Ford 60 Service Manual
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58 59 • A secondary fuel filter is mounted to the oil filter housing. • The secondary filter is a 4 micron cartridge style filter. • It also incorporates a fuel pressure regulator and an air bleed (to allow air to escape after a filter change). Fuel from the regulator is returned to the HFCM. • The fuel pressure regulator is mounted to the engine mounted fuel filter. • It regulates fuel pressure by routing unfiltered fuel from the filter housing to the HFCM via a spring loaded poppet style valve. • The cracking pressure(pressure at which the valve begins to open) of the valve is 60psi +\- 5psi. Actual fuel pressure may be above or below this specification. Fuel Inlet Check Valves Fuel Pressure Regulator FUEL SUPPLY SYSTEM 30 • Each cylinder head has a fuel inlet check valve at the front of the head. • The check valve is incorporated into the bolt for the banjo fitting that attaches the fuel line to the head. • The check valves are used to maintain constant fuel pressure in the fuel rail. • The fuel lines are sealed to the head by two copper gaskets. • Note: It is recommended that the copper gaskets be replaced if the bolt has been removed. Engine Mounted Fuel Filter 57 SECONDARY FUEL FILTER SECONDARY FUEL FILTER FUEL PRESSURE TEST PORT FUEL PRESSURE TEST PORTFUEL REGULATOR FUEL REGULATOR FUEL RETURN LINE FUEL RETURN LINE FUEL REGULATOR FUEL REGULATOR FUEL RETURN LINE FUEL RETURN LINE COPPER GASKETS COPPER GASKETS INLET CHECK VALVE INLET CHECK VALVE
• The air management system is made up of the air filter, turbocharger, charge air cooler, intake manifold, and the EGR system. Air Management System Features AIR MANAGEMENT SYSTEM Air Management System Components/Features • Air Filter/Filter Minder • Variable Geometry Turbocharger (VGT) • Charge Air Cooler • Intake Manifold • EGR System 60 Air management System Flow 31 FROM CHARGE AIR COOLER EGR VALVE COMPRESSOR OUTLET EGR COOLER TURBINE OUTLET COMPRESSOR INLETTHROTTLE BODY 61
AIR MANAGEMENT SYSTEM 62 32 manifold has a passage that connects it to the exhaust gas recirculation (EGR) cooler. • The exhaust gasses, cooled by the EGR cooler are sent to the EGR valve in the intake manifold. • The EGR valve controls the flow of exhaust gases into the intake system where the gases are mixed with intake air to reduce NOx (Nitrogen Oxide) emissions and noise. • The hot and expanding exhaust gases that are routed to the turbocharger turbine, spin the turbine wheel through flow and expansion. The spinning turbine wheel in turn spins the compressor wheel via a common shaft. • The CAC condenses the air by cooling it then the air returns to the engine through the intake manifold. • There is a throttle body on the intake manifold. The throttle body may or may not have a throttle plate. For 2003.25 the throttle plate will not be active in the pcm strategy • The intake manifold directs the air to the intake ports of the cylinder heads. • The burned air fuel mixture is pushed out of the cylinder into the exhaust manifold which collects the exhaust gases and routes them to the turbocharger turbine wheel. • The exhaust up pipe, connected to the passenger side exhaust • Air enters the system through the air filter where particles are removed from the air. The air filter has a filter minder on it to warn the operator of a restricted air filter. • After the air is filtered, the mass of the air and temperature is measured by the mass air flow sensor (MAF). • The filtered air is then directed past the crankcase ventilation system where crankcase vapors and fresh air are mixed. • After mixing with crankcase vapors the fresh air mixture is drawn into the turbocharger compressor where it is compressed and sent to the charge air cooler (CAC).System Flow VGT Control Valve
