Cooling Systems

n Theory and operation

n Components
n Thermostat
n Hoses
n Radiator
n Radiator cap
n Coolant recovery
n Fans
n Water pumps
n Anti-freeze

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 Theory and Operation

The cooling syst em

rem oves excess heat t o
keep t he inside of t he
engine at an efficient
t em perat ure, about
200o F (94o C).

Animation: Cooling System

2
 Coolant Flow
Coolant flows t hrough t he
wat er jacket s where it
absorbs heat . It t hen
flows t hrough t he radiat or
where heat is t ransferred
t o t he air passing
t hrough. The am ount of
flow is det erm ined by t he
wat er pum p. The flow
direct ion is cont rolled by
t he t herm ost at .
3
 Cold Engine

When an engine is cold,

t he t herm ost at is cold.
Coolant flow is t hrough
t he bypass hose and t he
wat er jacket s. This
allows t he engine t o
warm up evenly.

4
 Warm Engine

The t herm ost at opens

when t he engine warm s
up. This allows coolant
t o circulat e t hrough t he
radiat or and t he wat er
jacket s.

5
Theory and Operation
n Maintains operating temperature
of approx. 200-235 degrees
n When temperature is low, bypass
blocks coolant flow through
radiator
n When correct temperature is
reached, thermostat opens and
excess heat is absorbed through
water jackets and passed on to
air flowing through radiator
6
Problem:
n A cylinder head has been removed
from an engine
n Two exhaust valves are badly
burned
n The head is warped
n Coolant is in combustion chambers
n What caused this problem?
n What should be done to repair
this?
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 Thermostat

The spring in t his t herm ost at

has closed t he valve. When it
get s hot , t he heat m ot or will
push t he valve open.

Animation: Thermostat Operation

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Thermostat Operation
n Where is it located?
n How does it control the engine’s
temperature?
n Can it be installed incorrectly?
n How often should it be replaced?

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Thermostats

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What if…
n What is likely to happen if the
thermostat were removed from a
vehicle?

11
 Hoses

Reinforced rubber hoses t ransfer

t he coolant from t he engine t o t he
radiat or, coolant reservoir, and
heat er core.

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Hoses and Clamps

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Hoses
n Why are hoses necessary?
n How often should they be
replaced?
n Why do some hoses have internal
springs and what would happen if
they were removed?
n Why are hose clamps so critical to
the overall operation of the
cooling system? 14
 Radiator

The hot coolant flows t hrough

t he radiat or t ubes and heat is
t ransferred t o t he fins and t hen
t o t he air passing t hrough
radiat or.

15
 Radiator Types

Older vehicles used

downflow radiat ors wit h t he
coolant flowing from t he t op
t o t he bot t om . Modern
vehicles use crossflow
radiat ors wit h t he coolant
flowing from one side t o t he
ot her.

16
Radiator Composition
n Soldered copper or brass
n Repairable
n Aluminum cores with plastic tanks
n Lighter weight
n Corrosion resistant
n More inexpensive
n Better heat transfer
n

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Problem:
n A plastic/aluminum radiator is
leaking at it’s seam
n How can it be repaired?


n What is the main advantage of a

crossflow radiator over a
downflow radiator?

18
 Radiator Cap

The upper gasket prevent s

coolant from escaping t o t he
out side. The lower gasket keeps
a pressure in t he radiat or. The
cam lock pushes t he t wo
gasket s against t he sealing
surfaces when t he cap is
inst alled. The safet y st op
prevent s t he cap from being
opened t oo quickly.
Animation: Pressure Cap
19
 Radiator Pressure

Radiat or pressure result s from t he expansion

of t he coolant as t he engine warm s up.
Coolant volum e increases about 10% as t he
t em perat ure increases from 70 t o 180 o F (21 to 82o
C).
The radiat or cap creat es t he pressure by
holding t he coolant in t he radiat or.
The coolant’s boiling point increases about 3o F for
each psi increase in pressure.

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 Coolant Recovery
Reservoir

When t he engine warm s up,

t he radiat or cap allows t he
expanding coolant t o flow
int o t he coolant recovery
reservoir.
When t he engine and coolant
cool down, t he coolant ret urns t o
t he radiat or and wat er jacket s
t hrough t he vacuum valve in t he
cap.
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What will happen if:
n A customer’s vehicle has a very
slight leak at the thermostat
housing?


n What symptoms would the

customer most likely notice?

