report on turbo cooling system

8/20/2019 report on turbo cooling system

1/33

TURBO COOLING ENGINE SYSTEM Seminar Report 2015

SEMINAR R EPORT

ON

TURBO COOLINGENGINE SYSTEM

Submitted By:Deepak Kumar Dalabehera

Guided By:Pro! S"a#atika A$harya

Department Of Mechanical Engineering %

Gandhi Institute for Technology BBSR


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CERTI!IC"TE

Thi& i& to $ertiy that the &emi'ar o' #TURBO COOLING ENGINE SYSTEM$ i& a

bo'aide re$ord o the pro(e$t deli)ered by #%EE&"' 'UM"R %"L"BE(ER"$

)Regd*No+ ,-.,-/01..2 u'der my &uper)i&io' a'd #uida'$e% i' partial ulilme't o the

re*uireme't& or the a"ard o De#ree o Ba$helor o Te$h'olo#y i' Me$ha'i$al E'#i'eeri'#

rom G"N%(I INSTITUTE !OR TEC(NOLOGY% Bhuba'e&"ar or the year +,-./+,-0!

Se3inar Guide Se3inar Coordinator (O%


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"C'NO4LE%GEMENTS

The "ork pre&e'ted i' thi& di&&ertatio' "ould 'ot ha)e bee' po&&ible "ithout the

help a'd &upport o a lar#e 'umber o people! The author ir&t e1pre&&e& hi& heartie&t #ratitude

to hi& #uide a'd &uper)i&or &rof* S5agati6a "charya Departme't o Me$ha'i$al

E'#i'eeri'#% Ga'dhi I'&titute 2or Te$h'olo#y% Bhuba'e&"ar% Ori&&a% I'dia or hi& )aluable

#uida'$e% help a'd e'$oura#eme't i' the $our&e o the pre&e't "ork! The &u$$e&&ul a'd

timely $ompletio' o the "ork i& due to hi& $o'&ta't i'&piratio' a'd $o'&tru$ti)e $riti$i&m! I

take thi& opportu'ity to e1pre&& my deepe&t #ratitude to &rof* "3ar %as Co+Ordinator%

Departme't o Me$ha'i$al E'#i'eeri'# a'd al&o a$ulty member& o the Departme't o

Me$ha'i$al E'#i'eeri'#% GI2T% a'd Bhuba'e&"ar or $o'&ta't ad)i$e% u&eul di&$u&&io'&%

e'$oura#eme't a'd &upport i' pur&ui'# the B!Te$h "ork!

The help a'd $ooperatio' re$ei)ed rom the Pri'$ipal a'd Dea' A$ademi$% GI2T%

Bhuba'e&"ar are #rateully a$k'o"led#ed!

Na3e7 %ee8a6

'u3ar %ala9ehera Registration no7 ,-.,-/01..

B*Tech

Branch7 Mechanical Engineering

GI!T Bhu9anes5ar


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CONTENTS7

TIT3E PAGES

"9stract i

List of !igures ii

,*INTRO%UCTION ,

-*LITER"TURE RE:IE4 -

-*,*&UR&OSE O! COOLING SYSTEM ;

;*4OR'ING &RINCI&LE <

1*B"SIC &"RTS IN COOLING SYSTEM ,.

1*, Radiators ,.

1*- Radiator !ans ,,

1*; 4ater &u38 ,-

1*1 Ther3ostat ,;

1*< &ressure Ca8 and Reser=e Tan6 ,1

1*> !an ,<

1*? (eating Syste3 ,>

1*0 (eater Core ,>

*GENER"LIS"TION %I!!ICULTIES -,?*:ISU"L INS&ECTION --0*COOLING SYSTEM M"INT"NCE "N% RE&"IR -;/*"%:"NT"GES @ %IS"%:"NT"GES -<,.*CONCLUSION ->,,*RE!ERENCES -?

"BSTR"CT


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A turbo e'#i'e $ooli'# &y&tem ha& &eparate% $omplete e'#i'e a'd ater $ooler $oola't

loop& $o''e$ted by a li'ki'# $o'duit "ith a li'k )al)e a'd a a' apparatu& pro)idi'# air lo"

throu#h both e'#i'e a'd ater $ooler radiator&! The a' apparatu& i& $o'trollable to )ary air

lo" i' a &erie& o di&$rete $ooli'# le)el&! A' e'#i'e $ooli'# $o'trol i& re&po'&i)e to a $oola't

temperature i' the e'#i'e $oola't loop to $o'trol the a' apparatu& a'd to deri)e a'd output a

&i#'al i'di$ati)e o a de&ired le)el o $ooli'# bet"ee' the &ele$ted o'e a'd a' ad(a$e't o'e o

the di&$rete $ooli'# le)el&! A' ater $ooler $ooli'# $o'trol i& re&po'&i)e to a $oola't

temperature i' the ater $ooler $oola't loop a'd the &i#'al output by the e'#i'e $o'trol to

$o'trol the li'k )al)e &o a& to )ary the temperature o $oola't i' the e'#i'e $ooli'# loop% by

$o'trolled mi1i'# o $oola't% by $o'trolled mi1i'# o $oola't o lo"er temperature rom the

ater $ooler $ooli'# loop% &o a& to a$hie)e the de&ired le)el o $ooli'# i'di$ated by the &i#'al!

i

LIST O! !IGURES

Sl* no* Na3e Of the !igures &age no

- E'#i'e blo$k i#4a5 0

+ E'#i'e blo$k i#4b5 0

6 Radiator -,


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7 8ater pump -+

. Thermostat -6

0 Pressure cap and reserve tank -7

9 Fan -.

;eati'# &y&tem -0

< ;eater $ore i#4a5 -9

-, ;eater $ore i#4b5 -9

ii

C("&TER ,

,* INTRO%UCTION

Thi& i& a &y&tem o part& a'd luid& that "ork& to#ether to $o'trol a' e'#i'e=& operatio'

temperature or optimal perorma'$e! A' i'ter'al $ombu&tio' e'#i'e $ooli'# &y&tem

i'$orporati'# a motor/a&&i&ted turboa' i& di&$lo&ed! The turbi'e/dri)e' a' i& i'$rea&ed i'

rotatio'al &peed by e'er#i>i'# a motor atta$hed to the turbi'e a' &hat rom a' out&ide po"er


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&our$e to pro)ide re*uired $ooli'# air lo"! A "ater (a$ket i' the turbo/$har#er i& po&itio'ed at

the &ame le)el or hi#her tha' a "ater (a$ket i' a' e'#i'e $yli'der head! The turbo/$har#er

$ooli'# "ater $ir$ulatio' pa&&a#e"ay i'$lude& a "ater )olume or ta'k po&itio'ed at a le)el

hi#her tha' the turbo/$har#er $ooli'# portio'% a'd the )olume or ta'k i& $o''e$ted to a

$ooli'# "ater re&er)oir ta'k )ia a pre&&ure relie )al)e "hi$h i& ope'ed "he' pre&&ure i' the

)olume or ta'k e1$eed& a predetermi'ed )alue to &upply $ooli'# "ater to the )olume or ta'k!

