2019 Gatesabdsadp Instructors Preso 71819 PDF

We Can’t Do It Like We Used To!
An Introduction to R90
Systems Initiative
Note: there are video links to specific training embedded in the PDF. Please click on the
green arrow to play
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Confidential Information. Use and disclosure limited for Gates business purposes only. ©2018 Gates Inc. All rights reserved.
Systems Initiative
OUR CONVERSATION TODAY
• Industry Information / Warranties

• System Smart Initiative
• Gates Research Based Around ABDS /Coolant
System
• Change in Belt Technology
• Decoupler Pulley Update
• Condition of Coolant
• More
Resource Used;
• Gates Corporation /Bobby Bassett
• Amalgatech/Ed Eaton
• Seyfer Automotive / Donnie Seyfer
UNIVERSITY OF THE AFTERMARKET SCHOLARSHIPS 2018-2019
Scholarships totaling $130,000 have been awarded

to 80 students working either to become a
mechanical, collision or heavy duty repair
professional or who are pursuing a business or
engineering degree that will lead to a career in
the automotive aftermarket.
The recipients attend or will attend a two-year

vocational/technical college or a four-year
college or university and will each receive a UAF
scholarship worth $1,000 to $5,000 to advance
their education.
Text 720-903-2206 to begin your scholarship process
http://www.uofafoundation.com/
TRAINING 24 / 7 FROM GATES CORPORATION
http://navigates.gates.com
http://gatesaftermarkettrainingcenter.com/
SIMPLE ANALOGY “THE GIFT THAT KEEPS ON GIVING“
• Check the tire pressure. Fill with

air... Repeat as necessary…
• Tire repair in a can?
• Ignore the problem for as long as

you can – tire looks good. Tire
pressure doesn’t get that low. It
will be OK.
• Suggest finding the root cause of

the failure first. Anything else may
be a band aid solution!
SOMETIMES IT’S SIMPLE – SOMETIMES IT’S NOT

HAVE YOU NOTICED AN INCREASE IN WARRANTIES?
What are your top 5 reasons for increased component

failures/comeback?
1. ____________________________________________
2. ____________________________________________
3. ____________________________________________
4. ____________________________________________
5. ____________________________________________
Read All Instructions before beginning repair !

Warranties Tending Up
You Are Missing Something Important !
Surveys Say!
Up TO:
• 40% of Radiator failures due to condition of coolant
• 40% of Batteries returned, just needed charging
• 70% of Rotating Electrical performed as intended
• 90% of Timing Belts fail after just a belt is installed
• 91% - OE coolant hose failures are spiking at 10-11 years
• 95% of Water Pumps fail from lack of flushing
• 99.8% of Serpentine Belts returned were forced to fail
Sampling of alleged warranties returned to factory
You Are Missing Something Important !
Surveys Say!
Up TO:
• 40% of Radiator failures due to condition of coolant
• 40% of Batteries returned, just needed charging
• 70% of Rotating Electrical performed as intended
• 90% of Timing Belts fail after just a belt is installed
• 91% - OE coolant hose failures are spiking at 10-11 years
• 95% of Water Pumps fail from lack of flushing
• 99.8% of Serpentine Belts returned were forced to fail
Sampling of alleged warranties returned to factory
Second Time “Ø” Profits
If you are replacing the same

component for a second time for the
same reason, then fully inspect the
system for proper diagnosis before
reinstalling another component
It’s Not My Fault it Failed:
• Competitive situations
• Afraid to approach customer with additional cost
• Customer did not want to “pay” for it
• Did not see the need
• Never did it that way before (process change)
• Never recommended (counter / service writer)
• Misdiagnosed the system / failures
• Flat rate does not pay for diagnostics (short cuts)
• Lack of the latest knowledge or process change Who, ultimately pays for excessive warranties! ________
• Didn’t have the time / Too busy

• 2nd replacement / Supplier/Counter offered no solution to the problem
• Customer asking components to perform outside of their duty cycle
• Don’t understand the liability (Who owns the failure?)
TIME LINE IS IMPORTANT ! / WHEN TO SUGGEST
Replacement Rate by Mileage Ranges for the

