All about oil cooling radiators

Since the internal combustion engine is a heat engine, during its operation it generates excess heat that must be removed. A liquid radiator, inside of which antifreeze circulates, helps with this. Due to, for example, high efficiency with relatively small dimensions, automobile engines also have additional forced cooling. Simply put, car engines have a combined cooling system in which the liquid system does most of the work of removing heat. Air cooling elements are activated only at high coolant temperatures.

Please note: when talking about the engine cooling system, they often use the concept of antifreeze temperature. However, there are times when the engine oil also needs to be cooled. The oil comes into direct contact with engine components, which become very hot. If the oil temperature becomes critically high, it will lose many of its properties, which will be critical for the rubbing parts of the engine. The task of cooling the lubricant is taken over by an oil cooler, otherwise called an oil cooler. Avto.pro decided to look into its structure and key features.

Purpose of the oil cooler

The engine oil cooler is designed to protect the power unit from wear, which can be caused by oil overheating. This is especially true these days, when molded engines have become widespread and temperature control temperatures have increased significantly. If previously it was enough to create a reliable antifreeze cooling system, now a separate system for regulating the temperature of the engine oil is required. There are several reasons:

At high temperatures, the oil begins to boil away, which leads to a decrease in its volume and the formation of deposits;
Along with the decrease in volume at high temperatures, the viscosity of the oil also decreases - it should be neither low nor too high;
The lubricant quickly ages and loses its properties.

Despite the fact that modern oils have a well-thought-out set of additives, even they cannot protect it from overheating. As a rule, engine oil heats up a little more than antifreeze: 90-100°C versus 80-90°C . Additives demonstrate their effectiveness up to temperatures of 100°C (with rare exceptions), and when overheated they begin to work or decompose. As a result, after prolonged overheating, the engine oil can only be replaced - ignoring this problem can result in engine failure. The problem can be avoided by using an oil cooler, in which the lubricant is cooled to the optimum temperature.

Why don't they install it on some cars?

It's just not necessary. For example, in passenger cars, high-speed motors perfectly pump antifreeze through the system, removing excess temperature. And there are no such high loads of several tons as on trucks, so there is simply no reason to install an oil cooler there.

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Oil radiator design

At its core, this is still the same radiator with some modifications. Firstly, it should be relatively small, because the engine cooling system already takes up a lot of space, and the oil cooler may even be located right in front of the main radiator. Secondly, the layout of the radiator must be well thought out - there should be no pressure drops . Conventionally, oil radiators are divided into two types:

With natural cooling. The walls of the radiator are blown with oncoming air as the vehicle moves, which leads to cooling of the oil circulating inside the device;
With forced cooling. The radiator is blown not only by a counter flow of air, but also by a fan.

Both types of radiators have the same design. This is a series of steel or aluminum tubes of oval cross-section, and each of the tubes, as a rule, has a spiral wound on it - this allows you to increase the heat transfer area. In some radiator models, cooling plates . Another element of the oil cooler: a pair of tanks (lower and upper). Fittings are welded to the tanks, to which the oil supply and drainage pipes are connected. Of course, the radiator has special fasteners that allow it to be installed on a car.

As practice shows, passing through radiator tubes without a special fan, engine oil is cooled by 10°C . Forced cooling does not seriously increase the cooling temperature when the car is moving at high speeds, but at low speeds it is extremely effective. The main factors influencing the efficiency of the radiator are the following:

Material (heat transfer efficiency factor);
Tube geometry;
The temperature difference between the oil and the air surrounding the radiator.

It is also impossible not to talk about such an important element of a good radiator as an additional turbine. It improves the circulation of lubricant inside the radiator and prevents blockages. As a result, oil of almost any viscosity circulates properly in the radiator. Cases where the oil turns out to be too viscous and its movement through the radiator tubes is difficult should rather be attributed to engine problems - even an oil cooler without a turbine can “drive” the oil through the cooling circuit.

Making a stand

The stand is made from a metal corner or profile. Dimensions are set based on the overall size of the heater. To make it you will need a welding machine and an electric grinder – “grinder”. From a corner or profile we cut the elements of the future stand. Its shape is also arbitrary. It is only necessary to take into account such a point as the ease of disassembling it. It is quite possible that it will be necessary to disassemble the heater. For example, in the spring, when it is no longer needed.

