1

COOLING
SYSTEM
 Introduction
2

 IC Engines at best can transform about 25-30 % of

the chemical energy from the fuel in to mechanical energy.
 About 35 % of the heat generated is lost to the cooling
medium remainder being dissipated through exhaust and
lubricating oil.

1/3 Heat to Useful Wor k

1/3 Heat to cooling
System 1/3 Heat to exhaust
system
 Introduction
3

 The Purpose of Cooling System is to

🞑 Prevent Overheating
 Excess Heat generated in engine
 Peak temperatures exceed melting point of metal
🞑 Maintain the most efficient Temperature
 Regulate Temperature (Ensures proper
combustion, minimum emissions, and maximum
performance)
 Allow engine to warm up in cool weather
 Maintain engine in optimum range.
 Introduction
4

 Consequence of engine running too hot:

🞑 Pre-ignition
🞑 Detonation/Knock
 – All result in very high pressure rise and possible damage to engine part
🞑 Heat Fatigue of components
 Burnt Pistons
 Burnt Valves
🞑 Failure of lubrication system
 Oil breakdown
 Oil film at cylinder destroyed at 200C
 Scoring of piston & sleeves

🞑 Warping & fracture of components

 Introduction
5

 Consequence of engine running too cold:

🞑 Unnecessary Wear
🞑 Poor Fuel Economy
 Incomplete Combustion
 Lower coolant Temperature
 More energy transferred out of cylinder
 Energy is wasted & not available for work (Power)

🞑 Promotes corrosive conditions in engine

 Water of combustion reacts with sulfur oxides in
exhaust
 Forms acids
 Allows water & sludge to accumulate in crankcase
 Over time, fuel diluting the oil will accumulate
 Normally lighter volatile fuel will evaporate as temp.
 Introduction
6

 Variation of Gas Temperature Piston Temperature

Distribution
 Parameters Affecting Engine
9 Transfer
 Engine heat transfer depends upon many parameters, unless the effect of
these parameters is known, the design of a proper cooling system will
be difficult.
🞑 Fuel-Air Ratio
 A change in fuel-air ratio will change the temperature of the cylinder gases and
affect the flame speed.
🞑 Spark Advance
 More or less spark advance from the optimum value will result in increased
heat rejection to the cooling system
🞑 Pre-ignition and knocking
🞑 Engine output
 Engines which are designed for high M.E.P or high piston speeds, heat
rejection will be less
🞑 Cylinder wall temperature
 Characteristics of an efficient cooling
12 system
 The two main desired characteristics of an
efficient cooling system
🞑 It should capable of removing about 30 % of the heat
generated in the combustion chamber while maintaining
the optimum temperature of the engine under all
operating conditions of the engine

🞑 It should remove heat at a faster rate when engine is

hot. However during starting of the engine the cooling
should be minimum, so that the working parts of the engine
reach their operating temperatures in a short time
 Types of cooling System
13

 There are two types of system in general

🞑 Liquid or indirect cooling system
🞑 Air or direct cooling system
 Liquid cooling system
🞑 Mainly water is used and made to circulate through the
jackets provided around the cylinder, cylinder head, valve
ports and seats where it extracts most of the heat
🞑 The heat transferred from the cylinder wall and other parts
by convection and conduction
🞑 The heat from liquid in turn is transferred to air. Hence it is
called the indirect cooling system
 Methods of water-cooling
14
System
 Water cooling can be carried out by any one of
the following five methods

🞑 Direct or non return system

🞑 Thermosyphon system
🞑 Forced circulation cooling system
🞑 Evaporation cooling system
🞑 Pressure cooling system
 Direct or Non return System
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 This system is useful for large installations where plenty of

water is available.

 The water from a storage tank is directly supplied through

an inlet valve to the engine cooling water jacket

 The hot water is not cooled for reuse but simply discharged.
 Thermosyphon System
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 Heat is supplied to the fluid in the tank A, because of relatively lower density,
the hot fluid travels up
 Its place being taken up by comparatively cold fluid from the Tank B through
the pipe p2
 The hot fluid flows through the pipe P1 to the tank B where it gets cooled
 The fluid circulates through the system in the form of convection current
 Thermosyphon System
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 Tank A –represents the cylinder jackets

 Tank-B- represents a radiator and
 water acts as the circulating fluid.
 The advantages are
🞑 Its simplicity
🞑 Automatic circulation of cooling water

 The man limitation of the system is its inability to meet the

requirement of large flow rate of water, particularly for high output
engines.
 Forced circulation Cooling System
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 This system is added in a large number of Automobiles.