Serpentine Belt and Related Belt Driven Component
MICRO-V® BELT
Serpentine Belt
 Advantages  Disadvantages
 One belt runs everything!  One belt runs everything !
 Reduced space  Belt depends on correct tension to
 Less weight operate properly!
 Better friction compared to  Loses multiple critical accessory
multiple single v-belts functions when the belt is worn
 Increased belt life and  Loss of engine cooling (water
mechanical efficiency pump)
 Fuel saving  Battery not charging (alternator)
 Eliminates belt “flip over”  Loss of power steering (PS pump)
 Traditional v-belt have  Loss air condition (AC compressor)
the tendency to “flip  Fan not working (Fan)
over”
WE CAN’T DO IT LIKE WE USED TO SIMPLY DUE TO THE TECHNOLOGY ADVANCES
MICRO-V® BELT
Serpentine Belt
 Advantages  Disadvantages
 One belt runs everything!  One belt runs everything !
 Reduced space  Belt depends on correct tension to
 Less weight operate properly!
 Better friction compared to  Loses multiple critical accessory
multiple single v-belts functions when the belt is worn
 Increased belt life and  Loss of engine cooling (water
mechanical efficiency pump)
 Fuel saving  Battery not charging (alternator)
 Eliminates belt “flip over”  Loss of power steering (PS pump)
 Traditional v-belt have  Loss air condition (AC compressor)
the tendency to “flip  Fan not working (Fan)
over”
WE CAN’T DO IT LIKE WE USED TO SIMPLY DUE TO THE TECHNOLOGY ADVANCES
BELTS TODAY ARE HIGHLY ENGINEERED
Manufactured With:
EPDM Material (Ethylene Propylene Diene Monomer Rubber)
• Nylon Cord
• Polyester Cord
• Aramid Cord
• Carbon Cording
• Special Gum Properties
• Material can be modified for special applications
Manufactured With:
• Nylon Cord
• Polyester Cord
• Aramid Cord • EPDM wears differently so cracks are minimal, if any
• Carbon Cording • Just 5% of belt wear will allow the belt to slip under load
• Rib wear is the predominant wear indicator and visually difficult to see
• Special Gum Properties unless using a belt wear tool!
• The belt most always points to the root cause of the failure!
Manufactured With:
• Nylon Cord
• Polyester Cord
• Aramid Cord
• Carbon Cording
• Special Gum Properties
ACCESSORY BELT DRIVE SYSTEM (ABDS)
Belt Whip or Flutter

• Belt whips as it rotates over the
back side of the system
• Creates Torsional Vibration
Solution Create a Aramid cord belt
Click
Traditional belt wear signs no longer apply for EPDM belt !

ABDS (ACCESSORY BELT DRIVE SYSTEM)
Parts in the System:

 Serpentine Belt
 Tensioner
 Related Accessories
• Alternator Decoupler Pulley
 System Pulleys
Definition: The Accessory Belt Drive System (ABDS) is a system, on the engine, made up of idlers and accessory
components performing various rolls throughout the vehicle that depend on the belt, under tension, to transfer
power from the crank for peak operational efficiency.
ABDS (ACCESSORY BELT DRIVE SYSTEM)
What are the wear and tear parts of serpentine belt drive components ?
 Serpentine belt
 Transfers power from the crankshaft pulley to all belt driven accessories
 Automatic Tensioner
 Maintains the correct tension on the belt at all times throughout its duty cycle
and dampens Torsional vibration
 Idler Pulley
 Is a free-spinning pulley around which the belt travels to optimize belt routing
and suppress belt flutter
 Torsional vibration damper
 New type of crankshaft pulley with a rubber damping element to absorb
crankshaft vibrations and extends the lifespan of the crankshaft, the belt and
all belt driven components
 Overrunning Alternator Pulley
 New type of alternator pulley that allows the alternator to “free wheel” or
“overrun” every time the engine decelerates. It also dampens Torsional
vibrations at the alternator. This component extends the lifespan of the
alternator, belt and all belt driven components.
MICRO-V® BELT
How to use the belt wear gauge
GOOD BELT
When the gauge remains The gauge ribs will contact
tightly seated and resists the sides of the belt
movement, the belt has material and the body may
sufficient service life left. rest slightly above the belt
surface.
With the engine off, press the Attempt to rock the gauge
gauge ribs into the belt grooves in a lateral motion (left and
using gentle pressure too hold the right)
WORN BELT
gauge against the belt and seat
the ribs.
When the gauge allows lateral The gauge ribs will not
rocking motion, the belt is in contact the belt material
need of replacement. and the gauge body will
rest flat on the belt,
allowing movement in the
Order on line or call local Gates rep
tool.
QUICK AND EASY WAY TO INSPECT YOUR SERPENTINE BELT IN SECONDS

ABDSYSTEM “PAT”
› Pulleys
› Alignment
› Tension
!00% System Inspection if belt is remove for any reason.
Off Tracking
SPRAY BOTTLE TEST FOR NOISE
My Belts Squealing!
Tension Related Noise:
• Spray ABDS and “If” the noise goes up it is tension related Observe the system in Operation before
removing the belt
• Check ribs for wear using a belt wear
What Happens When a Belt Slips? tool
• Annoying belt squeal or noise • Inspect the tensioner for failure
• Clean all pulleys to improve belt/
• Accessories operate at a diminished output pulley interface
• Potential for DTCs such as PO300 Engine Misfire
• Creation of heat for the bearings/ premature bearing failure
• Excessive pulley wear as the belt slips
• Comeback if root cause is not found and corrected
• Reference Industry Warranty slide for percentages
PAT Related Belt Failures Click

