Radiator Help - Compiled Article

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It seems to be the freeway cliché when older cars are pulled off on the side of the road as steam billows from the open hood. The older your car gets, the more stress there is on its radiator and this is why vehicles more than five years old are often plagued with cooling system problems.

In almost all cases, radiator issues aren’t known until it’s too late. With the increased environmental factors merging with normal wear and tear, a car’s cooling system absorbs quite a bit of punishment. Salt, debris, bugs, chemicals, pollution and more slowly break down the metal and strength of a radiator, and this can ultimately lead to leaks or blown gaskets.

Few people realize how much heat is generated as your car is driven and heat can be quite destructive if the radiator isn’t operating at peak efficiency. Ideally, you’ll want to get your radiator (along with the entire cooling system) checked every 1-2 years depending on the age and mileage of your vehicle.

Your trusted auto body shop or dealership will be able to offer you a variety of radiator maintenance services such as flushing out the radiator, finding and repairing leaks, correcting damage to copper, brass, aluminum or plastic radiators and parts, checking thermostat accuracy, fixing hoses or belts, and much more. In many cases, a little radiator maintenance can go a long way to preventing emergencies and breakdowns somewhere down the road.

If you notice that your car is starting to overheat, there are a few things you can do to try and keep the heat down as you make your way to the repair shop. If you notice your car overheating while in standstill traffic, try to give it a little gas (while in park or neutral, of course) as this can help release some heat.

Another good tip whether you are driving or stuck in traffic is to turn on the heater. This will expel heat through the vents thereby easing the heat stress on your radiator. Granted, on a hot day this can be brutal, but with the windows down it should be bearable. As well, you’ll appreciate the extra mileage you’ll get from the radiator and cooling system.

If all else fails, you might want to safely pull off the road and turn off the vehicle for 15-20 minutes to let the engine cool down. As soon as you experience radiator issues, you’ll want to get your car inspected by a radiator specialist. Only they have the equipment and expertise it takes to find and repair cooling system problems.

 

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Radiator Maintenance Terms

While your car often operates silently and without issue, what goes on under the hood might surprise you. A car’s engine produces so much heat that it can literally destroy itself if the cooling system and radiator fail to keep the engine within the proper temperature range. The best way to ensure a long engine life is to make periodic maintenance checks and repairs. Oil changes, air filter replacement, and tune-ups are just some of the other routine checks you should make beyond your cooling system.

This article focuses on radiator care and the kind of preventative maintenance you can pursue to keep your car running cool. Depending on the age and total mileage of your car, you’ll want to have your cooling system checked every one to two years. If you notice your radiator acting up or running a bit hot, don’t hesitate to get it looked at by a professional.

When your radiator is being checked, here are a few common maintenance procedures you’ll hear about.

Radiator Flushing and Repair
Here, the radiator is removed, power cleaned, and flushed of its fluids. Once cleaned, it is then pressure tested, inspected for any cracks or leaks, and repaired if necessary. More will be discussed on radiator flushing in future articles.

Radiator Cleaning and Repair
Once the radiator is removed from your car, it will be cleaned inside and out by power washing and immersion with a powerful cleaner. After a thorough cleaner, it is flushed again before being pressure tested, closely inspected and repaired.

“Rod-out” and Repair
This is a more thorough version of the above. Once removed, the radiator is power cleaned externally, flushed, tested and repaired. One tank is then removed and a rod is used to loosen and remove debris from each tube. Once this is completed, the radiator is then replaced and tested thoroughly.

New Core or Recore
This is a process whereby a radiator is restored nearly to its original condition. By using restored existing parts (when salvageable) in conjunction with new or refurbished-as-new parts, the radiator’s performance and longevity is dramatically improved, especially with the installation of a new radiator core.

Radiator Tank and Gasket Replacement
Once the radiator is removed from the engine, it is placed in a special fixture to separate the damaged tank and gasket. Each is then replaced with a new or refurbished part, thereby avoiding the purchase of a brand new radiator. Once the radiator is reassembled, it is then tested and filled.

