WRITTEN ASSESSMENT

WRITTEN ASSESSMENT

Name of the student:

Name of the University:

Author’s Note:

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WRITTEN ASSESSMENT

1. List six WHS & OHS requirements to be followed while working on forced-
induction systems of a vehicle.
 Use of safety gloves and masks for protection
 Working in a safe environment
 Availability of safety measures
 Using the right tool for the right object
 Safety of the employees are to be looked into
 Proper training should be provided to the workers

2. Explain the operating principles of volumetric efficiency of an internal

combustion(IC) engine in about 60-80words

For a thermal engine, the combustion process depends on the air-fuel ratio inside the cylinder.
The more air we can get inside the combustion chamber, the more fuel we can burn, the higher
the output engine torque and power.

Since air has mass, it has inertia. Also, the intake manifold, the valves and the throttle are acting
as restrictions for the air flow into the cylinders. By volumetric efficiency we measure the
capacity of the engine to fill the available geometric volume of the engine with air. It can be seen
as a ratio between the volume of air drawn the cylinder (real) and the geometric volume of the
cylinder.

ηv=Va/Vd

The volumetric efficiency can be regarded also as the efficiency of the internal combustion
engine to fill the cylinders with intake air. The higher the volumetric efficiency the higher the
volume of intake air in the engine

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3. What tool is used to check the turbine rotating shaft end float and axial movement?
Write down the steps to inspect the axial endplay.

Run-out is the tool used to check the turbine rotating shaft and axial movement.

The steps to inspect the axial endplay is simple the automobile is opened to get entry to
the engine where different precaution methods are checked like overheating, leakage etc and if
any problem is found related to the engine then it is considered as axial endplay.

4. Explain how a basic turbo charger works in about 60-80 words.

A turbocharger is an exhaust-driven device that uses the waste energy in exhaust gases. About
30% of the total heat produced in an engine is usually lost through the exhaust, but some of this
can be utilised when a turbocharger is fitted. This energy is used to drive the turbocharger,
which then forces additional air or air–fuel.

Turbochargers are used on large and small engines. They are suitable for smaller engines
because they do not directly use engine power.

Pg 426

5. Describe the operation and purpose of different types of turbo chargers listed below
(in about 50-70words each).

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Twin scroll turbo

There are two entry ports—a primary and a secondary. At low engine rpm, gases to the
secondary port are blocked off and the exhaust gas passes through the primary port into the
turbine. This concentrates the gases at high speed. Also, the design of the scroll directs the gas
onto the blades of the turbine wheel at a sharp angle for maximum impact. At higher rpm, both
the primary port and the secondary port are open and both scrolls are delivering exhaust gas to
the turbine. This changes the angle at which the gas is directed across the blades.

431

Twin turbocharger

It is a turbocharged engine, which have two turbocharger for intake of air. The types of layouts
are of identical turbochargers in parallel and the other twin-turbo layouts have again two parts
like the sequential and the staged turbo charging.

Supercharger

It is fixed inside super cars where the engine is boosted to extreme level. It produces lot of
horsepower and thus the engine need a good turbocharger.

Variable geometry turbocharger

It is generally fixed in budget friendly cars where the power delivery generally lies between low
to medium level.

Waste-gate operation

The turbocharger is mainly controlled by the waste–gate valve. It is tested by vacuum, which is
considered as pressure lower than that of the atmospheric pressure also termed as negative
pressure. They are manufactured only for the testing of the car system for leakage. The process
started by connecting the pipe to the vacuum pipe. It is followed by ignition of the engine.

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Ref Book Wang, Y.Y., Cummins Inc, 2015. Turbocharger compressor diagnostic system. U.S.
Patent 6,298,718. Pg 412

6. Briefly discuss about turbo compounding in about 60-80 words.

Turbocompounding is the use of a power turbine to extract additional energy from the exhaust.
Mechanical turbocompounding has been used commercially in diesel engines for various
applications for many decades. In heavy-duty engines, series turbocompounding—where a
power turbine is connected in series with turbocharger turbine—is the most important
configuration. The technology can provide efficiency benefits of a few percent, but these
benefits can be negatively affected by EGR, which diverts gas flow from the power turbine.
Parallel turbocompounding is suitable when exhaust energy in excess of that needed by the
turbocharger is available and would otherwise need to be bypassed around the turbo..

