Chapter 06

OBJECTIVES
After studying Chapter 6, the reader should be able to:

1. Describe how the proper grade of gasoline affects
engine performance.
2. List gasoline purchasing hints.
3. Discuss how volatility affects driveability.
4. Explain how oxygenated fuels can reduce CO
exhaust emissions.
5. Discuss the advantages and disadvantages of
various alternative fuels.
Automotive Fuel and Emissions Control Systems, 2/e

By James D. Halderman and Jim Linder
2009 Pearson Higher Education, Inc.

Pearson Prentice Hall - Upper Saddle River, NJ 07458
AIR INTAKE FILTRATION

Gasoline must be mixed
with air to form a
combustible mixture.
Air movement into an
engine occurs due to low
pressure (vacuum) being
created in the engine.
FIGURE 6-1 Downward movement of the

piston lowers the air pressure inside the
combustion chamber. The pressure
differential between the atmosphere and
the inside of the engine forces air into the
engine.

FIGURE 6-2 Dust and dirt in the air are trapped in

the air filter so they do not enter the engine.


Filter Replacement
Air Filter Elements
Remotely Mounted Air
Filters and Ducts
FIGURE 6-3 Most air filter

housings are located on the side
of the engine compartment and
use flexible rubber hose to direct
the airflow into the throttle body of
the engine.


ALWAYS CHECK THE AIR FILTER
FIGURE 6-4 (a) Note the discovery as the air filter housing was opened during service
on a Pontiac Bonneville. The nuts were obviously deposited by squirrels (or some
other animal). (b) Not only was the housing filled with nuts, but also this air filter was
extremely dirty, indicating that this vehicle had not been serviced for a long time.

ENGINE AIR TEMPERATURE REQUIREMENTS

Some form of thermostatic control has been used
on vehicles equipped with a throttle-body fuel
injection to control intake air temperature for
improved driveability.
An air control valve or damper permits the air intake
of:
Heated air from the heat stove
Cooler air from the snorkel or cold-air duct
A combination of both


WHAT DOES THIS TUBE DO?
FIGURE 6-5 A resonance tube, called a Helmholtz resonator, is used on the intake
duct between the air filter and the throttle body to reduce air intake noise during
engine acceleration.

THROTTLE-BODY INJECTION INTAKE

MANIFOLDS
A throttle-body fuel injector
forces finely divided
droplets of liquid fuel into
the incoming air to form a
combustible airfuel
mixture.
FIGURE 6-6 A throttle-body injection (TBI)

unit used on a GM V-6 engine.

THROTTLE-BODY INJECTION INTAKE

MANIFOLDS
FIGURE 6-7 Heavy fuel droplets separate as they

flow around an abrupt bend in an intake manifold.

PORT FUEL-INJECTION INTAKE MANIFOLDS

The size and shape of port fuel-injected engine
intake manifolds can be optimized because the only
thing in the manifold is air.
The fuel injection is located in the intake manifold
about 3 to 4 inches (70 to 100 mm) from the intake
valve.
Therefore, the runner length and shape are
designed for tuning only.


FIGURE 6-8 The graph shows the effect of sonic tuning of the intake manifold
runners. The longer runners increase the torque peak and move it to a lower
RPM. The 600-mm-long intake runner is about 24 inches long.

FIGURE 6-9 Airflow through the large diameter upper intake manifold is
distributed to smaller diameter individual runners in the lower manifold in this
two-piece manifold design.

VARIABLE INTAKES
Many intake manifolds are
designed to provide both
short runners, best for
higher engine speed power,
and longer runners, best for
lower engine speed torque.
FIGURE 6-10 The air flowing into the

engine can be directed through long or
short runners for best performance and fuel
economy.

PLASTIC INTAKE MANIFOLDS

Plastic intake manifolds
have smoother interior
surfaces than do other
types of manifolds, resulting
in greater airflow.
FIGURE 6-11 Many plastic intake

manifolds are constructed using many
parts glued together to form complex
passages for airflow into the engine.