MISALIGNMENT CHALLENGES
My Belts Chirping!
• Spray and “if” the noise goes away and then comes back it is alignment related Gates Laser Alignment Tool
Misalignment
•Serpentine belts can only tolerate 1°of misalignment
•Add 30°of heat for each additional degree of misalignment
•Noise normally begins at the shortest pulley spans • Maximum recommended misalignment for V-ribbed
belts is 1/16 inch per 12 inches of belt span length
(1/3 degree).
• Check using a straight edge or a Laser Alignment tool
MICRO-V® BELT TROUBLE SHOOTING GUIDES
Simple STEPs of diagnosing the noise problems by using the spray bottle test
Step1. Ask if the problem is more noticeable under what
conditions?
1. In the morning while the engine is cool
2. During highway driving
Click
3. When idling or accelerating
4. A/C is under full load (switch on)
Step 2. Attempt to recreate the problem in the service bay

1. Spray water between the belt and pulley – if the noise level recedes for a
few seconds then returns = misalignment
2. If the noise immediately increases after the belt is sprayed with water,
lack of belt tension is the problem = rib wear or under-tensioned
Important Note : Never use Belt Dressing or Carb cleaner!

 Collects dirt and grit
 Deteriorates belt material
MISALIGNMENT CHALLENGES
Alignment Related Chirp / Engine off
• Observe system running noting tensioner operation/ belt

tracking
• Note any accessory that has been replaced recently and
check its alignment first
• Remove belt and review rib wear pattern Gates Laser Alignment Tool
• Use Laser Alignment tool #91075

Click
• Check harmonic balancer for wear
• Check pulleys for bearing wear (Off tracking)
• Check for bent or broken brackets
• Check for accessory run out
• “Spin Cycle” tensioner for pivot bushing failure
COMMON “PERCEIVED” BELT FAILURES (PAT)
#2 Pulley Problem
# 4 Contamination # 5 Contact with Engine

# 3 Pulley Misalignment
#1 Pilling
#6 Normal Wear
Belt normally
points to the
corrective action Rib Shear
Broken # 7 Belt Cracking

Belt
Sand Penetration
Glazing
CORRECT BELT TENSION IS ABSOLUTELY CRITICAL!
The tensioner performs two job functions
• Maintains the correct belt tension throughout the tensioners duty cycle
• Dampens the impulses from the engine as each cylinder fires (Torsional Vibration)
Cycles a billion times in 100,000 miles

THE ACCESSORY OPERATION REVOLVES AROUND THE TENSIONER!
TENSIONER TEST – SPIN CYCLE
Tensioner Has Four Failure Modes
• Spring begins to fail creating belt slippage Spin Cycle Test

With the engine running, observe the tensioner in
• Internal pivot bushing is worn out, creating operation. If you notice the tensioner arm bouncing, it is an
misalignment and belt off tracking indication the damper has worn and both the belt and
• Damper has failed allowing the tensioner arm tensioner should be replaced.
to hammer the system to death. (Torsional
Vibration.)
• Tensioner pulley bearing worn out
• Value line tensioner/case failure
• Minimal damping ability
HAVE YOU SEEN ONE OF THESE?
Click
Torsional Vibration / Hammering

BELT TROUBLESHOOTIING EXAMPLES
COMPRESSOR INSTALLATION
INSTRUCTIONS
Follow all Federal, State and Local
Regulations.
Proper A/C performance is dependent on
all systems performing properly. Make
certain that the engine cooling system is
at peak operation, and that the cooling
fan / fan clutch is operating properly.
Worn belts, idlers and tensioners can
cause poor cooling system performance
due to belt slippage. Low voltage at the
A/C clutch assembly can cause
premature compressor failure.
TIRE / BELT ANALOGY for PERFORMANCE
• A Tire has to have 4 things to insure Proper Performance
• Proper Tread
• Proper Alignment
• Proper Balance
• Proper Air Pressure
35
35
TIRE / BELT ANALOGY for PERFORMANCE
• A Belt has to have 4 things to insure Proper Performance
• Proper Rib Depth (Tread)

• Proper Alignment
• Proper Damping (Balance)
• Proper Belt Tension (Air Pressure)
Belts and tensioner were designed as a system

Correct alignment and tension are critical to the system
For best results preplace both together !
SIMPLE ANALOGY
Up to 70%
Up to 40%
BELT NOISE IS AS SIMPLE AS RIGHT HAND / LEFT HAND 38
Tension Alignment
• Check for belt wear Related Related
Part # 91075
• Check the Tensioner Problems Problem Alignment Challenges

for correct operation • Angular
• Parallel
• Run Out
Right Hand Left Hand

ALTERNATOR DECOUPLER PULLEY (ADP)
Moved to Hi Amp Alternators
 The purpose of an ADP is to allow the alternator to declutch/free

wheel/overrun from the ABDSystem upon deceleration
 Used primarily on 4 cylinder engines and high revving engines
 Removes torsional vibration from the ABDSytem
Referred to as : ADP (Alternator Decoupler Pulley),  Saves gas when the engine is at idle stage
OAP (Overrunning Alternator Pulley, OWC (One Way  Easily replaced with proper tool
Clutch Pulley)  Prevents belt slip/wear
IT’S A “SACRIFICIAL” COMPONENT DEVELOPED TO SAVE THE ALTERNATOR!
WHAT IS IT’S PURPOSE ?
HOW DOES THIS AFFECT THE SERPENTINE SYSTEM?
Click
Each time a cylinder fires

