0398383 JOHNSON DECAL SET

Illustration 1 g03636256
(1) Exhaust manifold (2) Intake manifold (3) Belt driven compressor (4) Belt driven compressor inlet (5) Belt driven compressor outlet (6) Aftercooler (7) Compressor side of turbocharger (8) Turbine side of turbocharger
Illustration 2 g03647540
Section view of the aftercooler with the belt driven compressor disengaged. (9) Compressor diverter air valve in the closed position
Illustration 3 g03647489
Section view of the aftercooler with the belt driven compressor engaged. (9) Compressor diverter air valve in the open positionThe components of the air inlet and exhaust system control the quality of air and the amount of air that is available for combustion. The components of the air inlet and exhaust system are the following components:
Air cleaner
Turbocharger
Belt driven compressor
Aftercooler
Cylinder head
Valves and valve system components
Piston and cylinder
Exhaust manifold
Compressor diverter valve
ECM controlled belt driven compressor clutch Inlet air is pulled through the air cleaner by the turbocharger compressor wheel. The air is compressed and heated before the air is forced to the aftercooler (4). The turbocharged air flows through the aftercooler and into the belt driven compressor inlet. The belt driven compressor is engaged via an ECM controlled electronic clutch. With the clutch engaged the compressed air opens compressor diverter valve (9), the belt driven compressed air flows through the front section of the aftercooler. The turbocharged air flows to belt driven compressor inlet (4) and through the compressor housing. The air is compressed and flows into the aftercooler. When the clutch is disengaged only the turbocharged compressor air flows through the aftercooler. As the air flows through the aftercooler the temperature of the compressed air lowers. Cooling of the inlet air increases combustion efficiency. Increased combustion efficiency helps achieve the following benefits:
Lower fuel consumption
Increased horsepower outputFrom the aftercooler, air is forced into the inlet manifold (2). Air flow from the inlet chambers into the cylinders is controlled by intake valves. There are two intake valves and two exhaust valves for each cylinder. The intake valves open when the piston moves down on the intake stroke. When the intake valves open, cooled compressed air from the intake port is pulled into the cylinder. The intake valves close and the piston begins to move up on the compression stroke. The air in the cylinder is compressed. When the piston is near the top of the compression stroke, fuel is injected into the cylinder. The fuel mixes with the air and combustion starts. During the power stroke, the combustion force pushes the piston downward. The exhaust valves open and the exhaust gases are pushed through the exhaust port into exhaust manifold (1) as the piston rises on the exhaust stroke. After the exhaust stroke, the exhaust valves close and the cycle starts again. The complete cycle consists of four strokes:
Inlet
Compression
Power
ExhaustExhaust gases from exhaust manifold (1) enter the turbine side of the turbocharger in order to turn turbocharger turbine wheel. The turbine wheel is connected to the shaft that drives the compressor wheel. Exhaust gases from the turbocharger exit the turbine housing via an exhaust outlet pipe.
Illustration 4 g03656240
(10) Optional sea water-cooled exhaust riser (11) Optional transmission oil coolerSea water from the heat exchanger flows through the transmission oil cooler and into the exhaust riser.
Illustration 5 g03656614
(12) Air inlet heaterThe air inlet heater is controlled by the ECM. The air inlet heater aids in engine start-up and reducing white smoke during engine start-up. Turbocharger
Illustration 6 g03645338
(13) Compressor wheel housing (14) Turbocharger compressor outlet (15) Oil inlet port (16) Turbine housing coolant outlet port (17) Turbine housing (18) Air inlet (19) Oil outlet port (20) Turbine housing coolant inlet port (21) Exhaust inletThe turbocharger is installed on the rear of the exhaust manifold. All the exhaust gases from the engine go through the turbocharger. The compressor side of the turbocharger is connected to the aftercooler by pipe.The exhaust gases enter turbine housing (17) through exhaust inlet (21). The exhaust gases then push the blades of the turbine wheel. The turbine wheel is connected by a shaft to the compressor wheel. The turbine housing is cooled from the jacket water cooling system. The coolant enters the turbine housing via turbine housing coolant inlet port (20). The coolant flows around the exhaust gas passage and out the turbine housing coolant outlet port to the sea water-cooled heat exchanger.Clean air from the air cleaners is pulled through compressor housing air inlet (18) by the rotation of the compressor wheel. The action of the compressor wheel blades causes a compression of the inlet air. This compression increases the amount of air that is induced into the combustion chamber. More fuel is required with the increase of intake air. An increase in the amount of fuel that is burned will increase the power of the engine.When the load on the engine increases, more fuel is injected into the cylinders. The combustion of this additional fuel produces more exhaust gases. The additional exhaust gases cause the turbine and the compressor wheels of the turbocharger to turn faster. As the compressor wheel turns faster, more air is forced into the cylinders. The increased flow of air gives the engine more power by allowing the engine to burn the additional fuel with greater efficiency.
Illustration 7 g03647643
(22) Canister (23) Line (boost pressure) (24) Actuating leverThe operation of the wastegate is controlled by the boost pressure. At high boost pressures, the wastegate opens in order to decrease boost pressure. At low boost pressure, the wastegate closes in order to increase boost pressure. When the engine is operating under conditions of low boost, a spring pushes a diaphragm in canister (22). This action moves actuating lever (24) in order to close the valve of the wastegate. Closing the valve of the wastegate allows the turbocharger to operate at maximum performance.As the boost pressure through line (23) incr