 

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Ensure Radiator Performance

If your car is experiencing radiator and cooling system problems, there can be any number of reasons as to why. To help protect your car’s longevity, it is important to get your vehicle looked at by a radiator specialist as soon as problems arise. Here are seven few common radiator areas you’ll want to have checked to ensure peak performance.

Check Your Thermostat
Even if the thermostat isn’t the cause of the overheating problem, it should still be tested after a problem exists to ensure that isn’t damaged. One method used is to start the engine and feel the upper radiator hose. Ideally, the hose should not feel uncomfortably hot until the engine has had time to warm up. If the hose does not get hot, then this could be indicative of a thermostat failing to open.

Another way to test the thermostat is to simply remove it and drop it into a pot of boiling water. It should open at this time and you can always test the exact opening temperature by using a thermometer.

If you find that the thermostat needs to be replaced, be sure to install one with the same temperature rating as the one you’re replacing. Most cars and trucks built after 1971 need thermostats rated at 192 or 195 degrees. Using a thermostat with a lower rating in an effort to cure overheating can actually increase fuel burning, ring wear and emissions.

Safeguard Against Leaks
A loss of radiator coolant due to a leak is probably the most common reason behind a car’s overheating problems. The trouble with leaks is that the source of the leak can often be difficult to find. Possible leak areas include hoses, the radiator itself, the heater core, water pump, thermostat, had gasket, plugs, radiator cap, and much more. As you can seem troubleshooting a radiator leak can be a daunting and meticulous task.

To start, try and make a visual inspection of the entire cooling system, not just the radiator. Look for any obvious signs of wear, cracking or splitting. A pressure test through a radiator specialist can reveal any internal leaks as well as seepage not visible to the naked eye. A leak-free radiator system will hold pressure for at least a few minutes.

Ensure Fan Health
Although common and often overlooked, mechanical fans with a faulty fan clutch is often the cause behind overheating problems. This and other fan issues can reduce a fan’s cooling ability by as much as 50%. In warmer weather or under harsh operating conditions, this can absolutely be enough to cause overheating.

If the fan clutch shows sign of leakage (you would notice streaks on the hub or blades), spins freely when the engine isn’t running, or seems loose when the fan is pushed, then it needs to be replaced. Failing to replace fans and maintain their efficiency can lead to overheating as the temperature continues to build unregulated.

 

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Ensure Radiator Performance

Check the Water Pump
While the engine is cool, check the water pump for any wobbling or signs of leakage. If you notice either of these then it’s time for a replacement. If a pump is corroded or loose then this can be a cause of engine overheating. In addition, an incompatible pump can cause overheating because of malfunctioning or unworkable parts.

Check Belts and Hoses
A loose belt that slips or breached hose that leaks can prevent the water pump from circulating coolant fast enough, prevent the fan from turning fast, and also leak valuable coolant. It is important to check the condition and tension of your car’s belts and hoses. In most cases, hoses should be replaced every five years or when there is noticeable wear and tear. Most likely, your radiator specialist will make checking the belts and hoses his or her first order of business.

Check the Radiator Itself
The most common radiator problems include clogging and leaks, even when not the result of a faulty system listed above. Everything from dirt, bugs and leaves can block airflow and also reduce the radiator’s ability to expel heat. If clogged, the radiator will need to be cleaned or even replaced.

Flushing a radiator and cooling system or using chemical cleaners to remove rust or build-up won't do anything to help a clogged radiator.


To recap, the most common causes of radiator and coolant system overheating, include:

Thermostat – Could be improperly installed, sticking closed, or incompatible.

Leaks – A common problem with a variety of different causes.

Fan – A bad blade or fan clutch can reduce cooling ability and cause overheating.

Water Pump – Will certainly fail in a car’s lifetime, important to ensure proper installation.

Belts and Hoses – Commonly causes leaks at connection points or from wear and tear.

Radiator – Older copper or aluminum radiators can get clogged and restrict coolant flow.


Most car owners take their cooling systems for granted, including replacing the coolant. If the coolant isn’t changed periodically, the passages can form a buildup of sludge that can reduce flow and cooling power. Your car’s radiator coolant should be changed every two years or 30,000 miles so that it doesn’t lose its effectiveness. It’s also important to do regular oil changes because old or dirty oil won’t flow as quickly and this can impede cooling.