• Crankshaft speeds up and slows down creating Torsional Vibration.
• These firing pulses speed up and slow down the alternator
• The lower the RPM, the higher the Torsional Vibration
• Without a Decoupler Pulley, the pulses create vibration for the driver and cause the belt
tensioner to exhibit increased movement
• Increased tensioner movement equals less durability for both the tensioner and belt, as
well as all the other components within the belt drive system (including the alternator).
REMOVAL TOOL IS SIMPLE TO USE
Simple!
EUROGRIP OE DRIVE COUPLER AND KITS
UNDERSTANDING FAILURES
• It’s a Sacrificial component and failure can show up as early as 40 to 60,000

miles
– Identify that the alternator does have an ADP first

– Alternator light is on but “ No Charge”
– Alternator has stopped charging because of insufficient rotor rpm (slipping belt, failing tensioner or
failed ADP)
– The failing decoupler pulley rotates in both directions “free spin failure” when turned by hand
– Decoupler pulley is locked in both directions, when spun by hand
– System may experience excessive tensioner motion / belt squeal
– Buzzing noise heard 5-10 seconds after the engine is turned off (indicates bearing failure)
ROOT CAUSE FAILURE ANALYSIS
Observe the ABDSystem in operation before removing belt

• Is this the second time replacing the same component?
Observe
• Perform simple belt analysis (look at the bottom)
• Is there belt system noise?
• Is there a DTC like 0300 Engine Misfire code that won’t recycle? Spin Cycle Test
• Spray bottle test for tension/alignment challenges

• Use laser alignment tool to check for alignment issues
Spray Bottle Test
• Review trouble shooting guide for latest information
• Inspect all accessories / clean all the pulleys
• Spin Cycle tensioner to test for failure Cotton Ball Test
BELT FAILURE BEGINS WITH ALIGNMENT / TENSION RELATED CHALLENGE

Solution to the Lack of Maintenance
Problem in the ABDS
GATES SOLUTION TO THE PROBLEM
Industry Challenges
• Lack of knowledge on the latest changes creates a challenge for
any “system” asking its components to perform past their intended
lifecycle
Why Kits?
• Without proper tension, even the best new belt can’t efficiently
transfer power
• Kits get to the root of the problem. A worn or noisy belt is only part
of the issue
• Tensioners wear at the same rate as the belt and should be replaced
together
• A worn tensioner can make a new belt wear up to 2x faster
• Loose parts take more time to source /or forgotten about during
the repair
• Performing a complete system repair doesn't add much time, but

adds a lot of value ( and protects against returns)
To be eligible for Lifetime Warranty Shop Registers at www.Gates.com/CompleteKits

LIFETIME WARRANTY 49
Shops will want to know:

 Doesn’t count against their current group warranties
 Submit the normal process (we just check database for reg.)
 Standard is $45 for labor hour
 Must submit invoice with Kit, then no quesions asked!
Process :
Benefits
 Reduce Warranty Returns
• Registered shop in the system
www.Gates.com/CompleteKits
 Increase Ticket Value & Shop Profitability
 Submit Warranty through normal process
 All in One Repair – No More Sourcing
 Standard labor rate is $45 per hour
 Happy, Protected Shop and Customer!
 Must submit invoice with Kit, no questions asked!
QUESTIONS
Don’t end up as part of the

survey, Offer the solution!
QUESTIONS?
Worn components put the entire system at risk!
Condition of Coolant
Systems Initiative
YOU'RE MISSING SOMETHING IMPORTANT!
Research Says!
•40% of radiator failure due to coolant contamination
•40% of batteries returned just needed charging
•70% of alternators retuned after replacement, nothing wrong with it
•90% of timing belts fail after belt replacement
•91% - OE coolant hose failures are spiking at 10-11
•95% of water pump failure due to “no flush”
•98.2% of serpentine belts returned were forced to fail

COOLING SYSTEM
Parts in the System:

• Radiator
• Heater Core
• Radiator Hoses 1.0 L EcoBoost 3
• Radiator Cap Cylinder
• Thermostat
• Water Pump
• Mechanical
• Electric
• Siphon
• Coolant
Develop a Systems Mentality
EXAMPLE OF SYSTEM CHANGE
Ford and others use a technique called thermo-siphoning to

protect and cool Turbo-Charger bearing housings after
shutdown. This is the Ford EcoBoost 2.0L.
ELECTRIC WATER PUMPS
Electric water pumps are becoming more popular among original

equipment manufacturers.
Why?
• Not driven by rotational energy from the engine
• Improved fuel economy and reduced emissions
• Sensors and electronics monitor coolant flows
• Managed temperature control
• Sectional cooling and heating
̶ Engine
̶ Batteries
̶ Turbo
ELECTRIC WATER PUMPS
Market Need
• Growing market segment
̶ Electric assist vehicles
̶ More turbo charged vehicles
̶ Some applications have multiple pumps
 Prius has 3 (main, auxiliary inverter, auxiliary heat)
 Pumps fail from coolant contamination, heat, moisture and age