Ref https://www.dieselnet.com/tech/engine_whr_turbocompound.php

7. Describe the importance of turbocharger lubrication and explain how the

turbochargers are cooled? In about 100 words

Lubrication is essential for turbochargers, which rotate at extremely high speeds to boost the
engine's power by forcing more air into the combustion chamber.

Lubrication and cooling The turbocharger gets a flow of oil from the engine’s lubrication
system. The oil lubricates and cools the bearings before returning to the oil pan. It does not
drain away from the turbocharger when the engine is stopped, and there is always a small
reservoir of oil in This is needed for both lubrication and cooling. To prevent high oil
temperatures, which could cause the oil to deteriorate, an oil cooler is fitted to the engine’s
lubricating system. (Some turbochargers are also fitted with a water-jacket.) This allows coolant
from the engine’s cooling system to be circulated through the turbocharger to remove heat

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8. Explain the function of the intercooler in about 40 words.

It is like a cooling device which intakes in cool air from outside and is generally situated over
the supercharged engine. The intercooler, which is present inside the engine, helps in cooling
the air compressed by the turbocharger and increase the level of density of the airflow inside the
engine.

Ref Book 428

9. Describe the types of inter cooler in about 40-50 words each.

There are two types of intercoolers; Air-to-Air and Air-to-Water.
Air-to-Air intercooler extracts heat from the compressed air by passing it through its network
of tubes with cooling fins. As the compressed air is pushed through the intercooler it transfers
the heat to the tubes and, in turn to the cooling fins. The cool air from outside, traveling at
speed, absorbs the heat from the cooling fins reducing the temperature of the compressed air.
This systems advantages are simplicity, lower cost and less weight.This also makes it by far the
most common form of intercooling. The down sides can be a longer intake length due to having
to get the intercooler to the front of the car and also more variation in temperature than an air to
water.

Air-to-Water intercooler uses water as a heat transfer agent. In this setup cool water is
pumped through the air/water intercooler, extracting heat from the compressed air as it passes
through. The heated water is then pumped through another cooling circuit (usually a dedicated
radiator) while the cooled compressed air is pushed into the engine.

Ref https://www.turbosmart.com/news/how-does-intercooler-work/

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10. Outline the step by step procedure to perform the following tests on the turbo
charger components

Intake manifold pressure and vacuum test

Vacuum test :( in about 90-100 words)

To check manifold pressure with a vacuum gauge, you need to locate a port on the intake
manifold or throttle body. Manufacturers install ports on their manifolds for lots of different
reasons: Brake Booster, PCV tube, EGR Switch, A/C vents. Find one small enough for the
vacuum gauge line to slide onto firmly.

The engine needs the optimum temperature, which will show action in the vacuum meter. The
increase in meter or decrease in meter determines the condition of the engine. A leak in the
cascade will result in low reading and if any external force is involved then it will result in rise of
vacuum level. This will be show by rise in the meter level.

Pressure testing Inlet manifold: (in about 70-90 words)

The efficiency of an engine can be checked by making a comparison of the pressure in the inlet
manifold with the information given in the TMI (Technical Marketing Information).

Use the following procedure in order to use an electronic service tool to measure the inlet
manifold pressure: 1. Connect the electronic service tool. 2. Operate the engine under the suspect
conditions. 3. Record the value 4. Compare the value that was recorded in Step 3 to the pressure
that is given in the TMI (Technical Marketing Information) or Microfiche, "Fuel Setting And
Related Information".

