1. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Publisher The Goodheart-Willcox Co., Inc. Tinley Park, Illinois by Russell Krick

2. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only

3. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only  Exhaust systems  Exhaust system service  Superchargers and turbochargers

4. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only  Purposes:  quiet engine operation  carry exhaust fumes to the rear of the vehicle

5. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Typical Exhaust System

6. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Exhaust System Components  Manifold  Header pipe  Catalytic converter  Intermediate pipe  Muffler  Tailpipe  Hangers, heat shields, and clamps

7. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Exhaust Back Pressure  The pressure developed in the exhaust system  High back pressure reduces engine power  Larger pipes and free-flowing mufflers can lower back pressure

8. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Single Exhaust  One path for exhaust flow  Components:  one header pipe  one main catalytic converter  one muffler and tailpipe

9. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Dual Exhaust  Two separate exhaust paths  Reduces back pressure  Used on high performance applications  Allows the engine to “breathe” better  Crossover pipe connects right and left header pipes to equalize back pressure

10. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Exhaust Manifold  Bolts to the cylinder head  Made of cast iron, stainless steel, or lightweight steel tubing  Mating surface is machined flat  Outlet end has round opening and holes for stud bolts  Gasket “doughnut” seals manifold to header pipe

11. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Exhaust Manifold Note the O 2 sensor

12. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only  Forces hot exhaust gas through exhaust passages in the intake manifold  Heat-sensitive spring or vacuum diaphragm forces valve closed on a cold engine, warming the intake manifold  Valve opens as the engine warms up  Improves cold engine fuel vaporization Exhaust Manifold Heat Valve

13. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Exhaust Manifold Heat Valve Also called a heat riser valve

14. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Exhaust Flow through the Intake Manifold Heating action helps vaporize fuel

15. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Exhaust Pipes  Made of rust-resistant steel tubing  One end is enlarged to fit over the end of the next pipe

16. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Heat Shields  Located in areas where exhaust system components are close to the vehicle’s body  Reduce the amount of heat transferred to the body or items under the vehicle

17. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Catalytic Converter and Muffler  Catalytic converter  reduces exhaust pollutants  Muffler  quiets pressure pulses and resulting noise

18. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Muffler Contains baffles, resonance chambers, and acoustic tubes to reduce noise

19. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only  Combustion produces water and acids, which cause components to rust and leak  Leaking exhaust can allow toxic gases to flow into the car  This can be deadly!

20. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Exhaust System Repairs  Wear safety glasses  Use rust penetrant for fastener removal

21. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Parts Removal Methods Use an air chisel, cut-off tool, cutting torch, or hacksaw

22. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Header Pipe Removal  Fasteners can be difficult to remove  Use six point sockets

23. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Pipe Expanders May be used to enlarge the inside diameter of pipes

24. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Pipe Shaper May be used to round dented pipe ends

25. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Muffler Clamp Installation Clamp must be positioned around both pipes

26. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Adapter Pipes May be used to make a muffler work on an existing system

27. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Exhaust Manifold Replacement  Manifold may be machined flat if it is warped  Gasket may be used  Install all heat shields  Torque bolts to specifications in a crisscross pattern

28. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Exhaust Manifold Replacement Cylinder head Stud bolt Exhaust manifold gasket Exhaust manifold

29. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Stainless Steel Exhaust System Repairs  Stainless steel pipes have a long service life  Use heavy-duty clamps for service, as stainless steel pipe is stiff  Pipe may be “red hot” when it looks cool

30. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only

31. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Turbochargers  Use an exhaust-driven fan to force air into the engine under pressure  Harness exhaust energy to improve engine efficiency

32. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Components  Turbine wheel and housing  Turbo shaft  Compressor wheel and housing  Bearing housing

33. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Turbocharger

34. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Operation  Hot exhaust gases from the exhaust manifold flow into the turbine housing, striking the fins on the turbine wheel  The turbine wheel is connected to the compressor wheel by the turbo shaft  The compressor wheel rotates, pulling in air  Centrifugal force throws air outward, out of the housing, and into the cylinders under pressure

35. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Turbocharger Flow

36. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Location  Usually behind the intake manifold or to one side of the engine  Exhaust pipe connects exhaust manifold to the turbine housing

37. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Turbocharger System

38. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Blow-Through System  Located before the carburetor or throttle body  Pressurizes air only  Fuel is mixed with the air after it leaves the compressor

39. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Draw-Through System  Turbocharger is after the carburetor or throttle body  Both air and fuel pass through the compressor on carbureted and throttle body injection systems

40. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Lubrication  Protects turbo shaft and bearings from damage  Turbocharger may operate up to 100,000 rpm  Lubrication system forces motor oil into the turbo shaft bearings  Oil supply line runs from the engine to the turbo

41. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Lubrication Oil flows through bearings and drains into the oil pan through a drain line

42. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Turbo Lag  Short delay before the turbo develops sufficient boost on acceleration  it takes time for the exhaust gas to bring the turbo up to operating speed  Modern systems suffer very little from turbo lag  components are very light and accelerate quickly

43. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Modern Turbo System

44. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Intercooler  Air-to-air heat exchanger cools the air entering the engine  Radiator-like device mounted at the pressure outlet of the turbo or supercharger

45. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Intercooler Operation  When air is compressed, temperature increases, reducing air density  Intercooler cools the compressed air before it enters the engine  This increases density and oxygen capacity of the air, increasing power

46. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Intercooler Cools the air charge entering the engine for increased horsepower

47. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Waste Gate  Limits boost pressure  Butterfly or poppet valve allows exhaust to bypass the turbine wheel  Without a waste gate, the turbo could produce too much pressure

48. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Turbo System with Waste Gate

49. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Waste Gate Operation  Operated by a diaphragm  Manifold pressure acts on the diaphragm to control the waste gate  Waste gate is closed by the diaphragm spring  If boost pressure becomes high enough to overcome spring force, it will open the waste gate and reduce boost

50. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Limits boost pressure by reducing the amount of exhaust acting on the turbine Waste Gate Operation

51. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Waste Gate Operation

52. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only  These modifications can help an engine withstand increased horsepower:  lower compression ratio  stronger rods  high volume oil pump  heavy-duty cooling system  improved head gasket  heat resistant valves  knock sensor Engine Modifications

53. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Engine Modifications

54. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Turbo Computer Control  Computer control may:  operate the waste gate to limit boost  retard timing advance if knock sensor indicates engine knock (detonation or ping)

55. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Computer Control System

56. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Turbocharger System Service  Problems:  inadequate boost pressure (lack of power)  leaking shaft seals (oil consumption)  damaged turbine or compressor wheels (vibration and noise)

57. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only System Scanning  Check for related trouble codes:  knock sensor  throttle position sensor  manifold pressure sensor  manifold temperature sensor

58. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only System Checks  Check the connection of all vacuum lines and oil lines  Use a regulated low-pressure air hose to check waste gate diaphragm leakage and operation  Use a test gauge to measure boost pressure  Use a stethoscope to listen for bad turbocharger bearings

59. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Turbocharger Checks  Remove the unit from the engine  Inspect wheels for physical damage  the slightest nick or dent will throw the unit out of balance  Use a dial indicator to check the turbo shaft for radial and axial play

60. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Turbocharger Removal After removing fasteners, lift off the turbocharger

61. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Dial Indicator Checks Check radial and axial play and compare to specifications

62. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Turbocharger Installation  Use new gaskets and seals  Torque all fasteners to specifications  Change the engine oil  Flush oil lines before startup

63. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Waste Gate Service  A faulty waste gate may cause too much or too little boost  If the waste gate is stuck open, the turbocharger will not produce boost pressure  If the waste gate is stuck closed, detonation and engine damage can result from excessive boost  Follow service manual instructions when testing or replacing a waste gate

64. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Compressor or blower driven by a belt, chain, or gears Superchargers

65. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Supercharged Engine Engine is modified with a stronger reciprocating assembly

66. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Supercharger Operation  A belt drives the supercharger  The supercharger turns, compressing the air inside the housing and forcing it into the intake manifold  An electromagnetic clutch is sometimes used to disengage the drive belt from the blower

67. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Advantages  No “turbo lag”  Instant boost pressure at low rpm  Instant throttle response

68. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Belt-Driven Supercharger Electric clutch turns the blower on under high load conditions

69. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only System Components Note the airflow through the components

70. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Supercharger Types

71. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Supercharger Service  Problems:  lack of power  blue engine smoke  noise

72. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only System Checks  Use a test gauge to measure boost pressure  If boost is low, check bypass actuator  If specified boost cannot be achieved with bypass actuator held closed, suspect supercharger wear  Use a stethoscope to listen for bad turbocharger bearings

73. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Bypass Actuator When boost pressure reaches a maximum value, air pressure overcomes spring tension to bypass extra air, limiting boost

74. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Supercharger Removal After removing the fasteners, pry lightly on the housing to free the blower from its gasket

75. © Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only Scanning  Check for trouble codes related to the:  knock sensor  throttle position sensor  manifold pressure sensor  manifold temperature sensor