electrical components components...

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Electrical Components

•Sensors

•Actuators

•ECM

•GlowPlugSystem

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ElEctrical componEnts

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Components Overview

• TheECMusesinformationfromthesensorstodecidewhichcommandstosendtotheactuators,andtheglowplugsystem.

Sensors Overview

• TheECMsendsareferencevoltage(Vref)of5.0volts(externalpower)tothepressuresensorsand5.0volts(internalpower)tothetemperaturesensors,exceptforCMPandCKPwhichgeneratevoltagethroughthecollapseofamagneticfield.

• ThesensorsignalsareconditionedbytheinterfacecircuitswithintheECM.Thesignalsareusedasinputstovariouscontrolstrategies.

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AP (Accelerator Pedal Position)

• TheAP(AcceleratorPedal)isathreetrackpedal.TheAPincorporatesthreepotentiometers.ThroughoutthemovementoftheAPtheresistancevaluesofthethreepotentiometersmustagree.DuringthemovementoftheAPifanyofthethreepotentiometerreadingsdonotagree,thecheckenginelightwillilluminateandthevehiclewillcontinuetoperformasnormal.IftwosignalsfromtheAParelosttheECMwillallowtheenginetoidleonlyandilluminatethecheckenginelight.

• Havingthree(3)signalsforcomparisonisanaddedsafetyfeature.

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Baro (Barometric Pressure)

• TheECMsuppliesa5voltreferencesignalwhichtheBarosensorusestoproducealinearanalogvoltagesignalthatindicatespressure.

• TheprimaryfunctionoftheBarosensoristoprovidealtitudeinformationsothattheECMcanadjusttiming,fuelquantity,glowplugontime,andturbochargercontrol.

• TheBarosensorislocatedinsidetheECM.Ifthesensorfails,theECMmustbereplaced.

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CKP (Crankshaft Position)• Thecrankshaftpositionsignalsourceisamagneticpickup

sensormountedintherightfrontsideoftheengineblock.

• Thesensorreactstoatriggerwheelpositionedonthecrankshaft.Thetriggerwheelisa60minus2toothsteeldiskwith58evenlyspacedteethandaslotthat’swidthisequivalenttoremoving2teeth(minus2slot)thatistheSYNCgap.

• Thesensorproducessinewaves(convertedtosquarewavesviatheECM)foreachtoothedgethatbreaksthemagneticfieldcreatedbythepermanentmagnetthatisintheendofthesensor.

• CrankshaftspeedisderivedfromthefrequencyoftheCKPsensorsignal.

• CrankshaftpositioncanbedeterminedbythesyncronizationoftheCMPpegsignaltotheCKPminus2slotsignal.

• DiagnosticinformationontheCKPinputsignalis

obtainedbyperformingaccuracychecksonfrequency.

• TheECMneedsboththeCKPandCMPsignaltocalculateengineposition.TheCKPcreatesasignalthatrelatestocrankshaftspeedandpositionrelativetoTDC(TopDeadCenter).TheCMPcreatesasignalrelativetowhichstrokethepistoniscurrentlyon(compressionorexhaust).

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• TheECMneedsboththeCKPandCMPsignaltocalculateengineposition.TheCMPcreatesasignalthattheECMusestoindicateaparticularbank.

• TheCMPcontainsapermanentmagnetwhichcreatesamagneticfield,whenthemagneticfieldisbrokenbythepegonthecamshaftasignalintheformofasinewaveiscreated(convertedtoasquarewavebytheECM).

Pressure Control Valve

VolumeControl Valve

Crankshaft Position Sensor

Throttle Body

EEn

gine

Cha

ssis

TurbochargerActuator

EGRValve

CMP (Camshaft Position)

• Thecamshaftpositionsignalsourceisamagneticpickupsensormountedontheleftfrontsideoftheengineblock.

• Thesensorreactstoapeg,pressedintothecamshaftatthefrontoftheengine.

• Thepegwillpassthesensoroncepercamshaftrevolution,thesensorwillproduceasinglepulsecorrespondingly.

• CamshaftspeedisderivedfromthefrequencyoftheCMPsensorsignal.

