internal combustion engine

The cooling system

Introduction

Cooling system is one system that affects the performance of the engine. it
serves to maintain engine temperature conditions to remain normal, ranging
between 90C , this system consists of mechanical components that work
together to reduce the pollution emission ,extend the life of the components and
reduce the fuel consumption.

Objective

1 ……….... ……………………...…………..why engine need Cooling system

2 …………...………………………..……...….…….cooling system main parts
3 ………………………………………...…..….the operation of cooling system
4………………………………………………....……………………..Thermostat
5………………………….……………………………………………Water Pump
5………………………….…….…………………………………...……..Radiator
6……………...………..Radiator Pressure Cap & Coolant recovery reservoir
7……………………………………...……….…...……….Electric Cooling Fans
8…………………………….………...Hoses & Water Jackets & Hose Clamps

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content

1. why engine need Cooling system

Internal Combustion ngine generates extreme heat during combustion

operation, Metal temperatures around the combustion chamber can run as high
as 1,000°F (537.7°C). This heat can destroy the engine and would cause
several problems:

1. Prevent Overheating: The high temperatures from fuel combustion can

cause engine components to overheat, which may lead to serious damage
or failure. Overheating can cause parts like the pistons, cylinder walls, and
valves to expand beyond their tolerance limits, leading to seizing or
warping.

2. Maintain Optimal Operating Temperature: Engines are designed to

operate efficiently within a specific temperature range. A cooling system
helps maintain this range, ensuring the engine runs at its peak
performance. If the engine is too cold, it won’t function efficiently, and if it's
too hot, it may fail.

3. Improve Fuel Efficiency and Emissions: Proper engine temperature

ensures better fuel combustion and reduces harmful emissions. If an
engine runs too hot or too cold, it can burn fuel inefficiently, leading to
higher emissions and fuel consumption.

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2. cooling system main parts

In a liquid-cooling system, each major component plays a specific role in

regulating engine temperature ,The major components of this system is Radiator
, Water pump , Thermostat , Thermostatic engine fan (Radiator Fan) , Coolant
recovery reservoir , Heater Core , Temperature Sensor , Radiator Cap and
radiator hose . These components work together to keep the engine within a
safe temperature range, ensuring efficient operation and preventing overheating

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3. the operation of cooling system

Heat is removed from around the combustion chambers by a heat-absorbing

iquid (coolant) circulating inside the engine Coolant then flows to the radiator
where the coolant’s heat is transferred to the outside air.

The pump moves the coolant through the engine block and then through the
cylinder head. A thermostat is used to control operating temperature. When the
coolant temperature is below the desired operating temperature, the thermostat
is closed, which allows the coolant to recycle through the engine. When normal
operating temperatures are reached, the thermostat opens to allow the coolant
to flow to the radiator. The coolant flows to the top of the radiator and loses heat
as it flows down through the radiator. Ram air and the airflow from the cooling
fan move through the radiator and cool the coolant. The cooled coolant leaves
the radiator and enters the water pump and then is sent back through the
engine.

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 Engine coolant is a mixture of water and anti-freeze/coolant. Engine coolant
has a higher boiling temperature and a lower freezing point than water. The
exact boiling or freezing temperatures depend on the mixture. The typical
recommended mixture is a 50/50 solution of water and antifreeze/coolant.

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4 Thermostat

The thermostat controls the minimum operating temperature of the engine.

The maximum operating temperature is controlled by the amount of heat
produced by the engine and the cooling system’s ability to dissipate the heat.

When you start a cold engine, it needs to warm up quickly to reach its
optimal operating temperature. The thermostat remains closed at this stage,
preventing the coolant from flowing to the radiator , If coolant were allowed to
circulate through the radiator when the engine is cold, it would take much longer
for the engine to reach the right temperature, and increased fuel consumption.

But when the engine temperature reaches a certain preset temperature

(typically around 85–95°C or 185–203°F), the thermostat opens , If the engine
continues to generate more heat than usual (for example, under heavy load or in
hot weather), the thermostat stays fully open, allowing maximum coolant flow to
the radiator for maximum cooling.

When the thermostat opens, coolant starts flowing from the engine to the
radiator, where it can release the heat absorbed from the engine into the air
through the radiator fins. This maintains the engine's optimal temperature,
preventing it from overheating.

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5 Water Pump
The pump is an important component of the engine cooling system, which is
a simple centrifugal pump driven by a belt connected to the crankshaft of the
engine. Its function is to provide energy to the fluid so it can flow through the
circuit. The pump circulates fluid whenever the engine is running.

On some engines the pump is driven by the chain, or an electric motor. No

matter how these units are driven, they all basically work the same way.

As a centrifugal pump, it uses a rotating impeller to increase the velocity of

the coolant. The impeller draws the coolant from the engine block and pushes it
through the cooling system.

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6 Radiator
The water pump is part of a closed-loop cooling system, where the coolant
absorbs heat from the engine and then flows to the radiator, where it is cooled
by airflow before returning to the engine.

A radiator is a type of heat exchanger. It is designed to transfer heat from the

hot coolant that flows through it to the air , Most cars use aluminum radiators.

The coolant flows from the inlet to the outlet

through many tubes mounted in a parallel
arrangement. The fins conduct the heat from the tubes
and transfer it to the air flowing through the radiator.

The tubes sometimes have a type of fin inserted

into them called a turbulator, which increases the
turbulence of the fluid flowing through the tubes.

