LESSON PLAN

Week: 06 Taught By: Engr. Kashif Usman

Subject: Problem in Internal Combustion Engine Class: 2nd Year

Mechanical Department Time: 70 minutes
Topic: Cooling System Problems
Objective(s): Students will be able to:
 Find the problems of engine overheating.
 Tension in Flat Belt
 Slow engine warm up
 Amount of Coolant
 Size of water pump
 Fan capacity
 Air distribution
 Heat Transfer
 Dirt, scale ooil and cavitations
Skill focused on: Engine overheating reasons
Resources:
White Board, Marker, PowerPoint Presentations
Methodology:
At the beginning of the class, I will give a brief introduction on engine overheating. After that, the
following topics will be taught using Working Model of engine:

Common reasons for overheating engines
Too little or no coolant. Driving without proper levels of coolant/antifreeze may cause a coolant
system failure. ...
Cooling system leaks. ...
A broken water pump. ...
Radiator issues. ...
Oil too low. ...
Thermostat failure. ...
Issues with the belts and hoses. ...
Heater core is plugged up.

5 Main Types of Blowers

 Positive Displacement / Rotary Lobe Blowers. A positive displacement blower has a
function that's straightforward yet effective. ...
  Helical Screw Blowers. Each helical screw blower has a main rotor with two lobes. ...
 Centrifugal Blowers. ...
 High Speed Blowers. ...
 Regenerative Blowers

Introduction:
A cooling system is extremely important to the performance and service life of an engine Major
engine damage could occur in minutes without proper cooling.
Combustion heat could effect in the metal engine parts. The heat could melt piston, crack or wrap
the cylinder head or hock, cause valves to burn or the head gasket to “blow”. This chapter
discusses these problems.
In an efficient cooling system in good order there is fairly equal distribution of heat throughout,
with higher temperature at components in higher position. Blockages and air locks can usually
detected by noting the sudden change in temperature at the location of the fault. Any engine oil
leaking into the coolant through a faulty head gasket or cracked jacket will soften the inner walls
of hoses. A thermometer should be used to check that the working temperature of the engine is
kept within the range recommended by the manufacturer, usually between 75°C and 95°C. The
fan belt should be free from cracks or loose material and must not he so thin as to ‘bottom’ in the
vee pulley when ii will slip under load.
A small crack in the cylinder head or a leaking gasket may shown-up only under heavy engine load
conditions. Loss of coolant or a high running temperature not found during stationary tests may
be due to these defects.
Faulty ignition, carbonation, and compression may each give rise to overheating. Overcooling
causes loose of power and poor fuel economy. A temperature test is an essential feature of check
of engine performance).

Overheating of Engine:
Too high a running temperature may lead to local boiling at critical sports in the cylinder head or
block — for example around the sparking plug and exhaust valve sealing. This is apt to cause pre-
ignition although there may be no outward sign of boiling.
Engine overheating is a serious problem that can cause major engine damage. The driver may
notice the engine temperature light glowing, temperature gauge reading high, or coolant boiling.
Boiling coolant will expand and blow out though the overflow as steam.
Common causes of engine overheating are:
1. Low Coolant Level (leak or lack of maintenance has allowed coolant level in engine and radiator
to drop too low.
2. Rust or Scale (mineral accumulations in system have clogged radiator core or built up in water
jackets).
3. Stuck Thermostat (thermostat fails to open normally, restricts coolant flow.
4. Retarted Ignition Timing (late ignition timing allows combustion flame to blow out open
exhaust valve transferring too much heat into exhaust valves, ports, and manifold).
5. Loose Fan Belt (water pump drive belt slips under load and reduces coolant circulation).
6. Bad Water Pump (broken pump shaft or damaged impeller blades prevent normally pumping
action).
7. Collapsed Lower Hose (suction from water pump may flatten hose if spring is missing or hose is
badly deteriorated).
8. Missing Fan Shoround (air circulates between fan and back of radiator, reducing air how
through radiator).
9. Ice In Coolant (coolant frozen from lack of antifreeze can block circulation and cause
overheating).
10. Engine Fan Problems (fan clutch or electric fan troubles can prevent adequate airflow through
radiation).
Any of these or other troubles can make the engine overheat. You must use your knowledge of
system operation and basic testing methods to find the problem’s sources.
Note: Some Scanners (computer testers) will give temperature sensor readings. This might be
helpful when trying to solve engine overheating and other related problems.)