-


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Cha8ter -

-* LITER"TURE R E:IE4

?ooli'# &y&tem& or turbo $ooli'# e'#i'e& o lo$omoti)e& are k'o"' "hi$h

pro)ide or $ooli'# o the e'#i'e a'd o a turbo$har#er ater $ooler! O'e &u$h &y&tem i&

de&$ribed i' @!S!May -+% -ed duri'# 'ormal temperature $o'ditio'& by $lo&i'# the li'k )al)e "he'

ma1imum e'#i'e $ooli'# i& 'ot re*uired!

-


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Cha8ter ;

;* T(EORY

;*,* &UR&OSE O! COOLING SYSTEM

?ar& a'd tru$k& u&i'# dire$t air $ooli'# 4"ithout a' i'termediate li*uid5 "ere built o)er a lo'#

period be#i''i'# "ith the ad)e't o ma&& produ$ed pa&&e'#er $ar& a'd e'di'# "ith a &mall a'd

#e'erally u're$o#'i>ed te$h'i$al $ha'#e! Beore 8orld 8ar II% "ater $ooled $ar& a'd tru$k&

routi'ely o)erheated "hile $limbi'# mou'tai' road&% $reati'# #ey&er& o boili'# $ooli'# "ater!

Thi& "a& $o'&idered 'ormal% a'd at the time% mo&t 'oted mou'tai' road& had auto repair

&hop& to mi'i&ter to o)erheati'# e'#i'e&!

A?S 4Auto ?lub Sui&&e5 mai'tai'& hi&tori$al mo'ume't& to that era o' the &u&tai' Pa&& "here

t"o radiator reill &tatio'& remai'! The&e ha)e i'&tru$tio'& o' a $a&t metal pla*ue a'd a

&pheri$al bottom "ateri'# $a' ha'#i'# 'e1t to a "ater &pi#ot! The &pheri$al bottom "a&

i'te'ded to keep it rom bei'# &et do"' a'd% thereore% be u&ele&& arou'd the hou&e% i' &pite

o "hi$h it "a& &tole'% a& the pi$ture &ho"&!

Duri'# that period% Europea' irm& &u$h a& Ma#iru&/Deut> built air/$ooled die&el tru$k&%

Por&$he built air/$ooled arm tra$tor& a'd olk&"a#e' be$ame amou& "ith air/$ooled

pa&&e'#er $ar&! I' the @SA% 2ra'kli' built air/$ooled e'#i'e&!

A typi$al 7 $yli'der )ehi$le $rui&i'# alo'# the hi#h"ay at arou'd ., mile& per hour% "ill

produ$e 7,,, $o'trolled e1plo&io'& per mi'ute i'&ide the e'#i'e a& the &park plu#& i#'ite the

uel i' ea$h $yli'der to propel the )ehi$le do"' the road! Ob)iou&ly% the&e e1plo&io'& produ$e

a' e'ormou& amou't o heat a'd% i 'ot $o'trolled% "ill de&troy a' e'#i'e i' a matter o

mi'ute&! ?o'trolli'# the&e hi#h temperature& i& the (ob o the $ooli'# &y&tem!

The moder' $ooli'# &y&tem ha& 'ot $ha'#ed mu$h rom the $ooli'# &y&tem& i' the model T

ba$k i' the C+,&! Oh &ure% it ha& be$ome i'i'itely more reliable a'd ei$ie't at doi'# itC& (ob%

6

http://en.wikipedia.org/wiki/World_War_IIhttp://en.wikipedia.org/wiki/Susten_Passhttp://en.wikipedia.org/w/index.php?title=Magirus-Deutz&action=edit&redlink=1http://en.wikipedia.org/wiki/Volkswagen_Beetlehttp://en.wikipedia.org/wiki/Franklin_(automobile)http://en.wikipedia.org/wiki/World_War_IIhttp://en.wikipedia.org/wiki/Susten_Passhttp://en.wikipedia.org/w/index.php?title=Magirus-Deutz&action=edit&redlink=1http://en.wikipedia.org/wiki/Volkswagen_Beetlehttp://en.wikipedia.org/wiki/Franklin_(automobile)


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but the ba&i$ $ooli'# &y&tem &till $o'&i&t& o li*uid $oola't bei'# $ir$ulated throu#h the e'#i'e%

the' out to the radiator to be $ooled by the air &tream $omi'# throu#h the ro't #rill o the

)ehi$le!

TodayC& $ooli'# &y&tem mu&t mai'tai' the e'#i'e at a $o'&ta't temperature "hether the

out&ide air temperature i& --, de#ree& 2ahre'heit or -, belo" >ero! I the e'#i'e temperature

i& too lo"% uel e$o'omy "ill &uer a'd emi&&io'& "ill ri&e! I the temperature i& allo"ed to

#et too hot or too lo'#% the e'#i'e "ill &el/de&tru$t!

7


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Cha8ter 1

1* 4OR'ING &RINCI&LE

The $ooli'# &y&tem i& made up o the pa&&a#e& i'&ide the e'#i'e blo$k a'd head&% a "ater

pump to $ir$ulate the $oola't% a thermo&tat to $o'trol the temperature o the $oola't% a

radiator to $ool the $oola't% a radiator $ap to $o'trol the pre&&ure i' the &y&tem% a'd &ome

plumbi'# $o'&i&ti'# o i'ter$o''e$ti'# ho&e& to tra'&er the $oola't rom the e'#i'e to

radiator a'd al&o to the $arC& heater &y&tem "here hot $oola't i& u&ed to "arm up the )ehi$leC&

i'terior o' a $old day!

