COOLING SYSTEMS

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COOLING SYSTEMS
AUTO 1
We will take notes in a little bit.
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WHAT MAKES AN ENGINE RUN?
NO! WHAT REALLY MAKES AN ENGINE RUN?
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• WHERE DOES THE HEAT COME FROM?

THATS RIGHT, BURNING FUEL

• HEAT CAUSES EXPANSION WHICH CAUSES?

• PRESSURE!

• PRESSURE PUSHES PISTON DOWN WHICH MAKES THE
  WHEELS GO ROUND AND ROUND

ENERGY.
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TYPES OF ENERGY

• ELECTRICAL
• CHEMICAL
• NUCLEAR

• THERMAL
• RADIANT
• MECHANICAL

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• FUEL IS CHEMICAL ENERGY
• WHEN BURNED COVERTS TO...
• THERMAL ENERGY (HEAT)
• WHICH CAUSES EXPANSION (PRESSURE)
• WHICH COVERTS TO
• MECHANICAL ENERGY
• WHICH WE USE TO MOVE THINGS
• THIS IS ENERGY CONVERSION

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ENERGY CONVERSION?

• REMEMBER, YOU CANT CREATE OR DESTROY ENERGY
• YOU CAN ONLY CHANGE ITS FORM
• THIS IS ENERGY CONVERSION
• IN OTHER WORDS, THERE IS ONLY SO MUCH ENERGY HERE
  ON EARTH AND WE CANT ADD TO IT OR RUN OUT OF IT.
  NEVER USE IT UP!
• WOW

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WE HAD BETTER WRITE THIS DOWN IN OUR FUEL NOTES.

• FUEL IS CHEMICAL ENERGY
• WHEN BURNED COVERTS TO...
• THERMAL ENERGY (HEAT)
• WHICH CAUSES EXPANSION (PRESSURE)
• WHICH COVERTS TO
• MECHANICAL ENERGY
• WHICH WE USE TO MOVE THINGS

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• YOU CANT CREATE OR DESTROY ENERGY, YOU CAN ONLY
  CHANGE ITS FORM!
• ITS FORM IS CHANGED BY A CHEMICAL REACTION.
• THE MOST COMMON TYPE OF CHEMICAL REACTION IS
  COMBUSTION
• LETS MOVE ON

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LETS CONCENTRATE ONWE HAD BETTER WRITE THESE
DOWN IF WE DONT ALREADY KNOW THEM

• HEAT IS THE RAPID MOVEMENT OF ATOMS OR MOLECULES
  IN A SUBSTANCE ABSOLUTE 0 IS-460F (-273C)
• HEAT IS A FORM OF ENERGY
• HEAT IS MEASURED BY.
• TEMPERATURE
• DEGREES IN FAHRENHEIT OR CELSIUS
• BTUs
• VOLUME OF HEAT

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BTU,s ????

• BRITISH THERMAL UNIT
• ONE (1) BTU WILL RAISE THE TEMPERATURE OF ONE (1)
  POUND OF WATER ONE (1) DEGREE FAHRENHEIT (F)

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WHAT IS THE DIFFERENCE BETWEEN TEMPERATURE AND
BTU,s ?

• TEMPERATURE IS THE DEGREE OF HEAT OR HOW HOT.
• FOR EXAMPLE, A MATCH MIGHT BURN AT 400 DEGREES F.
• BTU IS THE VOLUME OF HEAT OR HOW MUCH, BUT NOT
  TEMPERATURE.
• EXAMPLE, THE AMOUNT HEAT IT TAKES TO HEAT THIS
  ROOM, OR RAISE THE TEMPERATURE OF THIS ROOM

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• COMBUSTION TEMPERATURES CAN REACH UP TO
  __________ DURNING THE COMBUSTION PROCESS.
  PAGE 92 OF YOUR HOMEWORK.
• THINK ABOUT THIS QUESTION BEFORE YOU FORM AN
  ANSWER. WOULD YOU WANT THE VOLUME OF HEAT FROM
  ONE 6000 DEGREE F POWER STROKE TO HEAT THIS ROOM?
• NOT IN THE WINTER TIME