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Intake and exhaust leak test:

Intake leak test: (in about 120-140 words)

Air is pushed in the pipes or vacuum is used. The pipe is disconnected from the engine and is
connected to the vacuum gauge with a meter connected to it. If it is seen that the meter starts
decreasing then it mean that the air is entering from some leakage and therefore leakage is
detected. This type of leakage is caused by scraping against sharp object or due to bending of the
pipe. This leakage lead to release of air pressure in the car and in turns it reduced the total
produced speed. Moreover, the fuel is wasted more than it used for functioning. Thus, this
process is very important for saving fuel and all over cost for the vehicle.

Exhaust leak test: (in about 40-60 words)

Leaks in the system can be located by exhaust noise, or by grey-to-white deposits on the
surfaces of the pipes or muffler. Leaking joints that are otherwise in good condition can be
refitted after being coated with muffler putty or sealer. If corrosion has occurred, the muffler or
pipe must be replaced.

Turbo boost pressure leak: (in about 40-60 words)

This has a similar procedure as in the event of fumes spill test. Fumes has its very own sound
which if changes fundamentally decide any break. The motor is lighted and the throttle is
squeezed hard on the off chance that it is seen that the pneumatic stress is lessening definitely,
at that point it will be the reason for spillage

11. How would you inspect/check the turbo charger wheel and oil leaks? (in about 80
words)

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First off check shaft play. There is always a little side to side. But, it shouldn’t
touch the compressor housing. Next check the in and out play. You really
shouldn’t feel much at all. If you do, you are in the beginning stage of thrust
bearing failure. All of those can be fine and still leak. You can have carbon
failure. That is when burn oil has cut up the steel on the turbine shaft. That
makes the groove too big for the seals to keep the in the oil. This is the most
popular failure I see in the small frame turbochargers. Next you should check
crank case pressure. A bad PCV system can make the turbo leak. Also to much
piston blow by.

It’s as simple as blocking off the oil return line on the turbocharger. The return
line is connected to the crank case. The piston blow by back tracks up the return
line. It will then push oil through the seals. And the seals are more designed to
keep turbine and boost pressure out of the crank case

https://www.timsturbos.com/is-your-turbo-leaking-oil/

12. Describe the intercooler pressure and temperature testing procedure in about 40-70
words each.

Inter cooler pressure checks

The pressure created by the air inflow and outflow needs to be maintained. The excess of this
pressure causes the heating problem, which in turn reduces the engine efficiency. Moreover,
when this pressure becomes low then the turbocharger cannot produce the maximum amount
power from the burning of the fuel.

Inter cooler temperature testing

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By fabricating small type K thermocouple probes, these instruments give quick response and in
and out temperatures. The pressure causes the temperature rise and affects the engine
performance. The air conduction through the engine is the only process, which decreases the
temperature. It has an individual meter to keep an eye on the temperature rise. Sometimes when
the temperature rises above the optimum level the engine needs watering externally.

13. Describe the importance of oil supply to the turbo charger (in about 50-60words)

The turbocharger gets a flow of oil from the engine’s lubrication system. The oil lubricates and
cools the bearings before returning to the oil pan. It does not drain away from the turbocharger
when the engine is stopped, and there is always a small reservoir of oil in This is needed for
both lubrication and cooling. To prevent high oil temperatures, which could cause the oil to
deteriorate, an oil cooler is fitted to the engine’s lubricating system.

Ref .Pg 428

14. List the steps involved in testing the turbocharger vacuum operated waste-gate (in
about 140-160words)

To control the boost pressure, the turbocharger is fitted with a wastegate or bypass valve which
controls its speed by controlling the flow of exhaust gas to the turbine wheel and thus the
turbine speed.

Plug the vacuum gauge into the vacuum pump brake connector.You may prepare your watch to
count the seconds but a good pump will usually reach almost full vacuum in a second.Start the
engine and observe the vacuum gauge.In this case, it reached -0.98 bars in less than a second
denoting no trouble on the brake outlet side.

It is tested by vacuum, which is considered as pressure lower than that of the atmospheric
pressure also termed as negative pressure. They are manufactured only for the testing of the car
system for leakage. The process started by connecting the pipe to the vacuum pipe. It is
followed by ignition of the engine. The pipelines intake and out are needed to closed properly or
else the whole apparatus will not work. Now after 5 minutes we need to check the meter gauge

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continuously so that we can identify any drop in pressure. If it is seen then it is considered as
sign of leakage and then the pips and the other apparatus is checked properly to identify the
accurate location of the leakage. This process is effective for fast and accurate checking of the
cars before delivering it to its customers.