• DiagnosticinformationontheCMPinputsignalisobtainedbyperformingaccuracychecksonsignallevelsandfrequency.

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ECT (Engine Coolant Temperature)

• TheECTsensorisatwo(2)wirethermistorsensor.

• TheECTsensor’sinternalthermistorformsavoltagedividerwithapullupresistorinsidetheECM.

• TheECTsensorchangesresistancewhenexposedtodifferenttemperatures.

• Whenthetemperatureofthecoolantdecreases,theresistanceofthethermistorincreasesandthesignalvoltageincreases.

• Whenthetemperatureofthecoolantincreases,theresistanceofthethermistordecreasesandthesignalvoltagedecreases.

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EGRVP (EGR Valve Position)

• TheEGRVPsensorisathree(3)wirepotentiometertypesensor.

• TheECMsuppliesa5voltreferencevoltagethattheEGRVPusestoproducealinearanalogvoltagethatindicatestheamountofmovementofthevalve.

• TheECMmonitorsEGRVPastheengineisoperatingtomodulatetheEGRvalve.

• ThisisaclosedloopfunctionwhichmeansthattheECMcontinuouslymonitorstheEGRVPtoensurepropervalveposition.

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EOP (Engine Oil Pressure)

• TheEOP(EngineOilPressure)isaswitchthatclosesacircuittogroundafterengineoilpressurereachesapproximately5-7psi.

• Thisswitchcontrolstheoilpressuregaugeontheinstrumentpanel.Whenpressureisabove7psithegaugewillreadnormalandifthepressuredropsbelow5psithegaugewillshow0.

• TheinformationfromtheswitchisnotsentbacktotheECMinanywayandistobeusedasareferenceonly.

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EOT (Engine Oil Temperature)

• TheEOTsensorisatwo(2)wirethermistortypesensor.

• TheEOTsensor’sinternalthermistorformsavoltagedividerwithapullupresistorinsidetheECM.

• TheECMmonitorsengineoiltemperatureviatheEOTsensorsignaltoaidincontrollingfuelrailpressure(FRP)andfancontrol.

• TheEOTsignalallowstheECMtocompensateforoilviscosityvariationsduetotemperaturechangesintheoperatingenvironment,ensuringadequatepowerandtorqueareavailableforalloperatingconditions.

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IAT1 (Intake Air Temperature #1)

• TheIntakeAirTemperature1(IAT1)sensorisatwowirethermistorsensorthatislocatedinsidetheMassAirFlow(MAF)sensor.

• TheIAT1sensor’sinternalthermistorformsavoltagedividerwithapullupresistorinsidetheECM.

• TheIAT1sensor’sprimaryfunctionistomeasureintakeairtemperaturetoaidincontrollingEVTGandtheglowplugsystem.

• TheMAF/IAT1sensorismountedintheintakeairpipingaftertheairfilter.

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IAT2 (Intake Air Temperature #2)

• TheIAT2sensorisatwo(2)wirethermistortypesensor.

• TheIAT2sensorchangesresistancewhenexposedtodifferentairtemperature.

• TheprimaryfunctionoftheIAT2sensoristoprovideafeedbacksignaltotheECMindicatingmanifoldairtemperature.

• TheIAT2sensor’sinternalthermistorformsavoltagedividerwithapullupresistorinsidetheECM.

• TheECMmonitorstheIAT2signaltocontroltemperaturebyadjustingotherdevices.

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FRP (Fuel Rail Pressure)

• TheFRPsensorisa(3)wirevariablecapacitancesensor.

• TheECMsuppliesa5voltreferencesignal(Vref)whichtheFRPsensorusestoproducealinearanalogvoltagethatindicatespressure.

• TheprimaryfunctionoftheFRPsensoristoprovideafeedbacksignaltotheECMindicatingthepressureofthefuelinthefuelrail.

• TheECMmonitorsFRPastheengineisoperatingtomodulatethePCV.ThisisaclosedloopfunctionwhichmeanstheECMcontinuouslymonitorsandadjustsforidealFRPdeterminedbyconditionssuchasload,speed,andtemperature.

• TheECMmonitorstheFRPsignaltodetermineiftheperformanceofthefuelsystemissatisfactory.