 

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Radiator Overheating

When a car overheats, it can be caused by any number of things that decreases the radiator’s and cooling system’s ability to absorb and expel heat. The typical causes of overheating are discussed in another article, but we’d like to address what can happen if you don’t remedy overheating as soon as possible.

Heat always flows from a high temperature to a lower temperature so the only way to cool a radiator’s hot metal is to keep it in constant contact with cool liquid and cooler airflow. If the coolant cannot circulate or the fans can’t cool effectively, then temperatures will start to rise and the engine will begin to overheat.

As the engine overheats, it will start to lose power as the combination of the heat and pressure exceed the fuel’s octane rating. If this problem isn’t remedied, then damage to the rings, pistons and bearings can occur.

Overheating can also cause a blown head gasket because heat can make aluminum swell nearly three times as fast as cast iron. This level of stress can distort the head make it swell in the hotter areas. Most aluminum radiator heads will swell in the middle and this can actually crush the head gasket if it gets hot enough. This can ultimately cause seizure and breakage, which is why immediate care is needed if your radiator begins to overheat.

If the radiator coolant’s temperature rises hot enough to boil then this may cause older hoses or the older radiator to burst as a result of the pressure. Pistons can then swell, scuff or even seize. If this happens, massive engine problems will be forthcoming. As well, a burst radiator will undoubtedly leak coolant everywhere…from the crankcase to the other engine components. If this happens, then additional coolant system and engine parts may need to be replaced.

If your radiator warning light comes on or your gauge reads hot, this should never be ignored. In due time, often quickly, overheating will begin and bigger problems can soon arise. You can try a few things to reduce the heat in the engine (i.e. turning on your heater or pulling off to let the engine cool), but you need to see a radiator specialist as soon as possible.

 

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Radiator Replacement

When your radiator is replaced, you’ll probably be interested to know what takes place. Replacing a radiator isn’t as simply as just pulling out a part and replacing it with a new one. Instead, a number of precautions are taken to ensure proper operation after the radiator replacement is completed. After you purchase your radiator from RadiatorNet, your service center will handle its installation for you.

During the radiator replacement, hoses will be checked and the entire cooling system flushed and refilled. In most cases, the radiator mounts will also be checked to ensure that they are okay before installing the new parts.

If the technicians notice coolant dripping on the passenger side of the vehicle or the blowing of steam from the heater ducts, then this might be indicative of a leaky heater core. Replacing a heater core isn’t easy because they are often buried under the dash, but it may be a necessary fix if the radiator replacement tests indicate an issue.

When replacing a radiator, the measurements of the new and old parts should be close but they do not have to be exact. Sometimes, when people go from an aluminum radiator to a copper/brass radiator or the other way around, the height, width and thickness will vary. Even without an exact measurement match, the cooling capacity will be checked to ensure that it is the same or even greater than the original radiator.

As the new radiator is bolted into place, the mounting brackets and radiator supports will be checked to make sure that there isn’t any misalignment that could lead to cracking or failure due to increased stress or fatigue.

Once the new radiator is installed, the belts and hoses will be serviced and any recommended replacements will be made to help prevent future issues. The technician will also make sure that the new and old hoses are positioned and supported in a way that minimizes radiator stress.

One radiator part that is often taken for granted is the radiator cap. The cap is what holds pressure in the cooling system and helps prevent the formation of steam bubble and gaps inside the engine. While your radiator technician will ensure you have the right cap for your radiator, most cap pressures can range from 4 pounds to 18 pounds and he or she will check for the right rating for the application.

Too little and this can allow coolant loss, too much pressure and you can damage the radiator or water pump. Your radiator cap will be pressure-tested to check the condition and if it can’t hold the rated pressure for at least 1-2 minutes, then it will be replaced.

 

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Radiator Efficiency

Radiator efficiency is directly related to the care and maintenance of the cooling system. Once you better understand the level of stress that a car radiator goes through, you’ll probably be in a position to ensure long-term radiator care. This radiator article is written to help communicate the cooling power of the radiator.

