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CHAPTER 12

Turbocharging and Supercharging

OBJECTIVES
After studying Chapter 12, the reader will be able to:
1.

2.

3.
4.

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.

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Copyright 2010, 2007, 2003 Pearson Education, Inc.,


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KEY TERMS

bar
boost
bypass valve
compressor bypass valve
(CBV)
dump valve
intercooler
naturally (normally)
aspirated
Positive displacement

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relief valve
roots-type
superchanger
turbo lag
turbocharger
vent valve
volumetric efficiency
wastegate

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AIRFLOW REQUIREMENTS

Naturally 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 air
fuel requirements.

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AIRFLOW REQUIREMENTS

Engineers calculate engine airflow requirements


using these three factors:

Engine displacement
Engine revolutions per minute (RPM)
Volumetric efficiency

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AIRFLOW REQUIREMENTS
VOLUMETRIC EFFICIENCY

Volumetric 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.

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AIRFLOW REQUIREMENTS
VOLUMETRIC EFFICIENCY

FIGURE 121 A supercharger on a Ford V-8.

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AIRFLOW REQUIREMENTS
VOLUMETRIC EFFICIENCY

FIGURE 122 A turbocharger on a Toyota engine.


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AIRFLOW REQUIREMENTS
ENGINE COMPRESSION

Higher 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.

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SUPERCHARGING PRINCIPLES

The 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.

FIGURE 123 The more air and fuel that can be


packed in a cylinder, the greater the density of the air
fuel charge.
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SUPERCHARGING PRINCIPLES

The 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.

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SUPERCHARGING PRINCIPLES

Another way to achieve an increase in mixture


compression is called supercharging.
This method uses a pump to pack a denser air
fuel 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.

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SUPERCHARGING PRINCIPLES

In 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.

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SUPERCHARGING PRINCIPLES

FIGURE 124 Atmospheric pressure decreases with increases in altitude.

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SUPERCHARGING PRINCIPLES
BOOST AND COMPRESSION RATIOS

Boost 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.

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SUPERCHARGING PRINCIPLES
BOOST AND COMPRESSION RATIOS

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SUPERCHARGERS

A 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.

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SUPERCHARGERS

There are two general


types of superchargers:

Roots-type supercharger
Centrifugal supercharger

FIGURE 125 A roots-type supercharger


uses two lobes to force the air around the
outside of the housing and forces it into the
intake manifold.
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SUPERCHARGERS
SUPERCHARGER BOOST CONTROL

Many 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.

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SUPERCHARGERS
SUPERCHARGER BOOST CONTROL

FIGURE 126 The bypass actuator opens the bypass valve to control boost pressure.

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SUPERCHARGERS
SUPERCHARGER BOOST CONTROL

The 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.

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SUPERCHARGERS
SUPERCHARGER SERVICE

Superchargers 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.

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TURBOCHARGERS

By 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.

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TURBOCHARGERS

The 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.

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TURBOCHARGERS

FIGURE 127 A turbocharger uses some of the heat energy that would normally be
wasted.

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TURBOCHARGERS

FIGURE 128 A turbine wheel is turned by the expanding


exhaust gases.
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TURBOCHARGERS
TURBOCHARGER DESIGN AND OPERATION

A 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.

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TURBOCHARGERS
TURBOCHARGER DESIGN AND OPERATION

This 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.

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TURBOCHARGERS
TURBOCHARGER DESIGN AND OPERATION

FIGURE 129 The exhaust drives the turbine wheel on the left,
which is connected to the impeller wheel on the right through a shaft.
The bushings that support the shaft are lubricated with engine oil
under pressure.
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TURBOCHARGERS
TURBOCHARGER SIZE AND RESPONSE TIME

A 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.

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BOOST CONTROL

Both 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.

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BOOST CONTROL

The 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 PSI


1 atmosphere = 29.50 in. Hg
1 atmosphere = 1.0 bar
1 bar = 14.7 PSI

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BOOST CONTROL

FIGURE 1210 The unit on top of this Subaru that looks like a
radiator is the intercooler, which cools the air after it has been
compressed by the turbocharger.
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BOOST CONTROL
WASTEGATE

A 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.

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BOOST CONTROL
WASTEGATE

FIGURE 1211 A wastegate is


used on the first-generation
Duramax diesel to control
maximum boost pressure.

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Boost Is the Result of Restriction

The 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.

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BOOST CONTROL
RELIEF VALVES

A 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.

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BOOST CONTROL
RELIEF VALVES

There are two basic types of relief valves


including:

Compressor bypass valve or CBV


Blow-off valve or BOV

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BOOST CONTROL
RELIEF VALVES

FIGURE 1212 A blow-off valve is


used in some turbocharged systems
to relieve boost pressure during
deceleration.

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If One Is Good, Two Are Better

A 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.

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If One Is Good, Two Are Better

FIGURE 1213 A dual turbocharger system installed on


a small block Chevrolet V-8 engine.

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TURBOCHARGER FAILURES

When 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.

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SUMMARY
1.

2.

3.

4.

Volumetric 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.

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SUMMARY
5.

6.

7.

A 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.

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REVIEW QUESTIONS
1.

2.

3.

4.

5.

What 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?

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CHAPTER QUIZ
1. Boost pressure is generally measured in
________.

c.

in. Hg
PSI
in. H2O

d.

in. lb

a.
b.

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CHAPTER QUIZ
2. Two types of superchargers include ________.
a.
b.
c.
d.

Rotary and reciprocating


Roots-type and centrifugal
Double and single acting
Turbine and piston

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CHAPTER QUIZ
3. Which valve is used on a factory supercharger to
limit boost?
a.
b.
c.
d.

A bypass valve
A wastegate
A blow-off valve
An air valve

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CHAPTER QUIZ
4. How are most superchargers lubricated?
a.

b.
c.
d.

By engine oil under pressure through lines from


the engine
By an internal oil reservoir
By greased bearings
No lubrication is needed because the incoming air
cools the supercharger

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CHAPTER QUIZ
5. How are most turbochargers lubricated?
a.

b.
c.
d.

By engine oil under pressure through lines from


the engine
By an internal oil reservoir
By greased bearings
No lubrication is needed because the incoming air
cools the supercharger

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CHAPTER QUIZ
6. 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?
a.
b.
c.
d.

Technician A only
Technician B only
Both Technicians A and B
Neither Technician A nor B

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CHAPTER QUIZ
7. What is the purpose of an intercooler?
a.

b.
c.
d.

To reduce the temperature of the air entering the


engine
To cool the turbocharger
To cool the engine oil on a turbocharged engine
To cool the exhaust before it enters the
turbocharger

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CHAPTER QUIZ
8. Which type of relief valve used on a turbocharged
engine is noisy?
a.
b.
c.
d.

A bypass valve
A BOV
A dump valve
Both b and c

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CHAPTER QUIZ
9. 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?
a.
b.
c.
d.

Technician A only
Technician B only
Both Technicians A and B
Neither Technician A nor B

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CHAPTER QUIZ
10. What service operation is most important on
engines equipped with a turbocharger?
a.
b.
c.
d.

Replacing the air filter regularly


Replacing the fuel filter regularly
Regular oil changes
Regular exhaust system maintenance

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