Chapter 2.

1 –
Cooling System
Prepared by
MUHAMMAD HILMI BIN
ZAID
SUMMARY
 The topic covers basic theoretical knowledge on
engine cooling systems. Areas involving type,
function and working principles of cooling
systems and its components. Coolant or anti-freeze
is also discussed in this topic.
SYLLABUS
 Understand function, construction and operation of cooling system
and its components
 Describe types of cooling system:
 Air-cooled
 Water-cooled
 Explain the function, construction and operation of water cooling
system and its components:
 Radiator
 Water pump
 Thermostat
 Radiator pressure cap
 Radiator fan
 Water temperature indicator
 Expansion tank
 Understand different types of coolants/anti-freeze
 Explain various types of coolants/anti-freeze:
 Ethylene glycol
 Propylene glycol
 Organic Acid Technology
 Hybrid Organic Acid Technology
 INTRODUCTION

Metal temperatures
This heat can
Today’s engines Most of this heat is around the
destroy the engine
create a tremendous generated during combustion chamber
and must be
amount of heat. combustion. can run as high as
removed.
1,000°F (537.7°C).
Purpose of Cooling System
 Purpose - To remove the
excessive heat from the engine
to avoid components in the
engine damaged.
 Too much cooling is also not
desirable because it reduces the
thermal efficiency.
 The engine will perform best in
the desired operating
temperature.
TYPES OF COOLING
SYSTEM
 Air-cooledsystem
 Water-cooled system
Air-cooled System
 Air cooled system is generally used
in small engines such as 15-20 kW
and in aero plane engines.
 In this system fins or extended
surfaces are provided on the
cylinder walls, cylinder head, etc.
 Heat generated due to combustion in
the engine cylinder will be
conducted to the fins and when the
air flows over the fins, heat will be
dissipated to air.
Factors affect cooling efficiency
 The amount of heat dissipated to
air depends upon :
1) Amount of air flowing
through the fins.
2) Fin surface area.
3) Thermal conductivity of metal
used for fins
Advantages
 System is light because radiator/pump is absent.
 Coolant and antifreeze solutions are not
required.
 There are no leakages.
 Can be used in cold climates, where if water is
used it may freeze.
Disadvantages
 Comparatively it is less efficient.
 Only applicable to engines which are exposed to
air directly. (aero planes and motorcycle)
Water-cooled System
 In this method, cooling water jackets are provided
around the cylinder, cylinder head, valve seats etc.
 The water when circulated through the jackets, it
absorbs heat of combustion.
 This hot water will then be cooling in the radiator
partially by a fan and partially by the flow
developed by the forward motion of the vehicle.
 The cooled water is again recirculated through the
water jackets.
Types of water-cooled system
 Thermo Siphon System
 In this system the circulation of water is due to
difference in temperature (i.e. difference in densities)
of water. So in this system pump is not required but
water is circulated because of density difference only.
 Pump Circulation System
 In this system circulation of water is obtained by a
pump. This pump is driven by engine output shaft
through belts.
Thermo Siphon System
Pump Circulation System
Working principle of water-cooled system.

Heat is removed The cooled coolant

A pump moves the The coolant flows to Ram air and the
from around the leaves the radiator
coolant through the the top of the airflow from the
combustion and enters the water
engine block and radiator and loses cooling fan move
chambers by a pump then its sent
then through the heat as it flows down through the radiator
coolant circulating back through the
cylinder head. through the radiator. and cool the coolant.
inside the engine. engine.
Working principle of water-cooled
system.
Components
 Radiator
 Water pump
 Thermostat
 Radiator pressure cap
 Expansion tank
 Radiator fan
 Water temperature indicator
Radiator
 The radiator is basically a heat
exchanger, transferring heat from the
engine to the air passing through it.
 The radiator itself is a series of tubes and
fins (collectively called the core) that
expose the coolant’s heat to as much
surface area as possible.
 Plastic or aluminum tanks are attached to the sides
or top and bottom of the core.
 One tank holds hot coolant and the other holds the
cooled coolant.
 Cores are normally comprised of flattened
aluminum tubes surrounded by thin aluminum fins.
 The fins conduct the heat from the tubes to the air
flowing through the radiator.
 Most radiators have draincock or plugs near the
bottom.
 Coolant is added at the radiator cap or the recovery
tank.
 Design of radiators
 Radiators are normally based
on one of two designs:
 In a down-flow radiator,
coolant enters the top of the
radiator and is drawn
downward by gravity.
 In a cross-flow radiator,
coolant enters on one side,
travels through tubes, and
collects on the opposite side.
Water Pump
 The heart of the cooling system is
the water pump.
 Its job is to move the coolant
through the system.
 Typically the water pump is driven
by the crankshaft through pulleys
and a drive belt
 The pumps are centrifugal-type
pumps with a rotating impeller
to move the coolant.
 The shaft is mounted in the
water pump housing and rotates
on bearings.
 The pump has a seal to keep the
coolant from passing through it.
 The inlet of the pump connects
to the lower radiator hose, and
its outlet connects to the engine
block.
Thermostat
 A thermostat is a temperature-responsive coolant flow
control valve.
 It controls the temperature and amount of coolant entering the
radiator.
 Most thermostats are located on the top and front of an engine.
How it works?
 While the engine is cold, the thermostat remains closed, allowing
coolant to only circulate in the engine.
 This allows the engine to uniformly warm up.
 When the coolant reaches a specified temperature, the thermostat
begins to open and allows coolant to flow to the radiator.
 The hotter the coolant gets, the more the thermostat opens, sending
more coolant to the radiator.
Radiator Pressure Cap
 Radiator caps keep the coolant from
splashing out of the radiator.
 They also keep the coolant’s temperature
within a desired range by keeping the
coolant pressurized to a specified level.
 The pressure raises the boiling point of
the coolant.
 This allows the coolant to reach higher
than normal temperatures without
boiling.
 This also allows the coolant to absorb more heat
from the engine and more heat to transfer from
the radiator core to outside air.
 This is due to a basic law of nature that states that
the greater the heat difference is between two
objects, the faster the heat of the hotter object will
move to the cooler object.
 The pressure in the system is regulated by a
pressure relief or vent valve in the radiator cap.

