How Engine Cooling System Works

Posted in: Driving Tips.

How Engine Cooling System Works

The engine is an important part of your vehicle, it is saddled with the responsibility of
generating power to get your car –and you – moving. To do this, it burns fuel to operate and
in the process generates heat. To sustain the vehicle engine’s operation as well as
ensure peak performance of your vehicle, it is necessary to keep the engine running at the
optimum operating temperature range and this is where the engine cooling system
becomes important.

Are you interested in how engine cooling system works? Read on and learn how you can
keep your engine working properly so you don’t weld the piston rings to the engine cylinder
walls.

The Components of a Cooling System

The Radiator
 How Engine Cooling System
Works
The radiator’s job is to release heat generated from the engine into the surrounding. It is
usually made up of flattened aluminium fins and a plastic top or, in older car models, a
copper core and a brass top. It has various parts, which include inlet and outlet port,
pressure cap, and drain plug.

Radiator Cooling Fans

Radiator Cooling Fans

The radiator is equipped with fans that help force cool air through the radiator fins. The fans
can be one or two, but they all have a cover designed to protect fingers and direct airflow.
On older models, the fan comes on whenever the engine is running, but for newer models,
the fan is controlled by a computer which varies the fan speed depending on the
temperature of the engine.

Pressure Cap & Reserve Tank Water

Pressure Cap & Reserve Tank

Water
As the engine temperature rises from the initial starting temperature, the temperature of the
coolant circulating around the engine block also increase, which leads to expansion of the
coolant liquid. Since this expansion takes place in a sealed system, the internal pressure
will increase allowing the coolant to safely reach a temperature of 240 degrees without
boiling.

If the pressure keeps increasing, the valve within the pressure cap releases some coolant
into the reserve water tank. This right here is one reason why you should only fill this tank to
the recommended maximum if you do fill past the marked line, chances are your coolant will
be wasted when the liquid level starts to increase.

Coolant Temperature Sensor

 Coolant Temperature Sensor
The name alone should give you an idea of what this component does, it is a temperature-
sensing device that serves the purpose of reading the engine temperature. This is the
component that provides the necessary data used by the vehicle’s computer to control the
operation of the radiator fan, optimize the fuel injection and ignition timing of the engine, and
the source of the engine temperature reading displayed at the driver’s console.

Pump

Pump
The pump serves the same purpose as the heart – circulate the coolant. Within its casing is
a radial impeller which, with the help of a serpentine belt, is driven by the engine’s rotational
motion. Provided the engine is running, the pump will keep the coolant circulating.

Coolant

Technically speaking, the coolant is not considered a part of the cooling system. But, this is
what makes engine cooling a possibility. If the pump is considered the heart of the cooling
system, then the coolant will be the blood, without it the pump is useless. It could be in gas
or liquid form. As it circulates the engine, it absorbs heat generated and transfers the heat
to the radiator to get rid of.

Thermostat

Thermostat
The thermostat is simply a valve that checks the temperature of the coolant and allows it to
flow through to the radiator only when a certain temperature value has been exceeded.
What this means is that when you first start your engine, the coolant circulates the engine
(to avoid hot spots) until the engine has warmed up to an efficient operating temperature,
only then is the coolant allowed to flow through to the radiator and shed off the heat.

Bypass System
The bypass system is just what it sounds like. It’s a passage that redirects the coolant
towards the pump instead of flowing to the radiator. When the engine is just starting and its
temperature is not up to the efficient operating temperature, the thermostat closes so the
coolant can be re-circulated around the engine without losing heat at the radiator.

Hoses

Since the coolant has to leave its storage container and flow through the pump, engine
block, and radiator, it needs a connecting circuit and that’s what the hose does, connect
these separate parts.

Most vehicles make use of high-temperature-resistant rubber, but some engines have a
built-in passage in the front housing or make use of a metal tube. Either way, they are all
designed to withstand the pressure within the cooling system. If you notice the rubber
beginning to look cracked and dry, or becomes spongy and soft, or some ballooning at any
of the ends, then it is time to get them replaced.

Putting it all together

Putting it all together

As soon as you ignite the engine and the pistons start moving, heat is generated. From the
piston movement, the coolant pump gets its power source to circulate the coolant around
the engine block.
Assuming the engine was at a very low initial temperature, the thermostat blocks the
coolant from flowing through to the radiator (where it would have lost heat), channelling the
now warm coolant back to the pump which re-circulates it.

When the coolant temperature is at the optimum, the thermostat allows it to flow through to
the radiator to maintain that operating temperature.

