Internal Combustion Engines II

ENGINE COOLING SYSTEMS

Dr. Nouby Mahdy Ghazaly

Associate Professor, Mechanical Engineering Dept.,
Faculty of Engineering,
South Valley University,
Qena-83521, Egypt.
E-mail: Nouby.Ghazaly@eng.svu.edu.eg
Tel.: +201010561818

Dr. Nouby Mahdy Ghazaly

Dr. Nouby Mahdy Ghazaly
 ENGINE COOLING SYSTEMS

 Peak combustion temperatures in a gasoline engine may reach as high as 2500°C, while
that of a diesel engine may approach 3300°C.
 Cylinder wall temperatures must not be allowed to rise above 200°C to 250°C.
 For the best thermal efficiency, it is desirable to operate the engine at temperatures
closely approximating the limits imposed by the lubricating oil properties.
 Engines are designed to dissipate their heat into the air through which a vehicle passes.
 Modern cooling systems are designed to maintain an even temperature of about 180 to
230°F (82 to 110°C).
 The cooling system has four primary functions:

1. Remove excess heat from the engine.

2. Maintain a constant engine operating temperature.

3. Increase the temperature of a cold engine as quickly as possible.

4. Provide a means for heater operation (warming the passenger compartment).

Dr. Nouby Mahdy Ghazaly
 types of engine cooling.

1. direct air-cooling
2. indirectly by liquid cooling.

 air-cooled engines generally operate at a higher temperature than

liquid-cooled engines whose operating temperature is largely
limited by the boiling point of the coolant used.
 Consequently, greater clearances must be provided between the
moving parts of air-cooled engines to allow for increased
expansion.
 Also, lubricating oil of a higher viscosity is generally required.
 the cylinders are mounted independently to the crankcase so an
adequate volume of air can circulate directly around each cylinder,

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 direct air-cooling

The rate of the cooling is dependent upon the following:

 • Area exposed to the cooling medium
 • Heat conductivity of the metal used and the volume of the metal
or its size in cross section
 • Amount of air flowing over the heated surfaces
 • Difference in temperature between the exposed metal surfaces
and the cooling air

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 Main components of an aircooled

The main components of an air cooled system

are the fan, shroud, baffles, and fins.

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 Liquid-Cooled System

A simple liquid-cooled system consists of a radiator, coolant pump,

piping, fan, thermostat, and a system of water jackets and passages
in the cylinder head and block through which the coolant circulates

Some vehicles are equipped with a

coolant distribution tube inside the
cooling passages that directs
additional coolant to the points where
temperatures are highest.

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 The operation of a liquid cooled system

 • The pump draws the coolant from the bottom of the radiator, forcing the coolant
through the water jackets and passages, and ejects it into the upper radiator tank.
 • The coolant then passes through a set of tubes to the bottom of the radiator from
which the cooling cycle begins.
 • The radiator is situated in front of a fan that is driven either by the water pump or
an electric motor. The fan ensures airflow through the radiator at times when there
is no vehicle motion.
 • The downward flow of coolant through the radiator creates what is known as a
thermo siphon action. This simply means that as the coolant is heated in the
jackets of the engine, it expands. As it expands, it becomes less dense and
therefore lighter. This causes it to flow out of the top outlet of the engine and into
the top tank of the radiator.
 As the coolant is cooled in the radiator, it again becomes more dense and heavier.
This causes the coolant to settle to the bottom tank of the radiator.
 • The heating in the engine and the cooling in the radiator therefore create a natural
circulation that aids the water pump.
Dr. Nouby Mahdy Ghazaly
• Combustion
temperatures are
greater >4500-6000
deg F
• Cooling system
removes the bulk of
heat

• Coolant circulates
4,000 to 10,000 gallons
of coolant per hour.

Dr. Nouby Mahdy Ghazaly

 COOLING SYSTEM COMPONENTS

 Water Pump
 Cooling Fan
 Radiator
 Pressure Cap
 Thermostat
 Clamps and hoses
 Overflow tank

Dr. Nouby Mahdy Ghazaly

 Water Pumps

• Centrifugal Type Water Pump.

• Inlet comes from bottom of
Radiator.
• Outlet is through impeller to
engine.
• Water Pump Replacement
can be due to leaks or
bearing failure.

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 components of a radiator

 • Core—the center section of the radiator made

up of tubes and cooling fins.
 • Tanks—the metal or plastic ends that fit over
core tube ends to provide storage for coolant
and fittings for the hoses.
 • Filler neck—the opening for adding coolant. It
also holds the radiator cap and overflow tube.
 • Oil cooler—the inner tank for cooling
automatic transmission or transaxle fluid.
 • Petcock—the fitting on the bottom of the tank
for draining coolant.

