Intake and Exhaust Systems/
Turbochargers and
Superchargers
Chapter 42
© 2012 Delmar, Cengage Learning
Objectives
• Explain the operation of the air intake system
• Describe the parts and operation of exhaust
system components
• Understand the operation of a muffler
• Explain the differences between turbochargers
and superchargers
• Diagnose problems with turbochargers and
superchargers
© 2012 Delmar, Cengage Learning
Introduction
• This chapter deals with the parts, operation, and
service of:
– Intake systems
– Exhaust systems
– Turbochargers
– Superchargers
© 2012 Delmar, Cengage Learning
Intake System Fundamentals
• Two sources of engine contaminants
– Internal contaminants
– Dirt entering through air intake system
• Common types of filters in use today
– Dry paper type: made of pleated paper
– Oil wetted polyurethane type
• Air filters are rated
– Efficiency, flow, and capacity
© 2012 Delmar, Cengage Learning
© 2012 Delmar, Cengage Learning
Manifolds
• Kinds of manifolds used in the engine’s
breathing system
– Intake manifold
– Exhaust manifold
• Designed to provide a uniform air-fuel mixture to
cylinders
– Must be the proper size and design
© 2012 Delmar, Cengage Learning
Intake Manifolds
• Runners
– Passages in an intake manifold
• Port injection manifolds
– Look different
• Plenum
– Air space below a throttle body or carburetor
• Siamese runners
– Feed two neighboring cylinders
© 2012 Delmar, Cengage Learning
© 2012 Delmar, Cengage Learning
Intake Manifolds (cont'd.)
• Dual-plane manifold
– Each barrel is
independent
• Single-plane manifold
– Both barrels serve
all eight cylinders
• Port-injected engines
– No intake manifold
heating on
© 2012 Delmar, Cengage Learning
Intake Manifolds (cont'd.)
• Some high-performance late-model engines use
three, four, or five valves per cylinder
– Greater flow area for a given valve lift is possible
• Intake manifolds are designed for low-speed or
high-speed use
– Engines with four valves per cylinder and
variable valve timing are more capable of
breathing
– Speed of air movement is important to effective
engine breathing
© 2012 Delmar, Cengage Learning
Exhaust System Fundamentals
• Exhaust system functions
– Carries burned exhaust gases away from the
passenger compartment
– Quiets the engine
– Most new cars have one or more catalytic
converters
• Excessive backpressure
– Reduces performance and fuel economy
• Exhaust system flow
– Not severely affected by bends in the pipe
© 2012 Delmar, Cengage Learning
Exhaust Manifolds
• Mounted to cylinder head's exhaust ports
– Typically made of cast iron or steel
• Exhaust temperature
– Related to the amount of load on the engine
• Headers
– Aftermarket manifolds made of tube steel
– Sometimes require modification to install
© 2012 Delmar, Cengage Learning
© 2012 Delmar, Cengage Learning
© 2012 Delmar, Cengage Learning
Exhaust Pipes
• Usually three steel exhaust pipes
– Header, exhaust, and intermediate pipe
• Muffler
– Tubes and chambers smooth vibrations of air
• Resonator
– Second muffler in line with primary muffler
• Catalytic converters
– Contain catalysts to reduce engine emissions
• Muffler hangers
– Support the muffler and pipes
© 2012 Delmar, Cengage Learning
Exhaust System Service
• Exhaust systems rust because of acids and
moisture
– Exhaust gaskets suffer a good deal of abuse
– Header pipes collapse resulting in a restriction
• Tools used for exhaust work
– Chain-type pipe and roller-type exhaust cutters
– Pipe expander
– Deep sockets
– Chisel cutter
– Oxyacetylene torch
© 2012 Delmar, Cengage Learning
© 2012 Delmar, Cengage Learning
Turbochargers and Superchargers
• Supercharger is an air
pump
– Designed to increase
density of air in the
cylinder
• Superchargers and
turbochargers
– Draw-through
– Blow-through
© 2012 Delmar, Cengage Learning
Turbochargers
• Small radial fan pump driven by the energy of
the exhaust flow
– Helps a smaller engine provide more power
• Components and characteristics
– Centrifugal pump
– Diffuser and volute
– Size must match compressor
– Boost pressure: amount of air density provided
– Turbo lag: time required to bring the turbo up to a
functioning speed
© 2012 Delmar, Cengage Learning
Turbochargers (cont’d.)
• Supercharged systems
– Use different ways to prevent excess pressure
from accumulating
• Wastegate
– Prevents overpowering
– Internal and external
– Amount of boost can be changed
• Spring or boost controllers
• Valves
– Blow-off and compressor by-pass
© 2012 Delmar, Cengage Learning
© 2012 Delmar, Cengage Learning
Turbochargers (cont’d.)
• Variable geometry turbochargers
– Vary turbocharger geometry
• Aftercooler/intercooler
– Cooled by either air or water
• Turbocharger thrust/boost differential
– Occurs when pressure is higher in either the
turbine or the compressor
• Turbocharger parts
– Bearings, turbine shaft, compressor, turbine
wheels, and housings
© 2012 Delmar, Cengage Learning
Turbochargers (cont’d.)
• Turbocharger bearings
– Turbo thrust bearing
– Turbo ball bearings
• Compressor wheel design
– Most compressor wheels are cast aluminum
• Turbine wheel and shaft
– Most expensive part of the turbo
• Bearing housing
– Seals gas and controls oil
© 2012 Delmar, Cengage Learning
Turbochargers (cont’d.)
• Turbocharger oil control
– Turbochargers deflect oil, rather than using seals
for oil control
• Temperature and pressure gauges
– Located in intake manifold
• Turbocharger lubrication
– Critical
• Turbocharger care
– Heat: potentially damaging
© 2012 Delmar, Cengage Learning
Turbochargers (cont’d.)
• Turbocharger balance
– Turbos spin in excess of 100,000 rpm and are
balanced to run in excess of 150,000 rpm
• Turbocharger replacement
– Not usually attempted in repair shops
• Turbocharger troubleshooting
– Common failures: blockages, leaks, and foreign
object damage
© 2012 Delmar, Cengage Learning
Turbochargers (cont’d.)
• Diagnosing damage to a turbo
– Turbine damage
• Broken piston rings, valves, or pistons
– Compressor damage
• Results from objects entering the intake
• Thrust bearing failure
– Not common
© 2012 Delmar, Cengage Learning
Belt-Driven Superchargers/
Blowers
• Supercharger is an air pump
– Commonly called blowers
• Engine can easily produce 50% more power
• Spin at 10,000 to 15,000 rpm
• Positive displacement pump
– Delivers the same amount of air with each
revolution regardless of the speed
• Roots-type blower
– Most popular positive displacement supercharger
© 2012 Delmar, Cengage Learning
Belt-Driven Superchargers/
Blowers (cont’d.)
• Blower lubrication
– Not as big of a problem
• Pressure relief valves
– Different designs and purposes
• Blower problems
– Dependable
– Can be damaged if they ingest dirt
• Vacuum leaks
© 2012 Delmar, Cengage Learning