A $ooli'# &y&tem "ork& by &e'di'# a li*uid $oola't throu#h pa&&a#e& i' the e'#i'e blo$k a'd

head&! A& the $oola't lo"& throu#h the&e pa&&a#e&% it pi$k& up heat rom the e'#i'e! The

heated luid the' make& it& "ay throu#h a rubber ho&e to the radiator i' the ro't o the $ar!

A& it lo"& throu#h the thi' tube& i' the radiator% the hot li*uid i& $ooled by the air &tream

e'teri'# the e'#i'e $ompartme't rom the #rill i' ro't o the $ar! O'$e the luid i& $ooled% it

retur'& to the e'#i'e to ab&orb more heat! The "ater pump ha& the (ob o keepi'# the luid

mo)i'# throu#h thi& &y&tem o plumbi'# a'd hidde' pa&&a#e&!

.


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E'#i'e blo$k i#4a5

E'#i'e blo$k i#4b5

A thermo&tat i& pla$ed bet"ee' the e'#i'e a'd the radiator to make &ure that the $oola't &tay&

abo)e a $ertai' pre&et temperature! I the $oola't temperature all& belo" thi& temperature%

the thermo&tat blo$k& the $oola't lo" to the radiator% or$i'# the luid i'&tead throu#h a

bypa&& dire$tly ba$k to the e'#i'e! The $oola't "ill $o'ti'ue to $ir$ulate like thi& u'til it

rea$he& the de&i#' temperature% at "hi$h poi't% the thermo&tat "ill ope' a )al)e a'd allo" the

$oola't ba$k throu#h the radiator!

I' order to pre)e't the $oola't rom boili'#% the $ooli'# &y&tem i& de&i#'ed to be pre&&uri>ed!

@'der pre&&ure% the boili'# poi't o the $oola't i& rai&ed $o'&iderably! ;o"e)er% too mu$h

pre&&ure "ill $au&e ho&e& a'd other part& to bur&t% &o a &y&tem i& 'eeded to relie)e pre&&ure i

0

it e1$eed& a $ertai' poi't! The (ob o mai'tai'i'# the pre&&ure i' the $ooli'# &y&tem belo'#&


13/33


to the radiator $ap! The $ap i& de&i#'ed to relea&e pre&&ure i it rea$he& the &pe$iied upper

limit that the &y&tem "a& de&i#'ed to ha'dle! Prior to the C9,&% the $ap "ould relea&e thi& e1tra

pre&&ure to the pa)eme't! Si'$e the'% a &y&tem "a& added to $apture a'y relea&ed luid a'd

&tore it temporarily i' a re&er)e ta'k! Thi& luid "ould the' retur' to the $ooli'# &y&tem ater

the e'#i'e $ooled do"'! Thi& i& "hat i& $alled a turbo $ooli'# &y&tem!

Temperature $a' determi'e (u&t ho" mu$h po"er a' e'#i'e $a' make% ho" ei$ie'tly it "ill

ru'% a'd "hether or 'ot it "ill hold to#ether! E1$e&&i)e $ooli'# &y&tem temperature& $a' $au&e

ho&e& to bur&t% head #a&ket& to blo" a'd e)e' $yli'der head& a'd e'#i'e blo$k& to "arp the

a$t that theyCll lo&e &i#'ii$a't amou't& o po"er #oe& "ithout &ayi'#! ItC& 'ot #ood! ThatC&

"hy itC& importa't to keep "ater temperature& u'der $o'trol! ?ommo' $ool/do"' method&

i'$lude lar#er ro'tal area a'dor thi$ker alumi'um radiator&% "hi$h ha)e the ability to

di&&ipate more heat *ui$kly% but $a' al&o be airly e1pe'&i)e! Sometime& addi'# a lar#er or

&e$o'dary $ooli'# a' "ill help alle)iate lo"/&peed or idli'# $ooli'# i&&ue&! But e)e' addi'#

a'other a' or a lar#er o'e "ill $o&t you a bit o $a&h a'd may $au&e problem& "he' it $ome&

time to itti'# it i' pla$e! Either "ay% i your e'#i'e i& o)erheati'#% it ha& to be take' $are o

other"i&e youCll e'd up "ith e1pe'&i)e problem& that make the pri$e o a' alumi'um radiator

&eem more o' par "ith the amou't o $ha'#e youC)e #ot u'der your $ou$h $u&hio'!

The moder' day #a&oli'e e'#i'e i&'Ct all that ei$ie't% at lea&t 'ot a& mu$h a& "eCd like it to be!

2uel e'er#y that $ould pote'tially be u&ed to produ$e additio'al po"er i& $o'&ta'tly lo&t

throu#h the $ooli'# &y&tem! The pro$e&& i& $alled heat re(e$tio'% a'd i it did'Ct take pla$e%

thermal breakdo"' o the pi&to'&% $yli'der& a'd $yli'der head $ould o$$ur! ?all it a tradeo!

?ooli'# i& al&o importa't "he' it $ome& to the i#'itio' pro$e&& a'd the $ombu&tio' $hamber!

A& $ombu&tio' $hamber temperature& i'$rea&e% hi#her o$ta'e=& o uel or retarded &park

timi'# are 'eeded! The de'&ity o the airuel ratio i& al&o de$rea&ed a& heat ri&e&! To

$ompe'&ate% &ome )ehi$le& pull out i#'itio' timi'# automati$ally a& $ooli'# &y&tem

temperature& ri&e! I' other "ord&% hi#h temperature& rob hor&epo"er!

