Pacific college of engineering

pacific hills udaipur

Dept. of mechanical engineering cooling system

Submitted to Abhishek kumar Dept. of mechanical eng.

submitted by Pawan Kumar Bairwa

Contents

Theory and operation Components

Thermostat Hoses Radiator Radiator cap Coolant recovery Fans Water pumps

Theory and Operation

The cooling system removes excess heat to keep the inside of the engine at an efficient temperature, about 200o F (94o C).

Animation: Cooling System

Coolant Flow
Coolant flows through the water jackets where it absorbs heat. It then flows through the radiator where heat is transferred to the air passing through. The amount of flow is determined by the water pump. The flow direction is controlled by the thermostat.
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Cold Engine
When an engine is cold, the thermostat is cold. Coolant flow is through the bypass hose and the water jackets. This allows the engine to warm up evenly.

Warm Engine
The thermostat opens when the engine warms up. This allows coolant to circulate through the radiator and the water jackets.

Theory and Operation

Maintains operating temperature of approx. 200-235 degrees When temperature is low, bypass blocks coolant flow through radiator When correct temperature is reached, thermostat opens and excess heat is absorbed through water jackets and passed on to air flowing through radiator
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Thermostat
The spring in this thermostat has closed the valve. When it gets hot, the heat motor will push the valve open.

Animation: Thermostat Operation

Thermostats

Hoses
Reinforced rubber hoses transfer the coolant from the engine to the radiator, coolant reservoir, and heater core.

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Radiator

The hot coolant flows through the radiator tubes and heat is transferred to the fins and then to the air passing through radiator.

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Radiator Composition

Soldered copper or brass

Repairable

Aluminum cores with plastic tanks

Lighter weight Corrosion resistant More inexpensive Better heat transfer

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Radiator 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.

Animation: Pressure Cap

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Radiator Pressure
Radiator pressure results from the expansion of the coolant as the engine warms up.

Coolant volume increases about 10% as the temperature increases from 70 to 180o F (21 to 82o C).
The radiator cap creates the pressure by holding the coolant in the radiator. The coolants boiling point increases about 3o F for each psi increase in pressure.
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Coolant Recovery Reservoir

When the engine warms up, the radiator cap allows the expanding coolant to flow into the coolant recovery reservoir. When the engine and coolant cool down, the coolant returns to the radiator and water jackets through the vacuum valve in the cap.
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Radiator Cap Types

These caps are the same except for the vacuum valve. This valve opens to allow coolant to return from the CRR. The gravity vacuum valve opens much easier.

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Checking coolant level

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Radiator Air Flow

Air flows through the openings at the front of the vehicle, through the radiator and other heat exchangers, and exits past the engine. The fan with shroud assists the natural flow when the vehicle goes slow or is stopped.

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Fan and Fan Drive

Most rear wheel drive vehicles use a mechanically driven fan that is mounted onto the water pump. Some vehicles use a hydraulic cooling fan

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Fan Clutch

The fan clutch allows the use of a large fan that can be driven at slower speeds. A thermal fan clutch senses temperature and will drive the fan only when it becomes necessary.
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Electric Fans
Most front wheel drive vehicles use fan that is driven by an electric motor. This fan assembly includes the motor, fan, and shroud. Some vehicles use two fans and some of these have two speeds.

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Electric Fans

Electric fans can be mounted in front of or behind the radiator or combined Electric fans are controlled by relays that are energized by a vehicles PCM

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Drive Belt

The water pump and fan are driven by a flexible accessory drive belt that is driven by the crankshaft pulley.

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Water Pump

Water pumps are centrifugal pumps Some pumps are driven by accessory drive belts Some pumps are driven by engine timing belts Some pumps are driven by the engine timing chain
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Water Pumps

Weep holes:

Holes placed in bearing housing to keep coolant from infiltrating bearing Weep hole allows any anti-freeze that passes by seal to exit bearing housing If seal deteriorates, coolant will leak out of weep hole

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Thank you query

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