Cooling systems 32 www.aftermarketonline.net JUNE 2025 Top tips for dependable engine cooling Radiators are central to a vehicle’s cooling system Thermal management is always a balancing act because of the range of temperatures, altitudes and different conditions that vehicles need to operate under. DENSO’s products can rely on the expertise of the firm’s thermal systems R&D plant in Italy, which has a wind tunnel that can replicate the intense cold of Finland and also the merciless heat of the Sahara. This underlines the quality and reliability of DENSO’s entire thermal management range. DENSO’s HVAC systems regulate air temperature and flow volume to keep the cabin comfortable — while also providing the best cabin air quality. Today, the firm’s comprehensive range of AC and thermal parts for temperature control includes principal parts such as radiators, intercoolers and cabin blowers, as well as thermostats, which were introduced to the aftermarket programme last year. These thermostat types are not interchangeable and even those of the same design may differ in both their dimensions and the temperature that they activate. Vehicles must be fitted with the correct thermostat to maintain the engine temperature within the correct parameters to ensure optimum performance and minimise internal wear. Manufactured to strict OE specifications, the DENSO thermostat range encompasses all types and consists of 336 part numbers that will be launched in two stages, catering for 80% of the European car parc and providing independent workshops with dependable replacements. www.denso-am.eu Keeping thermal management in check Nissens’ engine cooling programme features more than 7,000 part numbers, covering over 30,000 OE references. The combustion process develops extreme temperatures, exposing the engine’s block and equipment to high thermal stress. Turbocharged combustion systems also need sufficient air cooling to obtain the proper charge performance. Manual gearboxes, as well as power transmission units, all need active thermal management to ensure each component is operating at its design temperature to achieve the optimum performance of the whole powertrain. Central to the cooling system is the radiator as it protects the engine from excessive heat and ensures its best performance. Therefore, only a replacement product of the correct design and highest quality should be used. Leaks and restrictions in the coolant flow can be the result of several causes such as the incorrect coolant, wrong or reused antifreeze or tap water. Other causes include thread damage. Meanwhile a malfunctioning intercooler causes engine efficiency to drop and lead to serious damage to the turbocharger, exhaust filters and, potentially, the entire engine. Intercoolers must always be replaced after the vehicle’s turbocharger has failed and whenever a new turbo is installed, because carbonised oil and metal chips from the damaged turbo can clog intercooler channels, causing the newly installed turbo to fail. In terms of oil coolers, their thin channels can become clogged by lowquality or contaminated oil, limiting flow and cooling performance. The oil and oil filter should be changed in accordance with the vehicle manufacturer’s service schedule. Meanwhile, a blocked expansion tank can cause a leak or even a burst in the cooling system. Always check the level of coolant in the expansion tank when the engine is cold. Once the engine reaches operating temperature, the level must rise. If not, it is not operating properly. Similarly, a malfunctioning water pump will cause excessive thermal stress on the engine. The pump’s design life will decrease rapidly if the wrong antifreeze is used, or is replaced irregularly, or not at all. Contaminated antifreeze will also damage the sensitive parts of the water pump. https://nissens.com/radiator
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