Air Induction and Exhaust Systems

APLTCL001 Air Induction and Exhaust Systems
Systems
Air Induction and Exhaust
Review
Intake Stroke
Review
Compression Stroke
Review
Power Stroke
Review
Exhaust Stroke
Types of Systems
Topic 1
Naturally Aspirated Intake and

Exhaust Systems
Components
Exhaust
Manifold Intake
Manifold
Exhaust
Stack
Pre-
cleaner Muffler
Air Cleaner
Pre-cleaner
Donaspin Pre-cleaner
APLTCL001 Air Induction and Exhaust Systems Cyclone Tube Exhaust Dust
Ejected Pre-cleaner
Donaldson Fin Cyclopac
Pre-cleaner
Ejected Dust
Duralife Filter
Donaldson Donalcine SBG
Dust Tube
Vacuator Valve
Pre-cleaner Fins Outer Air Cleaner Element
Inner or Safety Air Cleaner Element
Service Indicator Connection
Dust Cap
Vacuator Valve Air Cleaner Housing
Air Cleaner
Dry Air Cleaner Element
Dry Element Cleaning
Radial Seal Air Filter
A. Radial Seal Design

B. All Steel Adapter Ring
C. One-piece moulded urethane
end caps with integral seals
D. Densely Pleated Filter Paper
E. Built-in Pleat support and
positive pleat spacing
F. Heavy-duty metal inner and
outer wrap
G. Baked-on enamel outer filter
wrap
Service Indicator
Air Cleaner Service
Dial Indicator
Air Cleaner Service
Filter Indicator
Air Cleaner Service
Operating Conditions
Air Cleaner Service
Filter Servicing
• Turn engine off – ‘TAG OUT’

• Remove air cleaner element
• Clean element
• Check for faults in the filter
• Reset the air filter indicator
Exhaust System
Purpose
• Removes:
! Heat
! Combustion gases
• Reduce noise levels with a minimum
restriction to flow
Inlet Manifold
Exhaust System
Exhaust Manifold
Exhaust System
Exhaust System
Muffler
• Reduces the level of exhaust noise

• When gas flows through a muffler:
! Velocity decreases
! Pressure increases
• The more effective the silencing – the
greater the back-pressure
• Muffler selection by manufacturer:
! Compromise between noise reduction and
back – pressure increase
Straight-through Muffler
Reverse-flow Muffler
Spark Arrester Muffler
Catalytic Converter
Exhaust Back Pressure
• Is the pressure created in the

exhaust manifold due to the
restrictions of flow of the exhaust
gases through the muffler and
exhaust piping
Exhaust Stack
Activity 1.1 to 1.20

Activity Workbook
Topic 2
Forced Air Intake System

Volumetric Efficiency
• Engine output determined by the

amount of fuel mixture burnt
• Most efficient way of increasing
power – get more air/fuel mixture into
the cylinder
• Best method – increase volumetric
efficiency
Volumetric Efficiency
• Naturally aspirated engine – 85%

• Turbocharged engine – 130%
• Turbocharging achieves more power
output from a smaller engine
• Increases fuel economy
• A more complete combustion
• Reduction in pollutants
Components
1. Pre-cleaner
2. Air cleaner
3. Turbocharger
4. Intake Manifold
5. After Cooler
6. Exhaust Manifold
7. Exhaust Stack
8. Muffler
Normalizing
• Thinner Air
• Normal Power
• Higher Turbo RPM
• Quieter Exhaust
• Better Combustion
Boosting
• More Oxygen
• Higher Power
• Better Combustion
! Better Fuel Economy
! Cleaner Emissions
• Quieter Exhaust
Lubrication System
• Lubricating
• Cooling
• Cleaning
• Quantity and Quality Facts:
! Type and viscosity
! Oil level
! Oil filter evaluation
! SOS
! Operator Comments
Inlet Restriction Too High
Components
• Free spinning components often