̶ Failures result in expensive repairs!
 Primarily being serviced by Dealerships and Original Equipment Suppliers

EPDM HOSE 58
Most Radiator Hoses are made of EPDM and will last 7-10 years
• Hoses can get hard and damage radiators and plastic attaching
parts because they do not flex as designed anymore
Radiator Hoses Don't Do this Anymore
• Most OE’s have gone to spring clamp or heat shrinking hose
clamps to maintain even pressure and reduce cold leaks
• Hoses absorb the additive packs in antifreeze
• Anytime a hose is replaced the antifreeze should be replaced as
well to ensure adequate protection for other parts of the cooling
system
EXAMPLE OF CHANGE IN HOSES
Many hoses are now coming with restrictors or

check valves in them. Not all replacement hoses
have these devices and can be linked to a couple of
conditions.
• A gurgling sound in the heater core from coolant
moving too fast
• Heater core damage due to over-pressure and
pressure surges when the thermostat closes.
COOLING SYSTEM
Majority of shops do not indicate “flush” on a water pump Repair

Order
̶ Keeps cost down
̶ Keeps them competitive in their market
̶ Don’t understand the need even though they see an increase in coolant
system component failure
̶ Allows a faster car turn around
̶ Use the distributors as the fallback if there is a component failure
0.60%
0.50%
0.40%
0.30%
0.20%
0.10%
0.00%
< 5 K 5 K-9.9 10 K to 15 K to 20 K - 25 K - 30 K - 35 K to 40 K - 45 K - 50 K - 60 K - 70 K - 80 K - 90 K - 100 K - 125 K - 150 K - 175 - 200 K - 250 K - 300 K
K 14.9 K 19.9 K 24.9 K 29.9 K 34.9 K 39.9 K 44.9 K 49.9 K 59.9 K 69.9 K 79.9 K 89.9 K 99.9 K 124.9 149.9 174.9 199.9 249.9 299.9 +
K K K K K K
THE PROBLEM
LACK OF KNOWLEDGE / MISHANDLING OF CONTAMINATED COOLANTS ARE

CREATING PROBLEMS FOR THE AUTOMOTIVE AND HD COOLANT SYSTEMS!
CUSTOMER CONFUSION
̶ Industry confusion
̶ Misleading Labels
̶ Extended Life confusion
̶ Universal Coolant confusion
̶ What offers protection? Top off or a Full flush
̶ Inhibitor package – Never heard of it?
̶ Do not understand need to flush out contaminants
̶ Customer may drive the repair process
95% of the water pump

claims submitted
indicated “no flush”
completed on Repair
Order
NON-COMPATIBLE COOLANTS
Not all chemistries are the same › What happens when coolants are mixed?
Not all colors are the same › Depletion of inhibitors

› Metal failure
17% Intermix = Contamination › Build up of rust and scale
44oz in a 2 gallon (256 oz) system › Particles lodged between WP seals
› Resulting in component failure
Uncontaminated
Contaminated
Three Specific Problems for the Industry
1. “If” certain conditions exist in the coolant system, mixing dissimilar coolants can create a reaction
2. Metals failing because of lack of protection from diluted inhibitors
3. Suspended solids in the contaminate solutions are destroying the water pump seal prematurely
Partial replacements of coolants are part of the

problem!
95% of the water pump claims submitted indicated no flush completed
COOLANT CORROSION
Corrosion – Damage to a coolant systems metal components due to improper coolant protection leading to
component failure and leaks ( Metals revert back to original form)
Certain conditions will affect the degree and rate at which metal surfaces corrode
• Balanced PH (9.5-10 PH )
• High concentration of dissolved oxygen and carbon dioxides in a coolant
̶ Closed loop systems oxygen is normally consumed over time Overheating
• Incorrect coolant system temperature
• Acids form as the coolant wears
• Metal stress
Depleted coolant not
• Corrosion inhibitors diluted or not present in the coolant Protection package protecting
inadequate
Additive Package – Inorganic or organic chemicals in all
coolant that provide corrosion protection for coolant
systems
COOLANT CORROSION
Coolant corrosion can cause many problems

• Reduce heat transfer due to surface scaling
• Perforation (holes) creating leakage
• Stopped up water passages
• Damage to mechanical seals
The most common form of corrosion for aluminum is pitting

The most common form of corrosion for iron is rust
Inhibitors – Chemical compounds which are part of the coolants additive package that prevent
corrosion
Coolant system corrosion can be reduced through PH control and active inhibitors
66
WATER / WHAT TO USE?
Use only distilled, demineralized, deionized water or a 50/50 premix
 Chloride found in most tap water is corrosive

