Ford 60 Service Manual

IAT2 (Intake Air Temperature
#2)
ELECTRICAL COMPONENTS
11 4
 • The primary function of the IAT2
sensor is to provide a feedback 
signal to the PCM indicating 
manifold air temperature.
 • The PCM supplies a 5 volt 
reference signal which the IAT2
sensor uses to produce an analog
voltage that indicates temperature.
 • The PCM monitors the IAT2 signal
to determine if the temperature is
satisfactory.
 • During engine operation, if the PCM
recognizes that the IAT2 signal is
lower or higher than the expected...

ICP (Injection Control
Pressure)
ELECTRICAL COMPONENTS
11 5
61
monitors and adjusts for ideal ICP
determined by conditions such as
load, speed, and temperature.
 • The PCM monitors the ICP signal to
determine if the performance of the
hydraulic system is satisfactory.
 • During engine operation, if the PCM
recognizes that the ICP signal is
lower or higher than the value the
IPR is trying to achieve the PCM
will set a Diagnostic Trouble Code
(DTC) and illuminate the amber
malfunction indicator lamp on...

MAF (Mass Air Flow)
ELECTRICAL COMPONENTS
62
 • The Mass Air Flow (MAF) sensor
uses a hot wire sensing element to
measure the amount of air entering
the engine. Air passing over the hot
wire causes it to cool. This hot wire
is maintained at 200°C (392°F)
above ambient temperature as
measured by a constant cold wire.
 • The current required to maintain the
temperature of the hot wire is 
proportional to the air mass flow.
 • The MAF sensor then outputs and
analog voltage signal to the PCM
proportional to...

MAP (Manifold Absolute
Pressure)
ELECTRICAL COMPONENTS
63
11 7
 • The MAP sensor is a three (3) wire
variable capacitance sensor.
 • The PCM uses the MAP sensor 
signal to assist in the calculation of
EGR duty cycle.
 • The PCM measures the MAP signal
to determine intake manifold (boost)
pressure. 

11 9
120
 • The EGR (Exhaust Gas Recirculation) valve
is used to mix cooled exhaust gasses with
intake air to lower emissions and noise.
 • The EGR valve is duty cycle controlled, the
higher the duty cycle the more the valve
opens.
 • When the valve is disconnected it is in its
closed state.  • The IPR (Injector Pressure Regulator) is a
duty cycle controlled valve that the PCM
uses to control ICP (Injection Control
Pressure).
 • The IPR is a valve that blocks the path to
drain for oil coming out from...

121
123
FICM (Fuel Injection Control Module)
 • Other electrical system components include
the FICM, PCM, and the glow plug system.  • The VGTCV (Variable Geometry
Turbocharger Control Valve) is a duty cycle
controlled valve that directs oil flow to the
piston that controls the vanes in the 
turbocharger.
 • The valve controls pressure to both the open
and close side of the piston.
 • If the valve is disconnected the turbocharger
vanes will remain in a open state.
Other Electrical Components VGTCV...

124
125
126
 • The GPCM (Glow Plug Control Module) is a
unit that controls the glow plugs in order to
warm the air in the cylinders.
 • The GPCM uses a glow plug enable signal
to turn the glow plugs on for a time 
controlled by the PCM.
 • The GPCM is capable of diagnosing a 
problem with one glow plug and then 
sending a diagnostic signal to the PCM.
 • It also has the ability to turn off one glow
plug if a short is detected in that circuit.  • The glow plug system is used to warm the
air in the...

127
128
129
 • Each bank of glow plugs is connected to the
wiring harness via a glow plug buss bar.
 • The glow plug buss bar has four connectors
attached to a single metal rail.
 • The entire rail must be removed to gain
access to any of the glow plugs on that
bank.
Glow Plug Buss Bar Glow Plug Sleeve
Glow Plug 
ELECTRICAL COMPONENTS
67
 • The glow plug is used to heat the air in the
cylinder.
 • Inside the plug are two (2) coils (resistance)
connected in series, one to create heat and
one to control...

130
 • One way to verify diagnostic data from the
GPCM is to measure the amperage draw
with an inductive amp probe.
 • Once the glow plug system has been 
commanded on by the PCM (when engine
temperature is warm you may need to trick
the system into a cold condition) for about
40 sec., the glow plug amperage should be
stable. Each glow plug should draw between
10-12 amps.
 • When testing the glow plug system, it is best
to measure one bank of glow plugs at a
time. The bank with the lower current draw...

131
132
133
Injector: Removal
 • Remove the fuel filter lid and lift the filter 
element out of the housing and discard in
the appropriate location.
 • To avoid fuel spills, use a suction gun or 
simular device to remove the remaining fuel
from the fuel filter housing.
 • Install the new filter and tighten the fuel filter
lid to the specified torque.
 • Note: Before starting the vehicle, cycle
the key to the on position and let the fuel
pump run a full cycle 3 times to ensure
the fuel filter housing is...