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CHAPTER 12Turbocharging and Supercharging

Automotive Engine Performance, 3/eBy James D. HaldermanCopyright 2010, 2007, 2003 Pearson Education, Inc.,Upper Saddle River, NJ 07458 All rights reserved.*

OBJECTIVESAfter studying Chapter 12, the reader will be able to:Prepare for ASE Engine Performance (A8) certification test content area C (Fuel, Air Induction, and Exhaust Systems Diagnosis and Repair).Explain the difference between a turbocharger and a supercharger.Describe how the boost levels are controlled.Discuss maintenance procedures for turbochargers and superchargers.


KEY TERMSbar boost bypass valve compressor bypass valve (CBV) dump valve intercooler naturally (normally) aspirated Positive displacement relief valve roots-type superchanger turbo lag turbocharger vent valve volumetric efficiency wastegate


AIRFLOW REQUIREMENTSNaturally aspirated engines with throttle bodies rely on atmospheric pressure to push an airfuel mixture into the combustion chamber vacuum created by the downstroke of a piston. The mixture is then compressed before ignition to increase the force of the burning, expanding gases. The greater the mixture compression, the greater the power resulting from combustion.All gasoline automobile engines share certain airfuel requirements.


AIRFLOW REQUIREMENTSEngineers calculate engine airflow requirements using these three factors:Engine displacementEngine revolutions per minute (RPM)Volumetric efficiency


AIRFLOW REQUIREMENTSVOLUMETRIC EFFICIENCYVolumetric efficiency is a comparison of the actual volume of airfuel mixture drawn into an engine to the theoretical maximum volume that could be drawn in. Volumetric efficiency is expressed as a percentage, and changes with engine speed.


AIRFLOW REQUIREMENTSVOLUMETRIC EFFICIENCY


AIRFLOW REQUIREMENTSVOLUMETRIC EFFICIENCY


AIRFLOW REQUIREMENTSENGINE COMPRESSIONHigher compression increases the thermal efficiency of the engine because it raises compression temperatures, resulting in hotter, more complete combustion.However, a higher compression can cause an increase in NOX emissions and would require the use of high-octane gasoline with effective antiknock additives.


SUPERCHARGING PRINCIPLESThe amount of force an airfuel charge produces when it is ignited is largely a function of the charge density. Density is the mass of a substance in a given amount of space.


SUPERCHARGING PRINCIPLESThe greater the density of an airfuel charge forced into a cylinder, the greater the force it produces when ignited, and the greater the engine power.An engine that uses atmospheric pressure for intake is called a naturally (normally) aspirated engine. A better way to increase air density in the cylinder is to use a pump.When air is pumped into the cylinder, the combustion chamber receives an increase of air pressure known as boost and is measured in pounds per square inch (PSI), atmospheres (ATM), or bar.


SUPERCHARGING PRINCIPLESAnother way to achieve an increase in mixture compression is called supercharging. This method uses a pump to pack a denser airfuel charge into the cylinders. Since the density of the airfuel charge is greater, so is its weightand power is directly related to the weight of an airfuel charge consumed within a given time period. The result is similar to that of a highcompression ratio, but the effect can be controlled during idle and deceleration to avoid high emissions.


SUPERCHARGING PRINCIPLESIn addition to the increased power resulting from combustion, there are several other advantages of supercharging an engine including:It increases the airfuel charge density to provide highcompression pressure when power is required, but allows the engine to run on lower pressures when additional power is not required.The pumped air pushes the remaining exhaust from the combustion chamber during intake and exhaust valve overlap.The forced airflow and removal of hot exhaust gases lowers the temperature of the cylinder head, pistons, and valves, and helps extend the life of the engine.


SUPERCHARGING PRINCIPLES


SUPERCHARGING PRINCIPLESBOOST AND COMPRESSION RATIOSBoost increases the amount of air drawn into the cylinder during the intake stroke. This extra air causes the effective compression ratio to be greater than the mechanical compression ratio designed into the engine. The higher the boost pressure, the greater the compression ratio.


SUPERCHARGING PRINCIPLESBOOST AND COMPRESSION RATIOS


SUPERCHARGERSA supercharger is an engine-driven air pump that supplies more than the normal amount of air into the intake manifold and boosts engine torque and power. A supercharger provides an instantaneous increase in power without the delay or lag often associated with turbochargers.In basic concept, a supercharger is nothing more than an air pump mechanically driven by the engine itself.