 Hard water should not be considered as it introduces calcium and magnesium into the
coolant system
Abrasion Solids – Corrosion Inhibitors plus hard water components that have
dropped out of the coolant solution that leads to premature water pump failure,
plugging of radiator heater core
67
Coolant Challenges 68
Coolants Testing Methods

• OE’s are using many different coolants
• They are not interchangeable
• Current testing equipment is not reliable
• Current service methods are inadequate
• 95% of water pump repair claims indicate no cooling system flush was performed
• Universal coolants are NOT!
• Keep the coolant the car came with – Application specific
• Test and Servicing

• Refractometer to test protection - no hydrometer (no longer ASTM approved) coolants have different specific gravities
• Don’t worry about electrolysis. If a system has measurable voltage the coolant is already bad or you have another problem
• Dip Strips are only accurate +-10 degrees, coolant must be under 120 F
• Determine clarity and color by drawing a sample off the bottom of the system after a short cool down
• Old school flushing techniques are no longer adequate
Current coolant flushing methods are ineffective at cleaning the system!

OES ARE USING MANY DIFFERENT TYPES OF ANTIFREEZE
4 TYPES OF ANTIFREEZE/COOLANT CHEMISTRY
Types Pros Cons Common

Names
IAT  Depletes quickly, shorter fluid life
Inorganic Additive Technology  Very Protective
 High solids, may form deposits
 Fast Acting Corrosion Inhibitors Conventional
Silicate
OAT  Slow acting corrosion inhibitors

Organic Acid Technology  Incompatible with other coolant types
 Non-depleting technology  Reduced non-metallic compatibility Dex-Cool ®
Organic Acid Silicate Free  Aggressive on solder
HOAT  Non-depleting technogy

Hybrid Organic Acid Technology  Fast acting corrosion inhibitors  Not compatible with OAT G-05
 Compatible with green coolants
OAT w/Silicate
 *G-05 is “pre-charged” for diesels
P-HOAT
Phosphated HOAT Technology  Not compatible with HOAT & IAT
 Non-depleting technology Asian
OAT w/Phosphate
COOLANT INHIBITORS
Statements /Disclaimers on Compatibility Or Reliability
No Warranty for Partial Replacement or Top Off!
Disclaimer Gates Fully Supports the Coolant Manufactures
Will provide extended mileage up to 5 years with complete flush

No Warranty for Partial Replacement or Top Off!
Can be used to Top Off , However , to realize the 150k or 5 year maximum they recommend a complete
cooling system flush …….
• Statement: OAT chemistry “may” be damaging to cooling systems that specify HOAT chemistry
THE COOLANT TRIANGLE OF PROTECTION
Physical properties limit its use

Water Freezes at 0 degrees C (32 degrees F)
Boils at 100 degrees C (212 degrees F)
Protection Package
Freeze Depressant Corrosion Inhibitors
Forms a thin coating on metal and restricts

– Lower freeze point of solutions access to the metal
– Higher boiling point of solutions
THE COOLANT TRIANGLE OF PROTECTION
Physical properties limit its use

Water Freezes at 0 degrees C (32 degrees F)
Boils at 100 degrees C (212 degrees F)
Protection Package
Corrosion Inhibitors
Freeze Depressant
Forms a thin coating on metal and restricts

– Lower freeze point of solutions access to the metal
– Higher boiling point of solutions
WATER PUMP FAILURE
When water pumps fail there is almost always something wrong in the cooling
system. Mechanical failure rate on water pumps is only about 2%.
Common symptoms:
• Debris in cooling system
• Exhausted add packs in coolant
• Restrictions in radiator
• Blending of coolants
• Incorrect coolant mix
WATER PUMP FAILURE MAY BE AN INDICATION OF
IMPENDING FAILURES TO COME!
Mineral deposit buildup Incompatible fluid

HOAT / OAT Failure
Flush the system if the Suspended debris in coolant
pump looks like this!
Bearing seal leak due to

water pump seal leak
Cavitation Protection package inadequate
Weep hole leak due to If Flush and Fill has not been performed, on average, customer may see
contamination water pump failure begin around 7 months / 7,700 miles
HOW WEEP HOLE LEAKS CAUSE BEARING FAILURE
Unitized Bearing with

seals
Bearing
Coolant travel path
Weep Hole
Water Pump Seal
Undamaged Seal Ring
Surface Contamination
Coolant contamination damages water pump seal
Two Separate Issues Create Water Pump Failures
Coolant properties
 Raise and lower boiling/ freeze point
 Inhibits corrosion to the metal
• Your Car/Truck has an inhibitor on the outside, what

is it called?
• What would happen if I sanded the paint off your

car?
• How long will it take this metal to fail if the inhibitors

are nonexistent or diluted?
• Tell me the feeling you would have if I threw sand in

your glass of tea?
Cross coolant
contamination and
inhibitors not protecting
the metal!
Cross coolant
Suspended solids just
contamination and
waiting to strike the water
inhibitors not protecting
pump seal, Full flush to
the metal!
wash it out!
PLASTIC WATER PUMP IMPELLERS
Because of the ability to design more sophisticated impellers plastic is more

efficient
• Incorrect coolant/water mix or lack of maintenance are the most common cause of
plastic impeller failure
• Coolant must not exceed 50/50 in plastic applications
• Cavitation caused by restrictions is a major cause of failure.
• Many hybrid applications use small electric pumps that can be damaged by over-rich
coolant mix hitting them. Impeller wheels break.
• BMW, VW and Audi have made numerous changes to coolant chemistry to resolve this.
THERMOSTATS
How they Work

