COOLING SYSTEM

1. AIR COOLING
2. LIQUID COOLING

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AIR COOLING
 Direct Cooling

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 WATER COOLING (Indirect air-cooling)

 Thermo-Siphon Cooling System

 Forced Circulation (or) Pump Assisted
Pressurized Cooling System

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Heating System

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• The main component parts of a pump
assisted pressurized cooling system are:
1. Water jacket 4. Cooling fan
2. Radiator 5. Thermostat
3. Water pump 6. pressure cap

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 Water jacket

• Water jackets are cast as an integral part

of the cylinder block and cylinder head to
provide passages or galleries around the
cylinders, combustion chambers, valve
seats, etc., for the circulation of the
coolant

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 Radiator
• Is used to transfer heat from the coolant to the
surrounding air stream.
A radiator typically consists of five components:
• Radiator core—Center section of the radiator. Made
up of tubes and cooling fins.
• Radiator tanks—Metal or plastic ends that fit over the
core tube ends to provide storage for coolant and
fittings for hoses.
• Radiator filler neck—Opening for adding coolant,
Also holds the radiator cap and overflow tube.
• Radiator cap
• Radiator petcock—Fitting on the bottom of tank for
draining coolant.

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 Parts & Types

Down flow Cross flow 14

(Fins) 15
 Water pump
• The major parts of a typical water pump include the.

• Water pump impeller—Disk with fan-like blades, the

impeller spins and produces pressure and flow,
• Water pump shaft—Steel shaft that transfers turning
force from the hub to the impeller.
• Water pump seal—Prevents coolant leakage between
pump shaft and pump housing,
• Water pump bearings—Plain or ball bearings that
allow the pump shaft to spin freely in housing.
• Water pump hub—Provides mounting place for belt
pulley and fan.
• Water pump housing—Iron or aluminum casting
that forms the main body of pump.
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 Cooling fan
• A cooling system fan pulls air through the
core of the radiator and over the engine to
help remove heat.
• It increases the volume of air flowing
through the radiator, especially when the
car is standing still.
• The fan is driven by a fan belt from the
engine or an electric motor.
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 1.Engine-Powered Fans
• An engine-powered fan bolts to the water
pump hub and pulley.
• A flex fan has thin, flexible blades that alter
airflow with engine speed. At low speeds,
the fan blades remain curved and pull air
through the radiator. At higher engine
speeds, the blades flex until they are almost
straight. This reduces fan action and saves
engine power.

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2. A thermostatic fan clutch has a
temperature sensitive, bimetal spring that
controls fan action. The spring controls oil
flow in the fan clutch. When cold, the spring
causes the clutch to slip, speeding engine
warm up. After reaching operating
temperature, it locks the clutch, providing
forced-air circulation.
• The fan only operates when the engine is
hot and the spring activates the clutch
mechanism. 21
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 3.Electric Cooling Fans
• An electric cooling fan uses an electric
motor and a thermostatic switch (coolant
temperature sensor) to provide cooling
action.
• An electric fan is needed on front- wheel-
drive cars having transverse-mounted
engines. In these vehicles, the water pump is
normally located away from the radiator.
Nevertheless, electric engine fans can be
used on any engine/transmission layout. 23
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• The fan motor is a small dc (direct current)
motor. It mounts on a bracket secured to the
radiator. A metal or plastic fan blade mounts
on the end of the motor shaft to cause airflow.
• An electric fan saves energy and increases
cooling system efficiency. Because it only
functions when needed, it helps speed engine
warm-up. This reduces emissions and fuel
consumption. In cold weather, the electric fan
may shut off at highway speeds. There may be
enough cool air rushing through the grille to
provide adequate cooling.
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 Thermostat
• The thermostat senses engine temperature
and controls coolant flow through the
radiator.
• It reduces coolant flow when the engine is
cold and increases coolant flow when the
engine is hot.
• The thermostat normally fits under a
thermostat housing between the engine and
the end of the upper radiator hose.
• Thermostats can be located at either the
coolant inlet or outlet on the engine. 27
 Thermostat Rating
• A thermostat rating is stamped on the
thermostat to indicate the operating
(opening) temperature of the thermostat.
Normal ratings are between 180°F and
195°F (82°C and 91°C).