PLASTIC INTAKE MANIFOLDS
FIGURE 6-12 The exhaust gas recirculation system is more efficient at controlling
NOX emissions if the exhaust gases are cooled. A long metal tube between the
exhaust manifold and the intake manifold allows the exhaust gases to cool before
entering the engine.

UPPER AND LOWER INTAKE MANIFOLDS

Many intake manifolds are constructed in two parts.
A lower section, usually called the plenum, attaches to
the cylinder heads and includes passages from the intake
ports.
An upper manifold connects to the lower unit and includes
the long passages needed to help provide the ram effect
that helps the engine deliver maximum torque at low
engine speeds. The throttle body attaches to the upper
intake.


EXHAUST MANIFOLD DESIGN

The exhaust manifold is
designed to collect hightemperature spent gases
from the head exhaust
ports.
FIGURE 6-13 The exhaust gases are

pushed out of the cylinder by the piston on
the exhaust stroke.

EXHAUST MANIFOLD DESIGN
FIGURE 6-14 This exhaust manifold has a

heat shield to help retain the heat and help
reduce exhaust emissions.

FIGURE 6-15 Many exhaust manifolds are

constructed of pressed steel and are free
flowing to improve engine performance.

HOW CAN A CRACKED EXHAUST MANIFOLD

AFFECT ENGINE PERFORMANCE?
FIGURE 6-16 A crack in an exhaust manifold is often not this visible. A

crack in the exhaust manifold upstream of the oxygen sensor can fool the
sensor and affect engine operation.

EXHAUST MANIFOLD GASKETS

Gaskets are used on new
engines with tubing- or
header-type exhaust
manifolds.
The gaskets often include
heat shields to keep
exhaust heat from the spark
plugs and spark plug
cables.
They may have several
layers of steel for hightemperature sealing.

FIGURE 6-17 Typical exhaust manifold

gaskets. Note how they are laminated to
allow the exhaust manifold to expand and
contract due to heating and cooling.

THE CORRECT TOOLS SAVE TIME
FIGURE 6-18 An exhaust manifold spreader tool is a tool that is absolutely necessary
to use when reinstalling exhaust manifolds. When they are removed from the engine,
they tend to warp slightly even though the engine is allowed to cool before being
removed. The spreader tool allows the technician to line up the bolt holes without doing
any harm to the manifold.

MUFFLERS
Sound is air vibration.
When the vibrations are large, the sound is loud.
The muffler catches the large bursts of high-pressure

exhaust gas from the cylinder, smoothing out the pressure
pulses and allowing them to be released at an even and
constant rate.
FIGURE 6-19 Exhaust gases expand and cool as they travel through the passages in the muffler.

WHY IS THERE A HOLE IN MY MUFFLER?
FIGURE 6-20 A hole in the muffler allows condensed water to escape.


MORE AIRFLOW MORE POWER
FIGURE 6-21 A high-performance aftermarket air filter often can increase airflow
into the engine for more power.

SUMMARY
1.
2.
3.
4.
5.
All air entering an engine must be filtered.

Engines that use throttle-body injection units are equipped
with intake manifolds that keep the airflow speed through
the manifold at 50 to 300 feet per second.
Most intake manifolds have an EGR valve that regulates
the amount of recirculated exhaust that enters the engine
to reduce NOX emissions.
Exhaust manifolds can be made from cast iron or stainless
steel.
The exhaust system also contains a catalytic converter,
exhaust pipes, and muffler. The entire exhaust system is
supported by rubber hangers that isolate the noise and
vibration of the exhaust from the rest of the vehicle.

REVIEW QUESTIONS
1. Why is it necessary to have intake charge
velocities of about 50 feet per second?
2. Why can fuel-injected engines use larger (and
longer) intake manifolds and still operate at low
engine speed?
3. What is a tuned runner in an intake manifold?
4. How does a muffler quiet exhaust noise?


