Engine Cooling Systems

Chapter 39 – Modern Automotive Technology

1
 Engine Cooling Systems
Purpose of the Cooling system:

A cooling system must:

- Remove excess heat from the engine compartment
- Maintain a constant engine operating temperature
- Increase the temperature of a cold engine quickly
- Provide a means for warming the passenger compartment

2
 Engine Cooling Systems

Engine temperatures can reach up to 2500°C

 This heat needs to be controlled so the engine is not damaged!

If excess heat is not removed from the engine serious damage
can be caused to the engine in a matter of minutes.

3
 Engine Cooling Systems
Maintaining Operating Temperature:

The temperature the engine coolant reaches under normal

operating temperatures (180°F – 210°F or 80°C – 100°C)

At proper operating temperature parts expand to ensure:

-All part clearances are correct
-Proper combustion occurs
-Emission output is reduced
-Proper engine performance is achieved

4
 Engine Cooling Systems
Reaching Operating Temperature Quickly:

Warm up must happen rapidly to prevent:

- Poor Combustion
- Part wear
- Oil contamination
- Reduced fuel economy
- Increased emissions
- Etc.

5
 Heating the inside of the car…

• Hot engine coolant is sent to a heater core through the heater

hoses
• The heater fan blows air through the heater core to warm the
interior of the car
• The flow of coolant through the heater core is
controlled by the passengers in the vehicle

6
 Cooling the Coolant

 Once the engine coolant reaches ≈100°C or more, it must be re-cooled so that it can
continue to remove excess heat from the engine.

 The radiator, water pump and thermostat work together to lower coolant temperature

7
 Cooling the Coolant

The radiator removes excess heat from the engine coolant using
cold air that passes through its fins.

8
 Coolant Circulation
• The water pump pushes engine coolant out of the water jackets and
into the radiator so that excess heat from the coolant can be
removed.

9
 Coolant Circulation
• The thermostat opens when the coolant is hot to allow coolant to
flow to the radiator and closes when the coolant is cold to allow the
engine to maintain its proper operating temperature.

10
 Types of Cooling Systems

• Air Cooled - Not commonly found in passenger vehicles

- Mostly found on small engines / motorcycles

• Liquid Cooled - Most common type found in Passenger vehicles

• Both air & liquid cooling systems have 4 main jobs…

1) To remove excess heat from engine parts

2) To maintain a consistent operating temperature
3) To allow the engine to reach normal operating temperature as
quickly as possible
4) Provide a means of warming the passenger compartment

11
 Types of Cooling Systems
• Air Cooled - Not commonly found in passenger vehicles
- Mostly found on small engines / motorcycles

-Uses large fins and outside air to remove excess heat from the engine
-The fins increase the surface area of the metal around the cylinder
allowing enough heat to be transferred from the engine to the outside
air
-Commonly uses plastic
or metal ducts or shrouds
to route air over the cylinder
fins.
-Thermostatically controlled
flaps regulate airflow and
engine operating temperature 12
 Types of Cooling Systems

• Liquid Cooled - Most common type found in Passenger vehicles

Circulates coolant through the water jackets

Coolant collects excess heat and carries it out of the engine.

Advantages over air cooled:

- More precise control of engine operating temperature

- Less temperature variation inside engine
- Reduced exhaust emission because of better temperature
control
- Improved heater operation to warm passengers
13
 Controlling the Heat
 Hollow passages called water jackets surround
the cylinders and valve chambers.

 The water jackets are filled with a 50/50 mixture

of water and antifreeze (coolant).

 The engine coolant absorbs the excess heat from

the cylinders, valves & combustion chamber area.

14
 Types of Cooling Systems

Conventional and Reverse Flow Cooling:

Conventional Flow – hot coolant flows from the cylinder head to
the radiator and back to the engine block (most common)

Reverse Flow – Cool coolant enters the head and hot coolant
exits the block to return to the radiator.
- Helps keep a more uniform temperature throughout the
engine especially around the hot exhaust valves.
- Is mostly found in HIGH PERFORMANCE ENGINES.