• Duringengineoperation,iftheECMrecognizesthattheFRPsignalislowerorhigherthanthevaluethePCVistryingtoachievetheECMwillsetaDiagnosticTroubleCode(DTC)andilluminatetheambermalfunctionindicatorlamponthedash.

• TheFRPsignaltotheECMisoneofthesignalsusedtocommandthecorrectinjectiontiming.

• Thissensorisreplaceable.

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MAF (Mass Air Flow)

• TheMassAirFlow(MAF)sensorusesahotwiresensingelementtomeasuretheamountofairenteringtheengine.Airpassingoverthehotwirecausesittocool.Thishotwireismaintainedat200°C(392°F)aboveambienttemperatureasmeasuredbyaconstantcoldwire.

• Thecurrentrequiredtomaintainthetemperatureofthehotwireisproportionaltothemassairflow.

• TheMAFsensorthenoutputsafrequencysignaltotheECMproportionaltotheairmass.

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MAP (Manifold Absolute Pressure)

• TheMAPsensorisathree(3)wirevariablecapacitancesensor.

• TheECMusestheMAPsensorsignaltoassistinthecalculationofEGRdutycycle,FuelDelivery,andThrottleBodyPosition.

• TheECMmeasurestheMAPsignaltodetermineintakemanifold(boost)pressure.

NOTE: Washing a hot engine can have negative effects on this sensor!

NOTE: The 6.0L engine used a remote mounted MAP sensor.

NOTE: Pay special attention to differentiating between the MAP sensor and the EP sensor, do not interchange them!

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EP (Exhaust Pressure)

• TheEPsensorisathree(3)wirevariablecapacitancesensor.

• TheECMsupplesa5voltreferencesignalwhichtheEPsensorusestoproducealinearanalogvoltagethatindicatespressure.

• TheEPmeasuresexhuastbackpressuresothattheECMcancontroltheEGR,andthehighpressureturbochargerviatheturbochargeractuator.

NOTE: Washing a hot engine can have negative effects on this sensor!

NOTE: This sensor is gray in color for the 6.4L and black in color for the 6.0L. Some early 6.4L engines may be equipped with black sensors. Do not interchange 6.0L EP sensors with 6.4L EP sensors, these sensors are different.

NOTE: Pay special attention to differentiating between the MAP sensor and the EP sensor, do not interchange them!

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FTS (Fuel Temperature Sensor)

• TheFTSsensorisatwo(2)wirethermistorsensor.

• TheFTSsensor’sinternalthermistorformsavoltagedividerwithapullupresistorinsidetheECM.

• TheFTSsensorchangesresistancewhenexposedtodifferenttemperatures.

• Whenthetemperatureofthefueldecreases,theresistanceofthethermistorincreasesandthesignalvoltageincreases.

• Whenthetemperatureofthefuelincreases,theresistanceofthethermistordecreasesandthesignalvoltagedecreases.

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EGRT Outlet (EGR Cooler Outlet Temperature)

• TheEGRTOutletsensorisatwo(2)wirethermistortypesensor.

• TheEGRToutletsensor’sinternalthermistorformsavoltagedividerwithapullupresistorinsidetheECM.

• TheECMmonitorsexhausttemperaturefromtheEGRToutletsensorsignaltoaidincontrollingtheEGRvalvepositionandthrottleposition.

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Actuators & Control Modules

•PressureControlValve(PCV)

•VolumeControlValve(VCV)

•ExhaustGasRecirculationValve(EGR)

•TurbochargerActuator

•GlowPlugControlModule(GPCM)

•GlowPlugs

•PiezoElectricFuelInjectors

•ThrottleBody

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Control Devices

• The6.4LPowerStroke®Dieseluseseight(8)controldevices:PressureControlValve,VolumeControlValve,EGRValve,TurbochargerActuator,GlowPlugControlModule,GlowPlugs,FuelInjectors,andtheThrottleBody.

PCV (Pressure Control Valve)

• ThePCVgovernsthefuelpressurethatisdeliveredtothefuelinjectorsviathehighpressurefuelrailsandfuelsupplytubes.

