Ford 60 Service Manual
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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 pressure oil line connects the stand pipes to the high pressure oil rail. • High pressure oil rail is bolted to the cylinder heads and acts as a reservoir for high pressure oil. • Check valves incorporated in the inlet fitting for the high pressure oil rail, limit hydraulic disturbance/feed back from injector operation. • Injectors deliver fuel when the spool valve is positioned to allow oil to enter the area above the intensifier piston. 40 HIGH PRESSURE OIL RAIL RESERVOIR INJECTOR HIGH PRESSURE PUMP PUMP DISCHARGE LINE CHECK VALVE AND FITTING HIGH PRESSURE STAND PIPE HIGH PRESSURE OIL BRANCH HIGH PRESSURE PUMP GEAR REAR OF ENGINE
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 filtered, some is directed to the reservoir. • The reservoir provides oil to the high pressure pump. • The IPR (Injection Pressure Regulator) is PCM controlled and contains the system’s pressure relief valve which opens at 4000 psi. • The plumbing from the pump to the high pressure oil rails for each head contains a check valve and orifice. • The oil rails are not cast into the head but are removable 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, beneath the turbocharger turbine inlet pipes. • The high pressure pump is installed inside the crankcase. • The pump is a seven (7) piston swash plate style pump that is driven off of the rear gear train. • Minor leakage from the pump will not create external oil leaks. • Both banks of cylinders are supplied oil through one (1) pump outlet. HIGH PRESSURE PUMP COVERHIGH PRESSURE PUMP DISCHARGE LINE IPRICP AWA FITTING AWA FITTING END CAP
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 two (2) replaceable o-rings on the outside of the body, one (1) internal non-replaceable o-ring in the top of the injector, and one (1) replaceable copper combustion gasket on the tip of the injector. • The injector’s two (2) coils have a single four (4) pin connector that passes through the rocker arm carrier. • There is an open coil and a close coil on the injector that move the spool valve from side to side using magnetic force. • The spool valve has two positions, when the valve is in the open position it allows oil to flow from the high pressure oil rail into the injector. • When the valve is in the closed position it allows oil to drain from the injector back to the crankcase. • The total movement of the valve is only .017”.Fuel Injector Features • Digital Valve • 48 Volts • 20 Amps/coil • Short Coil On Times • Self extracting hold down clamp 90 INJECTOR COILSINTERNAL O-RING O-RINGS HIGH PRESSURE OIL IN COPPER GASKET COILCOIL SPOOL VALVE
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 fuel injection pressure is built. • When the plunger is pushed downward by the intensifier piston, it increases the fuel pressure in the barrel 7.1 times that of the ICP pressure. • The plunger is coated with a tungsten carbide coating to reduce the possibility of scuffing and poor performance. • The injection nozzle needle is an inwardly opening type which lifts off its seat when pressure overcomes the VOP (Valve Opening Pressure) of approximately 3100 psi. • Fuel is atomized at high pressure through the nozzle tip.INTENSIFIER PISTON BARREL PLUNGER PINTLE
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. • The needle control spring holds the needle on its seat so that fuel can not enter the combustion chamber.Three Stages of Injection • Fill • Main Injection • End of Main Injection 96 SPOOL VALVE CLOSED FUEL INLET PINTLE CLOSED INTENSIFIER PISTON AT REST
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 plunger passes the fuel spill port of the barrel. • Force on the nozzle needle begins to build. • The pulse width controlled current is shut off after 800 µsec (micro second or millionth of a second), but the spool remains in the open position. • High pressure oil from the rail continues to flow past the spool valve. • The intensifier piston and plunger continue to move and pressure increases in the barrel. • When fuel pressure rises above the VOP (Valve Opening Pressure) of about 3100 psi, the nozzle needle lifts off of it’s seat and injection begins. SPOOL VALVE OPEN INTENSIFIER PISTON MOVING DOWN PINTLE CLOSED SPOOL VALVE OPEN INTENSIFIER PISTON MOVING DOWN PINTLE OPEN
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 width controlled current is shut off after 800 µsec (micro seconds or millionth of a second), but the spool remains in the closed position. • The intensifier piston and plunger begin to return to their initial position. • Oil above the intensifier piston flows past the spool valve through the exhaust ports. • Fuel pressure decreases until the nozzle needle control spring forces the needle back onto its seat. SPOOL VALVE CLOSED SPOOL VALVE CLOSEDINTENSIFIER PISTON MOVING UP PINTLE OPEN INTENSIFIER PISTON AT REST PINTLE CLOSED
• 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 sensors then returned to the PCM for use in determining the fueling strategy. Sensors Overview Electrical Components • Sensors • Actuators • PCM • FICM • Glow plug System 102