spinning faster than 80,000 RPM
• Journal bearing speed – 30M/S
• Operating conditions demand:
! Near perfect balance and alignment
! Proper operating and maintenance
• Simple problems cause most failures
Components
• Invented in 1906
• Developed to a degree of reliability
and performance that it is now being
fitted to new IC engines
Components
Rotor
Turbine Housing Assembly Compressor Housing
Cross Section
Welding and Hardening
Compressor Wheels
Journal Bearings
Retaining Rings
Thrust Bearings
Seal Ring
Housing
Centre Housing
Turbine Housing
Compressor Housing
Backing Plate
Turbocharger Lubrication
Turbocharger Lubrication
Exhaust Manifold
Wastegates
Wastegates
1. Valve
2. Water cooled base
assembly
3. Inlet air
4. Diaphragm
5. Springs
6. Washers or spacers
7. Valve stop
8. Fitting
9. Breather
After Coolers
Water Cooled After Cooler
Air Cooled After Cooler
After Cooler Core
Turbocharger Operation
• Two types of turbocharger:

! Pulse type
! Constant pressure type
Turbocharger Operation
Pulse Type
Split Pulse
Constant Pressure
Summary
• Pulse Type Turbocharger:

! Offers quick excitation of the rotating
assembly
• Constant Pressure Turbocharger:
! Used mainly on diesel engines in
earthmoving and marine applications
Air Intake Condition
Lubrication
• Correct quality and viscosity is

essential
• Oil filters must be changed at correct
intervals
• Oil filters should be cut open
• Engine oil pressure should always be
at specified levels
Boost Pressure
• The pressure existing in the inlet manifold

when the engine is operating at normal or
rated power output
• Boost pressure is specified for each
engine model
• Measured at a location in the inlet
manifold:
! Measured in either mm HG in a mercury
manometer or kPa when a gauge is used
Measuring Boost Pressure
• Should always be compared with

standard inlet and fuel conditions of:
! 99 kPa dry barometric pressure
! 290C
! 35 API rated fuel
• If standard conditions are not
present, correction factors should be
applied
Pressure Control
Wastegate Problems
APLTCL001 Air Induction and Exhaust Systems Electronically Controlled
Wastegate
• Controlled by signal pressure to the

ECM
Altitude
• High Altitude – quantity of air (oxygen) is

reduced
• Without turbocharger
! Engine performance falls significantly
• With turbocharger:
• Power output reduced approx 1% per 300
M above sea level
• Above 2000 M, fuel delivery must be
decreased according to specifications
Series Turbocharging
Compound Turbocharging
Engine Starting Procedure
• Always allow a turbocharged engine

to idle after start up:
! Allow engine oil pressure to build up
• Starting with full throttle will result in
turbocharger operating with very
little oil circulating through its
bearings
Engine Shutdown
• Engine should be run at idle speed

for three to four minutes before
shutdown:
! Allows high-speed rotating assembly to
slow down
! Allows engine operating temperature to
normalise
! Allows excessive heat to dissipate from
the turbocharger
Engine Shutdown
• If shutdown while operating at high

speeds or under load:
! Rotating assembly will continue to rotate for
some time without oil
• Exhaust turbines run at high temperature
during operation – once oil flow stops:
! Heat is sufficient to decompose oils to form
gums and varnish – leaving no lubricating
residue and causing premature wear
Engine Shutdown
• Automatic timer unit:

! Overrides the stop control and allows engine
to idle before shutdown
! Protects the turbocharger against sudden
engine shutdown
• Oil accumulator mounted on the engine:
! Engine oil forced into the accumulator during
operation – on shutdown oil is forced into the
turbocharger
Rootes Type Supercharger
APLTCL001 Air Induction and Exhaust Systems Supercharger Construction
Operation
Measuring Blower Pressure

Activity Workbook
Topic 3
Causes of Failure, Inspection

and Repair Procedures for
Turbochargers
Identifying Causes
• Turbochargers fail in many different

ways and for many different reasons
Turbocharger Failure
Hot and Cold

Side Oil Leaks
Turbocharger Failure
• Hot shutdown
• Restricted air cleaner
• Air leaks in the intake
• Exhaust leaks
• Over fuelling
• High altitude operation
• Failure to prelube
• Leaking oil lines
• Turbocharger mounting bolts
APLTCL001 Air Induction and Exhaust Systems Turbocharger Inspection
Safety Warnings
• Disconnect battery
• Allow engine components to cool
• Careful of moving parts
• Never attempt adjustment while
machine is moving or engine is
running unless specified
• Machine must be parked on a level
surface and engine stopped
Notice
• Keep all parts clean of contaminants