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 Radiator Cap Types

These caps are t he sam e

except for t he vacuum
valve. This valve opens t o
allow coolant t o ret urn
from t he CRR. The gravit y
vacuum valve opens m uch
easier.

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Problem:
n If a customer’s pressure cap is
defective, what is the most likely
symptom the customer would
notice?
n How often should a pressure cap
be replaced?

24
What will happen if:
n At normal operating temperature,
you remove the radiator pressure
cap to check coolant level?


n How can the coolant level be

checked safely?

25
Checking coolant level

26
 Radiator Air Flow

Air flows t hrough t he

openings at t he front of t he
vehicle, t hrough t he radiat or
and ot her heat exchangers,
and exit s past t he engine.
The fan wit h shroud assist s
t he nat ural flow when t he
vehicle goes slow or is
st opped.

27
Fan and Fan Drive

Most rear wheel drive vehicles

use a m echanically driven fan
t hat is m ount ed ont o t he wat er
pum p.

Som e vehicles use a

hydraulic cooling fan

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 Fan Clutch

The fan clut ch allows t he

use of a large fan t hat
can be driven at slower
speeds. A t herm al fan
clut ch senses
t em perat ure and will
drive t he fan only when
it becom es necessary.

29
 Electric Fans

Most front wheel drive vehicles

use fan t hat is driven by an
elect ric m ot or. This fan
assem bly includes t he m ot or,
fan, and shroud.
Som e vehicles use t wo fans and
som e of t hese have t wo speeds.

30
Electric Fans
n Electric fans can be mounted in
front of or behind the radiator or
combined
n Electric fans are controlled by
relays that are energized by a
vehicle’s PCM


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Problem:
n How can an electric fan circuit be
tested?

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
Fans
n Why would a hydraulic cooling fan
be advantageous over a
traditional fan clutch?
n Why is fan operation so closely
controlled on a vehicle?
n How can a fan clutch be tested?

33
 Drive Belt

The wat er pum p and fan are

driven by a flexible accessory
drive belt t hat is driven by t he
crankshaft pulley.

34
Water Pump
n Water pumps are centrifugal
pumps
n Some pumps are driven by
accessory drive belts
n Some pumps are driven by engine
timing belts
n Some pumps are driven by the
engine timing chain
35
Water Pumps
n Weep holes:
n Holes placed in bearing housing to
keep coolant from infiltrating
bearing
n Weep hole allows any anti-freeze
that passes by seal to exit
bearing housing
n If seal deteriorates, coolant will
leak out of weep hole
36
Water Pumps
n How often should a weep hole be
inspected for leakage?
n How can leakage be detected?
n What would happen if the leak was
ignored and vehicle continued to
operate?
n Why is water pump replacement wise
on an application where the pump is
driven by the timing belt?

37
 Coolant and Antifreeze
Coolant is a m ixt ure of
ant ifreeze and wat er.
Ant ifreeze lowers t he freezing
point and raises t he boiling
point .
Coolant also prot ect s t he
syst em from rust and
corrosion.

38
Anti-freeze
n Coolant life is determined by the
life of the corrosion protection
package
n Older conventional coolants (IAT’s)
should be changed every two
years
n Newer extended life coolants (OAT/
HOAT’s) should be changed
every five years
39
Anti-freeze
n IAT: inorganic additive technology
n OAT: organic acid technology
n HOAT: hybrid organic acid
technology
n Extended and conventional anti-
freezes cannot be mixed
n EG: ethylene glycol
n PG: propylene glycol
40
Anti-freeze
n All anti-freezes contain:
n Corrosion inhibitors: silicates,
phosphates, borates
n pH buffers: maintain acid-alkaline
balance, prevent electrolytic
corrosion
n EG or PG base: to reduce freezing
point and increase boiling point
n Dye: to distinguish anti-freeze and
type
41
Anti-freeze
n Maximum concentration: 67% anti-
freeze
n Minimum concentration: 50% for
corrosion prevention
n Pure anti-freeze has higher
viscosity and does not flow well
n Does not transfer heat well



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