There is no trick to keeping your engine temperature at the optimum range. If the system is
faulty it will overheat. The most important maintenance tips are simple: ensure the coolant
is at the recommended level before driving off, flush and refill the coolant periodically, and
inspect the hoses and belts for leaks or signs of weakness.

Engine cooling System

ENGINE COOLING SYSTEM: COMPONENTS, TYPES AND WORKING PRINCIPLES

A vehicle's engine-cooling system serves not just to keep the engine cool, but also to keep its
temperature warm enough to ensure efficient, clean operation. System components include a
radiator to dissipate heat, a fan or fans to ensure adequate airflow for radiator cooling, a
thermostat valve that opens when the desired operating temperature is reached and a water pump
(or coolant pump) to circulate coolant through the engine, hoses and other components. Most
vehicles now employ an expansion tank that allows the coolant to expand, and exit, the cooling
circuit when hot, and to return when the car is turned off and the engine cools.
The cooling system also incorporates elements of the cabin's ventilation system, because engine
heat is used to warm the car's interior.
While running, an engine continuously produces heat and converts it into power.
This heat is derived by burning fuel in the engine.
But as we all know, there is no engine in the world which is 100% efficient.
There is always some amount of heat energy which gets wasted. If we do not transmit this heat
energy into the atmosphere, this heat will overheat the engine.
This overheating will result in engine seizing. In engine seizing, due to excess heat the piston
gets melted inside the cylinder.
It avoids this trouble of overheating a car is provided with the engine cooling system.
An engine cooling system is a system integrated with the engines. It carries away excess heat
from the engine with the help of a flowing fluid.
This fluid can be air or water.
COMPONENTS OF COOLING SYSTEM
1. RADIATOR:
Cools off the anti-freeze / coolant mixture by allowing air passing through the tube / fin area to
dissipate the heat generated by the engine.
2. WATER PUMP:
Draws the cooled anti-freeze from the radiator and pumps it through the engine block, cylinder
head (s), heater core and back to the radiator.
3. FREEZE PLUGS:
Is actually a steel plug designed to seal holes in the engine block and cylinder head (s) created
from the casting process. In freezing weather they may push out if there is not enough anti-freeze
protection.
4. HEAD GASKET / TIMING COVER GASKET:
Seals the major parts of the engine. Prevents oil, anti-freeze and cylinder pressure from mixing
together.
5. HEATER CORE:
Provides heat to the interior of the car by using heat removed from the antifreeze and blown in
by the blower motor. May cause steam, odor or actual dripping inside the car when it leaks.
6. THERMOSTAT:
Controls the minimum operating temperature of the engine. The thermostat is closed when the
engine is cold in order to speed warm-up and opens when the normal operating temperature is
reached to allow the anti-freeze / coolant to pass through the radiator.
7. HOSES (Radiator, Heater, By-pass):
Connect the other main components of the cooling system. Hose manufacturers recommend
replacing every 4 years regardless of appearance because there may be deterioration of the inside
of the hose which cannot be seen.
8. FAN CLUTCH:
Senses the temperature of the air coming through the radiator and either slips or binds up to pull
the required amount of air through the radiator.
9. ELECTRIC COOLING FAN:
Most front-wheel-drive cars use this because of the transversely mounted engine. It is turned on
by a system of sensors and relays when the engine reaches about 230 F and stays on until R is
cooled to about 200 F.
TYPES OF COOLING
Or we can say there are two types of cooling systems
1. Liquid or indirect cooling system
2. Air or direct cooling system
LIQUID OR INDIRECT COOLING SYSTEM
In a liquid cooling system, an engine is surrounded with water jackets. With the help of a pump,
this water gets circulated in this water jacket.
Water flowing in these jackets takes out heat from the engine. This hot water then flows through
a radiator, where it gets cooled from the cold heat blown through a fan.
In this system, the water takes heat from the engine and that water gets cooled by the air and then
again gets circulated to the engine.
This is an indirect cooling process, where an actual cooling thing that is air is not directly cooling
the system. The air is cooling the water and water is cooling the engine.
Liquid or indirect cooling system is mainly used in big engines, like that of cars and trucks.
Advantages
1. The compact design of engines
2. It provides even cooling to the engine
3. The engine can be installed at any location of the vehicle. It is not necessary to install an
engine at the front.
4. It can be used in both small and big engines
Limitations
1. Here water jacket becomes one extra part of the engine.
2. Water circulation consumes power, thus reduces engine efficiency.
3. In case of failure of the cooling system, serious damage could happen to the engine.
4. Cost of the system is considerably high.
5. It requires routine maintenance, and thus puts extra maintenance cost burden.
AIR OR DIRECT COOLING SYSTEM
In a direct cooling system, an engine is cooled directly with the help of air flowing through it. It
is the same cooling system which is used to cool our bike engines.
As we can see here, the air is in direct contact with the engine hence it is also known as a direct
cooling system.
Air cooling system is used for small engines, like that of bikes and grass cutter, etc.
Advantages
1. Design of the engine becomes simpler.
2. Repair is easy in case of damages.
3. Absence of bulky cooling system makes system maintenance easily.
4. No danger of coolant leakage.
5. The engine is not subjected to freezing troubles.
6. Weight of the system is less.
7. It is a self-contained unit, as it does not require a radiator, header, tanks, etc.
8. Installation of the air-cooled system is easy.
Limitations
1. It is applicable to only small and medium-sized engines.
2. It can only be used at the places where ambient temperatures are lower.
3. Cooling is not uniform.
4. Higher working temperature as compared to water-cooled engines.
5. It produces more aerodynamic noise.
6. Specific fuel consumption is slightly higher.
7. Lower maximum allowable compression ratios.
8. The fan, if used consumes almost 5% power generated by the engines.
Characteristics of an efficient engine cooling system
Following are two main characteristics of an efficient engine cooling system.
1. It should be capable of removing about 30% of the heat generated in the engine while
maintaining the optimum working temperature in the engine.
2. It should remove heat at a faster rate when the engine is hot and remove the engine at a slow
rate when the engine is cold.
 +2

