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What are the most common causes of overheating in diesel engines?

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Overheating is one of the most common and damaging problems that can affect diesel engines. It can lead to reduced performance, increased fuel consumption, engine wear, and costly repairs. If you are responsible for fleet operations, you need to know what are the most common causes of overheating in diesel engines and how to prevent them. In this article, we will cover six factors that can contribute to overheating and how to address them.

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Rafael Schuhli

Chief Engineer Verification & Validation
Jonatas Arend

Analista de Treinamento e Desenvolvimento | Logística e Transporte
Shalini Gupta

GTM Champion | Digital Transformation for Vessel & Cruise Business Lines ?? | Compliance Conformance with Maritime ? |…

1 Coolant level and quality

The coolant is a liquid that circulates through the engine and the radiator to remove excess heat. If the coolant level is too low, the engine will not be able to cool down properly and may overheat. Low coolant level can be caused by leaks, evaporation, or improper maintenance. You should check the coolant level regularly and top it up as needed. You should also check the quality of the coolant and replace it according to the manufacturer's recommendations. Old or contaminated coolant can lose its effectiveness and cause corrosion, clogging, or damage to the engine components.

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Jonatas Arend

Analista de Treinamento e Desenvolvimento | Logística e Transporte
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Um erro muito comum é a utiliza??o somente de água no sistema de arrefecimento. A água corrói o motor de dentro pra fora, causando entupimento das galerias e por consequência o superaquecimento. O líquido de arrefecimento na medida certa, evita que esses problemas aconte?am, pois ele permite que a água passe de 100°c, evitando a press?o excessiva no sistema, e também em locais muito frios (Argentina, Canada, e etc...), atua como anticongelante. Outro benefício é a redu??o da acidez da água, o que agride menos o bloco do motor e as outras pe?as que o líquido tem contato. Um correto nível, um produto de qualidade e uma verifica??o periódica, v?o garantir que casos de superaquecimento por causa do líquido sejam menos frequentes.

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2 Thermostat and water pump

The thermostat and the water pump are two components that regulate the flow of coolant through the engine and the radiator. The thermostat is a valve that opens and closes depending on the temperature of the engine. The water pump is a device that pumps the coolant through the system. If either of these components fails or malfunctions, the coolant flow will be disrupted and the engine will overheat. You should inspect the thermostat and the water pump regularly and replace them if they are faulty or worn out.

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3 Radiator and hoses

The radiator and the hoses are parts of the cooling system that transfer heat from the coolant to the air. The radiator is a metal device with fins that allow air to pass through and cool down the coolant. The hoses are rubber tubes that connect the radiator to the engine and the water pump. If the radiator or the hoses are damaged, dirty, or blocked, the heat exchange will be reduced and the engine will overheat. You should clean the radiator and the hoses regularly and repair or replace them if they are cracked, leaking, or clogged.

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4 Air flow and fan

The air flow and the fan are factors that affect the cooling efficiency of the radiator. The air flow is the amount of air that passes through the radiator and removes heat from the coolant. The fan is a device that helps to increase the air flow when the vehicle is stationary or moving slowly. If the air flow or the fan is insufficient, the radiator will not be able to cool down the coolant and the engine will overheat. You should ensure that there is enough space around the radiator and that nothing is blocking the air flow. You should also check the fan and its wiring and make sure it is working properly.

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5 Fuel injection and combustion

The fuel injection and the combustion are processes that generate power and heat in the engine. The fuel injection is the system that delivers fuel to the cylinders where it is mixed with air and ignited by the spark plugs. The combustion is the reaction that produces energy and exhaust gases. If the fuel injection or the combustion is faulty or inefficient, the engine will produce more heat than normal and may overheat. You should check the fuel injection system and the spark plugs regularly and adjust them if they are dirty, damaged, or out of sync.

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6 Engine load and speed

The engine load and the speed are factors that affect the amount of work and heat that the engine produces. The engine load is the force that the engine has to overcome to move the vehicle or perform a task. The speed is the rate at which the engine rotates and delivers power. If the engine load or the speed is too high, the engine will work harder and generate more heat than it can dissipate and may overheat. You should avoid overloading or overspeeding the engine and use the appropriate gear and throttle settings for the driving conditions.

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Rafael Schuhli

Chief Engineer Verification & Validation
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The speed mentioned in the article is the engine speed, usually measured in rotation per minute (rpm). This should avoid confusion with vehicle speed. Engine speed and cooling capacity does not have a direct connection. Some engines reject more heat to the coolant at maximum torque rpm, where some engines reject more heat to the coolant at the maximum power rpm. On the other side the vehicle speed has usually a direct connection with the cooling capacity - a better cooling performance can be expected with higher vehicle speed.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Shalini Gupta

GTM Champion | Digital Transformation for Vessel & Cruise Business Lines ?? | Compliance Conformance with Maritime ? | Turbocharge your inspection process ??
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Common causes of diesel engine overheating include: Cooling System Issues: Leaks, clogs, or insufficient coolant levels affect heat dissipation. Faulty Thermostat: Malfunctioning thermostat can hinder proper coolant flow. Radiator Problems: Damaged or blocked radiators reduce heat exchange efficiency. Water Pump Failure: Impairs coolant circulation, leading to overheating. Air in Cooling System: Air pockets hinder effective heat transfer. Faulty Fan: Inoperative cooling fan disrupts air circulation. Engine Load: Excessive load or towing can strain the engine, causing overheating. Regular maintenance and prompt diagnosis are crucial to prevent and address these issues.

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What are the most common causes of overheating in diesel engines?

1

2

3

4

5

6

7

1 Coolant level and quality

2 Thermostat and water pump

3 Radiator and hoses

4 Air flow and fan

5 Fuel injection and combustion

6 Engine load and speed

7 Here’s what else to consider

Fleet Operations

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What are the most common causes of overheating in diesel engines?

1

2

3

4

5

6

7

1 Coolant level and quality

2 Thermostat and water pump

3 Radiator and hoses

4 Air flow and fan

5 Fuel injection and combustion

6 Engine load and speed

7 Here’s what else to consider

Fleet Operations

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