SUPERCHARGERSThere are two general types of superchargers:Roots-type superchargerCentrifugal supercharger


SUPERCHARGERSSUPERCHARGER BOOST CONTROLMany factory-installed superchargers are equipped with a bypass valve that allows intake air to flow directly into the intake manifold bypassing the supercharger. The computer controls the bypass valve actuator.


SUPERCHARGERSSUPERCHARGER BOOST CONTROL


SUPERCHARGERSSUPERCHARGER BOOST CONTROLThe airflow is directed around the supercharger whenever any of the following conditions occur:The boost pressure, as measured by the MAP sensor, indicates that the intake manifold pressure is reaching the predetermined boost level.During deceleration.Whenever reverse gear is selected.


SUPERCHARGERSSUPERCHARGER SERVICESuperchargers are usually lubricated with synthetic engine oil inside the unit. This oil level should be checked and replaced as specified by the vehicle or supercharger manufacturer. The drive belt should also be inspected and replaced as necessary.


TURBOCHARGERSBy connecting a centrifugal supercharger to a turbine drive wheel and installing it in the exhaust path, the lost engine horsepower is regained to perform other work and the combustion heat energy lost in the engine exhaust (as much as 40% to 50%) can be harnessed to do useful work. This is the concept of a turbocharger.


TURBOCHARGERSThe turbochargers main advantage over a mechanically driven supercharger is that the turbocharger does not drain power from the engine. In a naturally aspirated engine, about half of the heat energy contained in the fuel goes out the exhaust system.


TURBOCHARGERS


TURBOCHARGERS


TURBOCHARGERSTURBOCHARGER DESIGN AND OPERATIONA turbocharger consists of two chambers connected by a center housing. The two chambers contain a turbine wheel and a compressor wheel connected by a shaft which passes through the center housing.To take full advantage of the exhaust heat which provides the rotating force, a turbocharger must be positioned as close as possible to the exhaust manifold.


TURBOCHARGERSTURBOCHARGER DESIGN AND OPERATIONThis allows the hot exhaust to pass directly into the unit with a minimum of heat loss. As exhaust gas enters the turbocharger, it rotates the turbine blades. The turbine wheel and compressor wheel are on the same shaft so that they turn at the same speed. Rotation of the compressor wheel draws air in through a central inlet and centrifugal force pumps it through an outlet at the edge of the housing.


TURBOCHARGERSTURBOCHARGER DESIGN AND OPERATION


TURBOCHARGERSTURBOCHARGER SIZE AND RESPONSE TIMEA time lag occurs between an increase in engine speed and the increase in the speed of the turbocharger. This delay between acceleration and turbo boost is called turbo lag. Like any material, moving exhaust gas has inertia. Inertia also is present in the turbine and compressor wheels, as well as the intake airflow. Unlike a supercharger, the turbocharger cannot supply an adequate amount of boost at low speed.


BOOST CONTROLBoth supercharged and turbocharged systems are designed to provide a pressure greater than atmospheric pressure in the intake manifold. This increased pressure forces additional amounts of air into the combustion chamber over what would normally be forced in by atmospheric pressure. This increased charge increases engine power.


BOOST CONTROLThe amount of boost (or pressure in the intake manifold) is measured in pounds per square inch (PSI), in inches of mercury (in. Hg), in bar, or in atmospheres. The following values will vary due to altitude and weather conditions (barometric pressure).1 atmosphere = 14.7 PSI1 atmosphere = 29.50 in. Hg1 atmosphere = 1.0 bar1 bar = 14.7 PSI


BOOST CONTROL


BOOST CONTROLWASTEGATEA turbocharger uses exhaust gases to increase boost, which causes the engine to make more exhaust gases, which in turn increases the boost from the turbocharger.To prevent overboost and severe engine damage, most turbocharger systems use a wastegate. A wastegate is a valve similar to a door that can open and close. The wastegate is a bypass valve at the exhaust inlet to the turbine.


BOOST CONTROLWASTEGATE


Boost Is the Result of RestrictionThe boost pressure of a turbocharger (or supercharger) is commonly measured in pounds per square inch. If a cylinder head is restricted because of small valves and ports, the turbocharger will quickly provide boost. Boost results when the air being forced into the cylinder heads cannot flow into the cylinders fast enough and piles up in the intake manifold, increasing boost pressure. If an engine had large valves and ports, the turbocharger could provide a much greater amount of air into the engine at the same boost pressure as an identical engine with smaller valves and ports. Therefore, by increasing the size of the valves, a turbocharged or supercharged engine will be capable of producing much greater power.