• Charged cylinder is filled with wax that expands with temp and
pushes the piston up opening the valve.
• Bypass valve keeps block and head temp more uniform during warm
up and often eliminates the need for a bypass hose
Lower temp regulator - helps engine maintain a minimum

temperature
• Helps engine warm up

• Activates bypass system
• Has no effect on upper engine temperature unless it sticks closed
or it is missing.
• Replaced following an overheat
• Replaced anytime vehicle warm up time increases
• Replaced during a modern flushing operation.
THERMOSTAT / RADIATOR CAP
Radiator Cap Recommended Practice , Always Test the Cap!
̶ Release too early heat buildup

̶ Release too late pressure build up
A 50/50 mixture Of Antifreeze and water boils at

approx. 227°F.
With 14 lbs. of pressure it will increase to 263°F.
Source: Spectra Premium

COOLANT SYSTEM FAILURE
› Failure Modes
• Using Tap water

• Partial replacement of coolants
• Incompatible coolant
• Condition or contaminated coolant
• Coolant system not regularly serviced
- Bad radiator cap
- Excessive heat
- Bad ground straps
HEAT EXCHANGERS 88
What Goes Wrong?

• Leaks caused by poor coolant or expansion/contraction
• Restriction caused by deposits and debris which can result in cavitation inside and poor heat exchange
outside
• This is all true of heater cores and aux coolers like intercoolers and hybrid drive coolers
Inspecting Exchangers
• Visually inspect for debris on either the radiator or heater core fins
• A boroscope can be handy in both situations
• Temperature drops across core
• Drain down some coolant and visually inspect if possible
Temperature drop testing
• Measure from inlet to outlet
• Difference should be 10-30 degrees fan running
• Less is restricted, more is low flow
• A/B thermometer good for road testing
Coolant mixture failure Plain water
Inappropriate rust inhibitor Hard tap water with heavy minerals and scale
Source: Spectra Premium build-up
Results of Stop Leak Thermo Cycling Thermostat/cap
Improper flush -Once contaminated system left debris that Depleted inhibitors not protecting the cooling
clog the radiator and cause erosion and other problems. system from corrosion.
CONDITION OF COOLANT

CONDITION OF COOLANT
Over Heating
Coolant without corrosion inhibitors become

acid and oxidizes the aluminum making it black.
Barrier Coatings / Failures
Add packs in antifreeze react with engine parts. Debris in system can be a result of:
• Different in each formula - not mixable • Add pack exhaustion causing fall out of silicates or
rust formation.
• Mixing can create a slimy coating that impedes heat sink effect with • Sand left in block from casting
coolant
• Component damage from cavitation breaking off
• OAT Coolants like Dexcool can take many miles to lay down a barrier small pieces.
coating. If there is too much of any other package in there rapid • Oxygen entering system due to leaks, low coolant,
corrosion can occur. bad cap
• Using an OAT coolant in a system not designed for it can cause • Using tap water
cavitation resulting in water pump and cylinder wall damage
• If a system has been contaminated you will have to flush with water and
a mild chemical cleaner to remove contamination and old barrier
coating.
Damage can be caused by:
• Over-mixing coolant causing too high of viscosity and low protection
levels
• Engine overheat - coolant should be flushed and replaced following an
overheat along with cap and t-stat.
• Wrong of mixed coolants
• Depleted add packs allowing corrosion or cavitation
BEST PRACTICES (RULE OF THUMB)
• About 3-5 years/60K

• Any time you replace a coolant component, flush the system to renew the coolant/inhibitors
• If you suspect the coolant is contaminated, flush the system to protect it
• If your customer can’t verify the validity of their coolant, flush and replace for your protection as well as
theirs
• If replaced component is discolored, pitted or rusty, the only option for long term protection is to flush and
replace the coolant
• If there is a overheat situation / replace, coolant, cap and stat
• To minimize mineral content, use only deionized or distilled water
• The use of hard water will escalate scaling on metal engine components
• Remember; the use of the wrong coolant can facilitate boil over, freezing, cavitation pitting, rust or
corrosion buildup or hose leaks
COOLANT EXCHANGE REVIEW PROCESS
Flush and Fill Procedure – (Acceptable Procedure)

 Coolant drained, repair made. Flush and Fill manually or with proper machine utilizing a flushing solvent. Add 50/50
coolant to water ratio. Test Glycol level after run & cool down . Provides best protection to years or mileage
Water Hose Wash Procedure (Unacceptable results)

 Coolant drained, repairs made and system flushed with a garden hose; new coolant/water added, possible
contamination once the engine is restarted
Drain and Refill Procedure (Unacceptable results)

 Coolant drained from radiator, repair made, radiator refilled with new coolant. Engine block can hold 15 to 30 percent
after drained contaminating new coolant. (Depending on automotive or HD Vehicle)
Only a 17% inter-mix of coolants can create catastrophic failures!

