Ford 60 Service Manual

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 • 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 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
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Air management System Flow
31
FROM  CHARGE AIR COOLER
EGR VALVE
COMPRESSOR
OUTLET
EGR COOLER
TURBINE OUTLET COMPRESSOR INLETTHROTTLE BODY
61 

AIR MANAGEMENT SYSTEM
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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...

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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...

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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
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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...

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...

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...

 • 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...

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...

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....