63 64 65 Air Filter Element • The charge air cooler is located in the front of the radiator. • It is an air to air cooler designed to lower the temperature of the air coming out of the turbocharger outlet before entering the intake manifold. • The new air filter element is made into the air filter housing. When replacing the filter, the entire housing will have to be replaced. • The air filter is capable of holding 1600 grams of particulates before needing replacement. • The filter element is a honeycomb design. • The air filter is located on the drivers side of the engine compartment between the battery and the radiator. • A filter minder, device used to measure filter restriction, is located on the back of the air filter housing. • Fresh air, from the drivers side fender and the grill area, is drawn into the air filter and particulates are removed from the air before going to the engine. Charge Air Cooler Air Filter / Filter Minder AIR MANAGEMENT SYSTEM 33 CHARGE AIR COOLER PIPES CHARGE AIR COOLER PIPES COMPRESSOR OUTLET COMPRESSOR OUTLET INTAKE MANIFOLD INTAKE MANIFOLD FILTER MINDERFILTER MINDER
67 68 VGT Turbine VGT Compressor VGT Features AIR MANAGEMENT SYSTEM VGT Turbocharger Features • Electronically Controlled Hydraulically actuated • Low & High Engine Speed Boost Control • Incorporates Fast Warm-Up Device 66 34 • The turbocharger for the 6.0LPower Stroke engine is designed to provide boost control at low and high speeds for improved throttle response. • The Variable Geometry Turbocharger (VGT) is electronically controlled and hydraulically actuated. • The VGT may also be referred to as EVRT. • When the vanes of the turbocharger are closed, the engine will have a higher exhaust back pressure and create more heat which will in turn warm the engine faster in cold ambient conditions. • The compressor on the VGT is similar to the compressor on a conventional turbocharger. • The compressor wheel is connected to the turbine via a common shaft. • The VGT uses a turbine wheel that is similar to a conventional turbocharger but the turbine housing has changed. • The turbine housing contains vanes that control the effective size of the housing. These vanes are hydraulically actuated and electronically controlled. COMPRESSOR HOUSING COMPRESSOR HOUSING TURBINE HOUSING TURBINE HOUSING TURBINE OUTLET TURBINE OUTLET TURBINE INLET TURBINE INLET
69 VGT Control Valve AIR MANAGEMENT SYSTEM 35 • The VGT control valve is commanded by the PCM, based on engine speed and load. The magnetic field generated by this signal moves a shaft in the control valve. This movement meters engine oil through the valve to either side of the piston. This design feature reacts quickly to changes in demand based on driving conditions. When one side of the piston is pressurized, the opposite side is vented. • Depending on which side of the piston is pressurized, the vanes either open or close. A cam follower at the end of the valve assembly provides feedback to the valve allowing it to reach a neutral position during times the vanes are not commanded to move.VGT COILOIL DRAIN TO PAN OIL TO CLOSE SIDE OF PISTON OIL SUPPLY OIL TO OPEN SIDE OF PISTONCAM FOLLOWER 70 VGTCV Flows • When the VGTCV is commanded to the full open position, low or no duty cycle, oil from the oil supply line is directed to the open side of the actuator piston. • Oil on the closed side of the piston is then directed through the actuator piston, back to the VGTCV, and then to drain. • Note: If the VGTCV is disconnected the valve will default to the open position. • Once the desired turbocharger vane position is obtained, the VGTCV goes to a neutral position and both the open and closed sides of the actuator piston is blocked off. • When the VGTCV is commanded to the full closed position, high duty cycle, oil from the oil supply line is directed through the actua- tor piston to the closed side of the piston. • Oil on the open side of the piston is directed back to the VGTCV and then to drain. 72 71
75 VGT Turbine Vanes Open AIR MANAGEMENT SYSTEM 36 • During engine operation at high engine speeds and load, there is a great deal of energy available in the exhaust. • Excessive boost under high speed, high load conditions can negatively affect component durability, therefore the vanes are commanded open preventing turbocharger overspeed. • Essentially, this allows the turbocharger to act as a large turbocharger. ACTUATOR PISTON UNISON RING VANES ACTUATOR PISTON UNISON RING VANES 74 UNISON RING VANES ACTUATOR PISTON 73 • During Engine operation at moderate engine speeds and load, the vanes are commanded partially open. • The vanes are set to this intermediate posi- tion to supply the correct amount of boost to the engine for optimal combustion as well as providing the necessary back pressure to drive EGR. • Note: The VGT control valve piston