CHAPTER QUIZ
1. Intake charge velocity has to be _____ to prevent
fuel droplet separation.
a)
b)
c)
d)
25 feet per second

50 feet per second
100 feet per second
300 feet per second


CHAPTER QUIZ
1. Intake charge velocity has to be _____ to prevent
fuel droplet separation.
a)
b)
c)
d)
25 feet per second

50 feet per second
100 feet per second
300 feet per second


CHAPTER QUIZ
2. The intake manifold of a port fuel-injected engine
_____.
a) Uses a dual heat riser
b) Contains a leaner airfuel mixture than does the intake
manifold of a TBI system
c) Contains only fuel (gasoline)
d) Contains only air


CHAPTER QUIZ
2. The intake manifold of a port fuel-injected engine
_____.
a) Uses a dual heat riser
b) Contains a leaner airfuel mixture than does the intake
manifold of a TBI system
c) Contains only fuel (gasoline)
d) Contains only air


CHAPTER QUIZ
3. Why are the EGR gases cooled before entering
the engine on some engines?
a) Cool exhaust gas is more effective at controlling NOX
emissions
b) To help prevent the exhaust from slowing down
c) To prevent damage to the intake valve
d) To prevent heating the airfuel mixture in the cylinder


CHAPTER QUIZ
3. Why are the EGR gases cooled before entering
the engine on some engines?
a) Cool exhaust gas is more effective at controlling
NOX emissions
b) To help prevent the exhaust from slowing down
c) To prevent damage to the intake valve
d) To prevent heating the airfuel mixture in the cylinder


CHAPTER QUIZ
4. A heated air intake system is usually necessary
for proper cold-engine driveability on _____.
a)
b)
c)
d)
Port fuel-injection systems

Throttle-body fuel-injection systems
Both a port-injected and throttle-body injected engine
Any fuel-injected engine


CHAPTER QUIZ
4. A heated air intake system is usually necessary
for proper cold-engine driveability on _____.
a)
b)
c)
d)
Port fuel-injection systems

Throttle-body fuel-injection systems
Both a port-injected and throttle-body injected engine
Any fuel-injected engine


CHAPTER QUIZ
5. Air filters can remove particles and dirt as small as
_____.
a)
b)
c)
d)
5 to 10 microns
10 to 25 microns
30 to 40 microns
40 to 50 microns


CHAPTER QUIZ
5. Air filters can remove particles and dirt as small as
_____.
a)
b)
c)
d)
5 to 10 microns
10 to 25 microns
30 to 40 microns
40 to 50 microns


CHAPTER QUIZ
6. Why do many port fuel-injected engines use long
intake manifold runners?
a)
b)
c)
d)
To reduce exhaust emissions

To heat the incoming air
To increase high-RPM power
To increase low-RPM torque


CHAPTER QUIZ
6. Why do many port fuel-injected engines use long
intake manifold runners?
a)
b)
c)
d)
To reduce exhaust emissions

To heat the incoming air
To increase high-RPM power
To increase low-RPM torque


CHAPTER QUIZ
7. Exhaust passages are included in some intake
manifolds. Technician A says that the exhaust
passages are used for exhaust gas recirculation
(EGR) systems. Technician B says that the
exhaust heat is used to warm the intake charge on
some engines equipped with a throttle-body-type
fuel-injection system. Which technician is correct?
a)
b)
c)
d)
Technician A only
Technician B only
Both Technicians A and B
Neither Technician A nor B

CHAPTER QUIZ
7. Exhaust passages are included in some intake
manifolds. Technician A says that the exhaust
passages are used for exhaust gas recirculation
(EGR) systems. Technician B says that the
exhaust heat is used to warm the intake charge on
some engines equipped with a throttle-body-type
fuel-injection system. Which technician is correct?
a)
b)
c)
d)
Technician A only
Technician B only

CHAPTER QUIZ
8. The lower portion of a two-part intake manifold is
often called the _____.
a)
b)
c)
d)
Housing
Lower part
Plenum
Vacuum chamber


CHAPTER QUIZ
8. The lower portion of a two-part intake manifold is
often called the _____.
a)
b)
c)
d)
Housing
Lower part
Plenum
Vacuum chamber


CHAPTER QUIZ
9. Technician A says that a cracked exhaust manifold
can affect engine operation. Technician B says
that a leaking lower intake manifold gasket could
cause a vacuum leak. Which technician is
correct?
a)
b)
c)
d)
Technician A only
Technician B only