! Contaminants cause rapid wear and
shortened component life
• Fluids must be contained as per local
regulations a requirements
APLTCL001 Air Induction and Exhaust Systems Before Inspecting a
Turbocharger
• Ensure inlet air restrictions are
within specifications
• Ensure exhaust restrictions are
within specifications
• Inspect:
! Compressor and housing
! Turbine wheel and housing
! Wastegate
APLTCL001 Air Induction and Exhaust Systems Inspection of Compressor
and Housing
1. Inspect compressor wheel
2. Clean compressor wheel
3. Turn rotating assembly by hand
4. Inspect for oil leaks:
a. Check oil level
b. Inspect air cleaner element
c. Engine crankcase breather
d. Remove drain line
5. If above steps do not detect a leakage,
then there is an internal leak
APLTCL001 Air Induction and Exhaust Systems Inspect Turbine Wheel and
Housing
1. Inspect turbine for damage
2. Inspect turbine wheel for build up
3. Turn rotating assembly by hand
4. Inspect for oil leakage:
a. Remove drain line
b. Check crankcase pressure
c. Replace drain line if damaged
d. Check drain line routing
5. If above step do not reveal source of
leakage, then the leak is internal
Canister
Actuating Rod
Line
Inspect Wastegate
Wastegate Inspection
• Levels of boost pressure indicate a

problem:
! Too high at full load conditions
! Too low at all lug conditions
• Refer to specifications for wastegate
• Remove air line and apply corresponding
amount of pressure to canister – DO NOT
EXCEED 200 kPa (29 psi)
• The actuating lever should move
• NOTE: the housing assembly is preset at
the factory and no adjustments can be
made
Amount of Pressure that is Required to Check Wastegate Vale

Letter Designation kPa psi
B 156 23
C 153 22
D 124 18
E 130 19
F 135 20
G 180 26
H 144 21
J 188 27
M 200 29
V 161 23
W 164 24
Turbocharger RPM
• Boost pressure control RPM

• Other factors also effect maximum RPM:
! Engine rating
! Horsepower demand
! High idle RPM
! Height above sea level
! Inlet air restriction
! Exhaust system restriction
Black Smoke
Turbocharger Failure Indicator
Air Cleaner
Turbocharger Failure Indicator
APLTCL001 Air Induction and Exhaust Systems Turbocharger Failure Indicator
Lack of Lubrication
• Can be caused by:
! Low oil level
! Low oil pressure
! Wrong oil
! High oil temperatures
• Can create such signs as:
! Temper colours
! Adhesive wear
! Weakened metal
! Wheel contact
! Wheel separation
Tempers Colours
APLTCL001 Air Induction and Exhaust Systems Continued Operation Without
Adequate Lubrication
Shaft Breakage
APLTCL001 Air Induction and Exhaust Systems Adhesive Wear and Presence
of Temper Colours
Temperature
Seizure Due to High
Fractures
Signs of High Temperature
Abrasive Damage
• Signs of abrasives in the oil:

! Scratches, cuts or grooves
! Little heat build-up
! Rapid wear
! Embedded debris
! Excessive bearing wear and centre shaft
motion
! Hot and cold wheel contact
! Seal ring leaking, collapsed, worn, missing
! Wheel separation
Contaminated Oil
Hot and Cold Side Bearings
Seal Ring Installation
Bearings
Cut and Grooved Shaft
Outside Abrasive Damage
Abrasive Cutting
Abrasive Identification
High Exhaust Temperatures
• High Exhaust Temperature Facts:

! Heat damage
! Worn bearings
! Wheel to housing contact
! Wheel to centre shaft separation
• High exhaust temperatures:
! Can force heat to penetrate centre housing
! Oxidation and distortion of parts
• Indicators:
! Extreme heat:
• Cooked or carburized oil
• Oxidation/scaling of metal parts
• Temper colours
• Turbine seal ring collapsed
! Worn bearings
! Wheel contact with housing
! Wheel separation from centre shaft
Visual Examination - External
Visual Examination - Internal
Foreign Object Damage
• Immediate and Serious Damage

• Unbalance is more destructive than
distortion
• Indicators:
! Bent and torn wheel blades:
• At the inside diameter of compressor blades
• At the outside diameter of turbine blades
! Bent centre shaft
! Normal wear and colour of bearings
! Occasional wheel separation
Turbine Blade Damage
Large Objects
Compressor Wheel Damage
Small Objects
Compressor Wheel Damage
Hot Shutdown Damage
Carburized Oil
Cooked Oil
Outside Surface Damage
Hot Shutdown
Quench Dots and Rings
Inertial Weld Failures
Weld Failures
Broken Wheel
Magnetic Indicator
Visual Inspection
Wheel Burst
Design and Material Problems
Wheel Burst Inspection
Wheel Burst Inspection
Casting Inclusions
• Trapped gas or other casting

problems, causing:
! Discontinuity
! Weakness
• Casting flaws will create severe
damage
Impact Damage
Broken Shaft
Blade
Inspection of Fractured
Casting Flaw
APLTCL001 Air Induction and Exhaust Systems Other Turbocharger Problems
Off Centre Shaft Stress
Passageway
Missing Lubrication
Passageway
Mislocated Drilled
Missing Blade
Fatigue Fracture
Workmanship
Compressor Wheel Nut
Rough Housing Bores
Rough Shaft Installation
Bent Shafts
Turbocharger Disassembly
• Remove exhaust extension

• Remove pre-cleaner
• Remove muffler
• Remove air cleaner
Disassembly Procedure
Inspection
• Inspect parts for defects to ensure

reusability
! Remove carbon
• Cleaning tank
• Bristle type brush
• All drilled passages
• Glass bead cleaner on some parts
• Emery polishing paper
! Place oil on cleaned parts to prevent corrosion
Assemblies
Turbine Wheels and Shaft
Turbine Wheel
Compressor Wheel
Centre Housing
Centre Housing
Removing Carbon Deposits
APLTCL001 Air Induction and Exhaust Systems Compressor and Turbine
Housing
After cleaning, use air under

pressure to remove foreign material
from the inside of the housing
APLTCL001 Air Induction and Exhaust Systems Turbine Wheel and Shaft
Assembly
1. Hub Area
2. Blade
3. Oil Ring Groove
4. Bearing Journals
5. Threaded Area
Turbine Wheel Blades
• Cracks in one blade

and one broken blade
• DO NOT use again
• One slightly bent

and no cracks
present
• Use Again
• Severely bent
blades
• Large amount of
damage due to
foreign material
• Small nicks and

can be used again
after burrs are
removed
• Light rubbing
around 3600 of the
wheel
• Use Again
• Heavy rubbing
Back Face of Turbine Wheel
• Heavy back face

rubbing
Oil Ring Seal Grooves
• Before grooves are checked, carbon

deposits must be removed
• Find the width of the seal groove
• If groove is more than specifications,
the turbine wheel and shaft assembly
cannot be used again
Seal Ring Groove
• Seal ring groove

has a wear step
(outboard groove)
• Use again
Seal Ring Groove
• Inboard groove has

wear, but outboard
groove width in
within the wear
specifications
• Use again
Seal Ring Groove
• Too much wear in

both seal ring
grooves
Seal Ring Groove
• Wheel and shaft

assembly has
damage to seal
ring groove
Wheel and Shaft Assembly
• Shows erosion in
the hub area of the
shaft
• Use again
Bearing Journals
• Deep scratches
and excessive
wear
Bearing Journal
• Metal deposits
from the bearing
Bearing Journals
• Light scratches or
shiny areas on the
bearing journals:
! Can be used again
after journals are
polished and within
wear specifications
After Polishing
Bearing Journals
Bearing Journals
• Single deep scratch