When the pressure reaches the pressure rating

of the cap, it pushes up on the spring in the
pressure relief valve.

This opens the valve and allows excess pressure

to exit the radiator.

When enough pressure has been released, to

drop system pressure below the cap’s rating,
the spring will close the pressure relief valve.
Expansion tank
 All late-model cooling systems
have an expansion or recovery
tank.
 Cooling systems with expansion
tanks are called closed-cooling
systems.
 They are designed to catch and
hold any coolant that passes
through the pressure cap.
 How it works?

The vacuum release

As the engine warms The coolant passes to valve inside the
up, the coolant an expansion tank. pressure cap opens and
expands. This When the engine is the coolant in the
eventually causes the shut down, the coolant expansion tank is
pressure cap to release. begins to shrink. drawn back into the
cooling system.
Radiator Fan
 The efficiency of the cooling system depends on
the amount of heat that can be removed from the
system and transferred to the air.
 At high speeds, the ram air through the radiator
should be sufficient/enough to maintain proper
cooling.
 At low speeds and idle, the system needs
additional air. This air is delivered by a fan.
 The fan may be driven by the engine, via a belt, or
driven by an electric motor.
 A belt-driven fan is bolted to a pulley on the water
pump and turns constantly with the engine.
 Thus, belt-driven fans always draw air through the
radiator from the rear.
 Water Temperature Indicator
 Coolant temperature indicators alert
the driver of an overheating condition.
 These indicators are a temperature
gauge and/or a warning light.
 A temperature sensor is threaded into a
bore in a water jacket.
Coolant/Anti-freeze
 Engine coolant is a mixture of water and antifreeze/coolant.
 Water alone has a boiling point of 100°C and a freezing point
of 0°C at sea level.
 Engine coolant has a higher boiling temperature and a
lower freezing point than water.
 The exact boiling or freezing temperatures depend on the
mixture.
 The typical recommended mixture is a 50/50 solution of water
and antifreeze/coolant.
Types of Coolant/Anti-freeze
 Ethylene glycol
 Propylene glycol
 Organic acid technology (OAT)
 Hybrid organic acid technology (HOAT)
Ethylene glycol
 This is the most commonly used
antifreeze/coolant.
 It is green in color and provides good protection
regardless of climate, but it is poisonous.
 Should be handled carefully and disposed of
properly.
 Sweet tasting (accidental ingestion or as a murder
weapon)
Propylene glycol
 This type has the same basic characteristics as
ethylene glycol-based coolant but is not sweet tasting.
 Less harmful to animals and children. (non-toxic
antifreeze)
 Used when ethylene-glycol is inappropriate such as in
food processing system or water pipes system in
homes.
 Propylene glycol-based coolants should not be mixed
with ethylene glycol.
Organic Acid Technology (OAT)
 This coolant is also environmentally friendly and
contains zero phosphates or silicones.
 This orange coolant is often referred to by a brand
name “DEX-COOL” and is used in all late-model
GM vehicles.
 Extended service life of 240 000 km.
Hybrid organic acid technology
(HOAT)
 This is similar to OAT coolant but has been
enhanced with additives (silicates or phosphates)
that make the coolant less abrasive to water
pumps
Advantages of Water-Cooled System
 Uniform cooling of cylinder, cylinder head and
valves.
 Fuel consumption improved by using water
cooling system.
 Engine is less noisy as compared with air cooled
engines, as it has water for damping noise.
Disadvantages of Water-Cooled
System
 It depends upon the supply of water.
 The water pump which circulates water absorbs
considerable power.
 If the water cooling system fails then it will result in
severe damage of engine.
 The water cooling system is high cost as it has more
parts.
 Also it requires more maintenance and care for its
parts.
VIDEO
 https://www.youtube.com/watch?v=V7inC4lOpGs
 https://www.youtube.com/watch?v=2OXMY0QpUWs
Exercise
 Why is cooling necessary for IC engine?
 Explain in brief the methods of cooling of IC
engine.
 Differentiate between air cooling system and water
cooling system.
 What is the purpose of the fins in an air-cooled
system?
 Explain the function of thermostat?
Thank You