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Fig. 4.10 An air control valve

advisable to check the tightness of the securing nuts and bolts periodically. These nuts and bolts must be tightened in the proper sequence, shown for a particular engine in Fig. 4.12.

Variable length induction tract

The length of the induction tract (tube) through which the engines air supply is drawn has an effect on the operating efficiency of the engine. For low to medium engine speeds a long induction tract is beneficial whereas a shorter induction tract is beneficial at high engine speed. Figure 4.13(a)

shows a simplified variable length induction system. An electronically controlled valve between the throttle valve and the engine switches air flow between the long and short tracts as required by engine speed. At low to medium engine speed this air valve is closed as shown in Fig. 4.13(b). As the engine speed rises the electronic control unit causes the air valve to open, as shown in Fig. 4.13(c) and the main mass of air enters the engine through by the short route.

Turbo charging
Engines that rely on atmospheric air pressure for their operation are known as naturally aspirated engines. The power output of naturally aspirated engines is limited by the amount of

Fig. 4.11 An air intake manifold

Fig. 4.12 Tightening sequence for exhaust manifold retaining hardware (nuts)

Engine air supply and exhaust systems

Air in Air in Throttle valve Air control valve Throttle valve Air control valve

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Filter Filter (b) Air in Throttle valve Air control valve

Filter (a) (c)

Fig. 4.13 (a) Variable length induction tract, (b) idling to medium speed, (c) high speed

air that can be induced into the cylinder on each induction stroke. Engine power can be increased by forcing air into the cylinders under pressure. The turbo charger is commonly used on modern engines to boost the pressure of the incoming air. The turbo charger consists of two main units, the turbine and the compressor mounted

on a common shaft. The turbine is driven by exhaust gas and utilises energy that would otherwise be wasted by being expelled through the exhaust system into the atmosphere. The general principle of turbo charging is shown in Fig. 4.14. Exhaust gas energy is directed to the small turbine which is

Exhaust from engine

Air to engine

Wastegate valve

Turbine

Compressor

Air inlet Exhaust outlet

Fig. 4.14 A turbo charger system

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connected to the shaft that also drives the compressor. After driving the turbine, the exhaust gas travels through the exhaust system and out through the tail pipe. Intake air is drawn into the compressor through the air filter. The compressor raises the pressure to approximately 0.5 bar above atmospheric pressure and the pressure is controlled by the waste gate valve that allows the exhaust gas to by-pass the turbine.

4.2 Exhaust system

A fundamental purpose of the exhaust system is to convey exhaust gas away from the engine and to expel it into the surrounding atmosphere at some point that is convenient to vehicle occupants. On motor cars this usually means through the tail pipe at the rear of the vehicle. On trucks it is often at some other point, often just behind the drivers compartment. Another function of the exhaust system is to deaden the exhaust sound to an acceptable level. This sound level is regulated by law. The exhaust system shown in Fig. 4.15 has a number of sections. Starting at the front of the vehicle the sections are: the down pipe, or front pipe; the unit marked 1, this is the catalytic convertor, an interconnecting pipe to the first silencer (2); a further length of pipe which is curved to take it round other units on the vehicle; this pipe connects to the rear silencer (3); and the gas finally leaves through the tail pipe. The exhaust system is mounted firmly to the exhaust manifold at the front end, but it is flexibly mounted to the underside of the vehicle for the remainder of its length. The flexible mountings are required to allow the system to move independently of the main vehicle structure. This allows for the fact that the engine itself is normally flexibly mounted, and the type of exhaust mountings used prevent noise and vibration being transmitted to the vehicle structure. In order to provide for ease of maintenance and economy when replacing parts, the

Service attention to the air supply system

A normal service requirement is to renew the air filter element at regular intervals. Should the filter element become clogged it will restrict the flow of air to the engine and cause the engine to run rich. This will obviously affect the engine performance and it will also cause the emission control system to malfunction. To guard against problems in this area, all vehicles should be properly serviced before they are tested for compliance with the emissions regulations, for example, a pre-MOT service and check-over. Other items that should receive regular attention include: sensor connections, condition of flexible hoses and tightness of joints and securing brackets. Air flow meters, throttle position sensors, etc. are normally quite reliable. In the event of problems with these items, it will normally be necessary to read out fault codes, either through the on-board diagnostic system or by the use of diagnostic code readers and other tools.

Fig. 4.15 Underside view of an exhaust system