Post on 13-Apr-2018
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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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ElEctrical componEnts
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AP (Accelerator Pedal Position)
• TheAP(AcceleratorPedal)isathreetrackpedal.TheAPincorporatesthreepotentiometers.ThroughoutthemovementoftheAPtheresistancevaluesofthethreepotentiometersmustagree.DuringthemovementoftheAPifanyofthethreepotentiometerreadingsdonotagree,thecheckenginelightwillilluminateandthevehiclewillcontinuetoperformasnormal.IftwosignalsfromtheAParelosttheECMwillallowtheenginetoidleonlyandilluminatethecheckenginelight.
• Havingthree(3)signalsforcomparisonisanaddedsafetyfeature.
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ElEctrical componEnts
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Baro (Barometric Pressure)
• TheECMsuppliesa5voltreferencesignalwhichtheBarosensorusestoproducealinearanalogvoltagesignalthatindicatespressure.
• TheprimaryfunctionoftheBarosensoristoprovidealtitudeinformationsothattheECMcanadjusttiming,fuelquantity,glowplugontime,andturbochargercontrol.
• TheBarosensorislocatedinsidetheECM.Ifthesensorfails,theECMmustbereplaced.
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ElEctrical componEnts
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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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ElEctrical componEnts
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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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ElEctrical componEnts
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ECT (Engine Coolant Temperature)
• TheECTsensorisatwo(2)wirethermistorsensor.
• TheECTsensor’sinternalthermistorformsavoltagedividerwithapullupresistorinsidetheECM.
• TheECTsensorchangesresistancewhenexposedtodifferenttemperatures.
• Whenthetemperatureofthecoolantdecreases,theresistanceofthethermistorincreasesandthesignalvoltageincreases.
• Whenthetemperatureofthecoolantincreases,theresistanceofthethermistordecreasesandthesignalvoltagedecreases.
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ElEctrical componEnts
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EGRVP (EGR Valve Position)
• TheEGRVPsensorisathree(3)wirepotentiometertypesensor.
• TheECMsuppliesa5voltreferencevoltagethattheEGRVPusestoproducealinearanalogvoltagethatindicatestheamountofmovementofthevalve.
• TheECMmonitorsEGRVPastheengineisoperatingtomodulatetheEGRvalve.
• ThisisaclosedloopfunctionwhichmeansthattheECMcontinuouslymonitorstheEGRVPtoensurepropervalveposition.
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ElEctrical componEnts
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EOP (Engine Oil Pressure)
• TheEOP(EngineOilPressure)isaswitchthatclosesacircuittogroundafterengineoilpressurereachesapproximately5-7psi.
• Thisswitchcontrolstheoilpressuregaugeontheinstrumentpanel.Whenpressureisabove7psithegaugewillreadnormalandifthepressuredropsbelow5psithegaugewillshow0.
• TheinformationfromtheswitchisnotsentbacktotheECMinanywayandistobeusedasareferenceonly.
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ElEctrical componEnts
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EOT (Engine Oil Temperature)
• TheEOTsensorisatwo(2)wirethermistortypesensor.
• TheEOTsensor’sinternalthermistorformsavoltagedividerwithapullupresistorinsidetheECM.
• TheECMmonitorsengineoiltemperatureviatheEOTsensorsignaltoaidincontrollingfuelrailpressure(FRP)andfancontrol.
• TheEOTsignalallowstheECMtocompensateforoilviscosityvariationsduetotemperaturechangesintheoperatingenvironment,ensuringadequatepowerandtorqueareavailableforalloperatingconditions.
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ElEctrical componEnts
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IAT1 (Intake Air Temperature #1)
• TheIntakeAirTemperature1(IAT1)sensorisatwowirethermistorsensorthatislocatedinsidetheMassAirFlow(MAF)sensor.
• TheIAT1sensor’sinternalthermistorformsavoltagedividerwithapullupresistorinsidetheECM.
• TheIAT1sensor’sprimaryfunctionistomeasureintakeairtemperaturetoaidincontrollingEVTGandtheglowplugsystem.
• TheMAF/IAT1sensorismountedintheintakeairpipingaftertheairfilter.
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ElEctrical componEnts
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IAT2 (Intake Air Temperature #2)
• TheIAT2sensorisatwo(2)wirethermistortypesensor.
• TheIAT2sensorchangesresistancewhenexposedtodifferentairtemperature.
• TheprimaryfunctionoftheIAT2sensoristoprovideafeedbacksignaltotheECMindicatingmanifoldairtemperature.
• TheIAT2sensor’sinternalthermistorformsavoltagedividerwithapullupresistorinsidetheECM.
• TheECMmonitorstheIAT2signaltocontroltemperaturebyadjustingotherdevices.
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ElEctrical componEnts
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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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ElEctrical componEnts
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MAF (Mass Air Flow)
• TheMassAirFlow(MAF)sensorusesahotwiresensingelementtomeasuretheamountofairenteringtheengine.Airpassingoverthehotwirecausesittocool.Thishotwireismaintainedat200°C(392°F)aboveambienttemperatureasmeasuredbyaconstantcoldwire.
• Thecurrentrequiredtomaintainthetemperatureofthehotwireisproportionaltothemassairflow.
• TheMAFsensorthenoutputsafrequencysignaltotheECMproportionaltotheairmass.
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ElEctrical componEnts
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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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ElEctrical componEnts
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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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ElEctrical componEnts
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FTS (Fuel Temperature Sensor)
• TheFTSsensorisatwo(2)wirethermistorsensor.
• TheFTSsensor’sinternalthermistorformsavoltagedividerwithapullupresistorinsidetheECM.
• TheFTSsensorchangesresistancewhenexposedtodifferenttemperatures.
• Whenthetemperatureofthefueldecreases,theresistanceofthethermistorincreasesandthesignalvoltageincreases.
• Whenthetemperatureofthefuelincreases,theresistanceofthethermistordecreasesandthesignalvoltagedecreases.
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ElEctrical componEnts
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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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ElEctrical componEnts
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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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ElEctrical componEnts
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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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ElEctrical componEnts
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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