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In the design of aluminum (Al) cooling system components for heavy duty diesel engines, coolant flow velocities are critical to the durability of the parts. The geometries of the individual component parts used in the system must be designed to minimize turbulence which will affect the rate and type of corrosion. In addition, flow passages must be “sized” to maintain coolant velocities below a critical value. In high velocity flow, a combination of the mechanical damage produced by the impingement of a liquid on a metal surface and the inherent corrodibility of the metal may result in erosion-corrosion and impingement attack. Aluminum alloys are very prone to this type of corrosion damage because of the low inherent hardness of the material as compared to other alloy systems. The development of aluminum cooling system parts for a new 15 liter diesel engine was undertaken to lower weight and make a more compact design for the engine profile.