MODULE: CARRYING OUT GENERAL MACHINE SERVICE .

UNIT03: SERVICING ENGINE COOLING SYSTEMS.

COOLING SYSTEM

Cooling system is a system in an engine that removes excess heat produced during
combustion to keep the engine operating at the correct temperature.

Functions of Cooling System

• Prevent engine overheating

• Maintain optimum engine temperature

• Improve engine efficiency

• Prevent damage to engine parts

• Reduce wear and tear

Advantages of Cooling system

• Longer engine life

• Better fuel efficiency

 • Reduced breakdowns

• Smooth engine operation

Types of Cooling System

1. Air Cooling System

Is a type of engine cooling system that uses air flow to remove heat directly from the engine
surfaces (usually through cooling fins).Common in motorcycles and small engines

Advantages of air cooling system

• The system is free from leakage.

• Low maintenance

• Engine warm quickly to it's normal running temperature.

• No coolant required

Disadvantages of air cooling system

• Fan is noisily and absorb fairly larger amount of cylinder must be spaced well apart
to allow sufficient depth of fins.

• Occupy large space as cylinder are placed apart.

• Engine overheating is more

1. Water Cooling System

Water cooling system is a type of engine cooling system that uses a liquid coolant (water +
antifreeze) to absorb heat from the engine and carry it to the radiator where it is cooled.

Common used in cars, trucks, and heavy machines

Advantages of water cooling system

• Is better to operate engine without overheating.

• Cylinder can be placed a close together.

• Fan used is smaller than air cooled fan.

• Uniform temperature control.

Disadvantages of water cooling system

• Constant risk of coolant leakage.

 • High maintenance

• Engine takes longer to warm up starting from cold weather.

• Heavy in weight due to radiator, water pump ,pulley and water.

Types of water cooling system

• Pressurized cooling system is a type of engine cooling system in which the coolant
(water + antifreeze) is kept under pressure to increase its boiling point and improve
cooling efficiency.

• Thermosiphon cooling system is a type of engine cooling system that circulates

coolant without using a water pump, relying on natural convection (movement
caused by temperature differences).

Main Components of Cooling System

1. Radiator is the device that used to store and cools hot coolant by transferring heat to the
air.

Types of radiator

• Cross flow radiator

• Down flow radiator

Component of radiator

• Radiator cap

• Radiator bottom tank

• Radiator top tank

• Radiator top hose

• Radiator bottom hose

• Radiator core

• Drain cock

2. Radiator cap: it act as filler cap and seals the radiator and allow the coolant to rise up to
1000 C or 2120F temperature without boiling.

Radiator cap contains two valves.

• Pressure relief valve

• Vacuum valve

Pressure relief valve: is the valve that open when temperature pressure of the coolant rise
above 14.2 psi in the radiator and allow the excess pressure to escape through over flow
hose to the reservoir tank.

Vacuum valve: is the valve that open automatically to allow coolant from reservoir tank to
return to the radiator when engine temperature is completely cold.

Radiator cap figure

3. Water Pump. Is the pump that used to suck water from radiator bottom tank to the water
jacket, cylinder head then to radiator top tank. Water pump is normally driven by crankshaft
pulley where by degree of water circulation is proportional to the engine speed.

Types of cooling water pump

• Impeller cooling water pump

• Centrifugal cooling water pump

Slipping of driven belt and defective water pump can reduce effectiveness of pump and
cause overheating of the engine. If water pump leaks check pump gasket, seal and bearing.

Component of water pump

• Seals

• Joint gasket

• Pump shaft

• Bearing

• Pump impeller

Water pump figure

4. Thermostat : is the valve that controls coolant flow based on [Link] is

fitted to the cylinder head water outlet passage below top hose.
Function of thermostat in cooling system

1. Is the valve that open and close due to temperature change.

2. Is the valve that used to control engine cooling temperature.

5. Cooling Fan: is the device that used to induce flow of air through [Link] fan is fitted
behind the radiator mounted on water pump shaft.

Types of cooling fan

• Belt driven cooling fan

• Electric motor driven fan.

• Hydraulic motor driven fan

• Pneumatic motor driven fan

Belt driven cooling fan

This is the fan that driven by belt at high speed resistance to engine power increase greater
fan noise and direct the follow of air through radiator and cold the coolant .

Electric motor driven fan.

This fan is driven by electric motor. When temperature rises, signal activate motor relay
turning on motor driven cooling fan. Fan operates only when needed.

Advantages of electric motor driven

• Engine reaches its operating temperature more quickly

• Reduce fuel consumption

• Reduce engine power loss.

• Reduce noise.

6. Coolant is a liquid mixture used in an engine cooling system to absorb heat from the
engine and transfer it to the radiator, where it is released into the air.

7. Hoses and Pipes: are tubes used in the engine cooling system to carry coolant between
different components such as the radiator, engine, water pump, and expansion tank.

8. Expansion Tank (Reservoir): is a container in the engine cooling system that stores
excess coolant when it expands due to heat and returns it to the system when it cools down.

9. Water jacket: is a network of hollow passages cast into the engine block and cylinder
head through which coolant flows to absorb and carry away heat from the engine.

Coolant chemical: are substances mixed with water to form coolant, used in the engine
cooling system to improve heat transfer, prevent freezing/boiling, and protect the system
from corrosion.

Function of coolant chemical

• Lowers freezing point of water

• Raises boiling point of coolant

• Prevents corrosion and rust

 • Protects engine components like radiator and water jacket

Working Principle of Cooling System

• Engine produces heat during combustion

• Coolant absorbs heat from engine block

• Water pump circulates hot coolant to radiator

• Radiator cools the coolant using air

• Cooled coolant returns to engine

• Thermostat regulates flow depending on temperature

Symptoms of Cooling System Problems

• Engine overheating

• Coolant loss

• White smoke (coolant entering combustion chamber)

• Poor engine performance

• Unusual temperature gauge readings

Maintenance of Cooling System

• Check coolant level regularly

• Flush radiator periodically

• Inspect hoses for leaks

• Replace thermostat if faulty

• Check fan operation

• Use correct coolant mixture

Safety Precautions

• Never open radiator cap when engine is hot

• Use protective gloves

• Dispose coolant properly (it is toxic)