Prof. Md.

Joynal Abedin
Dept. of Agricultural Engineering

ENGINE COOLING SYSTEM

Importance
At the time of power or firing stroke, the ignition temperature rises up to 1200°C in petrol
engine and 2000°C in diesel engine. The melting points of cast iron, steel and aluminum alloys
are 1100°C, 1450°C and 600°C respectively. In above situation the cooling is very essential and
very important to protect engine components from overheating and melting.
Functions
(1) Cooling system controls engine temperatures at the range of 80-90°C.
(2) The entering temperature of water into the cylinder block is 35-40°C and outlet
temperature is 75-80°C.
(3) Protects engine from overheating.
(4) Temperature controls around the cylinders.
(5) Protect engine components from melting.
(6) Keeps engine in certain temperature.
Methods of Engine Cooling
1. Air cooling system
2. Water cooling system
a) Hopper Cooling System
b) Thermo-Syphon Cooling System
c) Forced Circulation Cooling System

Air Cooling System: Normally used for small engines. The cylinder fins help to cool the
engines through radiation by leaving heat to the atmosphere. These fins actually increase the
cross sectional area of the engine cylinder where the heat spreads out towards outer edges of the
fins. Then atmospheric air absorbs the heat through radiation that results in the cooling of the
engine. This system is used in motor bike engines, baby-taxi engines, lawn mower engines and
some portable power sprayer engines.

Fig. 1. Air Cooling System

[Online Link of the Sheet: t.ly/9Nu7] Page | 1

 Prof. Md. Joynal Abedin
Dept. of Agricultural Engineering

Water Cooling System

i) Hopper Cooling System: The water jacket around the cylinder where water moves around
absorbs heat and keeps the engine cool. An open water tank is constructed over water jacket
where water is getting hot and lighter through convection process. Then this water goes up and
less hot and cool water comes down to fill that place. By running out of water through
evaporation and finally the addition of fresh cool water in the tank, thus and this ways the system
works continuously inside the engine. The defining feature of hopper cooling, amongst other
water-cooled engines, is that there is no radiator. It was used in steam engine, but now it is an old
and backdated system and not used anymore in these days.

Fig. 2. Hopper Cooling System

ii) Thermo-Syphon Cooling System: The system is so designed that the water may circulate
naturally because of the density difference of hot water and cold water. Fig.3 shows the
arrangement of an engine cooled on thermo-syphon principle.

Fig. 3. Thermo-Syphon Cooling System

The system consists of a radiator having upper and lower tanks connected to upper and lower
water jackets of the cylinder respectively through pipes. The hot water in the jacket rises and
flows into the upper tank due to lower density compared to cold water and the cold water from

[Online Link of the Sheet: t.ly/9Nu7] Page | 2

 Prof. Md. Joynal Abedin
Dept. of Agricultural Engineering

radiator flows to lower water jacket to replace the hot water. From upper tank the water travels
down the radiator tubes across which the cool air passes drawn by the fan driven by the engine
crankshaft. In order to increase the rate of heat transfer, the surface area of the radiator exposed
to the air blast is provided with fins. System is suitable for low capacity engines only limitation
of system. Radiator needs to be kept above engine cylinder level for flow of water to the engine
under gravity for its efficient functioning. Circulation of water is established only when engine
becomes hot. Not suitable for heavy duty engines where very high heat transfer rates are
required. Water level in radiator should be kept higher than delivery pipe; otherwise, circulation
of water may cease causing excessive temperature rise of cooling water with steam formation. It
causes formation of steam pockets, unequal heat flow and overheating of engine components.
Temperature of cooling water should not be allowed to exceed beyond 80°C in this system.
iii) Forced Circulation Cooling System: In this system the above all elementary parts of
thermo-siphon system are present, in addition of that there is a pump and thermostat valve are
present at their required position. The pump works in water jacket of engine and thermostat valve
is fixed and connected to the upper-hose pipe of radiator that opens at the temperature range of
74-80°C. The engine’s internal hollow structures is called water jacket. The water at the water
jacket absorbs heat from combustion chamber of engine cylinders raises the water temperature
up and becomes hot and lighter. This water temperature helps to open the thermostat valve which
allows water to pass into the radiator. There is an internal or external by-pass in this system that
helps in uniform warm up, eliminates hot spots, and prevents excessive coolant pressure in the
engine when the thermostat is closed.