8eCre 'ot typi$ally a'& o mira$le produ$t& that $ome i' a bottle% or a $a' or that matter! But

o)er the year& "eC)e be$ome a$$u&tomed to u&i'# $ooli'# &y&tem "etti'# a#e't&% a& theyC)e

bee' pro)e' to "ork almo&t e)ery time! @'like ri'# &ealer& i' a $a' a'd other my&teriou& leak

9

&eali'# produ$t& that 'e)er &eem to "ork% $ooli'# &y&tem additi)e& #e'erally do "ork! But

toa'&"er the *ue&tio' a& to (u&t ho" "ell &ome o the&e additi)e& #et the (ob do'e a'd "hi$h


14/33


rei#'& &upreme% "e de$ided to put our o them to the te&t!Our te&t apparatu& took the orm o

a' EG ;o'da ?i)i$ "ith a' ;++A7 Prelude e'#i'e &tued i'to pla$e! A $la&&i$ re$ipe or

o)erheati'# &i'$e ma'y tra'&pla't o"'er& ail to up#rade the radiator de&pite the more tha'

7,/per$e't lar#er di&pla$eme't e'#i'e 'ot to me'tio' it& &heer phy&i$al &i>e i'$rea&e! Our te&t

)ehi$le took the 'e$e&&ary pre$autio'& / &ort o! A thi$ker Del Sol Si TE? radiator "a&

&"apped i'to pla$e a& "a& a hi#her lo"i'# $ooli'# a'% but that doe&'Ct &top the ?i)i$ rom

e&$alati'# $ooli'# &y&tem temp&! 8ith a .,., mi1 o ;o'da a'tiree>e a'd di&tilled "ater%

temperature& &oared to +-. 2 routi'ely "hile &itti'# i' the dri)e/thru% a'd 'e)er really dropped

belo" the +,, mark e)e' u'der 'ormal lo" e'#i'e &peed dri)i'# $o'ditio'&! ?yli'der head

temperature& "ere e*ually a& &$or$hi'# i' the $a&e o our ;o'da mea&uri'# i' at 'early +-, 2!

A& &u$h% our radiator pro)ed rather i'ei$ie't% o'ly able to drop the &y&temC& temperature by a

a$tor o i)e per$e't!

2or our te&t "e rou'ded up our o the mo&t popular $ooli'# additi)e produ$t& o' the market:

Red 3i'e 8ater 8etter% DEI Radiator Relie% ;y/per 3ube Super ?oola't% a'd u&ti$e

Brother& Radiator ?ooler! 8e te&ted the&e produ$t& mi1ed "ith both a 6,9, a'tiree>e"ater

mi1ture a'd mi1ed "ith "ater alo'e! The key to a'y &u$$e&&ul te&t i& keepi'# a& ma'y o the

)ariable& the &ame a& po&&ible% a'd perormi'# a& ma'y te&t& a& po&&ible! T"o day& a'd 'early

6,, mile& later a'd "e had our re&ult&% a'd &ome 'a&ty bur' mark& o' our arm&! Note to &el:

allo" more tha' t"o day& "he' $ha'#i'# radiator luid almo&t -, time&! A&ide rom out&ide

air temperature&% "hi$h remai'ed airly $o'&ta't duri'# our te&ti'#% "e "ere able to $o'trol

almo&t e)erythi'# el&e! 8e kept to the &ame road&% a'd &tabili>ed load $o'ditio'& by repeati'#

&imilar e'#i'e a'd )ehi$le &peed& or ea$h te&t! 8e perormed our te&t& or ea$h mi1ture: 3o"

rpm% lo" mph &treet dri)i'# 7,,,rpm% 9.mph ree"ay &peed& .,,,rpm hill $limb& a'd

e1te'ded idli'#! 8e al&o perormed temperature readi'#& or both radiator i'let a'd outlet

temperature& a'd $yli'der head temperature&! No" "ould be a #ood time to me'tio' that

'o'e o the&e produ$t& are de&i#'ed to perorm mira$le&% a'd i your radiator i&'Ct up to the

ta&k% do'Ct e1pe$t a'ythi'# but a 'e" or lar#er radiator to i1 the problem!

All o them% but to diere't de#ree& a'd i' &li#htly diere't "ay&! But there "ere &tipulatio'&!

8he' mi1ed "ith $oola't% our temperature drop& "ere 'e#li#ible% but &till there! But "ith

&trai#ht "ater% the temperature drop& "ere 'othi'# &hort o impre&&i)e! 8e e1pe$ted thi&!


15/33


ThereC& 'o #ly$ol/ba&ed a'tiree>e% or a'y li*uid $ooli'# a#e't or that matter% that "eCre

a"are o that $a' di&&ipate or tra'&er heat a& "ell a& plai' old "ater! But you $a'Ct ru' plai'

old "ater% at lea&t 'ot "ithout ru&ti'# or de&troyi'# your e'#i'e!

9

Chapter 5


16/33


o'tally "ith the pla&ti$ ta'k o' either &ide! O' other $ar&% the tube& ru' )erti$ally "ith

the ta'k o' the top a'd bottom! O' older )ehi$le&% the $ore "a& made o $opper a'd the ta'k&

"ere bra&&! The 'e" alumi'um/pla&ti$ &y&tem i& mu$h more ei$ie't% 'ot to me'tio' $heaper

to produ$e! O' radiator& "ith pla&ti$ e'd $ap&% there are #a&ket& bet"ee' the alumi'um $ore

a'd the pla&ti$ ta'k& to &eal the &y&tem a'd keep the luid rom leaki'# out! O' older $opper

a'd bra&& radiator&% the ta'k& "ere bra>ed 4a orm o "eldi'#5 i' order to &eal the radiator!

4Radiator5

The ta'k&% "hether pla&ti$ or bra&&% ea$h ha)e a lar#e ho&e $o''e$tio'% o'e mou'ted to"ard&

the top o the radiator to let the $oola't i'% the other mou'ted at the bottom o the radiator o'

the other ta'k to let the $oola't ba$k out! O' the top o the radiator i& a' additio'al ope'i'#

-,

that i& $apped o by the radiator $ap! A'other $ompo'e't i' the radiator or )ehi$le& "ith a'

automati$ tra'&mi&&io' i& a &eparate ta'k mou'ted i'&ide o'e o the ta'k&! 2itti'#& $o''e$t

thi& i''er ta'k throu#h &teel tube& to the automati$ tra'&mi&&io'! Tra'&mi&&io' luid i& piped

throu#h thi& ta'k i'&ide a ta'k to be $ooled by the $oola't lo"i'# pa&t it beore retur'i'# the

tra'&mi&&io'!