is coupled to the vanes through a shaft and the unison ring. VGT Turbine Vanes Partially Closed • During engine operation at low engine speeds and load, little energy is available from the exhaust to generate boost. In order to maximize the use of the energy that is available, the vanes are closed. In doing so, the exhaust gas is accelerated between the vanes and across the turbine wheel. In general, this allows the turbocharger to behave as a smaller turbocharger than it actually is. • Closing the vanes also increases the back pressure in the exhaust manifold which is used to drive the exhaust gas through the EGR cooler and valve into the intake manifold. This is also the position for cold ambient warm up. VGT Turbine Vanes Closed
• The EGR cooler is a coolant to air heat exchanger that is used to cool the exhaust gases before they are sent to the EGR valve. • The exhaust gasses are routed into the EGR cooler from the exhaust up pipes at the rear of the engine. • The exhaust gasses are cooled by passing through metal tubes that are surrounded by engine coolant. Depending on conditions, the temperature drop across the cooler could be as much as 700°F. • The cooled gasses are then routed to the EGR valve that is mounted in the intake manifold. EGR Cooler EGR Flow EGR Valve AIR MANAGEMENT SYSTEM 37 • The PCM controlled EGR (Exhaust Gas Recirculation) valve adds cooled exhaust gases to the intake manifold to reduce NOx emissions. • The EGR valve is opened during steady state throttle positions when exhaust back pressures are higher than intake manifold pressures (boost). • The EGR valve has two valves connected by a common shaft. • Cooled exhaust gases come to the center of the valve through a passage in the intake manifold. • When the valves open they allow exhaust gases to flow into the intake air stream from the top and bottom of the passage. 76 78 77 EGR VALVE EGR COOLER EGR COOLER EXHAUST CONNECTION COOLED EXHAUST O-RING SEALSINTAKE
AIR MANAGEMENT SYSTEM 38 • The intake manifold on the 6.0LPower Strokeis made of aluminum and directs the flow of air to the intake ports in the cylinder heads . • The Intake manifold provides a path for coolant from the EGR cooler to the front cover. • There is a passage for EGR gasses to go to the EGR valve where they mix with compressed intake air. • The manifold absolute pressure sensor (MAP) port and the intake air temperature 2 (IAT2) sensor are both mounted in the intake manifold. • The passage at the rear of the manifold is to equalize pressure on both sides of the manifold. Intake Manifold INTAKE MANIFOLD EGR COOLER 81 NO THROTTLE PLATE 80 THROTTLE PLATE 79 • All 2003.25 6.0L Power Stroke engines are equipped with a throttle body. • Some early versions also have a throttle plate in the throttle body. Later versions will retain the throttle body, but not the throttle plate. • The throttle was designed to assist with EGR operation, but later was determined unnecessary. • The PCM software for controlling the throttle body was not added and the plate was removed. • The throttle body may become operational for the 2004 model year. • Note: All engines have the wiring plugged into the throttle body and position sensor even if the throttle plate is not present. EGR Throttle
FUEL MANAGEMENT SYSTEM • The generation II fuel management system uses high pressure oil and electronics to actuate and control fuel injection into the cylinders. Generation II Fuel Management System Diagram 82 Fuel Management System Major Components • Fuel Supply System • High Pressure Oil System • Lubrication System • Sensors • Injectors • Electrical Components • Actuators 83 • The fuel management system is comprised of several sub systems. • Fuel Supply System. • High Pressure Oil System. • Lubrication System. • Sensors. • Injectors. • Electrical Components. • Actuators. Generation II Fuel Management System Major Components Generation II Fuel Management System Advantages • Emissions and noise have been reduced through improvements in rate and timing control. • No external high pressure oil lines exist. • The high pressure system’s pressure relief is located in the IPR (Injection Pressure Regulator). Fuel Management System Features • Emissions • Noise • Rate Control • Timing Control • No External High Pressure Lines • IPR valve with integrated pressure relief 84 39