radiator or tanks. (Courtesy of Modine Manufacturing)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE If the fan is rotated, you should notice a definite drag of the fan clutch. Also check for excessive play in either a front-to-back or sideways direction (arrows).

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE A thermometer installed in the radiator filler neck can be used to check the temperature of the coolant. The adapter is also used for pressure checks. (Courtesy of Waekon Industries)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE An infrared thermometer allows fast temperature checks.Merely point the unit at the spot to be checked, pull the trigger, and read the temperature.(Courtesy of Raytek Corporation)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE Cooling system pressure testers include a style using a hand pump (a) and ones that use shop air pressure or cooling system pressure (b). (a courtesy of Stant Manufacturing; b courtesy of Waekon Industries)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE After wetting the cap gasket with coolant or water, it is placed on the adapter. Then the tester is pumped to the point where pressure is released. (This pressure should match the cap’s rating.) (Courtesy of Stant Manufacturing)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE A system’s pressure is checked by connecting the tester to the radiator and pumping it up to the proper pressure (a). Adapters are available to fit the various filler neck styles (b).(b is courtesy of Stant Manufacturing)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE (a) A pressure probe with regulator has been installed in the radiator neck using the same adapter shown in Figure 16-32(b). Shop air can be put into the system using the fitting (arrow). A similar style of tester (b). (a courtesy of Waekon Industries)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE A combustion leak will cause a rise in system pressure if the engine is started. Be ready to relieve any excess pressure.

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE A combustion leak is caused by a crack or a faulty head gasket, which allows combustion pressure to enter the water jackets.

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE A simple check for a combustion leak is to immerse the overflow/transfer tube into a container of water and run the engine. Bubbles from the hose indicate a combustion leak.

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE A combustion leak tester is partially filled with test fluid (a). Working the test bulb draws gases from the system through the fluid (b). There is a combustion leak if the fluid changes color.

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE Place a thin feeler gauge into the valve portion of a thermostat and suspend it by a string in a container of water. Heat the water; the valve should open to let the thermostat drop. This should occur at the thermostat’s rated temperature.

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE The end tank on some radiators can be removed to replace the tank, sealing gasket, or internal cooler. (Courtesy of Visteon)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE A flushing gun (a) and a flushing machine (b) can be used to flush a cooling system. This particular flushing machine will also recycle coolant. (a. Courtesy of Chrysler LLC; b. Courtesy of Wynn Oil Company)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE A radiator is backflushed by running water with added air bursts backward through the core.

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE Water jackets are backflushed by running water with added air bursts backward through them. Be sure to remove the thermostat before backflushing.

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE A heater core can also be backflushed, but be sure to keep the pressures low so as not to rupture the core.

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE A leaky core plug can often be repaired by installing an expandable plug into the core plug.

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE A cup plug can be removed by rotating the plug using a punch and hammer and pulling it out with pliers (a). Another way to do this is to use a slide hammer with a puller screw (b). (a. Courtesy of Chrysler LLC)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE Fan runout is measured by holding the fan stationary using a rubber band, mounting a dial indicator at one of the blades, and cranking the engine. Excessive runout indicates faulty fan or fan clutch mounting.

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE If replacing a fan, make sure that the replacement is designed to rotate in the correct direction. (Courtesy of Stant Manufacturing)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE An exploded view of radiator assembly showing parts removed during replacement. (Courtesy of Everco Industries)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE A thermostat is normally set in a recess in the engine or outlet housing; the gasket often prevents flow around the thermostat. (Courtesy of Stant Manufacturing)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE An exploded and cutaway view of a cap-mounted thermostat. (Courtesy of Stant Manufacturing)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE The thermostat is normally mounted near the heater hose outlet and temperature-sensing (ESA) switch. (Courtesy of Chrysler LLC)

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE The rubber band is holding the thermostat in place in the housing. After the housing is fastened in place, the rubber band will be removed.

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE A pair of guide pins is being used to hold the gasket in position as this water pump is installed.

Automotive Heating and Air Conditioning, Fifth Edition By Tom Birch © 2010 Pearson Higher Education, Inc. Pearson Prentice Hall - Upper Saddle River, NJ FIGURE A belt-driven water pump can rotate either clockwise or counterclockwise depending on which side of the belt is used to drive it. (Courtesy of Gates Corporation)