322-60006-0 Tohatsu GASKET, 8.1 - 15 - 1

Illustration 1 g00451885
Air inlet and exhaust system schematic (1) Inlet manifold (2) Aftercooler core (3) Inlet air line (4) Exhaust outlet from turbocharger (5) Turbine side of turbocharger (6) Compressor side of turbocharger (7) Air cleanerThe engine 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
Aftercooler
Cylinder head
Valves and valve system components
Piston and cylinder
Exhaust manifoldNote: This summary assumes that the engine is developing boost.The turbocharger compressor wheel pulls inlet air through the air cleaner and into the air inlet. The air is compressed and heated to about 150°C (300°F) before the air is forced to the aftercooler. The air flows through aftercooler core (2) and the temperature of the compressed air lowers to about 43°C (110°F). The combustion efficiency increases because of the cooler inlet air. This helps to provide increased horsepower output. Aftercooler core (2) is a separate cooler core that is mounted in front of the engine radiator. The engine fan and the ram effect of the forward motion of the vehicle causes ambient air to move across both cores. This cools the turbocharged inlet air and the engine coolant.Air is forced from the aftercooler into inlet manifold (1). The airflow from the inlet port into the cylinders is controlled by inlet valves.
Illustration 2 g00615497
Air inlet and exhaust system (2) Aftercooler core (4) Exhaust outlet (5) Turbine side of turbocharger (6) Compressor side of turbocharger (8) Exhaust manifold (9) Exhaust valve (10) Inlet valve (11) Air inletEach cylinder has two inlet valves (10) and two exhaust valves (9) in the cylinder head. The inlet valves open when the piston moves toward the bottom center on the inlet stroke. When the inlet valves open, cooled compressed air from the inlet port within the inlet manifold is forced into the cylinder. The inlet valves close when the piston moves toward top center on the compression stroke. The air in the cylinder is compressed and the fuel is injected into the cylinder when the piston is near the top of the compression stroke. Combustion begins when the fuel mixes with the super heated air. The force of combustion pushes the piston toward the bottom center on the power stroke. The exhaust valves open and the exhaust gases are pushed through the exhaust port into exhaust manifold (8). After the piston moves toward top center on the exhaust stroke, the exhaust valves close and the cycle begins again.The hot exhaust gases from the exhaust manifold flow into the turbine side of turbocharger (5). The hot exhaust gases cause the turbocharger turbine wheel to turn. The turbine wheel is connected to the shaft that drives the compressor wheel. Exhaust gases from the turbocharger pass through exhaust outlet (4), through the catalytic converter into a muffler, and through an exhaust stack.Turbocharger
Illustration 3 g00291064
Turbocharger (typical example) (1) Pipe (2) Exhaust manifold (3) TurbochargerTurbocharger (3) is mounted to exhaust manifold (2) of the engine. All of the exhaust gases go from the exhaust manifold through the turbocharger.
Illustration 4 g00291085
Turbocharger (4) Air inlet (5) Compressor housing (6) Compressor wheel (7) Bearing (8) Oil inlet port (9) Bearing (10) Turbine housing (11) Turbine wheel (12) Exhaust outlet (13) Oil outlet port (14) Exhaust inletThe exhaust gases enter the turbocharger and the exhaust gases turn the turbine blades of the turbocharger. Because the turbocharger turbine wheel is connected by a shaft to the turbocharger compressor wheel, the turbine wheel and the compressor wheel turn together. The turbocharger compressor wheel and the turbine wheel turn at very high rpm. The rotation of the compressor wheel draws clean air through the compressor housing air inlet. The action of the compressor wheel blades causes a compression of the inlet air. This compression allows a larger amount of air to enter the engine. With more air in the engine, the engine is able to burn more fuel. The overall effect is an increase in power.When the load on the engine increases or when a greater engine speed is desired, additional fuel is injected into the cylinders. This creates hotter exhaust gases, which will cause the turbine wheel and the compressor wheel to turn faster. Additional air is forced into the engine as the compressor wheel turns faster. The increased amount of air allows the engine to produce more power. The engine produces more power because the engine is able to burn additional fuel with greater efficiency.
Illustration 5 g00291087
Turbocharger with wastegate (15) Canister (16) Actuating leverLow boost is a condition that occurs when the turbocharger produces less than optimum boost pressure. There is a spring that is inside canister (15). Under low boost, the spring pushes on the diaphragm in canister (15). This moves actuating lever (16). The actuating lever closes the wastegate, which will allow the turbocharger to operate at maximum performance.Under conditions of high boost, the wastegate opens. The open wastegate allows exhaust gases to bypass the turbine side of the turbocharger. When the boost pressure increases against the diaphragm in canister (15), the wastegate is opened. The rpm of the turbocharger is limited by bypassing a portion of the exhaust gases around the turbine wheel of the turbocharger.Note: The calibration of the wastegate is preset at the factory. No adjustment can be made to the wastegate.Bearing (7) and bearing (9) in the turbocharger use engine oil that is under pressure for lubrication. The lubrication oil for the bearings flows through oil inlet port (8) and into the inlet port in the center section of the turbocharger cartridge. The oil exits the turbocharger through oil outlet port (13). The oil then returns to the engine oil pan through the oil drain line for the turbocharger.Wastegate Solenoid
Illustration 6 g00910753
(1) Outlet fitting (2) Inlet fitting (3) Vent (4) Wastegate solenoid (5) ManifoldThe wastegate solenoid allows the ECM to fine tune the amount of boost that is generated. A wastegate solenoid is necessary in order to prevent the turbocharger from overspeeding under