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DO WE HAVE THE IDEA OF THE DIFFERENCES BETWEEN
TEMPERATURE OF HEAT AND VOLUME OF HEAT?
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GALLON OF GASOLINE

• ONE GALLON OF GASOLINE HAS APPROXIMATELY 115,000
  BTU,s.
• THAT MEANS THE AVERAGE GALLON OF GASOLINE HAS THE
  ENERGY TO RAISE THE TEMPERATURE OF ONE POUND OF
  WATER 115,000 DEGREES F. (IMPOSSIBLE) OR
• RAISE 115,000 LBS OF WATER ONE DEGREE F. OR
• RASIE 1,150 LBS OF WATER (ABOUT 150 GALS.) 100
  DEGREES F.

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• OTHER FUELS HAVE DIFFERENT BTU,s
• DIESEL HAS APPROXIMAELY 135,000 BTU,s PER GALLON
• ALCOHOL HAS APPROXIMATELY 85,000 BTU,s PER GALLON

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HOW DOES THE ENGINE USE THIS ENERGY?
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ONE GALLON115,000 BTU
COST 1.30 - 1.60
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35 LOST OUT EXHAUST
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35 LOST TO COOLING SYSTEM
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15 LOST TO FRICTIONAL LOSSES
LOST TO COOLING
LOST TO EXHAUST
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APPROXIMATELY 15 LEFT TO MOVE THE CAR.
LOST TO EXHAUST
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WHAT A WASTE!!!!!
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IF TODAYS VEHICLES CAN AVERAGE 20 MILES PER
GALLON NOW USING JUST 15 OF THE ENERGY IN A
GALLON OF FUEL...

• WHAT KIND OF MILAGE COULD THEY GET IF WE COULD
  IMPROVE IT TO 50 OF THE ENERGY IN A GALLON OF
  FUEL???

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MILES PER GALLON AVERAGES

• TODAY
• 20 MPG USING 15 OF ENERGY

• TOMMOROW??
• 70 MPG USING 50 OF ENERGY

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SO WHY DO WE HAVE TO REMOVE 35 OF THE HEAT WITH
A COOLING SYSTEM?
WE JUST PAID BIG MONEY TO BUY FUEL TO CREATE HEAT!

• LIMITED BY CURRENT MATERIAL TECHNOLOGY
• LIMITED BY CURRENT LUBRICATION TECHNOLOGY

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CYLINDER WALL TEMPERATURE MUST BE KEPT BELOW 500
DEGREES F.WHY?

• OIL BREAKS DOWN (BURNS)
• CAN YOU SAY DRY FRICTION?

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HEAT TRANSFERMAKE SURE YOU GET THIS IN YOUR NOTES

• THE MOVEMENT OF HEAT FROM ONE PLACE TO ANOTHER

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THREE TYPES OF HEAT TRANSFER

• CONDUCTION
• CONVECTION
• RADIATION

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CONDUCTION

• TRANSFER OF HEAT THRU SOLIDS

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CONVECTION

• TRANSFER OF HEAT THRU LIQUIDS OR VAPORS

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RADIATION

• TRANSFER OF HEAT THRU LIGHT RAYS

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EXPERIMENT TIME
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DAY TWO
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LETS REVIEW

• CANT DESTROY OR CREATE ENERGY
• ENERGY CONVERSION
• SIX TYPES OF ENERGY
• IN AUTOMOBILES WE USE, ELECTRICAL, THERMAL,
  CHEMICAL, RADIANT, AND MECHANICAL. DONT USE
  NUCLEAR
• HEAT
• WHAT IT IS AND HOW IT IS MEASURED
• DIFFERENCES BETWEEN TEMP AND BTU

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• DIFFERENT FUELS HAVE DIFFERENT ENERGY CONTENT
  (BTU)
• TODAYS ENGINES ARE NOT VERY EFFICIENT

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APPROXIMATELY 15 OF THE ENERGY IN GASOLINE IS
USED TO MOVE THE CAR.
FRICTIONAL LOSES
LOST TO COOLING
LOST TO EXHAUST
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LET'S MOVE ON
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WHICH TYPE OF HEAT TRANSFER DO WE USE IN AN
ENGINE?