 Here the flow of water from radiators to water jackets is
by convection assisted by a pump
 Forced circulation Cooling System
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 Water or coolant is circulated through jackets around the parts of the

engine to be cooled is kept in motion by a centrifugal pump which
is driven by the engine
 The water is passed through the radiator where it is cooled by the
forward motion of the vehicle
 A thermostat is used to control the water temperature required for
cooling
 This system consists of 4 components
🞑 water pump
Radiator
thermostat
🞑 Fan
 Parts of Engine Cooling
21
System
Air Cooling Systems

 Large cylinder cooling fins and outside air remove excess

heat
 The cooling fins increase the surface area of the metal
around the cylinder
 This allows enough heat to transfer to the outside air
 Plastic or metal shrouds direct air over the cylinder fins

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Air Cooling versus Liquid Cooling

18
 Cooling System
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Construction
Radiator
Cap

Top Hose Radiator

Thermostat Fan

Water
Engine Block Pump
& Water
Jacket
 Cold Engine
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• When an engine is
cold, the thermostat
is closed.
• Coolant flow is through
the bypass hose and the
water jackets.
• This allows the
engine to warm up
quickly.
 Hot Engine
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 The thermostat opens when

the engine warms up.
 This allows coolant to
circulate through the
radiator and the water
jackets.
 Water jackets
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 Defined as the open space within in the cylinder block

and cylinder head where coolant flows
 Water jackets are designed to allow coolant flow to the
right spots so that maximum cooling can be obtained
 Water Pump
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 The purpose
🞑 Is to circulate the water through the cooling system
 Located on the front part of the engine
 In most of the vehicles it is driven by a belt is attached to the
crankshaft
 As the crankshaft turns the fan belt turns
 Thermostat
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 One of the most important parts of the cooling system

 Purpose
🞑 Is to keep the engine coolant at most efficient temperature

 The thermostat is used to bring the coolant temperature up

to operating as quickly as possible

 It is designed to sense the temperature of the coolant

 Thermostat
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 Radiator
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 Purpose
🞑 Is to allow fresh air to reduce the temperature of the coolant
 As the coolant passes through the tubes air is
forced around the tube
 This causes a transfer of heat from the hot coolant to
the cooler air.

 In this case, heat is exchanged from the liquid coolant

to air.
 Radiator
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 Coolant flows through the air fins

 The fins and tubes are cooled core
 Radiator
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Parts
 Radiator Hose and Hose Clamps
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 Purpose
🞑 Transport coolant from engine to radiator and
back
 Radiator pressure cap
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 Pressure caps are designed to

🞑 Increase the pressure on the cooing system
🞑 Reduce cavitations
🞑 Protecting the radiator hose
🞑 Prevent or reduce surging
 It is important to put pressure on the cooling
system. Radiator pressure caps are typically near 15 psi
 As the pressure increases the boiling point of the
coolant also increases (about 3 degrees for each 1 psi
increase
 Pressure Cap
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 Pressure cap
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 Pressure cap
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 Expansion tank
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 Expansion tank
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 Fa
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n
 Electric Fan
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Relay
 Coolant Temperature
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Indicator
 Coolant Temperature
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Indicator
 Types of Coolant
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 Coolant
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 Coolant
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 Coolant
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 Anti-freeze
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 IAT: inorganic additive technology

 OAT: organic acid technology
 HOAT: hybrid organic acid technology
 Extended and conventional anti-freezes cannot
be mixed
 EG: ethylene glycol
 PG: propylene glycol
 Anti-freeze
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 Maximum concentration: 67% anti-freeze

 Minimum concentration: 50% for
corrosion prevention
 Pure anti-freeze has higher viscosity and does
not flow well
🞑 Does not transfer heat well

Protected with Water only

 .
.