17/33


Mou'ted o' the ba$k o the radiator o' the &ide $lo&e&t to the e'#i'e i& o'e or t"o ele$tri$

a'& i'&ide a hou&i'# that i& de&i#'ed to prote$t i'#er& a'd to dire$t the air lo"! The&e a'&

are there to keep the air lo" #oi'# throu#h the radiator "hile the )ehi$le i& #oi'# &lo" or i&

&topped "ith the e'#i'e ru''i'#! I the&e a'& &topped "orki'#% e)ery time you $ame to a

&top% the e'#i'e temperature "ould be#i' ri&i'#! O' older &y&tem&% the a' "a& $o''e$ted to

the ro't o the "ater pump a'd "ould &pi' "he'e)er the e'#i'e "a& ru''i'# be$au&e it "a&

dri)e' by a a' belt i'&tead o a' ele$tri$ motor! I' the&e $a&e&% i a dri)er "ould 'oti$e the

e'#i'e be#i' to ru' hot i' &top a'd #o dri)i'#% the dri)er mi#ht put the $ar i' 'eutral a'd re)

the e'#i'e to tur' the a' a&ter "hi$h helped $ool the e'#i'e! Ra$i'# the e'#i'e o' a $ar "ith

a malu'$tio'i'# ele$tri$ a' "ould o'ly make thi'#& "or&e be$au&e you are produ$i'# more

heat i' the radiator "ith 'o a' to $ool it o!

The ele$tri$ a'& are $o'trolled by the )ehi$leC& $omputer! A temperature &e'&or mo'itor&

e'#i'e temperature a'd &e'd& thi& i'ormatio' to the $omputer! The $omputer determi'e& i

the a' &hould be tur'ed o' a'd a$tuate& the a' relay i additio'al air lo" throu#h the

radiator i& 'e$e&&ary!

I the $ar ha& air $o'ditio'i'#% there i& a' additio'al radiator mou'ted i' ro't o the 'ormal

radiator! Thi& FradiatorF i& $alled the air $o'ditio'er $o'de'&er% "hi$h al&o 'eed& to be $ooled

by the air lo" e'teri'# the e'#i'e $ompartme't! ou $a' i'd out more about the air

$o'ditio'i'# $o'de'&er by #oi'# to our arti$le o' Automoti)e Air ?o'ditio'i'#! A& lo'# a&the air $o'ditio'i'# i& tur'ed o'% the &y&tem "ill keep the a' ru''i'#% e)e' i the e'#i'e i& 'ot

ru''i'# hot! Thi& i& be$au&e i there i& 'o air lo" throu#h the air $o'ditio'i'# $o'de'&er% the

air $o'ditio'er "ill 'ot be able to $ool the air e'teri'# the i'terior!

--


18/33


• The timi'# belt that i& al&o re&po'&ible or dri)i'# o'e or more $am&hat&!

The "ater pump i& made up o a hou&i'#% u&ually made o $a&t iro' or $a&t alumi'um a'd a'

impeller mou'ted o' a &pi''i'# &hat "ith a pulley atta$hed to the &hat o' the out&ide o the

pump body! A &eal keep& luid rom leaki'# out o the pump hou&i'# pa&t the &pi''i'# &hat!The impeller u&e& $e'triu#al or$e to dra" the $oola't i' rom the lo"er radiator ho&e a'd

&e'd it u'der pre&&ure i'to the e'#i'e blo$k! There i& a #a&ket to &eal the "ater pump to the

e'#i'e blo$k a'd pre)e't the lo"i'# $oola't rom leaki'# out "here the pump i& atta$hed to

the blo$k!

48ater pump5

-+


19/33


4Thermo&tat5

I a'yo'e e)er ha& the $ha'$e to te&t o'e% a thermo&tat i& a' ama>i'# thi'# to "at$h be$au&e

"hat it doe& &eem& impo&&ible! ou $a' put o'e i' a pot o boili'# "ater o' the &to)e! A& it

heat& up% it& )al)e ope'& about a' i'$h% appare'tly by ma#i$H I youCd like to try thi& your&el%

#o to a $ar part& &tore a'd buy o'e or a $ouple o bu$k&!

The &e$ret o the thermo&tat lie& i' the &mall $yli'der lo$ated o' the e'#i'e/&ide o the de)i$e!

Thi& $yli'der i& illed "ith a "a1 that be#i'& to melt at arou'd -, 2 4diere't thermo&tat&

ope' at diere't temperature&% but -, 2 i& a $ommo' o'e5! A rod $o''e$ted to the )al)e

pre&&e& i'to thi& "a1! 8he' the "a1 melt&% it e1pa'd& &i#'ii$a'tly% pu&hi'# the rod out o the

$yli'der a'd ope'i'# the )al)e!

-6


20/33


4Pre&&ure $ap a'd pre&&ure ta'k5

The radiator pre&&ure $ap i& a &imple de)i$e that "ill mai'tai' pre&&ure i' the $ooli'# &y&tem

up to a $ertai' poi't! I the pre&&ure build& up hi#her tha' the &et pre&&ure poi't% there i& a

&pri'# loaded )al)e% $alibrated to the $orre$t Pou'd& per S*uare I'$h 4p&i5% to relea&e the

pre&&ure!

8he' the $ooli'# &y&tem pre&&ure rea$he& the poi't "here the $ap 'eed& to relea&e thi& e1$e&&

pre&&ure% a &mall amou't o $oola't i& bled o! It $ould happe' duri'# &top a'd #o trai$ o'

a' e1tremely hot day% or i the $ooli'# &y&tem i& malu'$tio'i'#! I it doe& relea&e pre&&ure

u'der the&e $o'ditio'&% there i& a &y&tem i' pla$e to $apture the relea&ed $oola't a'd &tore it i'

a pla&ti$ ta'k that i& u&ually 'ot pre&&uri>ed! Si'$e there i& 'o" le&& $oola't i' the &y&tem% a&

the e'#i'e $ool& do"' a partial )a$uum i& ormed! The radiator $ap o' the&e $lo&ed &y&tem&

ha& a &e$o'dary )al)e to allo" the )a$uum i' the $ooli'# &y&tem to dra" the $oola't ba$k i'to

the radiator rom the re&er)e ta'k 4like pulli'# the plu'#er ba$k o' a hypodermi$ 'eedle5

There are u&ually marki'#& o' the &ide o the pla&ti$ ta'k marked 2ull/?old% a'd 2ull ;ot!

-7

8he' the e'#i'e i& at 'ormal operati'# temperature% the $oola't i' the tra'&lu$e't re&er)e

ta'k &hould be up to the 2ull/;ot li'e! Ater the e'#i'e ha& bee' &itti'# or &e)eral hour& a'd

i& $old to the tou$h% the $oola't &hould be at the 2ull/?old li'e!

