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Air Intake

and
Exhaust
Air Cleaner System
Filter Media
Dust Cup
Screen
Air Cleaner Fiber
New fiber
Dust particle, being denser than air, has too
much velocity to go around fiber, so
particle hits and imbeds on fiber
Used fiber
Centrifugal
Type Air
Cleaner
Air Cleaner System
Centrifugal types
Baffle plate
Dust evacuator
What makes it discharge particles?
Air Intake Systems
Air Cleaner Styles (Kubota / After-market)
Plastic / Steel / Pre-cleaners
Single / Dual Element / Minders
Safety element
Air Cleaner System
Radial Seal type
Air filter element seats on
tapered cone in end of
canister.
Air Cleaner System
Check for good
seating of sealing
washer
Check for good seating of air
cleaner element against base of air
cleaner housing.
Conventional type
Air Cleaner System
Lip type
seal,
as air intake
restriction
increases, lip
seal tightens
NOT ALL SEALS ARE GOOD!
This type of seal cost big $$$$$
Square type seal
Air Cleaner System
Inspection of element

Any problems?
Air Cleaner System
Poor air inlet system
security, abrasive dust
can enter inlet and
engine failure results.
Air Intake Systems
Air Cleaner Location / Mounting
Intake Air Temperature
Output De-rate (altitude and inlet temp.)
Air Intake Restriction
Naturally aspirated:
High Idle engine
speed during test:

Turbocharged:
Full load, max rpm
Measuring inlet restriction
10. Exhaust back Pressure
Check exhaust system has no excessive
back pressure?
Performance with muffler removed?
1mmHg = 0.535inAq
Manometer Location
Exhaust Systems
Calculations / Measurements
Calculating Back Pressure
Vibration
Turbochargers
What is a Turbocharger?
Superchargers and turbochargers are
devices which increase the density of
air going into an engine
A supercharger is a constant volume
blower that is belt driven by the
crankshaft
A turbocharger is a centrifugal
compressor that is driven by an
exhaust gas turbine
Turbocharger vs. Supercharger
Both are driven by the
crankshaft, a
Supercharger
by belt, a turbocharger
by the exhaust stroke
pushing gas through
the turbine

Efficiency
Turbine is more efficient that belt drive
Turbocharger can take advantage of
exhaust gas energy (heat and pulse) that
is wasted with a supercharger
Residual/parasitic losses are lower with a
turbocharger
Why a Turbocharger?
Power Density: Increased air density
(pressure) means you can inject more
fuel and get more power per
displacement
Air Control: Increased air supply reduces
particulates and emissions
Altitude Correction: Derate for altitude is
much less because turbocharger moves
mass not volume
Turbocharger
Altitude De-rate
Engines move air
volume, so they
move less air at
altitude where
air is less dense.
When air
temperature
increases,
density also
reduces

Turbochargers use
centrifugal force
to move mass,
so de-rate is
much lower.
Turbocharger Air Flow
Turbocharger Oil Flow
Turbocharger Bearings
& Seals
Turbocharger Waste-gate
Limits boost by letting
exhaust gas bypass the
turbine wheel
Boost pressure pushes
on diaphragm and
spring and pushes
open gate valve when
boost setting is
reached
Why Waste-gate
A turbocharger turbine housing is like a
nozzle, a smaller nozzle creates higher
velocity, larger one allows more flow
Ideal turbocharger would have small
turbine for low end response and large
turbine for high end power
Simplest solution is to use small turbine
with waste-gate
Turbocharger Checks
Does rotating assembly rotate freely? No
metal to metal contact with housing. Note
that there can be considerable amount of
radial and axial play in new or used
turbocharger.
Does wastegate operate freely and does
the diaphragm hold air? It is not normally
necessary to check the calibration unless
it has been disassembled or damaged.
Preventive Maintenance
Run the engine at idle or no load for a
period of time before shutting down to
prevent coking and sludging
Clean air and good oil are essential for
long turbocharger life
Waste-gate Calibration
Install dial indicator on rod and pressure supply
with gauge on boost line 15psi max
Read pressure that moves rod 1mm (.039in)
D1105T 43015 mmHg (8.30.3 psi)
V1505T 43015 mmHg (8.30.3 psi)
V2003T 45015 mmHg (8.70.3 psi)
V3300T 53015 mmHg (10.20.3 psi)
Note that boost pressure on running engine will
be lower because exhaust pressure force also
pushes on poppet
Troubleshooting
Black Smoke/Low Power
Look for dirty air cleaner, blocked ducting
to turbocharger
Look for large air leaks in inlet ducting from
turbocharger
Check to see if turbocharger rotor rotates
freely, contact will reduce air flow
Stuck open wastegate
Troubleshooting
Blue Smoke/Oil Consumption:
Look for ring or valve guide problems first.
Some leakage at idle is normal because seal
is not positive, restricted air cleaner, high
blowby can contribute.
Oil drain blocked
Wheel contact with housing will destroy the
seals and cause leakage so look for primary
cause of damage

Troubleshooting
Noise
Turbochargers make noise, a low pitch
one per rev noise and a high pitch 6 per
rev noise.
Wheel contact with housing or foreign
object damage will generate significant
noise
FOD
NCR
Turbocharger Damage
NCR: No Cause for Removal
FOD: Foreign Object Damage
Lubrication Related Problems
Temperature Extremes
Materials & Workmanship
Foreign Object
Damage
Hard materials will
break off blade tips
Soft materials such
as shop rags or
rubber pieces will
bend back blades
Abrasives will
sandblast and wear
away blade surfaces
Lubrication
Problems
Abrasive material
Foreign material
Oil diluted with fuel
Degraded oil
Coking/Sludging
Temperature Extremes
Fuel injection problems
or restricted air intake
can cause temperature
problems
Black Smoke equals
High Temperature
Turbine housing warps
or scales
Repeat Damage
Three leading causes of turbocharger
damage have high likelihood of resulting in
repeat damage
Whatever caused original foreign object
damage may still be in ducting
Same goes for lubrication and temperature
related problems
Turbocharger Replacement
Use care in reinstalling as dirt can get
into oil passages. Make sure that gasket
sealant does not enter the oil passages
Squirt oil into the oil inlet on the
turbocharger and spin the rotor to make
sure oil gets everywhere inside.

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