Diesel Engine Operation System

Air Intake and Exhaust

Intake and Exhaust System Components

Efficient diesel engine operation requires that the proper amount of air can enter the combustion chamber and the exhaust gases can exit with minimal restriction. Both inlet air and exhaust gas temperatures are also critical for maximum engine performance and life.

Air System Components

The Air Inlet and Exhaust System contains the following major components: Air cleaner Turbocharger Aftercooler Cylinder head, valves, and pistons Exhaust manifold

Air Cleaner
Air is drawn into the engine through the air cleaner. The air cleaner houses a filter element which removes foreign material from the air before it enters the engine. Always refer to the operation and maintenance manual of the engine for the most accurate maintenance procedures.

Typical Service Indicator

Engine air cleaners should be serviced on a regular basis. Many air cleaners are equipped with a service indicator. The indicator monitors the amount of restriction through the air cleaners. The service indicator is the most accurate method to use to determine when the air cleaners are in need of service. Engine air cleaner elements should be serviced, cleaned or replaced, when either the yellow diaphragm enters the red zone or the red piston locks into the visible position.

Dry Element Air Cleaner

Dry element air cleaners are by far the most common type of air cleaners used . Dry element air cleaners are typically composed of a pleated paper filter media that is used to remove the dirt from the incoming air. This type of air filter requires replacement or cleaning when the service indicator is tripped.

Dry Element Cleaning

Dry element air cleaners can usually be cleaned with filtered, dry air with a maximum pressure of 30 psi. The element should be cleaned from the clean side out, holding the tip of the air nozzle parallel to the pleats of the air cleaner.

Turbocharger
Many diesel engines are equipped with a turbocharger to improve the performance and the efficiency of the engine. The turbocharger receives clean air flow from the air cleaner. The rotation of the turbocharger compressor wheel draws air in, compresses it, and delivers it under pressure to the cylinders.

Advantages of Turbochargers
Turbocharging has several important advantages: 1. Power Compressed air has more oxygen per volume. With more oxygen in the cylinder, more fuel can be injected for a higher energy output. 2. Efficiency Turbocharging allows a more efficient combustion for improved emissions and fuel consumption.

Turbocharger Operation
The exhaust gases flow past the blades of the turbine wheel and cause the turbine wheel to rotate. The turbine wheel is connected by a shaft to the compressor wheel. The exhaust gases push the turbine and subsequently the compressor wheel to a high rpm, about 30,000 -130,000 rpm. This causes the intake air to be compressed. When the load on the engine increases, more fuel is injected into the cylinders. The increased combustion generates more exhaust gases causing the turbine and compressor wheel to turn faster.

Turbocharger Operation
As the compressor wheel turns faster, more air is forced into the engine. The maximum rpm of the turbocharger is controlled by the fuel setting, the high idle speed setting and the height above sea level.

Aftercoolers
When the turbocharger compresses the intake air, the temperature of the air is increased. Hot air has less density, thus less oxygen. If the hot compressed air is delivered to the engine, some of the efficiency gained by compression will be lost.

Aftercoolers
Aftercoolers are used in conjunction with turbochargers to lower the temperature of the air coming from the turbocharger before the air enters the cylinders. This causes the air to be more dense and contain more oxygen in a given volume. This increase in oxygen in the cylinders translates into greater power and efficiency from the engine.

Aftercoolers
There are different types of aftercoolers used. All aftercoolers serve the same purpose however, to remove heat from the inlet air resulting in cooler and more dense air to the cylinder.

Air-to-Air Aftercooler
With the air-to-air aftercooled system, a separate cooler core is installed in front of the vehicle engine radiator. Ambient temperature air is moved across the aftercooler core by the engine fan. Pressurized air from the turbocharger is cooled by the air-to-air aftercooler before entering the intake manifold. This is an extremely effective method for cooling the turbocharged air when a large volume of fresh cool air can be pushed through the aftercooler. For this reason, the ATAAC configuration is found on most onhighway truck applications.

Jacket Water Aftercooler

The jacket water aftercooler system has a coolant charged core assembly. It uses the engine coolant to cool the air charge entering the cylinders. Coolant from the water pump flows through the aftercooler core. Pressurized air from the turbocharger is cooled by the aftercooler before entering the intake manifold.

Inlet Manifold
From the air cleaner (turbocharger/aftercool er, ) if equipped) the incoming air enters the inlet manifold. The inlet manifold directs the air into the cylinder head.

Intake Stroke
Air fills the inlet ports in the cylinder head. On the INTAKE stroke as the piston travels down in the cylinder the intake valves open, and air fills the volume of the cylinder.

Compression Stroke
On the COMPRESSION stroke, as the piston begins to travel up, the intake valves close. The air that is trapped in the cylinder is compressed. Compressing the air raises the air temperature to a point where it will cause fuel to ignite when it is injected into the cylinder.

Power Stroke
When the piston nears the top of its travel, fuel is injected into the cylinder. The fuel mixes with the hot air and combustion begins. The energy released by the combustion forces the piston down producing the POWER stroke.

Exhaust Stroke
Near the end of the POWER stroke the exhaust valves open. Any residual pressure from combustion will rush into the exhaust manifold. On the upward or EXHAUST stroke the gases are pushed out of the cylinder by the piston. At the top of the stroke the exhaust valves close and the cycle starts over.

Exhaust Flow
Exhaust gases leaving the cylinder enter the exhaust manifold and are then routed to the turbocharger, if equipped. From the turbocharger the exhaust gases pass through the exhaust pipe, muffler, and exhaust stack. The hot exhaust gases flowing out of the cylinders contain substantial unused heat energy. The turbocharger exhaust turbine captures some of this heat energy.