Fig. 4. Forced Circulation System

[Online Link of the Sheet: t.ly/9Nu7] Page | 3

 Prof. Md. Joynal Abedin
Dept. of Agricultural Engineering

Coolant
Engine coolant, (also known as antifreeze), is mixed with water to keep engine and radiator from
freezing in extreme cold and overheating in extreme heat. Coolant is made from either ethylene
glycol or propylene, water, some protection additives and is usually green, blue or red in color.
Radiator
The whole radiator looks like a honeycomb through which air can flow. In radiator, the coolant
flows from the header to the bottom tank through many thin water tubes mounted in a parallel
arrangement. The tubes are also in contact with numerous thin metal plates. The hot water enters
the radiator through the inlet port. And a fan is attached on behind the radiator to cool down the
hot water in the tubes. The fan blows the air and cools down the water. So the water is going to
come out cooler than it entered before and then go back to the engine to repeat the process.

Fig.5. Radiator

The Thermostat Valve & The Water Pump

As we know, the thermo-syphon system depends on atmospheric temperature. The forced
circulation system is established only when the engine becomes hot. In the winter atmospheric
air temperature is low and so there is a chance of overcooling while during summer there is a
chance of overheating.
In a forced circulation cooling system, as the pump starts it will start circulating cold water to the
cylinder and absorb heat at a faster rate from cylinder walls due to the large temperature
difference. As a result the engine takes more time to warm up to the desired level of temperature
particularly in cold weather. In this cooling system, the thermostat is mainly used to maintain a
predefined minimum water temperature around the engine cylinder, therefore no cold starting
problem during the cold weather. The thermostat cooling system consists of pump, radiator,
thermostat, and fan as shown in figure 4. The function of the pump is to circulate the water
through the water jacket to remove the heat from the engine and through the radiator where the
water is cooled by the flow of air. Thermostat is a temperature operated valve fitted in the upper

[Online Link of the Sheet: t.ly/9Nu7] Page | 4

 Prof. Md. Joynal Abedin
Dept. of Agricultural Engineering

Fig. 6. Thermostat Valve Fig. 7. Impeller Pump

hose connection which prevents the circulation of water from the water jacket to the radiator
below a certain temperature (usually up to 85°C), so that water in the engine gets heated up
quickly. Thermostat valve consists of thin copper tubes bellow partially filled with a volatile
liquid (such as alcohol). Alcohol evaporates at 78°C. During the warm up period (during starting
of the engine from cold) the thermostat valve remains closed, and while the engine is running the
water being pumped by the impeller pump raises the pressure in the thermostat and causes the
relief valve open. Relief valve returns the water back to the water jacket, so in this period of time
the pump circulates water in the water jacket only. The water does not pass through the radiator;
hence engine cooling does not take place. When the engine is reached at normal operating
temperature (say 78°C), the volatile liquid in the thermostat valve is vaporized, thus creating
enough pressure inside the bellows to expand and lift the valve as shown in figure 6. Hence the
thermostat valve is opened and water pressure falls, relief valve closes, and the water circulates
through the radiator, engine cooling takes place.
Frost Protection in Water Cooling
Water cooled engine which has to stand or operate in temperatures of freezing point or below
must have a properly anti-freeze solution mixed with the water. This will prevent damage to the
radiator and engine. When water freezes it expands with a considerable force fully capable of
fracturing cast-iron cylinder blocks, cylinder head or radiators.
An anti-freeze solution, ethylene glycol (which is used to make coolant) is usually protects the
cooling system from frost damage. A 25% solution of anti-freeze and water will protect the
system which lowers down to a temperature of about -18°C (0°F). A 25% solution consists of 2
liter of anti-freeze with 6 liter of water.
Anti-freeze does not prevent freezing, it only lowers the freezing point of the coolant. It lowers
the boiling points too. It is best to top up the cooling system with a ready mixed anti freeze
solution during the winter months.

[Online Link of the Sheet: t.ly/9Nu7] Page | 5