15
 Components of Cooling Systems

• Coolant • Coolant Temperature Sensor

• Water pump • Engine Cooling Fan
• Radiator • Interior Heater Fan
• Radiator Cap • Heater Core
• Radiator Hoses • Heater hoses
• Overflow (Reserve) Tank • Frost plugs
• Thermostat • Drive belt

16
 Water Pump

Water Pump: Impeller or centrifugal pump that forces coolant

through the engine block, cylinder head, intake manifold, hoses
and radiator.

- Usually belt driven off of the crankshaft pulley

- Can be made of steel or plastic.

- Blades can be curved or straight (straight blades, like

paddle wheels, are sometimes used to reduce engine power
consumptions.

17
 Water Pump
Water Pump parts:
Impeller: Disk with fan like blades; spins to produce
pressure and flow
Shaft: Steel shaft that transfers turning force from the hub
to the impeller
Seal: Prevents coolant leakage between pump shaft and
pump housing
Bearings: plain or ball bearings that allow the pump shaft
to spin freely in housing
Hub: Provides mounting place for belt pulley and fan
Housing: iron or aluminum casting that forms the main
body of pump
Gasket: Fits between the engine and pump housing to
prevent coolant leakage 18
Water Pump Parts

19
 Water Pump
Water Pump Operation:
The spinning engine crankshaft pulley causes the drive belt
to turn the water pump pulley, pump shaft and impeller. The
coolant trapped between the impeller blades is thrown outwards
by centrifugal force. Coolant is pulled out of the radiator into the
engine, circulates through the block, around the cylinders, up
through the cylinder head(s), through the thermostat and back to
the radiator.

20
 Radiator & Heater Hoses
Radiator hoses carry coolant between the engine
water jackets and the radiator.
Being Flexible, hoses can withstand the vibrating and
rocking of the engine on its motor mounts without
breakage
The upper radiator hose normally connects to the
thermostat housing on the intake manifold or
cylinder head. Its other end fits on the radiator.
The lower hose connects the water pump inlet to the
radiator

21
 Types of Hoses
Molded hoses – manufactured in a special shape to
clear the cooling fan and other parts.

22
 Types of Hoses
Flexible hose – Accordion shape and can be bent to
different angles. Also called a universal-type hose

23
 Types of Hoses
Hose spring – Frequently used in the lower radiator
hose to prevent its collapse (lower hose is exposed
to suction from the water pump)

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 Types of Hoses
Heater hoses – Small diameter hoses that carry
coolant to the heater core

25
 Types of Hoses
Hose clamps – Hold the radiator hoses and heater
hoses on their fittings
Worm-drive hose clamp – uses a worm gear that engages slots
in the clamp strap to allow tightening around the hose
(most common for replacement clamps)

26
 Radiator
Radiator – Transfers coolant heat to the outside air.
Normally mounted in the front of the engine.

27
 Radiator
Radiator 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 fro hoses.
Radiator filler neck – Opening for adding coolant.
Also holds the radiator cap and overflow tube.
Transmission oil cooler - Inner tank for cooling
automatic transmission or transaxle fluid.
Radiator petcock - Fitting on the bottom of the
tank for draining coolant.
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 Radiator
Radiator Action:
Under normal operation, hot engine coolant
circulates through the radiator tanks and core tubes.
Heat transfers into the core’s tubes and fins. Cooler
air flows over and through the radiator fins, so heat
is removed from the radiator. This reduced the
temperature of the coolant before it flows back into
the engine.

29
 Radiator
Radiator Types:
Downflow radiator – Tanks are on top and
bottom of the core and core tubes run vertically
between tanks.

Hot coolant enters the top

tank and flows downward
through to core tubes

After cooling, the coolant

flows out of the bottom tank
and back into the engine.

30
 Radiator
Radiator Types:
Crossflow radiator – Tanks are on sides of the
core and core tubes run horizontally between tanks.