If the fluid flowed very smoothly through the tubes, only the fluid actually
touching the tubes would be cooled directly. The amount of heat transferred to
the tubes from the fluid running through them depends on the difference in
temperature between the tube and the fluid touching it. So if the fluid that is in
contact with the tube cools down quickly, less heat will be transferred. By
creating turbulence inside the tube, all of the fluid mixes together, keeping the
temperature of the fluid touching the tubes up so that more heat can be
extracted.

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 Attached to the sides or top and bottom of the radiator core are plastic or
aluminum tanks One tank holds hot coolant and the other holds the cooled
coolant.

radiator cores are normally comprised of flattened aluminum tubes

surrounded by thin aluminum fins. The fins conduct the heat from the tubes to
the air flowing through the radiator.

Today’s radiators are designed to limit the amount of heat dissipated; this
keeps the coolant somewhat hot at all times. Keeping engines operating at a
high temperature is necessary to maintain low emission levels and save fuel
consumption.

Radiators are normally based on one of two designs: cross flow or down flow.

• In a cross-flow radiator, coolant enters on one side, travels through tubes,

and collects on the opposite side.

• In a down-flow radiator, coolant enters the top of the radiator and is

drawn downward by gravity.

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 All late-model cooling systems have an expansion or recovery tank. Cooling
systems with expansion tanks are called closed-cooling systems. They are
designed to catch and hold any coolant that passes through the pressure cap.
As the engine warms up, the coolant expands. This eventually causes the
pressure cap to release. The coolant passes to an expansion tank. When the
engine is shut down, the coolant begins to shrink. Eventually, the vacuum spring
inside the pressure cap opens and the coolant in the expansion tank is drawn
back into the cooling system.

Transmission Cooler:

Cooling the transmission fluid is essential to the efficiency and durability of an

automatic transmission.

Transmission Cooler Radiators used in vehicles with automatic transmissions

have a sealed heat exchanger, located in the coolant outlet tank of the engine’s
radiator. Metal or rubber hoses carry hot automatic transmission fluid to the oil
cooler. The coolant passing over the sealed oil cooler cools the fluid, which is
then returned to the transmission.

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6 Radiator Pressure Cap & Radiator Pressure Cap &
Coolant recovery reservoir
Radiator Pressure Cap :

The radiator pressure cap is a key component of an automobile's cooling

system, responsible for maintaining the optimal pressure in the cooling
system ,pressure cap consist of two valve design , pressure valve design &
vacuum valve design.

For the pressure valve , When the pressure

exceeds the cap’s set limit, the valve opens to
release excess coolant into an overflow tank,
preventing damage to the cooling system. and for
the vacuum pressure , when the engine cools
down, the vacuum valve opens to allow coolant
from the overflow tank back into the radiator,and
keeping it full.

W A R N I N G ! : Never remove the radiator cap from a hot engine.

Doing so can allow hot coolant and steam to shoot out and seriously burn
you.

Coolant recovery reservoir:

When the engine heats up, the coolant expands and creates extra pressure
in the system. This forces excess coolant to flow from the radiator into the
recovery reservoir, preventing overflow and spillage .after the engine cools
down, the coolant contracts, creating a vacuum. The recovery reservoir allows
the coolant to flow back into the radiator to keep it full, thanks to the vacuum
valve in the radiator cap.

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7 Electric Cooling Fans
The fan draws air through the radiator to cool down the coolant , Electric
cooling fans, are controlled by an electric motor and only operate when needed,
based on the engine’s temperature , they’re more efficient and common in
modern vehicles.

The temperature sensor, usually located near the thermostat or on the

radiator,is continuously monitors the coolant temperature When the coolant
reaches a set high temperature ( 200°F or 95°C), the sensor sends a signal to
activate the fan relay , Once the relay receives the signal from the temperature
sensor, it completes the circuit, allowing power to flow to the cooling fan and
turning it on.

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8 Hoses & Water Jackets & Hose Clamps
Hoses:

Coolant flows from the engine to the radiator and from the radiator to the
engine through radiator hoses. The hoses are usually made of butyl or neoprene
rubber hoses to cushion engine vibrations and prevent damage to the radiator.

Hose is typically made up of three parts:an inner rubber tube,some

reinforcement material, and an outer rubber cover . Cooling system hoses
must be able to endure heavy vibrations and be resistant to oil, heat, abrasion,
weathering, and pressure, Most vehicles have at least four hoses in the cooling
system , Two small diameter hoses send hot coolant from the water pump to the
heater core and back. Two larger diameter hoses move the coolant from the
water pump to the radiator and back into the engine block.

(bypass) hose
allows coolant to
circulate within
the engine when
the thermostat is
closed.

Hoses are sized according to their inside diameter. For example, common
heater hoses are 5⁄8 or 3⁄4 inch.

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Water Jackets:

Hollow passages in the block and cylinder heads surround the areas closest
to the cylinders and combustion chambers.

Water jackets are positioned around the cylinders and combustion chambers
where heat is generated during engine operation .These passages are
specifically designed to maximize contact between the coolant and the engine's
hottest surfaces.

Hose Clamps:

Hoses are attached to the engine and radiator with clamps ,Hose clamps are
designed to apply clamping pressure around the outside of the hose at the point
where it connects to the inlet and outlet connections at the radiator, engine
block, water pump, or heater core , The pressure exerted on this connection is
important to making and maintaining a seal at that point.

Conclusion

This is the basic components of cooling system with simple explanation of

working principle. These components work together to maintain optimal engine
temperature, ensuring efficient performance and preventing overheating. By
stabilizing temperature, the system enhances reliability and prolongs engine
lifespan.

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