3). What is the basic function of the engine cooling system?

Maintains optimal engine temperatures— the cooling system allows the engine to heat
up quickly and operate at a constant temperature with the following benefits:
Increased engine efficiency— the engine's oil will have a lower viscosity so that engine
components will move more easily using less power.

4). What are the 2 types of cooling system?

There are two types of cooling systems: (i) Air cooling system and (ii) Water-cooling
system. In this type of cooling system, the heat, which is conducted to the outer parts of
 the engine, is radiated and conducted away by the stream of air, which is obtained from
the atmosphere.

Parts of Cooling System

5). All engine cooling systems are based on the following components:
 Coolant radiator.
 Thermostat.
 Coolant pump (mechanical or electric)
 Expansion tank.
 tubes.
 Engine fan (V-belt driven or Visco®)
 Temperature sensor (engine control/indicator)

The main purpose of your car’s cooling system is to keep

your engine from overheating.
 Your car produces a
great deal of heat when it is running, and must be cooled down continuously to avoid
overheating and engine damage. In order to understand your car’s cooling system it is
important to understand all of the basic cooling system components.

1. Radiator
2. Radiator top hose
3. Radiator bottom hose
4. Water pump
5. Thermostat
6. Electric cooling fan
7. Thermo-time switch

Radiator
Your radiator is the most important part of your cooling system. Coolant that has traveled
through the engine is pumped through the tubes of the radiator and is cooled off for another
round.
Radiator Hoses
Your vehicle’s cooling system has a number of rubber hoses which move fluid from one
place to another. These Radiator hoses need to be replaced before they become brittle and
cracked.

Water pump
The water pump in your cooling system pumps the coolant through the system. In most cars
the pump is belt driven, with the exception of some race cars that use electric water pumps.

Thermostat
Your engine doesn’t always maintain the same temperature. Starting your car in cold
weather would take forever if your engine stayed at the same temperature all the time. The
thermostat controls the flow of coolant throughout your car’s cooling system, with the
temperature of the coolant cooling the engine down.

Electric Cooling Fan

Many modern cars have an electric fan for primary or added cooling. When the car is not
moving fast enough to generate enough airflow to cool the engine, the fan draws air through
the radiator.

Thermo Time Switch

Also known as the fan switch, this is the temperature sensor that tells the electric fan when
to blow.

Visit our 0800 Radiators blog to learn how to flush your radiator or sign up for our
monthly newsletter to stay updated with tips and tricks on maintaining your radiator.
6). How many liters of coolant does a car need?

Most car cooling systems hold around 5 liters and engine coolants are sold in 1 – 20 liters
containers, so it's easy to purchase the exact amount that you want. When empty and
depending on the capacity of your car's coolant, it should need around 5 liters of coolant
fluid.Jan 28, 2021

7). How Much Coolant Does My Car Need When Empty? [Guide]
https://sanedriver.com › how-much-coolant-does-car-need

Search for: How many liters of coolant does a car need?