• DURING COMBUSTION
• EXPLOSION WOULD HAVE TRANSFER THRU RADIATION TO
  HEAD, CYLINDER WALL, AND TOP OF PISTON
• ALSO TRANSFER THRU CONVECTION TO HEAD, CYLINDER
  WALL AND TOP OF PISTON and.

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• FROM INSIDE OF CYLINDER WALL AND HEAD
• HEAT TRANSFER THRU CONDUCTION TO OUTSIDE OF
  CYLINDER WALL AND HEAD
• FROM OUTSIDE OF CYLINDER WALL AND HEAD
• HEAT TRANSFER THRU CONVECTION
• TO SURROUNDING AIR ON AIR COOLED
• TO SURROUNDING LIQUID IN WATER JACKET ON LIQUID
  COOLED

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SO WE USE ALL TYPES OF HEAT TRANSFER TO COOL AN
ENGINE
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LET'S MOVE ON
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TYPES OF COOLING SYSTEMS

• AIR COOLED
• LIQUID COOLED

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LETS TAKE THE SIMPLE SYSTEM FIRST
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TYPES OF AIR COOLING
WE WILL NEED THIS IN OUR NOTES

• FORCED DRAFT
• OPEN DRAFT

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FORCED DRAFT
HAS A FAN TO FORCE AIR ACROSS ENGINE
USUALLY USED ON ENGINES THAT ARE STATIONARY
OR THAT ARENT MOVED VERY FAST
USES SHROUDS TO DIRECT AIR TO PROPER PLACES
ALL YOUR ENGINES ARE FORCED DRAFT
YOUR FLYWHEEL ACTS AS THE FAN
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LETS ADD THAT TO OUR ENGINE PARTS LIST PURPOSES
FOR THE FLYWHEEL

• A. TO KEEP ENGINE MOVING THRU NON POWER STROKES
• B. ACTS AS A FAN FOR THE COOLING SYSTEM
• C. WE WILL GET
• D. C. AND D. LATER

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SHROUDS FOR FORCED DRAFT
WHAT WOULD HAPPEN IF WE LEFT ONE OFF?
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THESE ARE CALLED HEAT DISAPATING FINS.
THEY ADD SURFACE AREA SO MORE HEAT CAN BE REMOVED.
WHAT WOULD HAPPEN IF WE BROKE ONE OFF?
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LETS LOOK AT AN OPEN DRAFT AIR COOLED ENGINE
HAS NO FAN
ENGINE MUST MOVE THROUGH AIR FOR AIR MOVEMENT
MAY OR MAY NOT HAVE SHROUDS
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REMEMBER ENGINE MUST MOVE THROUGH AIR TO GET
PROPER COOLING ON THE OPEN DRAFT DESIGN!
WITHOUT AIR MOVEMENT, ENGINE CAN
OVERHEAT. ESPECIALLY ON HOT DAYS.
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CHECK OUT THE HEAT DISAPATING FINS ON THIS CUT
AWAY ENGINE.
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LETS MAKE SURE WE HAVE THIS IN OUR NOTES

• OPEN DRAFT
• NO FAN, ENGINE HAS TO MOVE THRU AIR FOR COOLING
• FORCED DRAFT
• HAS FAN TO FORCE AIR FLOW FOR COOLING

SO WHAT DO WE NEED TO DO TO TAKE CARE OF AIR
COOLING SYSTEMS
?
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AIR COOLING MAINTENANCE
LETS MAKE SURE WE GET THIS IN OUR NOTES.
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• KEEP FINS CLEAN OF GREASE AND DEBRIS
• CLEAN WITH SOLVENT OR HOT SOAPY WATER OR CAN
  CLEAN WITH DEGREASERS
• DONT CLEAN WHILE ENGINE IS HOT
• MAY HAVE TO REMOVE SOME SHROUDS TO GET TO ALL
  FINS
• KEEP ALL SHROUDS IN PLACE DURING USE

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FOR AIR COOLING MAINTENANCE
IT IS THAT SIMPLE
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NEXT, WE ARE READY FOR LIQUID COOLING?
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LIQUID COOLING

• HERE WE COME!