First, more than 1/3 of the heat produced by your car’s engine ends up as what’s called “waste heat” in the radiator and cooling system. In fact, a gallon of gasoline will ultimately produce 19,000 to 20,000 BTUs of heat energy when it is burned. This is enough heat to boil more than 120 gallons of water, so you can understand the amount of heat your 2-3 gallons of coolant must deal with.

If the radiator isn’t efficient at removing heat through the circulation of the coolant, then overheating can quickly set in. But the coolant isn’t the only component that helps keep your engine running cool. You also have to have a fan to pull air through the radiator, a water pump to keep the coolant circulating, and a thermostat to help regulate the temperature of the engine.

In addition, the radiator coolant must have a good mix of water and antifreeze so that your car has adequate freezing and boiling protection. Finally, some corrosion inhibitors might be helpful as it can protect against rust, oxidation and electrolysis.

In order to keep your radiator and cooling system in good operating condition, be sure to check the following periodically:

Coolant Level
Checking the coolant level regularly can help you detect leaks before they lead to overheating. The coolant level should be checked from the coolant reservoir, not the radiator, because the radiator will actually siphon coolant from the reservoir as needed. Even without a leak, most cars will lose some radiator coolant due to evaporation. This is of little concern, but if a lot of coolant is lost in a short amount of time, then this is indicative of a radiator problem.

Strength of Antifreeze
The maximum strength of antifreeze should be limited to 65% to 70% (when compared to water) because too much antifreeze and not enough water will actually reduce the coolant’s ability to carry and process heat. In hotter weather or under heavier loads, the risk of overheating increases even more. By increasing the concentration of antifreeze in the coolant (within reason) you can help raise its boiling temperature and lower its freezing point.

Condition of Coolant
You won’t be able to gauge the condition of your radiator coolant by looking at it. Even if it looks like new, the chemistry must be right to avoid problems. The old rule of changing radiator coolant every two years or 30,000 miles is still acceptable for more green and yellow coolants. But even if your car uses “long-life” coolant, the same rule applies if the system may have been contaminated or inadvertently mixed with conventional coolant.

 

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Radiator System Checks

Radiator overheating is caused by anything that increases the heat load beyond what the radiator and cooling system can absorb and cool properly. Whether caused by a low coolant level, radiator leaks, malfunctioning radiator fans, a blocked thermostat, or more, overheating is often not a problem if the radiator is maintained and taken care of. Ultimately, the best way to minimize the risk of overheating is to maintain and service it properly so that it continues to operate at peak performance.

The best way to provide maximum cooling is to make sure that the coolant is at full level. Many radiators and cooling systems will overheat if the coolant level is below normal because the steam that forms in the cylinders can prevent the thermostat from operating properly. The radiator’s thermostat needs to be in contact with the liquid coolant and if it’s affecting by steam pockets then the cooling system won’t be able to perform.

If your engine or radiator overheats because of coolant loss then you should first try and find the source of the coolant leak. You should look at the hoses, the radiator itself, the heater core, water pump, thermostat and the plugs or gaskets.

Start by making a careful inspection of the entire cooling system, not just the radiator itself. If you have the skills and time, you can also pressure-test the cooling system and radiator cap as this will reveal any internal leaks or seepage. You’ll know if your system if leak-free if it holds pressure for at least a minute or two.

You can then test the water pump to make sure that there is no visible seepage around the shaft or vent. There should also not be any noise or loosening in the pump bearing itself. Follow by checking all of the hosing in and around the radiator or cooling system. If you find a hose that has cracks, bulges, or other visible damage, it will need to be replaced. Regardless of their condition, radiator and cooling system hoses that are more than five years old should be replaced to prevent damage.

 

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Radiator Leak Causes

Radiator leaks often caused by internal corrosion and split seams can be found almost anywhere on a radiator. While the most vulnerable radiator points are typically along the seams and where tubes join the radiator’s headers, leaks can occur in a wide variety of different places.

While the most common cause of radiator leaking is due to cooling system neglect or a lack of maintenance, it can also be caused from bad connections, fatigue cracks from vibration, mechanical stress or collision damage.