!"N7+

3ike the thermo&tat% the $ooli'# a' ha& to be $o'trolled &o that it allo"& the e'#i'e to

mai'tai' a $o'&ta't temperature!

2ro't/"heel dri)e $ar& ha)e electric fans be$au&e the e'#i'e i& u&ually mou'ted tra'&)er&ely%

mea'i'# the output o the e'#i'e poi't& to"ard the &ide o the $ar! The a'& are $o'trolled

either "ith a thermo&tati$ &"it$h or by the e'#i'e $omputer% a'd they tur' o' "he' o "he'

the temperature drop& belo" that poi't!


21/33


4a'5

Rear/"heel dri)e $ar& "ith lo'#itudi'al e'#i'e& u&ually ha)e engine+dri=en cooling fans!

The&e a'& ha)e a thermo&tati$ally $o'trolled )i&$ou& $lut$h! Thi& $lut$h i& po&itio'ed at the

hub o the a'% i' the airlo" $omi'# throu#h the radiator! Thi& &pe$ial )i&$ou& $lut$h i& mu$h

like the )i&$ou& $oupli'# &ometime& ou'd i' all/"heel dri)e $ar&!

-.


22/33


4;eati'# &y&tem5

The heater $ore% "hi$h i& lo$ated i' the da&hboard o your $ar% i& really a &mall radiator! The

heater a' blo"& air throu#h the heater $ore a'd i'to the pa&&e'#er $ompartme't o your $ar!


23/33


;eater $ore i#4a5 ;eater $ore i#4b5

-9

Cha8ter >

>* %ESCRI&TION O! &ROCESS7

Circulation7+

The $oola't ollo"& a path that take& it rom the "ater pump% throu#h pa&&a#e& i'&ide the

e'#i'e blo$k "here it $olle$t& the heat produ$ed by the $yli'der&! It the' lo"& up to the

$yli'der head 4or head& i' a type e'#i'e5 "here it $olle$t& more heat rom the $ombu&tio'


24/33


$hamber&! It the' lo"& out pa&t the thermo&tat 4i the thermo&tat i& ope'ed to allo" the luid

to pa&&5% throu#h the upper radiator ho&e a'd i'to the radiator! The $oola't lo"& throu#h the

thi' latte'ed tube& that make up the $ore o the radiator a'd i& $ooled by the air lo" throu#h

the radiator! 2rom there% it lo"& out o the radiator% throu#h the lo"er radiator ho&e a'd ba$k

to the "ater pump! By thi& time% the $oola't i& $ooled o a'd ready to $olle$t more heat rom

the e'#i'e!

The $apa$ity o the &y&tem i& e'#i'eered or the type a'd &i>e o the e'#i'e a'd the "ork load

that it i& e1pe$ted to u'der#o! Ob)iou&ly% the $ooli'# &y&tem or a lar#er% more po"erul

e'#i'e i' a hea)y )ehi$le "ill 'eed $o'&iderably more $apa$ity tha' a $ompa$t $ar "ith a &mall

7 $yli'der e'#i'e! O' a lar#e )ehi$le% the radiator i& lar#er "ith ma'y more tube& or the

$oola't to lo" throu#h! The radiator i& al&o "ider a'd taller to $apture more air lo"

e'teri'# the )ehi$le rom the #rill i' ro't!

Antifreeze:-

The u&e o "ater $ooli'# $arrie& the ri&k o dama#e rom ree>i'#! Automoti)e a'd ma'y other

e'#i'e $ooli'# appli$atio'& re*uire the u&e o a "ater a'd a'tiree>e mi1ture to lo"er the

ree>i'# poi't to a temperature u'likely to be e1perie'$ed! A'tiree>e al&o i'hibit& $orro&io'

rom di&&imilar metal& a'd $a' i'$rea&e the boili'# poi't% allo"i'# a "ider ra'#e o "ater

$ooli'# temperature&! It& di&ti'$ti)e odor al&o alert& operator& to $ooli'# &y&tem leak& a'd

problem& that "ould #o u''oti$ed i' a "ater/o'ly $ooli'# &y&tem! The heated "ater $a' al&o

be u&ed to "arm the air $o'ditio'i'# &y&tem i'&ide the $ar% i &o de&ired!

-

Radiator &ressure Ca8 Test7+

A radiator pre&&ure $ap i& de&i#'ed to mai'tai' pre&&ure i' the $ooli'# &y&tem at a $ertai'

ma1imum pre&&ure! I the $ooli'# &y&tem e1$eed& that pre&&ure% a )al)e i' the $ap ope'& to

bleed the e1$e&&i)e pre&&ure i'to the re&er)e ta'k! O'$e the e'#i'e ha& $ooled o% a 'e#ati)e

pre&&ure be#i'& to de)elop i' the $ooli'# &y&tem! 8he' thi& happe'&% a &e$o'd )al)e i' the

$ap allo"& the $oola't to be &ipho'ed ba$k i'to the radiator rom the re&er)e ta'k! I the $ap

&hould ail% the e'#i'e $a' ea&ily o)erheat! A pre&&ure te&t o the radiator $ap i& a *ui$k "ay

http://en.wikipedia.org/wiki/Antifreezehttp://en.wikipedia.org/wiki/Air_conditioninghttp://en.wikipedia.org/wiki/Antifreezehttp://en.wikipedia.org/wiki/Air_conditioning


25/33


to tell i the $ap i& doi'# it& (ob! It &hould be able to hold it& rated pre&&ure or t"o mi'ute&!

Si'$e radiator $ap& are *uite i'e1pe'&i)e% I "ould re$omme'd repla$i'# it e)ery 6 year& or

60%,,, mile&% (u&t or added i'&ura'$e! Make ab&olutely &ure that you repla$e it "ith o'e that

i& de&i#'ed or your )ehi$le!

