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| Illustration 1 | g03636256 |
(1) Exhaust manifold (2) Intake manifold (3) Belt driven compressor (4) Belt driven compressor inlet (5) Belt driven compressor outlet (6) Aftercooler (7) Compressor side of turbocharger (8) Turbine side of turbocharger | |
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| Illustration 2 | g03647540 |
Section view of the aftercooler with the belt driven compressor disengaged. (9) Compressor diverter air valve in the closed position | |
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| Illustration 3 | g03647489 |
Section view of the aftercooler with the belt driven compressor engaged. (9) Compressor diverter air valve in the open position | |
The components of the air inlet and exhaust system control the quality of air and the amount of air that is available for combustion. The components of the air inlet and exhaust system are the following components:
- Air cleaner
- Turbocharger
- Belt driven compressor
- Aftercooler
- Cylinder head
- Valves and valve system components
- Piston and cylinder
- Exhaust manifold
- Compressor diverter valve
- ECM controlled belt driven compressor clutch
Inlet air is pulled through the air cleaner by the turbocharger compressor wheel. The air is compressed and heated before the air is forced to the aftercooler (4). The turbocharged air flows through the aftercooler and into the belt driven compressor inlet. The belt driven compressor is engaged via an ECM controlled electronic clutch. With the clutch engaged the compressed air opens compressor diverter valve (9), the belt driven compressed air flows through the front section of the aftercooler. The turbocharged air flows to belt driven compressor inlet (4) and through the compressor housing. The air is compressed and flows into the aftercooler. When the clutch is disengaged only the turbocharged compressor air flows through the aftercooler. As the air flows through the aftercooler the temperature of the compressed air lowers. Cooling of the inlet air increases combustion efficiency. Increased combustion efficiency helps achieve the following benefits:
- Lower fuel consumption
- Increased horsepower output
From the aftercooler, air is forced into the inlet manifold (2). Air flow from the inlet chambers into the cylinders is controlled by intake valves. There are two intake valves and two exhaust valves for each cylinder. The intake valves open when the piston moves down on the intake stroke. When the intake valves open, cooled compressed air from the intake port is pulled into the cylinder. The intake valves close and the piston begins to move up on the compression stroke. The air in the cylinder is compressed. When the piston is near the top of the compression stroke, fuel is injected into the cylinder. The fuel mixes with the air and combustion starts. During the power stroke, the combustion force pushes the piston downward. The exhaust valves open and the exhaust gases are pushed through the exhaust port into exhaust manifold (1) as the piston rises on the exhaust stroke. After the exhaust stroke, the exhaust valves close and the cycle starts again. The complete cycle consists of four strokes:
- Inlet
- Compression
- Power
- Exhaust
Exhaust gases from exhaust manifold (1) enter the turbine side of the turbocharger in order to turn turbocharger turbine wheel. The turbine wheel is connected to the shaft that drives the compressor wheel. Exhaust gases from the turbocharger exit the turbine housing via an exhaust outlet pipe.
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| Illustration 4 | g03656240 |
(10) Optional sea water-cooled exhaust riser (11) Optional transmission oil cooler | |
Sea water from the heat exchanger flows through the transmission oil cooler and into the exhaust riser.
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| Illustration 5 | g03656614 |
(12) Air inlet heater | |
The air inlet heater is controlled by the ECM. The air inlet heater aids in engine start-up and reducing white smoke during engine start-up.
Turbocharger
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| Illustration 6 | g03645338 |
(13) Compressor wheel housing (14) Turbocharger compressor outlet (15) Oil inlet port (16) Turbine housing coolant outlet port (17) Turbine housing (18) Air inlet (19) Oil outlet port (20) Turbine housing coolant inlet port (21) Exhaust inlet | |
The turbocharger is installed on the rear of the exhaust manifold. All the exhaust gases from the engine go through the turbocharger. The compressor side of the turbocharger is connected to the aftercooler by pipe.
The exhaust gases enter turbine housing (17) through exhaust inlet (21). The exhaust gases then push the blades of the turbine wheel. The turbine wheel is connected by a shaft to the compressor wheel. The turbine housing is cooled from the jacket water cooling system. The coolant enters the turbine housing via turbine housing coolant inlet port (20). The coolant flows around the exhaust gas passage and out the turbine housing coolant outlet port to the sea water-cooled heat exchanger.
Clean air from the air cleaners is pulled through compressor housing air inlet (18) by the rotation of the compressor wheel. The action of the compressor wheel blades causes a compression of the inlet air. This compression increases the amount of air that is induced into the combustion chamber. More fuel is required with the increase of intake air. An increase in the amount of fuel that is burned will increase the power of the engine.
When the load on the engine increases, more fuel is injected into the cylinders. The combustion of this additional fuel produces more exhaust gases. The additional exhaust gases cause the turbine and the compressor wheels of the turbocharger to turn faster. As the compressor wheel turns faster, more air is forced into the cylinders. The increased flow of air gives the engine more power by allowing the engine to burn the additional fuel with greater efficiency.
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| Illustration 7 | g03647643 |
(22) Canister (23) Line (boost pressure) (24) Actuating lever | |
The operation of the wastegate is controlled by the boost pressure. At high boost pressures, the wastegate opens in order to decrease boost pressure. At low boost pressure, the wastegate closes in order to increase boost pressure.
When the engine is operating under conditions of low boost, a spring pushes a diaphragm in canister (22). This action moves actuating lever (24) in order to close the valve of the wastegate. Closing the valve of the wastegate allows the turbocharger to operate at maximum performance.
As the boost pressure through line (23) increases against the diaphragm in canister (22), the valve of the wastegate is opened. When the valve of the wastegate is opened, the rpm of the turbocharger is limited by bypassing a portion of the exhaust gases. The exhaust gases are routed through the wastegate which bypasses the turbine wheel of the turbocharger.
Note: The turbocharger with a wastegate is preset at the factory and no adjustment can be made.
The turbocharger bearings use engine oil under pressure for lubrication and cooling. The oil comes in through oil inlet port (15). The oil then goes through passages in the center section in order to lubricate the bearings. This oil also cools the bearings. Oil from the turbocharger goes out through oil outlet port (19) in the bottom of the center section. The oil then goes back to the engine oil pan.
Belt Driven Compressor
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| Illustration 8 | g03649988 |
(25) Oil inlet port (26) Oil outlet port (27) Compressor inlet (28) Compressor outlet | |
The belt-driven compressor is mounted to right-hand side of the front gear housing. The compressor is driven by an ECM controlled electronic clutch. Air enters the compressor inlet (28) via a passage in the aftercooler. Compressed air exits the compressor housing through compressor outlet (26). The compressed air opens diverter valve (9). Air then flows through the aftercooler and into the air intake manifold.
Valve System Components
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| Illustration 9 | g03645332 |
(29) Rocker arm (30) Valve bridge (31) Valve spring (32) Valve | |
The valve system components control the flow of inlet air into the cylinders during engine operation. The valve system components also control the flow of exhaust gases out of the cylinders during engine operation.
The crankshaft gear drives the camshaft gear through an idler gear. The camshaft must be timed to the crankshaft in order to get the correct relation between the piston movement and the valve movement.
The camshaft has two camshaft lobes for each cylinder. The lobes operate the inlet and exhaust valves. As the camshaft turns, lobes on the camshaft cause the rocker arms to move up and down. Upward movement of the rocker arms (29) results in downward movement (opening) of valves (32) .
Each cylinder has two inlet valves and two exhaust valves. The valves are actuated at the same time by a valve bridge (30). Valve springs (31) close the valves when the lifters move down.