0439519 JOHNSON PISTON & RING ASSY., 0.030 in. O.S. (port)

Illustration 1 g01448580
Air flow schematic
(1) Air line
(2) Aftercooler core
(3) Air inlet elbow
(4) Exhaust outlet from turbocharger
(5) Turbine side of turbocharger
(6) Compressor side of turbocharger
(7) Air cleaner The components of the air inlet and exhaust system control the quality of the air that is available for combustion. These components also control the amount of the air that is available for combustion. The components of the air inlet and exhaust system are listed below:
Air cleaner
Turbocharger
Aftercooler
Cylinder head
Valves and valve system components
Piston and cylinder
Exhaust manifoldInlet air is pulled through the air cleaner. The inlet air is then compressed and heated by the compressor wheel of turbocharger (6) to about 150°C (300°F). The inlet air is then pushed through air-to-air aftercooler core (2) and the inlet air is moved to air inlet elbow (3). The temperature of the inlet air at air inlet elbow (3) is about 43°C (110°F). Cooling of the inlet air increases the combustion efficiency. Increased combustion efficiency helps to lower fuel consumption. Also, increased combustion efficiency helps to increase horsepower output.Aftercooler core (2) is a separate cooler core. Aftercooler core (2) is installed in front of the core (standard) of the engine radiator on the machine. Air that is ambient temperature is moved across the aftercooler core by the engine fan. This cools the turbocharged inlet air.From aftercooler core (2), the air is forced into the cylinder head in order to fill the inlet ports. Air flow from the inlet port into the cylinder is controlled by the inlet valves.
Illustration 2 g01448586
Air inlet and exhaust system
(2) Aftercooler core
(4) Exhaust outlet from turbocharger
(5) Turbine side of turbocharger
(6) Compressor side of turbocharger
(8) Exhaust manifold
(9) Exhaust valve
(10) Inlet valve
(11) Air inlet There are two inlet valves and one exhaust valve for each cylinder. Inlet valves open when the piston moves down on the inlet stroke. When the inlet valves open, cooled compressed air from the inlet port is pulled into the cylinder. The inlet 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. After the power stroke is complete, the piston moves upward. This upward movement is the exhaust stroke. During the exhaust stroke, the exhaust valve opens, and the exhaust gases are pushed through the exhaust port into the exhaust manifold. After the piston completes the exhaust stroke, the exhaust valve closes and the cycle starts again. The complete cycle consists of four stages:
Inlet stroke
Compression stroke
Power stroke
Exhaust strokeExhaust gases from exhaust manifold (8) enter the turbine side of turbocharger (5) in order to turn the turbine wheel. The turbine wheel is connected to a shaft which drives the compressor wheel. Exhaust gases from the turbocharger pass through the exhaust outlet pipe, the muffler and the exhaust stack.Turbocharger
Illustration 3 g01448601
Turbocharger
(12) Air inlet
(13) Compressor housing
(14) Compressor wheel
(15) Bearing
(16) Oil inlet port
(17) Bearing
(18) Turbine housing
(19) Turbine wheel
(20) Exhaust outlet
(21) Oil outlet port
(22) Exhaust inlet The turbocharger is installed on the center section 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 a pipe.The exhaust gases go into turbine housing (18) through exhaust inlet (22). The exhaust gases then push the blades of turbine wheel (19). The turbine wheel is connected by a shaft to compressor wheel (14).Clean air from the air cleaners is pulled through compressor housing air inlet (12) by the rotation of compressor wheel (14). The action of the compressor wheel blades causes a compression of the inlet air. This compression gives the engine more power by allowing the engine to burn more air and more fuel during combustion.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.Bearings (15) and (17) for the turbocharger use engine oil under pressure for lubrication. The oil comes in through oil inlet port (16). The oil then goes through passages in the center section in order to lubricate the bearings. Oil from the turbocharger goes out through oil outlet port (21) in the bottom of the center section. The oil then goes back to the engine lubrication system.
Illustration 4 g01448617
Turbocharger with wastegate
(23) Actuating lever
(24) Canister
(25) Line (boost pressure)
(26) Pressure relief orifice When the engine is operating under conditions of low boost, a spring pushes on a diaphragm in canister (24). This action moves actuating lever (23) in order to close the valve of the wastegate. Closing the valve of the wastegate allows the turbocharger to operate at maximum performance.
Illustration 5 g01448618
(27) Inlet manifold
(28) Wastegate solenoid Wastegate solenoid (28) allows the engine ECM to more precisely regulate the boost pressure to the engine. By closing or partially closing the wastegate solenoid, the ECM can increase the boost pressure. Typical wastegates will limit boost pressure to a preset limit. Wastegate solenoid (28) blocks air from reaching the wastegate and this allows boost pressure to increase. Air is routed from inlet manifold (27) to wastegate solenoid (28). The wastegate solenoid (28) senses the air pressure of the inlet air and the wastegate solenoid adjusts the wastegate accordingly. The pressure relief orifice (26) allows air to escape from the line (boost pressure) when the pressure is too high.As the boost pressure through line (25) increases against the diaphragm in canister (24), the valve of the wastegate is opened. When the valve of the wastegate is opened, the rpm of the turbocharger is limited by bypassing a portion of the exhaust gases. The exhaust