Most types of radiator failure are found where inlet and outlet fittings connect to end tanks, header connections, or where the brackets for radiator support connect to the radiator. Most types of damage resulting from radiator leaks can be repaired if the radiator is in somewhat good condition. If the coolant is testing ok and the radiator is performing to standard, the connections will probably be tested for leaking.

A radiator problem called “solder bloom” is actually internal corrosion that can amass when a car owner neglects radiator coolant, fails to maintain or service the radiator, or when rust reacts with the soldered joints in a copper and brass radiator.

As these kinds of deposits begin to grow in the radiator, the tubes can become blocked and ultimately restrict the flow of coolant. This kind of radiator problem isn’t as easily fixed and almost always requires that the radiator be re-cored or replaced. The cooling system itself should also be cleaned and flushed to remove any remaining deposits and sediment.

If your radiator leaks are caused by small punctures and the radiator is in otherwise healthy condition, the radiator can often be fixed by simply soldering, brazing or even sealing the leak area. If the radiator leaking is severe, found in multiple locations, or full of corrosion, then patching the radiator or its casing is not going to last for long. In this case, the radiator will have to be replaced or at least re-cored.

Ordinary radiator leaks will be easy enough to diagnose because you can often see a dripping or spraying of coolant and quickly recognize the location of the split or crack. If you do notice leaking, you’ll want to get the radiator serviced right away as a loss of coolant will lead to engine overheating.

If not found and corrected, the leak can cause more and more damage. While there are additives available that can help inhibit leaking, these are most useful on small leaks and even then, sealers are only a temporary radiator fix.

 

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Causes of Radiator Failure

While there are certainly dozens of causes of radiator failure, here are sixteen of the more common causes. If you notice a degradation in radiator performance or obvious signs of damage (noise, steam, etc.) then you may need a radiator replacement. You will want to take your car's radiator to a professional but be sure to visit RadiatorNet when it comes time to purchase a new radiator for your engine.

Tube-to-Header Leaks
Failure of the radiator solder joint on a radiator header and tubes can result in coolant loss.

Steam Erosion
Steam can break down the plastic tank and this can produce thinning and ultimately holes in the radiator's plastic tank.

Solder Bloom
Solder corrosion caused by rust and leak inhibitors in radiator antifreeze. Tube-to-header joints can then be weakened and corrosion can restrict radiator coolant flow.

Over Pressurization
Excessive pressure in the radiator caused by defective pressure cap or engine. An exhaust leak can ultimately destroy the car's radiator.

Loose Side Piece
Can lead to the flexing of the core as well as radiator tube failure.

Leaky Tank-to-Header Seam
Failure of the solder joint can eventually lead to radiator coolant loss.

Leaky Oil Cooler
If radiator coolant shows traces of oil, engine damage can result. The mixing of coolant with any transmission fluid or engine oil can damage radiators.

Internal Deposits
Rust and leak inhibitors can form solids that slowly collect in the radiator cooling system and eventually restrict flow.

Fin Deterioration
A chemical deterioration of the radiator fins is often caused by road salt or sea water.

Fin Bond Failure
This is a loss of solder bond between fins and tubes. Fins loose in radiator core can cause loss of heat transfer and reduce radiator strength.

Fan Damage
A minor collision or a failed water pump can eventually result in radiator damage.

Electrolysis (External)
Stray electrical current can cause an electrochemical reaction that will produce voids in the radiator tubes and cause radiator damage.

Electrolysis (Internal)
Stray electrical current can cause excessive corrosion of the radiator's metal components.

Cracked Plastic Tanks
High stress in the radiator can cause premature radiator plastic tank failure.

Blown Tank-to-Header Seam
If the radiator has been subjected to extreme pressures resulting from exhaust leaking into the cooling system, damage can occur.

Leaky Inlet/Outlet Fitting
Leaks in the radiator inlet/outlet area can be caused by fatigue or solder-joint corrosion.

 

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A very special thanks to RadiatorNET website. Source are taken from RadiatorNET Dot Com and every single credit goes to them.



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