How much water does a car cooling system use?

Fill your radiator with a mixture of 60 percent coolant and 40 percent water. This mix will
provide the best corrosion protection, and protect against freezing [source: 2carpros]. Fill the
reservoir to about an inch (2.5 centimeters) of the top, so there aren't any air pockets

8). What are two types of automotive air conditioning systems?

At present, two major air conditioning systems are applied in the automobile industry-
the expansion valve system and the fixed orifice tube system. The main difference
between these two is the type of device that is used to lower the refrigerant pressure.
10JUN
 Air Conditioning

Why Your A/C Compressor is Leaking

Oil or Refrigerant
 a/c oil leak, automobile leaking refrigerant, classic car leaking refrigerant, leaking air conditioner
  6 comments
Many people ask what maintenance steps they should take for their classic’s factory a/c system. Our
tech guys always give the same, straightforward advice: “USE your air conditioning!” Contrary to
popular belief, refrigerant is not consumed by using the air conditioning. I know, you have been lied
to your whole life.
A very common source of lost refrigerant or oil in a functioning, leak-free system is at the
compressor shaft seal. This is typically the result of cars and trucks that aren’t driven on a daily basis
and/or experience sporadic use. Shaft seal leaks have been known to develop with periods of
inactivity as short as two weeks. The common result is partial refrigerant loss and/or shaft seal oil
leaks.
SANDEN COMPRESSOR

It’s fairly common for someone to install a rebuilt or even new factory-style compressor, (A5, A6, R4,
RV2, York, Tecumseh, etc.) only to find that the compressor shaft seal is leaking refrigerant or oil. A
little-known fact about A/C compressors is that the shaft seal is kept lubricated the entire time the
compressor is engaged and running. Believe it or not, this is true.
Many factory a/c systems lose their charge when the a/c system is not being used. This happens as
an under-lubricated seal around the compressor’s crankshaft dries up and develops a leak that
allows for refrigerant and/or oil to escape. Not so much of a problem years ago when you could bring
your car to any service station and get R12 topped off for 99 cents; but those days are gone like the
old Freon.

UNDERCHARGED SYSTEMS
Below are some symptoms often seen in systems that are slightly undercharged. These conditions
can indicate a loss of refrigerant as a result of your car’s air conditioning sitting dormant. (Please
note: this is not an exhaustive list and your classic car may exhibit some or all of the symptoms
below.)
• Clutch quickly cycles on/off (Not related to Suction valve system such as General Motors POA,
HGV or STV systems, Ford POA systems or Mopar EPR systems.)

• Slightly low suction & discharge (low & high) pressure.

• Cool, not cold air at the vents. (Result of cold, but not frigid evaporator temp.)

• If you are using R12 refrigerant in your ac compressor, bubbles in the sight-glass ** TIP – the sight-
glass will never be clear on a 134a system.

• Oil splashing the underside of the hood after slinging from the area of the clutch. While this
symptom can also indicate other problems, (contaminants in the system, bad shaft seal, high head
pressures). It can be the result of oil leaking from the shaft seal as it dries up from not being used
and gathering around the clutch & pulley until being used.
SANDEN TOP PORTS

Air conditioning systems that are drastically undercharged may likewise exhibit some of
the symptoms below:
• Compressor clutch doesn’t engage (If system equipped with a low-pressure switch.)
• There is very low suction pressure. (System not in a vacuum.)

• Very low discharge pressure.

• Warm air at the vents.

• If you are using R12 refrigerant in your ac compressor, bubbles in the sight-glass ** TIP – the sight-
glass will never be clear on a 134a system.

• Oil splashing the underside of the hood after slinging from the area of the clutch. While this
symptom can also indicate other problems, (contaminants in the system, bad shaft seal, high head
pressures) it can be the result of oil leaking from the shaft seal. This happens as it dries up from not
being used and gathering around the clutch & pulley until being used.
For more information on the compressors and clutches check out this blog here.
Now, if your car is not used often and/or is stored for much of its life, simply start the car and run
your air conditioning (with the compressor engaged) for approximately 30 seconds. Doing this every
couple of weeks or so keeps the compressor shaft-seal lubricated, which can prevent most shaft
seal failures. In most cases, the shaft seal will re-seal itself once you start using the air conditioning
again, though your system might require “topping off” of refrigerant and/or a good wiping down of the
under-hood compartment until any oil clears the pulley assembly.

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