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F2.8 Air Handling System

Scene Number: Scene Title Course Information
2074 1000
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All numbers and specifications listed in this program are used for illustration purposes only.
Current information can be found in the Service Manuals located on QuickServe Online.
Scene Number: 2074 1010 Scene Title Objectives

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Upon completion of this course the technician will be capable of:
Describing the air flow through the F2.8 engine's air handling system and
Identifying the F2.8 engine air handling system components.
Scene Number: 2074 1030 Scene Title Turbocharger

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Cummins F2.8 series engines feature a wastegate turbocharger. The turbocharger’s
wastegate allows a more efficient turbocharger to be installed on a smaller engine to create
higher boost pressures at low RPMs to increase low-end torque, but reducing excessive
boost pressure at higher engine RPMs to protect the engine.
Different mounting angles are available to allow the engines to adapt to more vehicle
applications.
Scene Number: 2074 1040 Scene Title Compressor

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A cast aluminum compressor wheel is featured on F2.8 series engine turbochargers. The
compressor wheel is shaft driven by the turbine.
Care should be exercised whenever handling the turbocharger or whenever the compressor
wheel is exposed. The compressor housing on F2.8 series engines cannot be rotated.
Scene Number: Scene Title Turbine
2074 1050
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A cast iron turbine is featured on F2.8 series engines. The turbocharger scavenges wasted
thermal energy from the engine in the form of hot exhaust gases. The exhaust gases force the
rotation of the turbine, which drives the cross shaft that rotates the compressor wheel and
compresses additional intake air for improved combustion.

Tuesday, November 03, 2009 Page 1 of 5

 F2.8 Air Handling System
Scene Number: Scene Title Charge Air Cooler
2074 1070
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The turbocharging process involves compression of air. As air molecules are compressed,
friction occurs. This friction creates heat that increases the temperature of the air. Cummins
F2.8 series engines require an air-to-air heat exchanger to reduce the temperature of the air
entering the intake manifold. This heat exchanger is termed a Charge Air Cooler or CAC.
A CAC is more effective than an aftercooler using engine coolant to reduce the temperature
of the charge air entering the engine.
Scene Number: Scene Title Engine Air Intake
2074 1080
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Cummins F2.8 series engines feature cast aluminum intake air connections.
These connections are bolted to the intake manifold and sealed with an o-ring.
The air inlets are fixed and cannot be rotated.
Scene Number: Scene Title Intake Air Heater
2074 1100
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The F2.8 series engines require the use of an intake air heater to warm intake air prior to
starting and to aid combustion following cold starting. The intake air heater is powered
through an OEM supplied relay that is controlled by the ECM. The ECM uses sensed intake
manifold temperature to determine if pre-start heating is required or if post-start heating may
also be required.
During engine cranking the ECM will de-energize the intake air heater relay to allow more
amperage for engine cranking.
The intake air heater is located at the inlet of the intake manifold. The intake air heater is
internally grounded and has one external positive connection.
Scene Number: Scene Title Intake Manifold
2074 1110
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The F2.8 series engines feature a true intake manifold. The manifold is cast aluminum and
bolted to the fuel pump side of the cylinder head. The manifold contains the intake air heater
and the combination intake manifold temperature and pressure sensor. The manifold is
sealed to the cylinder head with a molded gasket.
Scene Number: 2074 1120 Scene Title Exhaust Manifold

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The exhaust manifold is a one-piece design.
ISF2.8 E engines will have an additional port on the exhaust manifold to supply exhaust gas
to the EGR cooler.