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LIQUID COOLING IS MUCH MORE EXPENSIVE THAN AIR
COOLING.
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PURPOSE OF COOLING SYSTYEMBETTER GET THIS IN OUR
NOTES

• KEEP ENGINE AT MOST EFFICIENT OPPERATING
  TEMPERATURE
• TOO COLD WASTED ENERGY (BTU)
• TOO HOT LOSS OF LUBRICATION
• AIR COOLED IS NOT ACCURATE
• DESIGNED TO OVERCOOL
• LIQUID COOLING IS DESIGNED TO GET THE ENGINE TO
  WARM UP QUICKLY YET NOT OVERHEAT

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HERE ARE THE COMPONENTS OF THE LIQUID COOLING
SYSTEM.
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WHAT IS THE LIQUID?
COOLANT
LETS GET THIS IN OUR NOTES

• COOLANT IS MADE UP OF A MIXTURE OF WATER AND
  ANTIFREEZE

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DAY THREE
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LETS REVIEW

• ENERGY
• ENERGY CONVERSION
• TYPES OF ENERGY
• HEAT
• WHAT IT IS AND HOW IT IS MEASURED
• DIFFERENCES BETWEEN TEMP AND BTU
• WHY WE HAVE COOLING SYSTEMS
• AIR COOLING
• TYPES
• FINS, SHROUDS, AND FANS
• MAINTENANCE

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FOUR PURPOSES OF USING ANTIFREEZE

• 1. LOWER FREEZING POINT OF WATER

PURE WATER 32F
25 ANTIFREEZE 10F
PURE ANTIFREEZE -10F
50 ANTIFREEZE -34F
68 ANTIFREEZE -92F
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FOUR PURPOSES OF USING ANTIFREEZE

• 1. LOWER FREEZING POINT OF WATER

2. RAISE BOILING POINT OF WATER
PURE ANTIFREEZE BOILS AT 320F
50 ANTIFREEZE BOILS AT 225F
25 ANTIFREEZE BOILS AT 218F
WATER BOILS AT 212F
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FOUR PURPOSES OF USING ANTIFREEZE

• 1. LOWER FREEZING POINT OF WATER

2. RAISE BOILING POINT OF WATER
3. PREVENT RUST/CORROSION AND DEPOSITS
IS AN ADDITIVE THAT EVENTUALLY NEEDS REPLACED
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RUST/CORROSION AND DEPOSIT SLOW DOWN THE HEAT
TRANSFER
ACTS AS A BLANKET
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FOUR PURPOSES OF USING ANTIFREEZE

• 1. LOWER FREEZING POINT OF WATER

2. RAISE BOILING POINT OF WATER
3. PREVENT RUST/CORROSION AND DEPOSITS
IS AN ADDITIVE THAT EVENTUALLY NEEDS REPLACED
4. LUBRICATES WATER PUMP SEAL
IS AN ADDITIVE THAT EVENTUALLY NEEDS REPLACED
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THERE ARE DIFFERENT KINDS OF COOLANT

• GREEN (CONVENTIONAL)
• RECOMMENDED TO BE CHANGED ONCE A YEAR
• PINK (DEX COOL)
• RECOMMENDED TO BE CHANGED EVERY 5 YEARS (SOME
  PROBLEMS)
• ORANGE

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WARNING
DONT MIX DIFFERENT KINDS
DISPOSE OF PROPERLY SMELLS SWEET CHILDREN AND
ANIMALS WILL DRINK IS TOXIC
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COMPONENTSLETS GET THESE IN OUR NOTES UNDER
LIQUID COOLING

• WATER JACKETS
• PASSAGES MADE (CAST) INTO CYLINDER BLOCKS AND
  HEADS
• SPACES WHERE COOLANT FLOWS

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WATER PUMP

• CAUSES COOLANT TO FLOW
• USUALLY DRIVEN BY BELT FROM CRANK
• SHAFT SUPPORTED BY BEARNING
• SEAL PREVENTS COOLANT LEAKAGE

