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
value it will set a Diagnostic Trouble
Code (DTC) and illuminate the
amber malfunction indicator lamp
on the dash.  • The IAT2 sensor is a two (2) wire
thermistor type sensor.
 • The IAT2 sensor changes 
resistance when exposed to 
different air temperature.
 • When temperature decreases, the
resistance of the thermistor 
increases. This causes the signal
voltage to increase.
 • When the temperature increases,
the resistance of the thermistor
decreases. This causes the signal
voltage to decrease.
60 
						

							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 the
dash.
 • The ICP signal from the PCM is one
of the signals the FICM uses to
command the correct injection 
timing.  • The ICP sensor is a three (3) wire
variable capacitance sensor.
 • The PCM supplies a 5 volt 
reference signal which the ICP
sensor uses to produce a linear
analog voltage that indicates 
pressure.
 • The primary function of the ICP
sensor is to provide a feedback 
signal to the PCM indicating ICP.
 • The PCM monitors ICP as the
engine is operating to modulate the
IPR. This is a closed loop function
which means the PCM continuously 
						

							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 the air mass.
11 6 
						

							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 high pressure
pump. As duty cycle signal increases at the
IPR the restriction to drain increases, thus
increasing ICP.
 • When the valve is disconnected it is in its
open or drain state and the engine should
not start.
 • The IPR valve also contains the pressure
relief valve for the high pressure oil system.  • Actuators convert electrical output from the
PCM to hydraulic, mechanical, or electronic
work.
 • The 6.0LPower Strokeuses four (4) 
actuators: Injection Pressure Regulator,
Exhaust Gas Recirculation Valve, Variable
Geometry Turbocharger Control Valve, and
Glow Plug Control module.
EGR (Exhaust Gas Recirculation)
Valve IPR (Injection Pressure Regulator) Actuators
ELECTRICAL COMPONENTS
64
Actuators
 • Injection Pressure Regulator (IPR)
 • Exhaust Gas Recirculation Valve (EGR)
 • Variable Geometry Turbocharger Control
Valve (VGTCV)
 • Glow Plug Control Module (GPCM)
11 8
OIL IN O-RINGS
OIL OUT
O-RINGSCOOLED EXHAUST
INTAKE AIR
INTAKE AIR 
						

							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 (Variable Geometry
Turbocharger Control Valve)
ELECTRICAL COMPONENTS
65
 • The FICM (Fuel Injection Control Module)
receives Information from the PCM (like 
volume of fuel desired, RPM, EOT, ICP and
others) and uses those signals to calculate
injector start of injection and duration.
 • After calculating injector fuel delivery time
the IDM sends a 48 volt 20 amp pulse to the
correct injector so that the correct amount of
fuel will be delivered to the cylinder at the
correct time.
Other Electrical Components
 • Fuel Injection Control Module (FICM)
 • Powertrain Control Module (PCM)
 • Glow Plug System
122
CLOSE OPEN
OIL SUPPLY DRAIN TO PAN VGT COIL
X3 CONNECTOR
X2 CONNECTOR
X1 CONNECTOR 
						

							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 cylinders to enhance cold weather
startability and reduce start up smoke.
 • The glow plug system is PCM controlled.  • The Powertrain Control Module (PCM),
which is mounted behind the battery on the
drivers side inner fender panel, uses sensor
inputs to control actuators and send fueling
commands to the FICM.
 • The PCM controls the fuel and air 
management systems on the 6.0LPower
Stroke.
GPCM (Glow Plug Control Module) Glow Plug System
ELECTRICAL COMPONENTS
66
PCM (Powertrain Control Module)
PCM
GPCM GPCM 
						

							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 heat at its peak.
 • The glow plug sleeve is used to protect the
glow plug from engine coolant and is made
of stainless steel.
GLOW PLUG BUSS BAR GLOW PLUG BUSS BAR 
						

							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
would be the bank with the bad glow plug
and/or wiring concerns.
ELECTRICAL COMPONENTS
68
Glow Plug System Diagnostics
GLOW PLUG
WIRING INDUCTIVE
AMP METER 
						

							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 full of fuel before
starting the vehicle.
Fuel Filter: Replacement Oil Filter: Replacement
UNIQUE SERVICE PROCEDURES
69
 • First loosen the oil filter cap which will open
the oil filter drain and allow the oil from the
filter housing to drain into the crankcase.
 • Drain the oil from the oil pan.
 • After all of the oil has drained from the oil
pan remove the oil filter and discard it in the
appropriate location.
 • Note: The oil filter snaps into the oil filter
lid.
 • Install the new oil filter element and tighten
the oil filter cap to the recommended torque.
This will close the oil filter drain.
 • Refill crankcase with correct volume of 
recommended oil.
 • After removing the valve cover(s), 
disconnect the snap to connect fitting for the
high pressure oil line leading to the high
pressure oil rail using tool #303-755.
 • Remove the eight (8) high pressure oil rail
bolts that mount the oil rail to the rocker arm
carrier.
 • Pull the oil rail straight up to remove it.
 •Note: Do not pry against the valve cover
sealing surface to remove the rail.
 • Note: Oil will come out of the rail when
the rail is removed.
OIL FILTER ELEMENTOIL FILTER LID
FUEL FILTER LIDFUEL FILTER LID
FUEL FILTER ELEMENTFUEL FILTER ELEMENT
TOOL #303-755 TOOL #303-755