BOOST CONTROLRELIEF VALVESA wastegate controls the exhaust side of the turbocharger. A relief valve controls the intake side. A relief valve vents pressurized air from the connecting pipe between the outlet of the turbocharger and the throttle whenever the throttle is closed during boost, such as during shifts. If the pressure is not released, the turbocharger turbine wheel will slow down, creating a lag when the throttle is opened again after a shift has been completed.


BOOST CONTROLRELIEF VALVESThere are two basic types of relief valves including:Compressor bypass valve or CBVBlow-off valve or BOV


BOOST CONTROLRELIEF VALVES


If One Is Good, Two Are BetterA turbocharger uses the exhaust from the engine to spin a turbine, which is connected to an impeller inside a turbocharger. This impeller then forces air into the engine under pressure higher than is normally achieved without a turbocharger. The more air that can be forced into an engine, the greater the power potential. A V-type engine has two exhaust manifolds and so two small turbochargers can be used to help force greater quantities of air into an engine.


If One Is Good, Two Are Better


TURBOCHARGER FAILURESWhen turbochargers fail to function correctly, a drop in power is noticed. Bearing failure is a common cause of turbocharger failure, and replacement bearings are usually only available to rebuilders.Another common turbocharger problem is excessive and continuous oil consumption resulting in blue exhaust smoke. Turbochargers use small rings similar to piston rings on the shaft to prevent exhaust (combustion gases) from entering the central bearing.


SUMMARYVolumetric efficiency is a comparison of the actual volume of airfuel mixture drawn into the engine to the theoretical maximum volume that can be drawn into the cylinder.A supercharger operates from the engine by a drive belt and, while it does consume some engine power, it forces a greater amount of air into the cylinders for even more power.A turbocharger uses the normally wasted heat energy of the exhaust to turn an impeller at high speed. The impeller is linked to a turbine wheel on the same shaft and is used to force air into the engine.There are two types of superchargers: roots-type and centrifugal.


SUMMARYA bypass valve is used to control the boost pressure on most factory-installed superchargers.An intercooler is used on many turbocharged and some supercharged engines to reduce the temperature of air entering the engine for increased power.A wastegate is used on most turbocharger systems to limit and control boost pressures, as well as a relief valve, to keep the speed of the turbine wheel from slowing down during engine deceleration.


REVIEW QUESTIONSWhat are the reasons why supercharging increases engine power?How does the bypass valve work on a supercharged engine?What are the advantages and disadvantages of supercharging?What are the advantages and disadvantages of turbocharging?What turbocharger control valves are needed for proper engine operation?


CHAPTER QUIZ1.Boost pressure is generally measured in ________.in. HgPSI in. H2Oin. lb


CHAPTER QUIZ2.Two types of superchargers include ________.Rotary and reciprocatingRoots-type and centrifugalDouble and single actingTurbine and piston


CHAPTER QUIZ3.Which valve is used on a factory supercharger to limit boost?A bypass valveA wastegate A blow-off valveAn air valve


CHAPTER QUIZ4.How are most superchargers lubricated?By engine oil under pressure through lines from the engineBy an internal oil reservoirBy greased bearingsNo lubrication is needed because the incoming air cools the supercharger


CHAPTER QUIZ5.How are most turbochargers lubricated?By engine oil under pressure through lines from the engineBy an internal oil reservoirBy greased bearingsNo lubrication is needed because the incoming air cools the supercharger


CHAPTER QUIZ6.Two technicians are discussing the term turbo lag. Technician A says that it refers to the delay between when the exhaust leaves the cylinder and when it contacts the turbine blades of the turbocharger. Technician B says that it refers to the delay in boost pressure that occurs when the throttle is first opened. Which technician is correct?Technician A onlyTechnician B onlyBoth Technicians A and BNeither Technician A nor B


CHAPTER QUIZ7.What is the purpose of an intercooler?To reduce the temperature of the air entering the engineTo cool the turbochargerTo cool the engine oil on a turbocharged engineTo cool the exhaust before it enters the turbocharger


CHAPTER QUIZ8.Which type of relief valve used on a turbocharged engine is noisy?A bypass valveA BOV A dump valveBoth b and c


CHAPTER QUIZ9.Technician A says that a stuck-open wastegate can cause the engine to burn oil. Technician B says that a clogged PCV system can cause the engine to burn oil. Which technician is correct?Technician A onlyTechnician B onlyBoth Technicians A and BNeither Technician A nor B


CHAPTER QUIZ10.What service operation is most important on engines equipped with a turbocharger?Replacing the air filter regularlyReplacing the fuel filter regularlyRegular oil changesRegular exhaust system maintenance

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