Ford 60 Service Manual

High Pressure Oil System Flow
FUEL MANAGEMENT SYSTEM
85
 • Oil reservoir is filled by the lube oil
system and contains approximately
1 qt.
 • High pressure pump is sealed
inside the crankcase, and has only
one (1) outlet.
 • High pressure pump discharge line
connects the pump to the left and
right branches and to the IPR valve
in the high pressure pump cover.
 • High pressure oil stand pipe 
connects to the branch outlets and
provides a path through the
pushrod area to the high pressure
lines. • High...

High Pressure Oil System
Schematic
FUEL MANAGEMENT SYSTEM
Oil Pump
Oil Cooler
Oil FilterOil Reservoir for
High Pressure
Pump 0.95 Qt.
High
Pressure
PumpHigh Pressure Oil RailHigh Pressure Oil Rail
Pump
Bypass
70 PSI Cooler
Bypass
25 PSIFilter
Bypass
20 PSI
IPR Valve
Drain to Crankcase
High Pressure Oil System Schematic
Contains
4000 PSI
Relief Valve
Check Valve  with  Orifice
ICP
Sensor
86
41
fastened to the cylinder head and
connected to the top of the 
injectors.
 • After lube oil is cooled and...

87
88
89
High Pressure Oil Rail with AWA
Feature IPR (Injection Control Pressure
Regulator) & ICP (Injection Control
Pressure Sensor) High Pressure Pump & Cover
FUEL MANAGEMENT SYSTEM
42
 • The high pressure oil rail has special AWA
(Acoustic Wave Attenuation) features to
dampen hydraulic noises.
 • To accomplish this an AWA fitting is placed in
the center of the high pressure oil rail and
two specially designed end caps are used.  • The IPR and ICP are both installed into the
high pressure pump cover,...

FUEL MANAGEMENT SYSTEM
Fuel Injector Features
Injector & O-rings
Injector Coils & Spool Valve
91
92
43
 • The injector uses two (2) 48 volt 20 amp
coils to control a spool valve that directs oil
flow in and out of the injector.
 • The injector coils are turned on for 
approximately 800 µsec (micro second or
millionth of a second).
 • No special tools are needed to remove the
injectors from their bore. The injector is
slowly removed from its bore by removing
the hold down clamp bolt.
 • The injector has...

93
94
95
Injection Nozzle Plunger & Barrel
Intensifier Piston
FUEL MANAGEMENT SYSTEM
44
 • When the spool valve is in the open position,
high pressure oil is allowed to enter the
injector and pushes the intensifier piston and
plunger downward.
 • Since the intensifier piston is 7.1 times
greater in surface area than the plunger, the
injection force is also 7.1 times greater at
the plunger than what the injection control
pressure (ICP) is.
 • The bottom of plunger and barrel of the
injector is where the...

97
Fill Cycle Stages of Injection
FUEL MANAGEMENT SYSTEM
45
 • The injection cycle has three (3) stages.
 • Fill.
 • Main injection.
 • End of main injection.
 • During some conditions the injector will 
perform all three steps of the injection cycle
two times per firing cycle. This is called pilot
injection.
 • During the fill stage, the spool valve is in the
closed position.
 • High pressure oil from the oil rail is dead
headed at the spool valve.
 • Low pressure fuel fills the port below the
plunger....

98
99
Main Injection Step 2 Main Injection Step 1
FUEL MANAGEMENT SYSTEM
46
 • Pulse width controlled current energizes the
open coil, magnetic force moves the spool
valve to the open position.
 • High pressure oil flows past the spool valve
into the intensifier piston chamber.
 • Oil pressure overcomes the intensifier piston
spring force and the intensifier starts to
move.
 • Fuel inlet check ball seats due to an
increase of fuel pressure under the plunger.
 • Fuel pressure starts to build once the...

100
101
End of Main Injection Step 2 End of Main Injection Step 1
FUEL MANAGEMENT SYSTEM
47
 • When the IDM (Injector Drive Module) 
determines that the correct injector on time
has been reached (meaning that the correct
amount of fuel has been delivered), it sends
a pulse width controlled current to the close
coil of the injector.
 • The current energizes the close coil.
Magnetic force moves the spool valve to the
closed position.
 • High pressure oil is dead headed against the
spool valve.
 • The pulse...

48
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 • The PCM uses information from the sensors
to decide which commands to send to the
FICM, the actuators, and the glow plug 
system.
Generation II Electrical Components
Overview
ELECTRICAL COMPONENTS
103
49
 • The PCM sends a Vref of 5.0 volts
to the engine sensors except for
CMP and CKP which generate 
voltage through the collapse of a
magnetic field.
 • The PCM uses 5 volts as the 
reference voltage to maintain 
consistency throughout all 
operating conditions.
 • The Vref is conditioned by the...