AIR INTAKE SYSTEM AIR INTAKE SYSTEM

GROUP 540

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Summer Intake Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Winter Intake Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Intake Diverter (Hydraulically Controlled Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1. INTRODUCTION
The diesel engine requires about 12,500 gallons of air for every gallon of fuel that burns. For the engine to operate efficiently, it must breathe freely; the intake and exhaust must not be restricted. If there is too little air to burn all the fuel, some of the excess fuel will cause a smokey exhaust -- a sign of wasted dollars and lost horsepower. In addition, the excess fuel washes lubricating oil off cylinder walls resulting in seized pistons and bearing failures. A dirty air cleaner element is a common cause of air restriction. However, over-servicing an engine air cleaner system can be as detrimental to the engine as lack of service. Each time the element is removed, a small amount of ambient dirt is introduced into the engine. Filter removal should be done only on an as required basis. Never run the engine with the filter element removed.

Servicing schedule is based on the restriction of air flow through the filter element. A restriction indicator is provided with the P2 and is located on the air intake piping (Figure 1). When the filter becomes loaded with dirt to a point where air flow restriction exceeds the engine manufacturers recommendations for maximum restriction, the red portion of the indicator becomes visible. Although the indicator has popped into the red, there is no real cause for alarm. The element is designed with a sufficient safety factor to withstand several times these maximums without collapsing or leaking dirt into the engine through the filter paper. Some power loss may be experienced however, and the element should be changed as soon as possible.

Air Cleaner Housing

Restriction Indicator

Air Cleaner Cover

90 Degree Intake Elbow

Air Cleaner Cover Clamps (3 Places)

Fig. 1. Air Cleaner Assembly

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Use of the correct replacement filter element is essential. Absence of proper sealing between the element and the air cleaner housing may occur if elements other than original equipment replacements are used. This will result in dirt passing between the filter sealing surface and air cleaner housing and into the engine, eventually leading to engine contamination and failure. When the air cleaner is disassembled for element replacement or cleaning, sealing surfaces should be inspected and any indications of an improper seal must be corrected. Lubricate any clamp bolts or nuts to assure that the new element will be properly sealed when installed. All hose-piping connections should be checked for tightness. Each connection between the air cleaner and the engine intake manifold must be air tight. If dirt deposits are discovered in the piping or at any point on the clean-side of the air cleaner, the leak must be isolated and corrected. Spraying piping connections with ether is a common, approved method of isolating intake system leaks. With the engine running at approximately 1000 RPM, an increase in engine speed will be noticed if ether leaks into the inlet system. After servicing the air cleaner, reset the air restriction indicator.

AIR INTAKE SYSTEM

1.1 Summer Intake Setting. If your truck is not equipped with the intake diverter switch on the dash board, it is a manual model that requires the intake diverter to be changed under the hood. If the temperature will be consistently above 32o F, set the diverter plate as shown in Figure 2. (1) (2) Open both the left and right side hood access doors and secure with prop rods. If the truck is currently in the winter mode, the summer cover plate will be stored beneath the hood intake duct as shown in the Winter Installation portion of Figure 3. Unbolt the summer cover plate from the storage position on both the left and right side of the hood. Remove the diverter plates from the winter position inside the hood ducts on both the left and right side of the hood. See Figure 3. Flip the diverter plates over so they are angled inside the hood. Install the summer cover plates between the diverter plates and the hood. Bolt both plates into position on the hood duct. When installed correctly, diverter plates on both the left and right side of the hood should have the angled tab facing up (towards top of hood) as shown in Figure 2. SUMMER CONFIGURATION Summer Air Cover Plate

(3)

(4)

(5)

(6)

Hood Vent Intake Diverter Passengers Side (Not Shown) Intake Diverter Drivers Side

Fig. 2. Air Intake Diverter Summer Configuration

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AIR INTAKE SYSTEM

1.2 Winter Intake Setting. If your truck is not equipped with the intake diverter switch on the dash board (Fig. 4), it is a manual model that requires the intake diverter to be changed under the hood. If the temperature will be consistently below 32o F, set the diverter plate as shown in Figure 3. (1) (2) Open both the left and right side hood access doors and secure with prop rods. If the truck is currently in the summer mode, the summer cover plate will be installed behind the diverter plate as shown in the Summer Installation (Figure 2). Unbolt both the summer cover plate and the WINTER CONFIGURATION Intake Diverter

GROUP 540
intake diverter from the hood vent on both the left and right side of the hood. (4) Install the summer cover plates in the winter storage position beneath the hood ducts on both the left and right side of the hood. See Figure 3. Flip the diverter plates over so they are angled inside the vents in the hood. Bolt both plates into position in the hood duct. When installed correctly, diverter plates on both the left and right side of the hood should have the diverter facing into the vent and the angled tab facing up (towards top of hood).

(5)

(6)

(3)

Summer Air Cover Plate

Intake Diverter Drivers Side (Not Shown)

Hood Vent

Fig. 3. Air Intake Diverter Winter Configuration

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1.3 Intake Diverter (Hydraulically Controlled Models). Use the intake diverter to control the engine intake air during operation in hot and cold temperatures. During warm weather operation (Above 32oF) select

AIR INTAKE SYSTEM

outside air, and during cold weather operation (Consistently below 32oF) select under hood air. See Figure 4.

Fig. 4. Intake Diverter Dash Control (Electro-Hydraulic Models)

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AIR INTAKE SYSTEM 2. TROUBLESHOOTING

Trouble
Engine will not deliver full power: 1. 2.

GROUP 540

Probable Cause
Clogged air intake system. Foreign material lodged in compressor or turbine wheel. Excessive dirt buildup in compressor. Leak in air cooler or piping to the engine (Refer to group 520) 1. 2.

Remedial Action
Check air cleaner and clean air intake ducts. Remove, disassemble and clean turbocharger. Refer to the Engine Manufacturers Service Manual. Thoroughly clean compressor assembly. Clean air cleaner and check for leaks. Check all connections for secure clamps. Replace humped hose connections if they are cracked. The air cooler must be replaced if damaged. Do not attempt to patch or weld the unit as further damage to fins or header joints will result. Check that underhood diverter is set correctly for the prevailing temperature. Clean and replace filter element. Remove obstruction. Switch underhood air diverter to winter position. Check air cleaner restriction indicator. Check filter for icing in wet/freezing conditions. Replace filter if necessary. Clean and/or replace oil lines to turbocharger. Refer to Engine Manufacturers Service Manual. Remove, disassemble and inspect turbocharger. Refer to Engine Manufacturers Service Manual. Tighten all loose connections or replace exhaust manifold and/or manifold gaskets as necessary. Remove and overhaul turbocharger. Refer to the Engine Manufacturers Service Manual.

3.

3.

4.

4.

5.

Intake Diverter set incorrectly

5.

Black or gray exhaust smoke (engine water temperature 60_F (71_ minimum) indicating incompletely burned fuel. Engine running rough, misfiring.

1. 2. 1.

Air cleaner clogged. Obstruction in air inlet piping. Underhood air diverter set on summer mode in sub--freezing temperature. Air cleaner clogged or restricted.

1. 2. 1.

2.

2.

Turbocharger noisy or vibrating:

1.

Wheel shaft bearings are not being lubricated. Improper clearance between turbine wheel and housing. Leak in turbocharger air intake or exhaust connection.

1.

2.

2.

3.

3.

4.

Rotating assembly bearing seizure. 4.

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AIR INTAKE SYSTEM

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