Cooling System Theory

ADX 150 Engine Repair

ADX 170 Climate
Controls

Purpose
Normal operation produces heat that must
be carried away by coolant
Cooling system transfers heat to cooler
outside air when engine is hot.
Cooling system keeps heat in the engine
when engine is not warm enough.
Modern cooling systems are designed to
maintain an even temperature of about 180
to 230F (82 to 113C).

Cooling System Operation

System

design removes 35% of total

heat.
If not equipped with factory A/C, cooling
system is usually not able to handle
additional heat load of aftermarket units.

Components
COOLING

SYSTEM COMPONENTS

Water Pump
Cooling Fan
Radiator
Pressure Cap
Thermostat
Clamps and hoses
Overflow tank

Water Pumps
Centrifugal

Type Water Pump.

Inlet comes from bottom of Radiator.
Outlet is through impeller to engine.
Water Pump Replacement can be due to
leaks or bearing failure.
Transfer pump parts and use correct
gaskets.

Weep Hole
Coolant will often leak
out of the weep hole.
This indicates the
shaft seals in the
water pump have
failed.
Water pump
replacement will be
required.

Water Pumps
Water

pumps can be driven off of the

serpentine belt, the timing belt, or the
camshaft.
When driven off of the timing belt, most
technicians suggest replacement when
replacing the timing belt.

Water Pumps

Water Pumps

Radiators
Allows

for heat to move from coolant to the

outside air.
Cooler air flowing through the radiator cools
the coolant.
Most radiators about 28-35 sq. feet.
Can have multiple cores to increase area.
Two types
- Cross flow
- Down flow

Radiators

Radiators

Radiators
Many

radiators will have oil coolers built

into them.
These can be for the engine oil or the
ATF.
Should either of these crack, oil could
get into the coolant and coolant into the
oil.

Coolant Expansion
Radiator pressure results from the
expansion of the coolant as the engine
warms up.
A small amount of air used to be kept in the
radiator to allow for this expansion.
Since air leads to rust and corrosion, the
radiator needs to be filled completely with
coolant.
The pressure cap and coolant reservoir
work together to allow for this expansion.

Pressure Cap
The upper gasket prevents
coolant from escaping to the
outside. The lower gasket
keeps a pressure in the
radiator. The cam lock pushes
the two gaskets against the
sealing surfaces when the cap
is installed. The safety stop
prevents the cap from being
opened too quickly.

Pressure Cap

Pressurizing a liquid
increases the boiling
point of that liquid.
Cooling systems are
pressurized so that the
boiling point of the
coolant is raised.
Many cooling systems
are pressurized to 15
psi.

The coolants boiling point

increases about 3 F for each
psi increase in pressure.

Pressure Cap
The

pressure cap allows the pressure to

build, and release past a specified point.

Equipped with Vacuum and Pressure Valve

Used to raise Pressure in system

Pressure Cap

Pressure Cap

Pressure Cap
The

pressure cap also improves the

operation of the water pump.
By keeping the radiator pressurized, the
water pump has a constant supply of
coolant to draw from.
If pressure became too low, the coolant
would boil and the water pump would
draw only air.

Overflow Tank
Contains

reserve coolant.
When cap releases coolant due to
coolant expansion, coolant goes to
overflow tank.
When cooling system cools off and
creates a vacuum, coolant is pulled from
overflow tank.

Overflow Tank
Some

closed cooling systems do not

have a cap on the radiator.
The overflow tank is pressurized with the
rest of the cooling system.
The coolant level will be checked in the
overflow tank.

Pressurized Tanks
Systems

with a pressurized overflow tank

keep a small amount of air in the tank.
This allows the coolant to expand and
compress the air.
Most tanks like this will have a pressure
cap on the tank and no cap on the
radiator.

Pressurized Tank

Odd Cap Location (Durango)

Opening a Hot System

Slowly

turn the cap with a rag and do not

turn it past the safety lock.

Thermostat
Speeds

up engine warm up.

Regulates flow and temperature of engine
coolant.
Most are on the outlet side of coolant flow.
Maintains optimum engine operating
temperature for best emissions and
economy.

Thermostat

Thermostat
temperature is the
opening temperature
Thermostat should be
fully open 20F above
opening temperature
195F thermostat =
fully open at 215F
180F thermostat =
fully open at 200F

Thermostat
The

thermostat contains a wax pellet on

the engine side of the thermostat.
Wax melts and expands when engine
heats up.
As the wax expands, it overcomes spring
pressure and opens the valve.

Thermostat

Thermostat

Thermostat Bleeder

Some thermostats
have a jiggle pin
that should be
installed at the top
to aid in bleeding air
from the system.

Clamps and Hoses

Hoses

direct coolant from the engine to

the radiator, heater core, and the
overflow tank.
Clamps hold hoses in place.

Clamps

PowerGrip Clamp
PowerGrip

clamps are
larger than
the hose
and must
be heated
to shrink
and seal
the hose.

Hoses
Preformed

hoses are made specifically

for an application.
Flex hoses are used for a variety of
applications.
Some lower radiator hoses contain a
spring to prevent them from collapsing
due to water pump suction.

Coolant Flow
The

water pump pumps coolant through

the block.
If the thermostat is closed, coolant flows
through the block, heater core, and the
thermostat bypass.
The bypass leads back to the water pump.
There will be no flow through the radiator
when the thermostat is closed.

Thermostat

When the
thermostat is
closed, coolant
is directed back
into the block
through the
bypass
passage.

Coolant Bypass

Some thermostats are designed to block off

the bypass passage when they are open.

Coolant Flow
When

the thermostat is open, coolant is

then allowed to flow from the block to the
upper part of the radiator.
The coolant is then cooled in the radiator.
The water pump draws the coolant out of
the bottom of the radiator so that it can then
be circulated throughout the block to cool
the engine.

Water Jackets

When an engine cylinder block and head are

cast, cavities called water jackets are formed
around the cylinder walls and combustion
chambers.
These water jackets allow coolant to circulate
around the very hot areas, including the exhaust
valve seats, as well as the relatively cooler areas
of the lower cylinders.
The coolant absorbs heat from the hot areas and
transfers this heat to the colder areas in the
engine or radiator.

Water Jackets

Coolant Flow

Coolant Flow

Some manufacturers position the thermostat on

the inlet side of the water pump.
As the cooled coolant hits the thermostat, the
thermostat closes until the coolant temperature
again causes it to open.
This reduces thermal cycling (expanding and
contracting of the metal).
Thermal cycling can damage aluminum engine
components.

A modern style cooling system

showing how the coolant flows
through the block first, then
through the cylinder head, and
finally through the radiator
after the thermostat opens.

Block Heaters
Block heaters are small, electrical-resistance
heater units that can be mounted in the
block.
These heaters are plugged into ordinary 110volt ac outlet and are used in very cold areas
to warm an engine while it is shut off.
Block heaters provide easier engine starting
and faster warm-up, especially for diesels.

Block Heaters

Typical block
heaters install in
one of the core plug
holes.

Aftermarket Block Heaters

Aftermarket

block heaters generally

should not be installed in late model
vehicles.
The computer checks the ambient air vs.
the coolant temperatures after sitting for
several hours.
If the two disagree, the MIL will illuminate
and a DTC will set.