WEEP HOLE TO PREVENT LEAKING COOLANT AWAY FROM
BEARING
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OVER TIGHTING BELT WILL CAUSE BEARING FAILURE
UNDER TIGHTING WILL CAUSE BELT SLIPAGE ENGINE
OVER HEAT WILL RESULT BELT FAILURE WILL RESULT
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RADIATORS
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DAY FOUR
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LETS REVIEW

• AIR COOLING
• LIQUID COOLING
• COOLANT
• PURPOSES OF ANTIFREEZE
• HOW TO HANDLE
• WATER JACKETS
• WATER PUMPS

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HAVE LARGE SURFACE AREA FOR HEAT TRANSFER. FINS
ON RADIATOR ADD SURFACE AREA FOR HEAT TRANSFER.
COOLANT USUALLY TRAVELS FROM TOP TO BOTTOM.
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PRESSURE CAPS
SEALS COOLING SYSTEM TO ALLOW PRESSURE TO FORM
FROM EXPANDING COOLANT
PRESSURE RAISES BOILING POINT OF WATER 1 LB OF
PRESSURE RAISES BOILING POINT 3 DEGRES F
PREVENTS A VACUUM FROM FORMING AS COOLANT COOLS
AFTER SHUT DOWN
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WARNING! WARNING! WARNING!
NEVER REMOVE CAP FROM HOT RADIATOR
THIS ISN'T GOING TO BE PRETTY!
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PRESSURE CAP OPERATION
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ALLOWS COOLING SYSTEM TO REMAIN FULL AT
ALL TIMES. PREVENTS CORROSION AND ALLOWS
CHECKING OF COOLANT LEVEL WITHOUT REMOVING CAP.
CAP FOR RECOVERY SYSTEM HAS TO HAVE TWO SEALS.
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LET'S MOVE ON
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THERMOSTAT OPERATION
NOTE! WATER PUMP CIRCULATES ANYTIME ENGINE IS
RUNNING
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ENGINE UP TO TEMPERATURE
WAX PELLET EXPANDS PUSHING VALVE OPEN.
VALVE OPEN, COOLANT CAN FLOW TO RADIATOR TO COOL.
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THERMOSTAT NOTES

• CLOSED COOLANT TRAPED IN ENGINE, GETS HOT
• OPEN COOLANT CAN FLOW TO RADIATOR TO COOL
• ALLOWS JUST THE RIGHT AMOUNT TO FLOW TO KEEP EVEN
  TEMPERATURE
• MOST MODERN VEHICLES CALL FOR 195 F.
• USED TO BE AS LOW AS 140 F.
• MORE HEAT MORE POWER AND GAS MILAGE (BTUs)

• STUCK CLOSED
• ENGINE OVERHEATS
• STUCK OPEN
• LESS POWER
• LESS EFFIENCY (MPG)
• CONTAMINATED OIL
• MORE EMISSIONS
• HEATER BLOWING COLD AIR

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DAY FIVE
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HEATER CORE

• HOW WE HEAT PASSENGER COMPARTMENT
• CONTROLLING HEAT
• HEATER CONTROL VALVE
• BLEND DOOR
• LEAKS
• LOSS OF HEAT
• THERMOSTAT STUCK OPEN
• PLUGGED
• LOW COOLANT LEVEL / NO FLOW

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SOFT PLUGS

• ALSO CALLED
• FREEZE PLUGS
• EXPANSION PLUGS
• SAND PLUGS
• CORE PLUGS
• LEAKS
• CHANGING

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HOSES

• TYPES
• PRE-FORMED
• FLEX
• SPRINGS
• WHEN TO CHANGE
• HARD
• SOFT
• BULGING
• BEFORE THEY BREAK
• RECOMMENDED EVERY 6 YEARS

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FANS

• PURPOSE
• PROVIDE AIR FLOW THRU RADIATOR AT LOW SPEEDS.
  NOT NEEDED AT HIGH SPEEDS
• TYPES
• SOLID
• ENERGY CONSERVING
• FLEX
• CLUTCH
• ELECTRIC

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ONE MORE TIME, COMPONENTS OF THE LIQUID COOLING
SYSTEM.
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TOOLS

• HYDROMETER
• BELT TENSION GAUGE
• PRESSURE TESTER
• THERMOMETER
• Ph TEST STRIPS OR METER

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THATS ALL