• ThePCValsoactsasadampeningdeviceforthefluctuationsinpressurethatoccurduringfueldeliverythroughthepumpandtheinjectionprocess.

• ThePCViscontrolledbytheECMtomaintainoptimalfuelpressurethroughoutallengineoperatingconditions.

• ThePCVispermanentlymountedtothehighpressurepumpandisnottoberemoved.RemovalofthePCVwillresultinreplacementofthehighpressurefuelinjectionpump.

NOTE: Fuel caps have been left off for visualization purposes. Always use fuel caps when servicing the high pressure fuel system!

VCV (Volume Control Valve)

• TheVCVregulatesthedeliveryoffuelfromtheinternaltransferpump(ITP)tothehighpressurepumpingelements.

• TheVCVadjuststhelowpressuresideofthesystemtomatchtheneedsoftheenginethusincreasingefficiency.

• TheVCVispermanentlymountedtothehighpressurepumpandisnottoberemoved.RemovaloftheVCVwillresultinreplacementofthehighpressurefuelinjectionpump.

NOTE: Fuel caps have been left off for visualization purposes. Always use fuel caps when servicing the high pressure fuel system!

Pressure Control Valve (PCV)

Volume Control Valve (VCV)

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Exhaust Gas Recirculation Valve (EGR Valve)

• TheEGRvalveisusedtomixcooledexhaustgaseswithintakeairtoloweremissionsandnoise.

• TheEGRvalveissteppermotorcontrolled

• Thevalveispoweredinboththeopenandclosedirections.

Turbocharger Actuator

• Theturbochargeractuatorisanelectronicmotorthatcontrolsthepositionofthevanesinsideofthehighpressureturbocharger’sturbinehousing.

• Theturbochargeractuatorismounteddirectlytothehighpressureturboandisconnectedtothevanesinsidetheturbinehousingbyacontrolarm.

Throttle Body

• ThethrottlebodyisoperatedbyasteppermotorcontrolledbytheECMandassistswiththeexhaustaftertreatmentsystem.

TurbochargerActuator

Control Arm

Throttle Body

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ECM (Engine Control Module)

• TheECM,whichismountedbehindtheengineonthepassengersidecowl,usessensorinputstocontrolactuatorsandsendfuelingcommandstothefuelinectors.

• TheECMcontrolsthefuelandairmanagementsystemonthe6.4LPowerStroke®Diesel.

Glow Plug System

• Theglowplugsystemisusedtowarmtheairinthecylinderstoenhancecoldweatherstartabilityandreducestartupsmoke.

• TheglowplugsystemisECMcontrolled,andpoweredbytheGPCM.

Glow Plug Control Module(GPCM) & Glow Plug Harness

• TheGPCMisaunitthatcontrolstheglowplugsinordertowarmtheairinthecylinders.

• TheGPCMusesaglowplugenablesignaltoturntheglowplugsonforatimecontrolledbytheECM.

• TheGPCMiscapableofdiagnosingaproblemwithoneglowplugandthensendingadiagnosticsignaltotheECM.

• Italsohastheabilitytoturnoffoneglowplugifashortisdetectedinthatcircuit.

• Eachbankofglowplugsisconnectedtotheenginewiringharnessviaaglowplugharness,eitherleftbankorrightbank.

• Theglowplugharnesshasfourconnectorsthatsupplypowertotheglowplugsandsealoilfromescapingthroughtheglowplugaccessholes.

Glow Plug Harness

Chassis ConnectorEngine Connector

GPCM

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Glow Plug

• Theglowplugisusedtoheattheairinthecylinder.

• Theglowplugutilizesasystemofsendingvoltagethrougharesistancecoiltocreateheat.

NOTE: The 6.4L glow plug is very similar to the glow plug used on the 6.0L Power Stroke® Diesel, but they are different. The glow plugs must not be interchanged!

NOTE: The 6.4L glow plug uses a green isolator.

Fuel Injector

• Thefuelinjectoriscontrolledbyanextremelyprecisepiezoelectricactuatorthatcanaccomplishmultipleinjectionspercombustionevent.

NOTE: Never unplug a fuel injector while the engine is running, serious engine damage could occur!

Piezo Actuator

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