FLUSHING THE SYSTEM
Flushing
• Flushing equipment should be updated to a pulsing component by component approach
• As a solution, Gates has a tool that is recommended by OE’s for back flushing heater cores. This tool works
extremely well to flush the engine and radiator
• It is most effective to flush components backwards and then forwards
• Many vehicles will need the thermostat removed to effectively flush the engine
• If you capture the debris you wash out of the system customers will have a visual understanding of how this is
a benefit
• Some water is left behind so you must blow out, add virgin antifreeze and use your refractometer to get the
mix right.
If you have a
flush machine ….
Teach With IT!
SYSTEM REFILL AFTER POWER CLEAN
• Some water left behind - blow it out

• Use an air lift system to ensure there are no leaks
• Add approximate amount of virgin antifreeze first to offset left over water in engine.
• Fill rest of system with 50/50 premixed coolant leaving it about a pint to a quart low
depending on system capacity
• Run engine for a couple of minute to mix coolant
Garden Hose Power Clean
Engine Flush Results

Engine Flush
Results – Garden
Hose vs. Power
Clean Radiator Flush Results
Heater Core Flush Results

FLUSHING THE SYSTEM WITH POWER CLEAN #91002
Engine Flush
Results – Garden
Click Hose vs. Power
Clean
Garden Hose Power Clean
Engine Flush
Results
Radiator
Flush Results
Heater Core
Power Clean # 91002 Flush Results
TRAINING 24 / 7 FROM GATES CORPORATION
http://navigates.gates.com
Vist phone app store for NAViGates for
your phone For Student Learning
http://gatesaftermarkettrainingcenter.com/
YOU ARE THE
For additional information on this presentation or the Gates https://www.youtube.com/user/GatesAutoAftermarket

Tools for Schools program contact Bobby Bassett
robert.bassett@gates.com or your local Gates representatives Trained
Systems Initiative
TOOLS FOR KNOWLEDGE
Part # 91078
Part # 91075

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We Can’t Do It Like We Used To!

• Industry Information / Warranties

Scholarships totaling $130,000 have been awarded

The recipients attend or will attend a two-year

Text 720-903-2206 to begin your scholarship process

• Check the tire pressure. Fill with

• Tire repair in a can?

• Ignore the problem for as long as

• Suggest finding the root cause of

SOMETIMES IT’S SIMPLE – SOMETIMES IT’S NOT

What are your top 5 reasons for increased component

Read All Instructions before beginning repair !

Sampling of alleged warranties returned to factory

If you are replacing the same

• Didn’t have the time / Too busy

Replacement Rate by Mileage Ranges for the

• Material can be modified for special applications

• Material can be modified for special applications

• Material can be modified for special applications

Belt Whip or Flutter

• Creates Torsional Vibration

Solution Create a Aramid cord belt

Traditional belt wear signs no longer apply for EPDM belt !

Parts in the System:

How to use the belt wear gauge

QUICK AND EASY WAY TO INSPECT YOUR SERPENTINE BELT IN SECONDS

!00% System Inspection if belt is remove for any reason.

PAT Related Belt Failures Click

Step 2. Attempt to recreate the problem in the service bay

Important Note : Never use Belt Dressing or Carb cleaner!

Alignment Related Chirp / Engine off

• Observe system running noting tensioner operation/ belt

• Use Laser Alignment tool #91075

# 4 Contamination # 5 Contact with Engine

Broken # 7 Belt Cracking

The tensioner performs two job functions

Cycles a billion times in 100,000 miles

Tensioner Has Four Failure Modes

• Spring begins to fail creating belt slippage Spin Cycle Test

Torsional Vibration / Hammering

• A Tire has to have 4 things to insure Proper Performance

• A Belt has to have 4 things to insure Proper Performance

• Proper Rib Depth (Tread)

Belts and tensioner were designed as a system

• Check the Tensioner Problems Problem Alignment Challenges

Right Hand Left Hand

Moved to Hi Amp Alternators

 The purpose of an ADP is to allow the alternator to declutch/free

Each time a cylinder fires

• These firing pulses speed up and slow down the alternator

• The lower the RPM, the higher the Torsional Vibration

• It’s a Sacrificial component and failure can show up as early as 40 to 60,000

– Identify that the alternator does have an ADP first

Observe the ABDSystem in operation before removing belt

• Spray bottle test for tension/alignment challenges

BELT FAILURE BEGINS WITH ALIGNMENT / TENSION RELATED CHALLENGE

• Performing a complete system repair doesn't add much time, but

To be eligible for Lifetime Warranty Shop Registers at www.Gates.com/CompleteKits