Tuesday, November 03, 2009 Page 2 of 5

 F2.8 Air Handling System
Scene Number: Scene Title EGR engines
2074 1130
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Some F2.8 series engines will require an exhaust gas recirculation system, or EGR, to meet
emission certification requirements.
For these engines the exhaust manifold will feature a second outlet. This flanged outlet will
supply exhaust gasses to the EGR cooler and control valve assembly.
The exhaust manifold will also act as a mounting location for the cooler and control valve
assembly.
Scene Number: Scene Title EGR System Overview
2074 1150
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The EGR system does not operate during all times of engine operation. The principal of
EGR is to reduce peak combustion temperatures in the combustion chamber. Peak
combustion temperatures allow the creation of NOx, and by preventing these peak
temperatures, the engines NOx emissions can be reduced in cylinder.
By mixing exhaust gases with intake air, some oxygen is replaced in the combustion
chamber, which slows down the combustion process, thereby reducing the temperatures. F
2.8 series engines featuring the EGR system have other features when compared to the non-
EGR engines. Let’s take a look at these components.
Scene Number: Scene Title EGR Cooler
2074 1160
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The EGR cooler is constructed of stainless steel and cooled with coolant from the water
jacket of the cylinder block. The function of the cooler is to cool the exhaust gases, which
reduces the volume of the gas before it is mixed with intake air.
Scene Number: Scene Title EGR Control Valve
2074 1170
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The control valve is an intelligent device that communicates with the ECM via the SAE
J1939 data link. When the ECM determines that conditions in the combustion chambers
could allow for the creation of NOx, the ECM determines the temperature and pressure of
exhaust gas in the EGR system and commands the EGR control valve to open to a
percentage based on those readings and other parameters.
Scene Number: 2074 1180 Scene Title Air Intake Connection

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The air intake connection directs air to the air intake manifold.

Tuesday, November 03, 2009 Page 3 of 5

 F2.8 Air Handling System
Scene Number: Scene Title Engine Throttle Actuator
2074 1190
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The engine throttle actuator is an intelligent device found on F2.8 series engines featuring
EGR systems.
The engine throttle actuator is used by the ECM to optimize the EGR system by balancing
the pressures of the charge air from the turbocharger and the EGR gases from the exhaust
system.
This pressure balance is required due to the difference in pressures created by these two
systems.
Scene Number: 2074 1230 Scene Title Air Flow

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The following section will cover the air flow through the F2.8 liter engine.
Scene Number: Scene Title Turbocharger Air Flow
2074 1240
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The intake air is drawn through the air cleaner into the compressor side of the turbocharger.
Scene Number: Scene Title Charge Air Cooler Air Flow
2074 1250
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After leaving the turbocharger, the hot intake air flows to the charge air cooler through
charge air tubing.
Once inside the charge air cooler, heat from the intake air is transferred to the outside air
flowing around the fins of the cooler, decreasing the temperature of the intake air.
The cooled intake air leaves the charge air cooler and enters the air inlet connection through
charge air tubing.
Scene Number: Scene Title Intake Manifold Air Flow
2074 1260
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Air flow from the air inlet connection travels through the intake manifold and continues
through the inlet ports creating a swirl pattern into the combustion chambers.
Scene Number: 2074 1270 Scene Title Exhaust Manifold Air Flow

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After combustion, the exhaust gases flow from the combustion chambers to the opposite
side of the cylinder head and through the exhaust manifold to the turbo housing of the
turbocharger.
From here the gases exit the exhaust system.

Tuesday, November 03, 2009 Page 4 of 5

 F2.8 Air Handling System
Scene Number: Scene Title F2.8 Air Flow with EGR
2074 1280
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Engines equipped with EGR, redirect a portion of the exhaust gas from the exhaust manifold
to an EGR valve.
Scene Number: 2074 1290 Scene Title EGR Cooler Air Flow

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When the EGR valve opens the exhaust gas travels to the EGR cooler, where the exhaust gas
is cooled by coolant traveling perpendicular to the exhaust gas.
Scene Number: 2074 1300 Scene Title Intake Manifold with EGR Air Flow

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Once cooled, the exhaust travels to the intake manifold through EGR tubing where it is
mixed with fresh intake air.
Scene Number: Scene Title Conclusion
2074 4000
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You are about to leave the Virtual Classroom and take the assessment.
Select "Next" to continue to the assessment. Select "Back" to return to the Virtual Classroom
or click on the Program Guide icon to view the program guide.
Note: If you are in Review Mode selecting "Next" will either return you to the Main Menu if
you have completed all of the courses in your Play List, or it will take you to the next course
in your Play List.
Scene Number: Scene Title Assessment
2074 4010
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True or False: During engine cranking the ECM will de-energize the intake air heater relay
to allow more amperage for engine cranking.
Scene Number: 2074 4020 Scene Title Assessment

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The EGR control valve is an intelligent device that communicates with the ECM via which
data link?
Scene Number: Scene Title Assessment
2074 4030
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How many pieces make up the exhaust manifold?
Scene Number: 2074 4040 Scene Title Assessment

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How many pieces make up the air intake manifold for this engine?

Tuesday, November 03, 2009 Page 5 of 5