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components of a radiator

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 Radiators

• Allows for heat to move from coolant to the outside

air.
• Cooler air flowing through the radiator cools the
coolant.
• Most radiators about 28-35 sq. feet.
• Can have multiple cores to increase area.
• Two types…
- Cross flow
- Down flow

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Radiators

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 Coolant Expansion

Radiator pressure results from the expansion of the

coolant as the engine warms up.
A small amount of air used to be kept in the radiator to
allow for this expansion.
Since air leads to rust and corrosion, the radiator
needs to be filled completely with coolant.
The pressure cap and coolant reservoir work together
to allow for this expansion.

Dr. Nouby Mahdy Ghazaly

 Pressure Cap

The upper gasket prevents

coolant from escaping to the
outside. The lower gasket keeps
a pressure in the radiator. The
cam lock pushes the two gaskets
against the sealing surfaces
when the cap is installed. The
safety stop prevents the cap from
being opened too quickly.

Dr. Nouby Mahdy Ghazaly

 Pressure Cap

Pressurizing a liquid The coolant’s boiling point

increases the boiling increases about 3° F for each psi
point of that liquid. increase in pressure.
Cooling systems are
pressurized so that the
boiling point of the
coolant is raised.
Many cooling systems
are pressurized to 15
psi.
Dr. Nouby Mahdy Ghazaly
 Pressure Cap

 The pressure cap allows the pressure to build, and release past a
specified point.
 Equipped with Vacuum and Pressure Valve
 Used to raise Pressure in system

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Pressure Cap

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 functions of the pressure cap

 • Seals the top of the radiator tiller neck to prevent leakage.

 • Pressurizes the system to raise the boiling point of the coolant.
 • Relieves excess pressure to protect against system damage.
 • In a closed system, it allows coolant flow into and from the coolant
reservoir.
 The pressure cap also improves the operation of the water pump.
 By keeping the radiator pressurized, the water pump has a
constant supply of coolant to draw from.
 If pressure became too low, the coolant would boil and the water
pump would draw only air.

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 Overflow Tank

Contains reserve coolant.

When cap releases coolant due to coolant expansion,
coolant goes to overflow tank.
When cooling system cools off and creates a vacuum,
coolant is pulled from overflow tank.

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 Overflow Tank

Some closed cooling systems do not have a cap

on the radiator.
The overflow tank is pressurized with the rest of the
cooling system.
The coolant level will be checked in the overflow
tank.

Dr. Nouby Mahdy Ghazaly

Expansion recovery tank.

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 Opening a Hot System

Slowly turn the cap with a rag and do not turn it

past the safety lock.

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 Thermostat

Speeds up engine warm up.

Regulates flow and temperature of engine coolant.
Most are on the outlet side of coolant flow.
Maintains optimum engine operating temperature for
best emissions and economy.
Thermostat temperature is the opening temperature
Thermostat should be fully open 20°F above opening
temperature
195°F thermostat = fully open at 215°F
180°F thermostat = fully open at 200°F
Dr. Nouby Mahdy Ghazaly
 Thermostat

 The thermostat contains a wax pellet on the engine side of the

thermostat.
 Wax melts and expands when engine heats up.
 As the wax expands, it overcomes spring pressure and opens the
valve.

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Thermostat

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 Coolant Bypass

Some thermostats are designed to block off the

bypass passage when they are open.

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Dr. Nouby Mahdy Ghazaly
Dr. Nouby Mahdy Ghazaly
 Water Jackets

 When an engine cylinder block and head are cast, cavities called
water jackets are formed around the cylinder walls and combustion
chambers.
 These water jackets allow coolant to circulate around the very hot
areas, including the exhaust valve seats, as well as the relatively
cooler areas of the lower cylinders.
 The coolant absorbs heat from the hot areas and transfers this heat
to the colder areas in the engine or radiator.

Dr. Nouby Mahdy Ghazaly

 Coolants and Antifreeze

 Antifreeze has several functions:

 • Prevents winter freeze up, which can cause serious damage to
the engine and cooling system.
 • Prevents rust and corrosion by providing a protective film on the
metal surfaces.
 • Lubricates the water pump, which increases the service life of
the pump and seals.
 • Cools the engine; prevents overheating in hot weather.

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 General Requirements of Coolant

1. Good heat conductor.

2. Low freeze point.
3. High boiling point.
4. Non-corrosive to metals.
5. Non-foaming.
6. Compatible with other commercial coolants.

Dr. Nouby Mahdy Ghazaly1

LINER PITTING or cavitation
corrosion caused by
imploding vapor bubbles
will pit through the liner
wall.

Shock wave impact

measured at 15 to 20,000
PSI

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 What does liner pitting really look like?

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 Diagnosing Cooling System Problems

Causes of cooling system problems:

 Coolant level
 Restricted radiator
 Stuck thermostat
 Defective water pump
 Fan shroud
 Frozen coolant
 Defective cooling fan
 Exhaust blockage
 Inoperative EGR valve

Dr. Nouby Mahdy Ghazaly

THANK YOU

Dr. Nouby Mahdy Ghazaly