Ther3ostat Chec6 !or &ro8er O8ening "nd Closing:/

Thi& &tep i& o'ly 'e$e&&ary i you are ha)i'# problem& "ith the $ooli'# &y&tem! A thermo&tat

i& de&i#'ed to ope' at a $ertai' $oola't temperature! To te&t a thermo&tat "hile it i& &till i' the

e'#i'e% &tart the e'#i'e a'd let it $ome to 'ormal operati'# temperature 4do 'ot let it

o)erheat5! I it take& a' u'u&ually lo'# time or the e'#i'e to "arm up or or the heater to

be#i' deli)eri'# hot air% the thermo&tat may be &tu$k i' the ope' po&itio'! I the e'#i'e doe&

"arm up% &hut it o a'd look or the t"o radiator ho&e&! The&e are the t"o lar#e ho&e& that

#o rom the e'#i'e to the radiator! 2eel them $areully 4they $ould be )ery hot5! I o'e ho&e i&

hot a'd the other i& $old% the thermo&tat may be &tu$k $lo&ed!

I you are ha)i'# problem& a'd &u&pe$t the thermo&tat% remo)e it a'd pla$e it i' a pot o

"ater! Bri'# the "ater to a boil a'd "at$h the thermo&tat! ou &hould &ee it ope' "he' the

"ater rea$he& a boil! Mo&t thermo&tat& ope' at about -


26/33


+,

Cha8ter ?

?* GENER"LIS"TION %I!!ICULTIES

It i& dii$ult to make #e'erali>atio'& about air/$ooled a'd li*uid/$ooled e'#i'e&! Air/

$ooled olk&"a#e' kombi& are k'o"' or rapid "ear i' 'ormal u&e a'd &ometime& &udde'

ailure "he' dri)e' i' hot "eather! Alter'ately% air/$ooled Deut> die&el e'#i'e& are k'o"' or

reliability e)e' i' e1treme heat% a'd are ote' u&ed i' &ituatio'& "here the e'#i'e ru'&

u'atte'ded or mo'th& at a time!

http://en.wikipedia.org/wiki/Volkswagenhttp://en.wikipedia.org/wiki/VW_Type_2http://en.wikipedia.org/wiki/Deutz_AGhttp://en.wikipedia.org/wiki/Diesel_enginehttp://en.wikipedia.org/wiki/Volkswagenhttp://en.wikipedia.org/wiki/VW_Type_2http://en.wikipedia.org/wiki/Deutz_AGhttp://en.wikipedia.org/wiki/Diesel_engine


27/33


Similarly% it i& u&ually de&irable to mi'imi>e the 'umber o heat tra'&er &ta#e& i' order to

ma1imi>e the temperature diere'$e at ea$h &ta#e! ;o"e)er% Detroit Die&el +/&troke $y$le

e'#i'e& $ommo'ly u&ed oil $ooled by "ater% "ith the "ater i' tur' $ooled by air!

The $oola't u&ed i' ma'y li*uid/$ooled e'#i'e& mu&t be re'e"ed periodi$ally% a'd $a' ree>e

at ordi'ary temperature& thu& $au&i'# perma'e't e'#i'e dama#e! Air/$ooled e'#i'e& do 'ot

re*uire $oola't &er)i$e% a'd do 'ot &uer e'#i'e dama#e rom ree>i'#% t"o $ommo'ly/$ited

ad)a'ta#e& or air/$ooled e'#i'e&! ;o"e)er% $oola't ba&ed o' propyle'e #ly$ol i& li*uid to /..

?% $older tha' i& e'$ou'tered by ma'y e'#i'e& &hri'k& &li#htly "he' it $ry&talli>e&% thu&

a)oidi'# e'#i'e dama#e a'd ha& a &er)i$e lie o)er -,%,,, hour&% e&&e'tially the lietime o

ma'y e'#i'e&!

It i& u&ually more dii$ult to a$hie)e lo" emi&&io'& or lo" 'oi&e rom a' air/$ooled e'#i'e%

t"o more rea&o'& mo&t road )ehi$le& u&e li*uid/$ooled e'#i'e&! It i& al&o ote' dii$ult to

build lar#e air/$ooled e'#i'e&% &o 'early all air/$ooled e'#i'e& are u'der .,, k8% "herea&

lar#e li*uid/$ooled e'#i'e& e1$eed , M8!

+-

Cha8ter 0

0* :ISU"L INS&ECTION7

8hat you are looki'# or i& the $o'ditio' o the belt& a'd ho&e&! The radiator ho&e& a'd

heater ho&e& are ea&ily i'&pe$ted (u&t by ope'i'# the hood a'd looki'#! ou "a't to be &ure

that the ho&e& ha)e 'o $ra$ki'# or &plitti'# a'd that there i& 'o bul#i'# or &"elli'# at the

e'd&! I there i& a'y &i#' o problem&% the ho&e &hould be repla$ed "ith the $orre$t part

'umber or the year% make a'd model o the )ehi$le! Ne)er u&e a u'i)er&al ho&e u'le&& it i& a'

emer#e'$y a'd a proper molded ho&e i& 'ot a)ailable!

http://en.wikipedia.org/wiki/Detroit_Dieselhttp://en.wikipedia.org/wiki/Coolanthttp://en.wikipedia.org/wiki/Propylene_glycolhttp://en.wikipedia.org/wiki/Celsiushttp://en.wikipedia.org/wiki/Kilowatthttp://en.wikipedia.org/wiki/Megawatthttp://en.wikipedia.org/wiki/Detroit_Dieselhttp://en.wikipedia.org/wiki/Coolanthttp://en.wikipedia.org/wiki/Propylene_glycolhttp://en.wikipedia.org/wiki/Celsiushttp://en.wikipedia.org/wiki/Kilowatthttp://en.wikipedia.org/wiki/Megawatt


28/33


;eater ho&e& are u&ually &trai#ht ru'& a'd are 'ot molded% &o a u'i)er&al ho&e i& i'e to u&e

a'd ote' i& all that i& a)ailable! Make &ure that you u&e the proper i'&ide diameter or the

ho&e bei'# repla$ed! 2or either the radiator ho&e& or the heater ho&e&% make &ure that you

route the repla$eme't ho&e i' the &ame "ay that the ori#i'al ho&e "a& ru''i'#! Po&itio' the

ho&e a"ay rom a'y ob&tru$tio' that $a' po&&ibly dama#e it a'd al"ay& u&e 'e" ho&e $lamp&!

Ater you reill the $ooli'# &y&tem "ith $oola't% do a pre&&ure te&t to make &ure that there are

'o leak&!