Radiator cap is normally

on outlet tank

Can be shorter than a

downflow radiator allowing
for a lower hood line

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 Radiator
Radiator Tubes:
Can be made of metal or plastic
With metal tanks, the core and tanks are soldered
together.
With plastic tanks, rubber
seals fit between the tanks
and core to prevent leakage

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 Transmission Oil Cooler
Transmission Oil Cooler:
Often placed in radiator on cars with automatic
transmissions or transaxles to prevent the
transmission fluid from overheating.
A small tank enclosed in one of the main radiator tanks
Since transmission fluid is hotter than engine coolant,
heat is removed as it passes through the radiator
In downflow radiators, the transmission oil cooler is
located in the lower tank, in crossflow radiators, the
oil cooler is in the tank having the radiator cap.

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 Radiator Cap
Radiator Cap:
Performs several functions:
1. Seals the top of the radiator filler neck to prevent
leakage
2. Pressurizes the system to raise the boiling point of
coolant. This keeps coolant from boiling and turning
to steam
3. Relieves excess pressure to protect against system
damage
4. In modern closed systems, it allows coolant flow
between the radiator and the coolant reservoir.

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 Radiator Cap
Radiator Cap Pressure Valve:

Spring-loaded disc that contacts the filler neck

Spring pushes the valve into the neck to form a seal

Under pressure, water’s boiling point increases,

normally water boils at 212°F (100°C), however for
every pound of pressure increase, water’s boiling
point goes up about 3°F

35
 Radiator Cap
Radiator Cap Pressure:

Typically is between 12 & 16 psi

This raises the engine coolant boiling point to 250-260°F

(121-127°C)

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. This prevents
high pressure from rupturing the radiator, gaskets,
seals, or hoses.
36
 Radiator Cap
Radiator Cap Vacuum Valve:

Opens to allow flow back into the radiator when the

coolant temperature drops after engine operation.

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.
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 Radiator Cap Operation
 as the coolant heats up and expands, a pressure valve opens
& excess pressure is sent to the expansion bottle

 when the engine is turned off and the coolant begins to cool,
a vacuum valve opens & allows coolant to return back to the
radiator

 this is called a closed cooling system

 The pressure inside the cooling systems allows the boiling

point to rise keeping the system safe
 14-15 psi = 25°C

38
 Closed & Open Cooling Systems
Closed Cooling System:

Uses an expansion tank, or reservoir and a radiator cap

with pressure and vacuum valves.

The overflow tube is routed into the bottom of the

reservoir tank.

Pressure & vacuum valve action pull coolant in and out

of the reservoir tank as needed. This keeps the
cooling system correctly filled at all times.

39
 Closed & Open Cooling Systems
Closed Cooling System:

40
 Closed & Open Cooling Systems
Closed Cooling System Operation:

When the engine heats up, the coolant expands and

opens the cap pressure valve. Instead of leaking onto
the ground, the coolant flows into the reservoir.

After the engine has been shut off, the coolant

temperature drops and its volume decreases. This
causes the vacuum valve to open. Atmospheric
pressure (system suction) then forces coolant back
into the radiator.

This compensates for any small system leak, keeping the

system properly filled. 41
 Closed & Open Cooling Systems
Open Cooling System:

Does not use a coolant reservoir

The overflow tube allows excess coolant to leak onto

the ground

Does not provide a means of adding fluid automatically

No longer used on automobiles, it has been replaced by

the closed system which requires less maintenance

42
 Cooling System Fans
Cooling System Fan:

Pulls air through the core of the radiator and over the
engine to help remove heat.

Increases the volume of air flowing through the

radiator, especially when the car is standing still.

Driven by a belt or an electric motor.

43
 Cooling System Fans
3 types of fans include:
 Electric fan
 Engine powered flex fan)
 Engine powered fluid coupling fan clutch
Shrouded fans are used to direct air flow

some engine powered fans have thermostatic clutches –

these spin the fan only when the air temperature thru
the radiator reaches a predetermined level
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 Cooling System Fans
Engine Powered Fans:

Bolt to the water pump hub and pulley, sometimes a fan

spacer fits between the fan and pulley to move the
fan closer to the radiator.