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 Types of Thermostats
1.Bellows Type Thermostat

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Operation
• Engine cold: When the engine is cold, the disc
valve of the thermostat is held on its seating by the
contraction of the bellows. In this situation there can
be no flow of coolant between the cylinder head and
the radiator.
• Engine hot: As the engine warms up, the coolant in
the jacket is heated, which in turn heats the volatile
liquid contained within the bellows. This increase in
pressure causes the bellows to expand and lift the
valve off its seat. The coolant is then free to flow
through the open valve and circulate through the
radiator to be cooled.

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2.Wax Type Thermostat
A) When coolant is cold, the thermostat
remains closed due to spring tension. The water
pump forces coolant to circulate in engine, but
not through the radiator.

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B) When coolant is hot, the thermostat
opens. The pump can then push coolant
through the engine and the radiator.

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 pressure cap
The radiator cap performs several functions:
• Seals the top of the radiator filler neck to prevent
leakage.
• Pressurizes the system to raise the boiling point
of coolant. This keeps coolant from boiling and
turning to steam.
• Relieves excess pressure to protect against
system damage.
• When cold it prevents the radiator from
collapsing by allowing coolant flow to the
radiator.
• In closed systems, it allows coolant flow between
the radiator and the coolant reservoir (expansion
tank).
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Radiator Cap Pressure Valve
• The radiator cap pressure valve, consists of a
spring-loaded disk that contacts the filler neck. The
spring pushes the valve into the neck to form a seal
and increase the pressure.
• When water is placed under pressure, its boiling
point increases.
• But If the engine overheats and pressure exceeds
the cap rating, the pressure valve opens. Excess
pressure and steam force the coolant out of the
overflow tube and into the reservoir (or onto the
ground in older systems). This prevents high
pressure from rupturing the radiator, gaskets, seals,
or hoses.
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Radiator Cap Vacuum Valve
• The radiator cap vacuum valve opens to
allow flow back into the radiator when the
coolant temperature drops after engine is
stoped. It is often a small valve located in
the center of the bottom of the cap.
• The cooling and contraction of the coolant
and air in the system decrease the coolant
volume and pressure. Without a cap
vacuum valve, the radiator hoses and
radiator tanks could collapse from outside
pressure. 35
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PRESSURE VALVE OPENED

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 Anti-Freeze & Inhibiting Solutions
Antifreeze
• Antifreeze, usually ethylene glycol, is
mixed with water to produce engine
coolant.
Functions of Anti freez:
• It prevents winter freeze up,
• prevents rust and corrosion,
• lubricates the water pump, and cools the
engine.
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Caution!
• Plain water should never be used in a
cooling system, If used the four
antifreeze functions just discussed
will not be provided.

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Inhibiting Solutions
• Corrosion inhibitors such as benzotriazole
or tolytriazole are added to coolant which
prevent corrosive attack on the internal
components of the cooling system.
• Other compounds such as phosphoric acid
and sodium tetra borate may be added to
improve the quality of the antifreeze
solution.
• A dye stuff like fluorescein may be used to
give the solution an identifying colour.

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 Flushing a Cooling System
• Flushing (cleaning) of a cooling system should be
done when rust or scale is found in the system.
Flushing involves running a cleaning chemical through
the cooling system. This dissolves and washes out
contaminants.
• Reverse flushing of a radiator requires a special
adapter that is connected to the radiator outlet tank by
a piece of hose. Another hose is attached to the inlet
tank. Compressed air, under low pressure, is used to
force a cleaning solution backwards. This can be done
on the engine block as well.

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 Cooling System Pressure Test

• A cooling system pressure test is used

to quickly locate leaks. Low air pressure is
forced into the system. This will cause
coolant to pour or drip from any leak in the
cooling system.
• A pressure tester is a hand-operated air
pump used to pressurize the cooling
system for leak detection. It is one of the
most commonly used and important
cooling system testing devices.
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