Cooling & thermal management

How a car keeps its engine, battery and electronics at exactly the right temperature

What the cooling system does

An engine turns only about a third of its fuel's energy into motion; most of the rest becomes heat that has to go somewhere. Cooling moves it away: a pump circulates liquid coolant through passages in the engine, the liquid carries the heat to a radiator, and air flowing through the radiator carries it off to the outside. But cooling is not only about getting rid of heat — engines and batteries also work best, and wear least, inside a fairly narrow temperature window. So a thermostat stops a cold engine from cooling too much, and in an electric car the same job is done even more precisely, by pumps, valves and a chiller that can warm the battery as well as cool it.

Not the same as the cabin's climate control

This page covers the hardware that keeps the engine, the battery and the power electronics at the right temperature. Air conditioning, cabin heating and the heat pump's refrigerant loop belong to the Climate & HVAC section, and the Engine section gives a short overview of the engine cooling system. Where they meet — a heater core fed with hot engine coolant, or a chiller borrowing the A/C refrigerant — it is mentioned here only as a tie-in.

Open Climate & HVAC →

Open Engine →

How an engine or a battery gets cooled

From fins in the airstream to a shared loop that moves heat where it is useful

Liquid cooling (engine)

ICE

Coolant — water mixed with antifreeze — is pumped through passages cast into the engine block and cylinder head, soaks up heat, and flows to the radiator to be cooled by passing air. A thermostat stays shut on a cold engine so it warms up quickly, then opens to send coolant through the radiator once the engine reaches roughly 90 °C. The whole system is sealed and pressurised, which raises the coolant's boiling point.

Components

  • Water pump, belt-driven or electric
  • Thermostat
  • Radiator with an electric fan
  • Expansion tank and pressure cap
  • Coolant passages in the block and head

Air cooling

ICE

No liquid at all: the cylinders and heads are covered in thin metal fins that give the heat a large surface to escape from, and a fan or simply the passing air blows across them. It is lighter and simpler — nothing to leak, boil or freeze — but harder to hold at an even temperature, which is why it survives mostly in older small cars, motorcycles and a few compact electric cars with passively cooled battery packs.

Components

  • Finned cylinders and cylinder heads
  • Cooling fan or ram air
  • Shrouds and air ducting
  • Oil cooler (oil carries a lot of the heat)
  • Thermostatic air flaps

Electric-car liquid loops

Electric

The battery, the motor and the power electronics each get a liquid-cooled loop, moved by electric pumps that run only as hard as needed. A battery pack is happiest at roughly 20–40 °C — hot cells age fast and cold cells charge poorly — while the motor and inverter tolerate far more heat, so they often sit on a separate, hotter loop. A multi-way valve decides which loops are joined and which are kept apart.

Components

  • Electric coolant pump
  • Multi-way coolant valve
  • Battery cold plate
  • Motor and inverter cooling jackets
  • Low-temperature radiator

Integrated thermal management

Electric

Newer electric cars tie all the loops together so heat is moved around instead of wasted. A chiller lets the air-conditioning refrigerant pull heat out of the battery coolant during a fast charge, and in winter the waste heat of the motor and inverter can be sent on to warm the battery or the cabin. One controller and a handful of valves pick the best route; the refrigerant loop itself is explained in the Climate & HVAC section.

Components

  • Chiller (coolant-to-refrigerant heat exchanger)
  • Valve manifold joining the loops
  • Tie-in to the heat pump
  • Waste-heat recovery from motor and inverter
  • Thermal management controller

Cooling differences by vehicle type

One big heat source, two temperature windows, or a dozen small ones

ICE

Everything revolves around one big heat source. A coolant loop holds the engine near 90 °C, the thermostat governs warm-up, and the same hot coolant supplies the cabin heater for free. The hardware is mostly mechanical — a belt-driven pump, a fan and a radiator behind the grille — and what it needs is simply to shed a lot of heat reliably.

Hybrid

Two heat sources with different needs: the engine, and the battery and power electronics, which have to stay much cooler. Hybrids usually add a separate low-temperature loop for the electronics, and an electric water pump so coolant can keep moving — or the engine can be kept warm — while the engine itself is switched off.

Electric

There is no engine heat to dump, but far more precision to deliver: the battery, motor, inverter and charger each have their own limits, so the loops are electrically pumped, valve-controlled and shared with the heat pump. Fast charging is the hardest moment — the pack can give off several kilowatts of heat, and the chiller has to carry it away.

What the cooling system is made of

The parts that carry heat away, and the parts that decide when

Where the cooling parts sit (top view)

Click a node to see its description in the cards below

6 Coolant 7 Oil cooler and intercooler 1 Radiator 4 Fan and shroud 2 Thermostat 5 Expansion tank 8 Temperature sensor 3 Water pump 9 Electric pump and valve 10 Chiller and cold plate

Radiator

A flat core of thin tubes and fins at the very front of the car. Hot coolant runs through the tubes while air passing between the fins carries its heat away — the engine's main way of shedding heat. Modern radiators are aluminium with plastic end tanks.

Thermostat

A temperature-sensitive valve between the engine and the radiator. A wax-filled capsule expands as it heats and pushes the valve open: shut on a cold engine so it warms up quickly, open once it is hot so coolant can reach the radiator. Stuck open means a slow warm-up and a weak heater; stuck shut means overheating.

Water pump

An impeller that pushes coolant around the loop. On most combustion engines a belt or chain drives it, so it spins faster as the revs rise; many newer engines and every hybrid or EV use an electric pump that can run at exactly the speed needed, even with the engine off.

Radiator fan and shroud

At speed the air rushing through the grille is plenty. In traffic an electric fan pulls air through the radiator instead, sitting inside a shroud that funnels it through the whole core rather than just the patch next to the blades. It switches on by itself when the coolant gets hot — which is why you can sometimes hear it after the engine is off.

Expansion tank and pressure cap

Coolant expands as it heats, so the loop needs somewhere to put the extra volume: the translucent expansion tank, with MIN and MAX marks. Its cap is a pressure valve that lets the system run above atmospheric pressure, raising the coolant's boiling point by roughly 20 °C. Never open it on a hot engine.

Coolant (antifreeze)

Usually about half water and half glycol-based antifreeze, with corrosion inhibitors mixed in. Water carries heat superbly; the glycol stops the mixture freezing in winter (down to around −35 °C) and raises its boiling point. The inhibitors protect aluminium and rubber parts and wear out with time, so coolant has to be replaced every few years.

Oil cooler and intercooler

Two smaller radiators with their own jobs. An oil cooler takes heat out of engine or gearbox oil, often through a compact plate exchanger fed with engine coolant. An intercooler cools the air a turbocharger has compressed and heated before it enters the engine, so the engine gets denser air and makes more power.

Coolant temperature sensor

A thermistor — a small element whose electrical resistance changes with temperature — screwed into a coolant passage. The engine computer reads it to enrich the mixture on a cold start, to switch the fan on and to drive the dashboard gauge and warning light. It is the eyes of the whole cooling system.

Electric pump and multi-way valve

Electric cars swap the belt-driven pump for small electric ones that run only when needed. A multi-way rotary valve — a switchyard for coolant — then joins or separates the battery, motor and cabin-heating loops on command, so the car can send heat where it is wanted rather than just throw it away.

Chiller and battery cold plate

A cold plate is a flat aluminium plate with coolant channels, laid under or between the battery cells to draw heat out of them — or put heat in during winter. A chiller is a compact heat exchanger where the air-conditioning refrigerant takes heat from that coolant, which is what keeps a pack cool during a fast charge on a hot day.