CHAPTER QUIZ
9. Technician A says that a cracked exhaust manifold
can affect engine operation. Technician B says
that a leaking lower intake manifold gasket could
cause a vacuum leak. Which technician is
correct?
a)
b)
c)
d)
Technician A only
Technician B only


CHAPTER QUIZ
10. Technician A says that some intake manifolds are
plastic. Technician B says that some intake
manifolds are constructed in two parts or sections:
upper and lower. Which technician is correct?
a)
b)
c)
d)
Technician A only
Technician B only


CHAPTER QUIZ
10. Technician A says that some intake manifolds are
plastic. Technician B says that some intake
manifolds are constructed in two parts or sections:
upper and lower. Which technician is correct?
a)
b)
c)
d)
Technician A only
Technician B only



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OBJECTIVES

After studying Chapter 6, the reader should be able to:

Automotive Fuel and Emissions Control Systems, 2/e

2009 Pearson Higher Education, Inc.

AIR INTAKE FILTRATION

FIGURE 6-1 Downward movement of the

2009 Pearson Higher Education, Inc.

AIR INTAKE FILTRATION

FIGURE 6-2 Dust and dirt in the air are trapped in

2009 Pearson Higher Education, Inc.

AIR INTAKE FILTRATION

FIGURE 6-3 Most air filter

Automotive Fuel and Emissions Control Systems, 2/e

2009 Pearson Higher Education, Inc.

ALWAYS CHECK THE AIR FILTER

2009 Pearson Higher Education, Inc.

ENGINE AIR TEMPERATURE REQUIREMENTS

Automotive Fuel and Emissions Control Systems, 2/e

2009 Pearson Higher Education, Inc.

WHAT DOES THIS TUBE DO?

2009 Pearson Higher Education, Inc.

THROTTLE-BODY INJECTION INTAKE

FIGURE 6-6 A throttle-body injection (TBI)

2009 Pearson Higher Education, Inc.

THROTTLE-BODY INJECTION INTAKE

FIGURE 6-7 Heavy fuel droplets separate as they

2009 Pearson Higher Education, Inc.

PORT FUEL-INJECTION INTAKE MANIFOLDS

Automotive Fuel and Emissions Control Systems, 2/e

2009 Pearson Higher Education, Inc.

PORT FUEL-INJECTION INTAKE MANIFOLDS

2009 Pearson Higher Education, Inc.

PORT FUEL-INJECTION INTAKE MANIFOLDS

2009 Pearson Higher Education, Inc.

FIGURE 6-10 The air flowing into the

2009 Pearson Higher Education, Inc.

PLASTIC INTAKE MANIFOLDS

FIGURE 6-11 Many plastic intake

2009 Pearson Higher Education, Inc.

PLASTIC INTAKE MANIFOLDS

2009 Pearson Higher Education, Inc.

UPPER AND LOWER INTAKE MANIFOLDS

Automotive Fuel and Emissions Control Systems, 2/e

2009 Pearson Higher Education, Inc.

EXHAUST MANIFOLD DESIGN

FIGURE 6-13 The exhaust gases are

2009 Pearson Higher Education, Inc.

EXHAUST MANIFOLD DESIGN

FIGURE 6-14 This exhaust manifold has a

Automotive Fuel and Emissions Control Systems, 2/e

FIGURE 6-15 Many exhaust manifolds are

2009 Pearson Higher Education, Inc.

HOW CAN A CRACKED EXHAUST MANIFOLD

FIGURE 6-16 A crack in an exhaust manifold is often not this visible. A

2009 Pearson Higher Education, Inc.

EXHAUST MANIFOLD GASKETS

Automotive Fuel and Emissions Control Systems, 2/e

FIGURE 6-17 Typical exhaust manifold

2009 Pearson Higher Education, Inc.

THE CORRECT TOOLS SAVE TIME

2009 Pearson Higher Education, Inc.

The muffler catches the large bursts of high-pressure

2009 Pearson Higher Education, Inc.

WHY IS THERE A HOLE IN MY MUFFLER?