• Use again after
polishing
Shaft Areas
• Shaft discoloration
• Used again after
cleaning
Shaft Areas
After Polishing
Shaft Areas
• Damage from
compressor wheel
turning on the
shaft
Shaft Areas
• Damaged thread
that can be made
usable by use of a
thread die
• Use again
Shaft Areas
• Bent shaft
• Use again after shaft
is straightened
Shaft Areas
Measuring Bends
Shaft Areas
Straightening Bends
Turbocharger Assembly
• Verify that all components are clean

and free of foreign material
• Check O-ring seals for wear or
damage
• Lubricate O-ring seals lightly
Turbocharger Installation
APLTCL001 Air Induction and Exhaust Systems Cleaning Compressor
Housing and Wheel
• Maximum performance (max boost)
cannot be maintained if there is:
! Oil deposits or
! Dirt on the compressor wheel, housing
or connecting links
Shaft End Play

Tolerance Checks
APLTCL001 Air Induction and Exhaust Systems Tolerance Checks
Radial Clearance
Dial Indicator
Installing Turbocharger
• Check intake and exhaust manifolds for

foreign material
• Ensure manifold bolts are torqued
• Ensure mounting flanges are clean and
gaskets are in correct position
• Use antiseize lubricant on mounting bolts
• Loosen V clamp that fastens turbine
housing to compressor housing
Installing Turbocharger
• Align compressor and turbine housing

• Tighten mounting bolts and V clamp
• Connect turbocharger to inlet manifold (or
aftercooler)
• Connect oil inlet and return lines (avoid
sharp bends and 300 from vertical)
• Keep air intake cover on to prevent foreign
material from entering turbocharger
Exhaust System - Disassembly
• Prior to disassembly, check for:

! Leaks
! Vibration
! Back pressure
! Excessive noise
• Disassembly
! Ensure cleanliness (carbon deposits)
! Manifold Checks:
• Cracks
• Mounting surfaces
• Threaded bores
• Broken studs
• To prevent damage to the engine:

! Remove all loose deposits and residue
Assembly
• New manifold gasket

• Multisection manifold – install centre
section first
• Tighten manifold bolts to specified
torque (in the correct sequence)

Activity Workbook

Air Induction and Exhaust Systems

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APLTCL001 Air Induction and Exhaust Systems

Naturally Aspirated Intake and

Pre-cleaner Fins Outer Air Cleaner Element

Inner or Safety Air Cleaner Element

Service Indicator Connection

A. Radial Seal Design

• Turn engine off – ‘TAG OUT’

• Reduces the level of exhaust noise

• Is the pressure created in the

Activity 1.1 to 1.20

Forced Air Intake System

• Engine output determined by the

• Naturally aspirated engine – 85%

• Free spinning components often

• Two types of turbocharger:

• Pulse Type Turbocharger:

• Correct quality and viscosity is

• The pressure existing in the inlet manifold

• Should always be compared with

• Controlled by signal pressure to the

• High Altitude – quantity of air (oxygen) is

• Always allow a turbocharged engine

• Engine should be run at idle speed

• If shutdown while operating at high

• Automatic timer unit:

Activity 2.1 to 2.40

Causes of Failure, Inspection

• Turbochargers fail in many different

Hot and Cold

• Keep all parts clean of contaminants

• Levels of boost pressure indicate a

Amount of Pressure that is Required to Check Wastegate Vale

• Boost pressure control RPM

• Signs of abrasives in the oil:

• High Exhaust Temperature Facts:

• Immediate and Serious Damage

• Trapped gas or other casting

• Remove exhaust extension

• Inspect parts for defects to ensure

After cleaning, use air under

• Cracks in one blade

• One slightly bent

• Small nicks and

• Heavy back face

• Before grooves are checked, carbon

• Seal ring groove

• Inboard groove has

• Too much wear in

• Wheel and shaft

• Single deep scratch

• Verify that all components are clean

Shaft End Play

• Check intake and exhaust manifolds for

• Align compressor and turbine housing

• Prior to disassembly, check for:

• To prevent damage to the engine:

• New manifold gasket

Activity 3.1 to 3.22

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