15. List the step by step procedure to remove the turbo charger: adjust the linkages and
services the inter cooler (in about 160-180 words).

Remove the turbo charger

1)Before you begin to remove the turbo, it is recommended that you allow the engine to run until
it is at the functional temperature, before turning it off and draining the engine oil extremely
carefully due to hot temperatures.

2) Next, you need to remove the old oil filter and discard it. We need to ensure everything is
clean before we can even begin to think about installing a new turbo. Also, the oil feed pipe
needs to be disconnected.

3) Now, for the next step of replacing a turbocharger; it’s time to prepare for the removal of the
old turbo. So, you need to locate the exhaust pipe, more commonly knows as the downpipe, that
connects your turbo and the remainder of the exhaust. Once found, all the bolts linking the turbo
and the downpipe together need to be unscrewed

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4) Unscrew all the nuts and bolts that hold them both together, and then when you are ready, lift
the turbo through the top of the engine compartment or below it.

5) On to the fun part – installing the new turbocharger. You need to ensure that the new
turbocharger you’re installing is the correct type for your vehicle, so you should compare it with
the old one to be sure that all the linking parts are located in the same areas. After confirmation
of having the correct device, you can join the new turbocharger to the exhaust manifold with all
the necessary nuts and bolts, ensuring they are tightened to the appropriate degree

6) As you removed everything, it’s time to connect them all back. Starting with the turbo
intercooler, then the air intake system and finally the exhaust downpipe. Once you’ve triple-
checked they are all connected properly to the new turbocharger, you’re nearly close to the finish
line!

7) Furthermore, you should replace the oil feed pipe, the banjo bolts and copper washes which fit
on either end of the pipe. They are inexpensive and its good practice.

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8) Finally, if you remember in the beginning, you flushed the oil and removed the old oil filter.
Now, you can fit a brand new one in and also restock your vehicle with the correct grade of oil
required for your engine.

16. Describe the post repair testing for forced-induction system (in about 80-100 words)

It is a general process of power delivery into the internal chamber. It is done checking the inlets
and outlets using the same vacuum method. The increase and decrease in the gauge meter will
mean some leakage, and thus it will need repair. This decreases the combustion pressure
generated inside the engine and thus disabling the car to reach the top speed. In addition, causes
loss of fuel, which bears up in the cost of the owner.

Ref Book Kitsukawa, I., Sugano, T., Abe, Y., Kimura, H., Iijima, A., Ishibashi, N. and Sakashita,
S., Isuzu Motors Ltd, 2016. Turbocharger system. U.S. Patent 9,334,833. Pg 110

17. How turbocharger shaft bearings are lubricating? Explain the oil circulation to the
shaft and return to the sump. (40-50 words)

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The turbocharger gets a flow of oil from the engine’s lubrication system. The oil lubricates and
cools the bearings before returning to the oil pan. It does not drain away from the turbocharger
when the engine is stopped, and there is always a small reservoir of oil in the bearing housing.

Oil circulation

1 When the engine is started, the pump supplies oil to the system. At engine idle speed, the port
is closed by the plunger. All the oil from the pump enters the system and provides a low oil
pressure.

2 As engine speed increases, the pump speed also increases and so more oil is delivered into the
system. This increases the pressure in the system. Pressure on the top of the plunger moves it
down its bore.

When the system reaches a certain pressure, which is determined by the strength of the plunger
spring, the plunger will have moved far enough to open the port.

4 Oil which is not needed to maintain pressure in the system will then pass through the port and
return to the intake side of the pump.

5 The plunger will open and close the port as needed, to release surplus oil and limit the pressure
in the system. Whether the port is open or closed will depend on the engine speed and the
temperature of the oil. It will also depend on the condition of the engine.

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