Anti Freeze:
Antifreeze, usually ethylene glycol is mixed with water to produce the engine coolant. Antifreeze
has several functions.
Prevent winter freeze up
Antifreeze keeps the coolant from freezing in very cold weather (outside temperature below 32°F
0°C).
Coolant freezing can cause serious cooling system or engine damage. As ice forms, it expands.
This expansion can produce tons of force. The water pump housing, cylinder head, engine block,
radiator, or other parts could be cracked and ruined.

Prevent rust and corrosion

Antifreeze also prevents rust and corrosion inside the cooling system. It provides a protective film
on par surfaces.
Lubricates water pump.
Antifreeze acts as a lubricant for the water pump. Ii increases the service life of the water pump
bearings and seals.
Cools the engine
Antifreeze conducts heat better than plain water and, therefore, cools the engine better. It is
normally recommended in hot weather.
For example, air conditioning increases the temperature of the air flowing through the radiator.
Antifreeze can help prevent overheating in very hot weather when the air conditioning is on.
Antifreeze/water mixture.
For ideal cooling and winter protection from freeze up, a 50/50 mixture of water and antifreeze is
usually recommended. It will provide protection from ice formation to about — 34°F (-36.7°C).
higher ratios of antifreeze may produce even lower freezing temperatures but this much
protection is not normally needed.
Note
Plain water should never be used in cooling system or low antifreeze functions just discussed will
not be provided.
Effect of Diet, Scale, Oil and Contaminations on Heat Transfer:
In an automotive engine, heat flows or transfer from the iron or aluminum cylinder to the cooling
water, and from coolant to the copper or aluminum radiator, iron, aluminum, copper and water
are all good conductors of heat, if they are in good contact with one another, the heat will flow
readily from one to another.
The following are the defects that may causes engine overheat due to the dirt, scale, oil and other
contaminants.
Scale deposits collect in corners to pockets of the water jacket, where the water circulation is
sluggish. The result is a mass of insulating sludge and scale, which does considerable harm to the
engine. This can he avoided by proper maintenance of the cooling system by periodic flushing on
the cooling system.
Oil leakage into cooling system will cause sludge may occur. An accumulation of sludge in the
radiator passage which act as an insulator to prevent heat flowing from water to copper radiator
core. This reduces the size of the passages and thus reduces the amount of water going through
core. Therefore les heat is extracted.
Most important of all, it must be borne in mind that almost always the trouble is the result o
several minor defects rather than one major fault.
For example, some dirt on the radiator core, plus a slipping fan belt, plus a long hill, plus a hot
day. No single one of these things would be liable to cause trouble but in combination they can
cause serious overheating. Therefore, when trying to overcome difficulty in cooling system, it is
necessary to make a thorough check rather than decide than the trouble is in the radiator.

Cooling System Problems:

A cooling system is extremely important to the performance and service life of an engine Major
engine damage could occur in minutes without proper cooling. Combustion heat could effect in
the metal engine parts. The heat could melt piston, crack or wrap the cylinder head or hock,
cause valves to burn or the head gasket to “blow”. This chapter discusses these problems. In an
efficient cooling system in good order there is fairly equal distribution of heat throughout, with
higher temperature at components in higher position. Blockages and air locks can usually
detected by noting the sudden change in temperature at the location of the fault. Any engine oil
leaking into the coolant through a faulty head gasket or cracked jacket will soften the inner walls
of hoses. A thermometer should be used to check that the working temperature of the engine is
kept within the range recommended by the manufacturer, usually between 75°C and 95°C. The
fan belt should be free from cracks or loose material and must not he so thin as to ‘bottom’ in the
vee pulley when ii will slip under load.
A small crack in the cylinder head or a leaking gasket may shown-up only under heavy engine load
conditions. Loss of coolant or a high running temperature not found during stationary tests may
be due to these defects.
Faulty ignition, carbonation, and compression may each give rise to overheating.
Overcooling causes loose of power and poor fuel economy. A temperature test is an essential
feature of check of engine performance).
Activity– 1:Discussion on engine overheating by Group-1
Success Criteria:

C.W: Nil
H.W:Maintain Practical Notebook

HoD Sign: ______________ Date: __________________