Flex Fan Thermostatic fan Clutch

45
 Cooling System Fans
Engine Powered Fans:

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 speeds, the blades flex
until they are almost straight reducing the fan action
and saving engine power.

46
 Cooling System Fans
Engine Powered Fans:

Fluid Coupling fan Clutch – designed to slip at higher

engine speeds.

It performs the same function as a flexible fan.

The clutch is filled with silicone-based oil.

At a specific fan speed, there is enough load to make

the clutch slip.

47
 Cooling System Fans
Engine Powered Fans:

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.

48
 Cooling System Fans
Electric Cooling Fans:

Use an electric motor and a thermostatic switch

(coolant temperature sensor) to provide cooling
action.

Needed on Transversally mounted engine vehicles

where the water pump is located away from the
radiator

Can be used on any engine/transmission layout.

49
 Cooling System Fans
Electric Cooling Fan Motor:
Small DC (Direct Current) motor.

Mounts on a bracket secured to the radiator.

Metal or plastic fan blades mount on the end of the

motor shaft to cause airflow.

Saves energy and increases cooling system efficiency.

Only functions when needed speeding up engine warm-

up, reducing emissions and fuel consumption.

May shut off at high speeds due to cool air flowing

through grill 50
 Cooling System Fans
Electric Engine Fan Circuits:
The fan switch is a temperature sensitive switch that
controls fan motor operation.
The coolant temperature sensor , relays, and engine
control module (ECM) operate the engine cooling fan
motors.
When the engine is cold the coolant sensor signals the
ECM it is cold and the ECM does not energize the fan
relays, keeping the fan off and warming up the engine
faster.
When the engine warms up the coolant sensor signals
the ECM to send power to the cooling fan. 51
 Cooling System Fans
Radiator Shroud:
Helps ensure that the fan pulls
air through the radiator.

Fastens to the rear of the

radiator and surrounds the
area around the fan.

When the fan is spinning, the shroud keeps air from

circulating between the back of the radiator and the
front of the fan resulting in a huge amount of air
flowing through the radiator core.

Without the shroud the engine could overheat. 52

 Thermostats
Thermostat:
Senses engine temperature and controls coolant flow
through the radiator.

Reduces coolant flow when the engine is cold and

increases coolant flow when the engine is hot.

Usually located under a thermostat housing between

the engine and the end of the upper radiator hose.

Can be located at the inlet or the outlet of the engine

53
 Thermostats
Thermostat Construction:
Thermostats contain a wax filled pellet inside a
contained cylinder and piston assembly

When the thermostat heats up the pellet expands

pushing the valve open, as it cools spring tension
overcomes pellet expansion and the valve closes.

54
 Thermostats
Thermostat Ratings:
Stamped on the thermostat to indicate the operating
(opening) temperature of the thermostat.

Normal ratings are between 180°F & 195°F (82°C &

91°C)
High thermostats heat ranges are
used in modern automobiles to
reduce exhaust emissions and
increase combustion efficiency.

55
 Thermostats
Thermostat Operation:
When the engine is cold the , the thermostat will be
closed and coolant cannot circulate through the
radiator.

A bypass valve and bypass hose or passage permit

coolant circulation through the engine when the
thermostat is closed. If the coolant cannot circulate,
hot spots could develop inside the engine.

56
 Thermostats
Bypass Thermostat:
A bypass thermostat has a second valve for routing all
the hot coolant through the radiator, not just most of
the hot coolant.

The main thermostat valve

regulates flow through
the engine and radiator
like a conventional
thermostat. The added
valve blocks off the
bypass once the engine
has reached operating
temperature. 57
 Thermostats
Thermostat Jiggle Valve:
A small valve fit into a hole formed in the thermostat. It
helps prevent air pockets from forming in the housing.

58
 Consistent Operating Temperature
Engine too Cold
Inefficient – Combustion in incomplete
May run rough
Have excessive emissions
Excessive blow-by

Engine too Hot

Oil lubricating film breaks down
Internal engine parts can warp, bend or melt
Pre-ignition can occur

59
Coolant Circulation

60
 Cooling System Instrumentation
Most vehicles are equipped with a temperature warning
light. Some vehicles also have an engine temperature
gauge. It is important that you understand the
operation of both.