Before you start making the stand, you need to draw its diagram, determine the dimensions and prepare the blanks.

To do this, use a grinder to carefully cut the required number of corners and sand their edges. All that remains is to “cook” the pieces cut according to the pattern. After welding, the seams are cleaned and the stand is prepared for painting.

Advantages and disadvantages of oil radiators

An engine oil cooler is not a required part of most cars. For example, such radiators are installed on cars with a powerful engine, such as BMW 335i E92 . Also, almost all agricultural machinery, trucks and many van models need oil cooling. the advantages of oil radiators , but let's list them all. The oil cooler provides:

Stability of lubricant temperature;
Maintaining normal temperature of the power unit;
Increasing the service life of engine oil.

Spare parts for BMW 2500

Windshield washer fluid
2500 M30B25 (32/40INAT)

Spare parts for Mazda 2

Rear engine mount (support) 1.4 CD F6JA
Despite the obvious advantages, the oil cooler, as stated, is an optional component for most cars. Consequently, it places an obligation on the driver to promptly diagnose and maintain it. Here are the disadvantages of an oil cooler:

It needs maintenance, like cleaning the surface;
More lubricant needs to be poured into the oil system - some of its volume will be “taken” by the radiator;
Quite a high price (exception: radiators from lower-level packagers and Asian manufacturers).

As you can see, the advantages of oil coolers look more convincing than their disadvantages. For this reason, they are sometimes installed on cars standard equipment did not include such devices. We'll talk about this, but for now let's figure out how to identify a faulty oil radiator.

Height length

When screwing in the heating element, rarely does any of it reach the last section. Usually their length varies between 35-40cm.

There are also exclusive models for all sections, but made to order (for example, Grepan). Here are comparative tables of uniform heating of the same battery (10 sections) with a standard short heating element and an extended one from Grepan.

However, most of us still use short ones. How then can we ensure uniform heating over the entire area?

What you should know about malfunctions

The oil radiator is operated under rather harsh conditions, but the pressure inside the device is not very high, which a positive effect on the service life. As a rule, car enthusiasts are faced with the need to replace radiators every 3-5 years, although in some cases replacement may be required earlier. It is worth paying attention to the following things:

Increase in oil temperature;
The appearance of dark deposits on the walls of the expansion tank of the cooling system;
Presence of oil leaks.

Let us immediately note one important point: the circulation of coolant and the circulation of oil in their respective systems are interconnected . If the circuits become leaky, one fluid can mix with another, which will have a detrimental effect on the engine. For example, oil may get into the expansion tank. It is strictly forbidden to operate a car with such a malfunction - a seemingly insignificant breakdown in the long term will certainly lead to engine malfunction.

It is recommended to carry out a visual inspection of the oil cooling radiator once a year, or even more often. Oil leaks, dark deposits and greasy spots will indicate that the radiator is depressurized. More often you can observe a violation of the integrity of the oil supply and drainage pipes. Oil may leak around the fitting . These elements of the oil system should be checked first. A less common problem is a violation of the integrity of the radiator itself. Although the radiator is made of metal, its tubes have low mechanical strength - gravel from the road can pierce one of the tubes.

Working with pipes

After the oil heater circuit has been selected, it is necessary to manufacture its body. We make a drawing, determine the dimensions and start working with an angle grinder. The pipes are cut to length in the required quantity. After cleaning the ends, they are carefully and thoroughly welded. The performance of the heater as a whole will depend on the quality of welding. A leaking seam is not only a nuisance, but also a possible cause of fire. When welding the ends of the pipes, leave one (on the lowest pipe) free. Subsequently, a heating element will be inserted into it. This means that the stub will be of a different configuration.

The finished pipes are tied together. The piping is done with pipes, only of a smaller diameter. On the topmost pipe it is necessary to provide a place where the filler plug will be located. Structurally, it can be made in the form of a welded short pipe with a coupling, one side of which will be welded. Using your plumbing and mechanical experience, the heater configuration can be made more aesthetically pleasing, unlike the one in the photo. By the way, the body can be not only tubular. Radiators from cars, old cast-iron radiators and other closed containers are well suited for this purpose.