O' older )ehi$le&% the "ater pump i& dri)e' by a belt or &erpe'ti'e belt o' the ro't o the

e'#i'e that i& al&o re&po'&ible or dri)i'# the alter'ator% po"er &teeri'# pump a'd air

$o'ditio'er $ompre&&or! The&e type& o belt& are ea&y to i'&pe$t a'd repla$e i they are "or'!

ou are looki'# or dry $ra$ki'# o' the i'&ide &ura$e o the belt!

O' later )ehi$le&% the "ater pump i& ote' dri)e' by the timi'# belt! Thi& belt u&ually ha& a

&pe$ii$ lie e1pe$ta'$y at "hi$h time it mu&t be repla$ed to i'&ure that it doe& 'ot ail! Si'$e

the timi'# belt i& i'&ide the e'#i'e a'd "ill re*uire partial e'#i'e di&a&&embly to i'&pe$t% it i&

)ery importa't to repla$e it at the $orre$t i'ter)al! Si'$e the labor to repla$e thi& belt $a' be

&i#'ii$a't% it i& a #ood idea to repla$e the "ater pump at the &ame time that the belt i&

repla$ed! Thi& i& be$au&e


29/33


build& up a'd be#i'& to $lo# the thi' lat tube& i' the radiator a'd heater $ore $au&i'# the

e'#i'e to e)e'tually o)erheat! The a'ti/$orro&io' $hemi$al& i' the a'tiree>e pre)e't thi&% but

they ha)e a limited lie &pa'!

Ne"er a'tiree>e ormulatio'& "ill la&t or . year& or -.,%,,, mile& beore re*uiri'#

repla$eme't! The&e a'tiree>e& are u&ually red i' $olor a'd are reerred to a& FE1te'ded 3ieF

or F3o'# 3ieF a'tiree>e! GM ha& bee' u&i'# thi& type o $oola't i' all their )ehi$le& &i'$e

-e! I a'y #ree' $oola't i& allo"ed to

mi1 "ith the red $oola't% you mu&t re)ert to the &horter repla$eme't $y$le!

3ook or a &hop that $a' re)er&e/lu&h the $ooli'# &y&tem! Thi& re*uire& &pe$ial e*uipme't

a'd the remo)al o the thermo&tat i' order to do the (ob properly! Thi& type o lu&h i&

e&pe$ially importa't i the old $oola't look& bro"' or ha& &$ale or debri& loati'# arou'd i' it!

I you remo)e the thermo&tat or a re)er&e lu&h% al"ay& repla$e it "ith a 'e" thermo&tat o

the proper temperature! It i& $heap i'&ura'$e!

The Natio'al Automoti)e Radiator Ser)i$e A&&o$iatio' 4NARSA5 re$omme'd& that motori&t&

ha)e a &e)e'/poi't pre)e'tati)e $ooli'# &y&tem mai'te'a'$e $he$k at lea&t o'$e e)ery t"o

year&! The &e)e'/poi't pro#ram i& de&i#'ed to ide'tiy a'y area& that 'eed atte'tio'!+6

It $o'&i&t& o:

• a )i&ual i'&pe$tio' o all $ooli'# &y&tem $ompo'e't&% i'$ludi'# belt& a'd ho&e&

• a radiator pre&&ure $ap te&t to $he$k or the re$omme'ded &y&tem pre&&ure le)el

• a thermo&tat $he$k or proper ope'i'# a'd $lo&i'#

• a pre&&ure te&t to ide'tiy a'y e1ter'al leak& to the $ooli'# &y&tem part& i'$ludi'# the

radiator% "ater pump% e'#i'e $oola't pa&&a#e&% radiator a'd heater ho&e& a'd heater

$ore

• a' i'ter'al leak te&t to $he$k or $ombu&tio' #a& leaka#e i'to the $ooli'# &y&tem

• a' e'#i'e a' te&t or proper operatio'

• a &y&tem po"er lu&h a'd reill "ith $ar ma'ua$turerC& re$omme'ded $o'$e'tratio' o

$oola't

http://www.narsa.org/http://www.narsa.org/


30/33


+7

C("&TER ,.

,.*, "%:"NT"GES7

There i& 'o leaka#e i' thi& $ooli'# pro$e&&!

Thi& &y&tem $a' be u&ed al&o i' $old $limate!

@'iorm $ooli'# o $yli'der% $yli'der head a'd )al)e& take& pla$e!

E'#i'e i& le&& 'oi&y tha' other $ooli'# &y&tem&!


31/33


,.*- %IS"%:"NT"GES7

@&ed i' aeropla'e& e'#i'e& "here the e'#i'e& are e1po&ed to air dire$tly!

It ab&orb& $o'&iderable po"er!

I it ail& it $au&e& &e)ere dama#e o e'#i'e!

It i& more $o&tly a'd re*uire& more mai'te'a'$e!

+.

CONCLUSION

It i& $o'$luded that thi& &y&tem help $oola't& hi#her &pe$ii$ heat $apa$ity% de'&ity% a'd thermal

$o'du$ti)ity! Thi& allo"& "ater to tra'&mit heat o)er #reater di&ta'$e& "ith mu$h le&&

)olumetri$ lo" a'd redu$ed temperature diere'$e! 2or $ooli'# ?P@ $ore&% thi& i& it& primary

ad)a'ta#e: the treme'dou&ly i'$rea&ed ability to tra'&port heat a"ay rom &our$e to a

&e$o'dary $ooli'# &ura$e allo"& or lar#e% more optimally de&i#'ed radiator& rather tha'

&mall% i'ei$ie't i'& mou'ted o' or 'ear a heat &our$e &u$h a& a ?P@ $ore! The F"ater

(a$ketF arou'd a' e'#i'e i& al&o )ery ee$ti)e at deade'i'# me$ha'i$al 'oi&e&% "hi$h make&

the e'#i'e *uieter!

http://en.wikipedia.org/wiki/Specific_heat_capacityhttp://en.wikipedia.org/wiki/Thermal_conductivityhttp://en.wikipedia.org/wiki/Thermal_conductivityhttp://en.wikipedia.org/wiki/CPUhttp://en.wikipedia.org/wiki/Radiatorhttp://en.wikipedia.org/wiki/Specific_heat_capacityhttp://en.wikipedia.org/wiki/Thermal_conductivityhttp://en.wikipedia.org/wiki/Thermal_conductivityhttp://en.wikipedia.org/wiki/CPUhttp://en.wikipedia.org/wiki/Radiator


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RE!ERENCES

Apr


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report on turbo cooling system

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