61
 Cooling System Instrumentation
Temperature Warning Light:
Informs the driver when the engine is overheating,
when the coolant becomes too hot.

When coolant becomes too hot, a temperature sending

unit in the engine block closes completing the circuit,
making the indicator light on the dash glow.

When the coolant is at normal operating temperature,

the sending unit circuit is open and the light remains
off.

62
 Cooling System Instrumentation
Temperature Warning Light:
With many late model vehicles, the engine temperature
warning light is energized by the engine control
module. If the sensor detects an overheating engine,
the ECU sends current to the warning light.

63
 Cooling System Instrumentation
Engine Temperature Gauge:

Shows the exact operating temperature of the engine

coolant. A variable resistance sending unit and a
gauge are used in the circuit.
A cold engine gives a high
resistance (less current)
and no needle
deflection, a hot engine
gives low resistance
(more current) and lots
of needle deflection
64
 Antifreeze
Usually ethylene glycol, is mixed with water to produce
engine coolant.

Antifreeze has several functions:

Prevents from freeze up
Prevents rust and corrosion
Lubricates the water pump
Cools the engine

65
 Antifreeze
Prevents from freeze up:

Antifreeze keeps the coolant from freezing in very cold

weather.

Coolant freezing can cause serious cooling system and

engine damage.

As ice forms it expands. This expansion can produce

great force, the water pump housing, cylinder head,
engine block, radiator, or other parts could be cracked
and ruined by this force.

66
 Antifreeze
Prevents Rust and Corrosion:

Antifreeze prevents rust and corrosion inside the

cooling system.

It provides a protective film on part surfaces.

Even in hot climates, antifreeze should be used to

protect internal parts from corrosion.

67
 Antifreeze
Lubricates the water pump:

Antifreeze acts as a lubricant for the water pump and

thermostat.

Antifreeze increases the service life of the water pump

bearings and seals.

Antifreeze prevents thermostat wear and corrosion.

68
 Antifreeze
Cools the Engine:

Antifreeze conducts heat better than water and

therefore, cools the engine better.

It is normally recommended in hot weather.

For example:
Using the air conditioning in your car increases the
temperature of the air flowing through the radiator,
antifreeze can prevent overheating when the air
conditioning is on.

69
 Antifreeze
Antifreeze : Water Mixture:

For ideal cooling and 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 (-37°C)

Higher ratios of antifreeze may produce even lower

freeing temperatures, but this is not normally
needed.

Plain water should never be used in a cooling system 70

 Block Heater
Block Heater:
May be used on an engine to aid engine starting in cold
weather.

71
 Block Heater
Block Heater:
It is simply a 120 volt heating element mounted in the
block water jacket.

The heater power cord is plugged into a wall outlet.

This keeps the engine warm when the vehicle is not

being used, then when the owner cranks the engine it
will start more easily.

Most commonly used on diesel engines as they are

harder to start in cold weather.

72
 Ch. 39 Cooling System Fundamentals Review

For ideal cooling of an engine, what mixture of water to

antifreeze do we use?

50/50

73
Ch. 39 Cooling System Fundamentals Review

The component in the cooling system that controls

coolant flow is called the:

Thermostat

74
Ch. 39 Cooling System Fundamentals Review

A water pump is located on the __________ of an

engine.

Front

75
Ch. 39 Cooling System Fundamentals Review

What can be used to prevent coolant leakage between

the water pump housing and the engine block?

A Gasket
RTV Sealant
Or
An O-Ring

76
Ch. 39 Cooling System Fundamentals Review

Core, Petcock and Transmission Cooler are all

components of what cooling system part?

Radiator

77
Ch. 39 Cooling System Fundamentals Review

The radiator cap provides functions, what are they?

Seals radiator filler neck

Allows excess pressure to escape
Pressurizes the cooling system
Allows coolant to flow from radiator to overflow and
vise versa

78
Ch. 39 Cooling System Fundamentals Review

Why do we use a radiator shroud?