To increase operational safety, it is advisable to install a pressure-sensitive safety valve on the upper pipe.

Selecting an oil cooler

If your car has a standard “supplemented” oil system, then you can search for its components using the VIN code, the parameters of your vehicle, or the radiator code. It’s easier to search for car parameters in online stores - this gives a fairly accurate result. This way you can find codes for both the original radiator and the closest analogues. If the standard equipment of your car did not include an oil cooler, then you will have to select it yourself. Here's what to remember:

It is better to install the oil cooler together with a temperature sensor and an oil pressure sensor;
Some models of oil coolers have a built-in fan, but their installation is very difficult, and in some cases it is almost impossible;
To install the sensors properly, you will need a spacer for the oil filter;
When choosing between a spacer with or without a thermostat, it is better to give preference to the first option;
The location for installing radiators must be selected taking into account the fact that the oil supply and drain pipes should not sag.

You can often see branded oil cooler installation kits on sale. This kit may not be cheap, but we do not recommend saving. Also, you should not save on tubes, adapters, fittings and other “little things” that may not be included in the kit - how long the entire oil cooling system will work before depressurization due to mechanical stress or natural aging of materials will depend on the quality of its execution. As for choosing the radiator itself for a non-standard installation, everything will depend on the engine parameters of your car. Many experts advise first installing temperature and oil pressure sensors, and then selecting a radiator based on their readings.

It is better to entrust the installation of the radiator to a specialist. If the device does not have special fasteners, the technician will make them himself. As a rule, the radiator is placed in front of the main engine cooling radiator. The technician will also install a special spacer. It often happens that the spacer does not fit into the regular place of the oil filter - then you will need to install something like a gasket with it. In this case, a fairly long fitting may be required for further installation of the spacer.

Selection of materials

As is clear from the above, to obtain a homemade heater you will need to get the following components somewhere:

frame;
oil;
heating element;
mobile stand;
control and automation devices.

As a housing, you can borrow an old radiator from a central heating system, sheet or sectional. A car, or any similar product, the design of which will allow fluid to circulate inside naturally or artificially (using an electric motor), is also quite suitable. You can also make a closed loop from steel pipes with your own hands.

The main thing is not to forget that an indispensable condition for the normal functioning of the system will be to ensure the tightness of the housing. If the liquid begins to leak, then it is unlikely that such a homemade device will bring more benefit than it will cause trouble.

As for the oil, firstly, its quantity should be based on the calculation

85% of the body volume. The rest of the cavity is filled with air. This 15% area is maintained so that during operation the oil does not crush the housing due to thermal expansion.

Secondly, the quality characteristics of the liquid must satisfy at least two criteria: purity and heat resistance. Dirt and impurities will shorten the life of the heating element by causing scale to settle on it. A decent temperature of the heating element indicates that you should select technical oil of the appropriate brand. A suitable option would be, for example, a transformer.

Excursion to the manufacturers

When choosing a suitable oil cooling radiator, you should pay attention to the manufacturer. If you understand engine radiators, then everything is simple: look for oil cooler radiators in their assortment - almost all major radiator manufacturers produce them too. Unfortunately, their products cost a lot of money, but the price corresponds to the quality. Radiators from the following companies are worthy of attention:

Nissens (Denmark);
NRF (Netherlands);
Hella (Germany):
AVA (Netherlands).

Not as high quality, but much cheaper analogues are offered by ]DP Group[/anchor] (Turkey), Polcar (Poland), 3RG (Spain), Vika (Taiwan), Dello (Germany), Thermotec (Poland). In fact, these are packers selling products from Turkish, Chinese and Taiwanese factories. There is nothing wrong with Asian auto parts; the cheapest auto parts from these countries are another matter. As a rule, they have a high percentage of defects and non-compliance with the original geometry. In their production, low-quality raw materials are often used. In the case of radiators, this is critical, so Avto.pro advises buying much higher quality products from companies from the list above.