To direct (control) airflow

79
Ch. 39 Cooling System Fundamentals Review

Explain how a thermostat works

It is closed when the engine is cold, when the engine

coolant is hot enough it makes the wax filled pellet in
the thermostat expand pushing the piston open to
allow coolant to flow to the radiator and cool down.

80
Ch. 39 Cooling System Fundamentals Review

Why is a block heater useful in diesel engines?

It keeps the coolant warm which allows the engine to

start easier (compression ignition) in colder
temperatures.

81
 Ch. 39 Cooling System Fundamentals Review

What are the 4 functions of the cooling system?

Remove excess heat from the engine compartment

Maintain operating temperature
Allow engine to reach operating temperature quickly
Provide a means of heating the passenger compartment

82
Ch. 39 Cooling System Fundamentals Review

Name the parts of the Water pump below

Impeller
Outlet to Water
Housing Jacket
Pump Shaft

Fan Hub
Sealed Inlet from
Bearings Radiator 83
Ch. 39 Cooling System Fundamentals Review

What type of fan is used on front wheel drive vehicles

with transverse engines?

Electric Fan

84
 Ch. 39 Cooling System Fundamentals Review

What allows coolant flow through the engine when the

thermostat is closed?

A bypass hose
and
a bypass valve in the thermostat

85
Ch. 39 Cooling System Fundamentals Review

What cooling system circulates coolant around the

engine?

Water pump

86
Ch. 39 Cooling System Fundamentals Review

Antifreeze has 4 functions, what are they?

Prevents winter freeze up

Prevents rust and corrosion
Lubricates the water pump
Cools the engine

87
Ch. 39 Cooling System Fundamentals Review

By raising the pressure in the cooling system you also

increase the ___________ _________ of the coolant

Boiling point

88
 Ch. 39 Cooling System Fundamentals Review

A temperature _____________ on the engine is used to

operate the temperature warning light.

Sensor

89
Ch. 39 Cooling System Fundamentals Review

It is ok to remove a thermostat in warm weather

because the engine will run warmer.

True False

The engine will take longer to warm up and will wear

out faster.

90
 Ch. 39 Cooling System Fundamentals Review

Liquid cooling systems have replaced air cooling systems

in automobiles.

True False

91
Ch. 39 Cooling System Fundamentals Review

Downflow radiators are used in small front wheel drive

cars because they allow for a lower hood line.

True False

Crossflow radiators are used in these vehciles

92
 Ch. 39 Cooling System Fundamentals Review

Some transmission oil coolers are built into the radiator.

True False

93
 Ch. 39 Cooling System Fundamentals Review

An open cooling system uses an overflow tank to collect

and return extra coolant to the system during warm
up and cool down.

True False

A closed cooling system does this. An open cooling

system spills overflow onto the ground.

94
 Ch. 39 Cooling System Fundamentals Review

A small diameter hose that carries coolant to the heater

core is called a:

Heater hose

95
Ch. 39 Cooling System Fundamentals Review

A hose that is manufactured in a special shape, with

bends to clear the cooling fan and other parts is
called a:

Molded hose

96
Ch. 39 Cooling System Fundamentals Review

What is commonly used in a lower radiator hose to

prevent its collapse?

A Spring

97
Ch. 39 Cooling System Fundamentals Review

What carries coolant from the water jackets in the

engine to the radiator?

Radiator Hoses

98
Ch. 39 Cooling System Fundamentals Review

The part of the water pump that provides a mounting

place for the belt pulley and the fan is called:

The Water Pump Hub

99
Ch. 39 Cooling System Fundamentals Review

What is the difference between a water pump seal and

a water pump gasket?

The seal is internal to prevent leakage between the

pump shaft and pump housing and the gasket is
between the housing and the engine block

10
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Ch. 39 Cooling System Fundamentals Review

Do you feel ready for the Test?

If YES ------- GREAT!

If NO ---------- Start studying!

Don’t forget to make notes if you haven’t already

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