Repair of electrical equipment KAMAZ

Type of repair	price, rub.
Diagnostics of electrical equipment operation by visual inspection	600
Computer diagnostics of the Engine Control Unit	3000
Computer diagnostics of the Exhaust Gas Neutralization Control Unit (Urea)	1500
Computer diagnostics of ABS (SCREEN)	1500
Replacing the fuse and relay box n/o	2500
Replacing the fuse and relay block	1500
Replacing the engine control unit	1200
Replacing the interior climate control unit	1200
Replacing the ABS block	840
Computer diagnostics of ABS (WABCO)	2500
Replacing the brake light switch	360
Replacing the generator Engine CUMMINS	2500
Replacing the generator Engine KAMAZ	1800
Replacing the rear light lens	360
Replacing the rear light	840
Replacing the turn signal/repeater	480
Replacing the side light	480
Replacing the sound signal	840
Replacing the turn signal switch	1200
Replacing the cabin light	600
Replacing the fog lamp	640
Starter replacement	1800
Replacing headlight glass	360
Replacement Headlights n/a	1200
Replacing the headlight	840
Replacing the instrument panel N/O	1800
Replacing the instrument panel	1200
Replacing the fuel level indicator N/O	800
Replacing the fuel level indicator	540
Replacing the air pressure indicator	640
Replacing the oil pressure indicator	720
Replacing the electric heater motor	1200
Replacement of electrical wiring (complete)	27000/45000
Checking the operation of the brake light and troubleshooting	450
Installation of a car radio with 2 speaker systems	3500
Adjusting the sound signal	480
Charging the battery	480
Starting the car with a starting device	360
Remove and install battery	960
Replacement of windshield wiper assembly n/a	2520
Replacing the windshield wiper assembly	1800
Replacing the mains switch	840
Installation of a 24/12 convector with output to the cigarette lighter	2000
Replacing the air pressure sensor	450
Replacing the speedometer sensor	840
Replacing the ABS sensor (on the wheel) wheels and brake drum removed	960
Replacing the ABS sensor (on the wheel) with removing the wheel and brake drum	3600
Replacing the air filter clogging sensor	300
Replacing the fuel level sensor	450
Replacing the reverse light sensor	360
Replacing the coolant temperature level sensor	360
Replacing the oil pressure sensor	360
Replacing the speedometer	720
Checking the speedometer (calibration)	2000
Replacing the axle lock sensor	360
Replacing the instrument cluster	840
Replacing the fuse	120
Replacing the bimetallic fuse	120
Diagnostics of the diarrhea	720
Railway repair	3000
Replacement of electric pump PZD	1600
Replacing the spark plug	720
Replacing the temperature sensor	720

* 1. For special equipment, a coefficient of 1.1 is applied 2. For vehicles aged 5-10 years, a coefficient of 1.1 is applied

Conclusion

An engine oil cooling radiator is not included in the standard equipment of all cars, but it copes so effectively with the task of controlling the oil temperature and protecting the engine that many car enthusiasts decide to install this device on their vehicles. The radiator cannot be called a durable car part - it has little mechanical strength, and the connecting elements of the oil system tend to gradually age and depressurize. An engine oil leak should never be ignored, and in systems with a special cooler it can also be observed in the radiator. If the car requires replacement of the oil cooler, we recommend purchasing spare parts from well-known European manufacturers. Although they will not be cheap, they will guarantee the efficiency and durability of the engine oil cooling system.

Making a heater for the garage

To maintain a comfortable temperature in the garage, it is not difficult to make your own heater using waste oil. At the same time, the problem of its disposal will be solved, which is also a pressing issue for car owners. To assemble it, almost all the elements and spare parts can be found in your own garage.

When making a heater you will need:

metal pipes;
heating element (heating element);
used oil;
wire with plug.

Structurally, the body can be made in any form convenient for placement in the garage. The photo shows one of the possible circuits of the device.

Diagram of a homemade oil heater

Metal pipes are used of any diameter. It must be taken into account that the thinner they are, the more of them will be needed. The temperature of the room will depend on the area giving off heat. The length of the pipes is also arbitrary, it is desirable that it be maximum, but at the same time ideally harmonize with the dimensions of the wall where it will be installed. The metal from which the pipes are made is not significant. The thickness of the pipe walls can be any.