Ford F150 Pickup. Instruction — part 1647
PCM CONTROLLED CHARGING SYSTEM
Description
PCM controlled charging system provides many additional benefits over integral generator regulator system.
First benefit is improved battery life. In an integral generator regulator system, regulator set point is established
by a temperature sensor in the regulator which estimates battery temperature. With PCM controlled generator,
regulator voltage set points are determined by PCM and communicated to regulator via generator
communication line. PCM uses a calibratable algorithm to estimate battery temperature. Improving battery
temperature will reduce battery damage caused by over and undercharging.
Second benefit is improved engine performance. Whenever PCM senses a Wide Open Throttle (WOT), PCM
will momentarily lower regulator voltage set point. This reduces torque load of the generator on engine and
improves acceleration. PCM has a calibratable time limit on this reduced voltage feature. This prevents the
generator output from being cut back for an extended WOT period, which could cause battery discharge.
Third benefit is improved idle stability. In response to PCM generator communication signal, regulator uses a
generator monitor signal to provide feedback to PCM. Generator monitor signal provides PCM with charging
system information. If the charging system receives a transient electrical load which would normally affect idle
stability, the PCM is notified. Because PCM can anticipate additional loads, actions can be taken to minimize
idle sag. PCM can choose to either reduce regulator set point or increase engine idle speed.
Fourth benefit is reduced cranking efforts. PCM can reduce mechanical load on starter by initially commanding
a low voltage set point. This may improve start times.
If PCM detects a charging system error, charge indicator will illuminate. Charge indicator will illuminate if
PCM fails to see a signal on generator monitor line for a time period greater than 500 milliseconds. This
command will also be used to indicate over-voltage conditions detected by generator.
Each time ignition switch is turned to RUN position, cluster will perform a bulb check by illuminating charge
indicator. PCM will send a low voltage command if charging system is functioning properly. This message
should be sent 250-450 milliseconds after ignition switch is turned to RUN position. If a low voltage command
is not received by cluster, cluster will continue to illuminate charge indicator indefinitely.
Generator Communication
PCM controlled charging system provides improved battery life and improved engine performance. PCM
controlled generator regulator voltage set point is determined by PCM and communicated to the regulator by the
Generator Communication (GEN COM) circuit. PCM will use a calibratable algorithm to estimate battery
temperature, reducing damage to battery by overcharging or undercharging. At Wide Open Throttle (WOT),
PCM will momentarily lower the regulator voltage set point, reducing torque load on engine and improving
acceleration. PCM has a calibratable time limit on the reduced voltage feature to prevent decreased generator
output for an extended WOT period, which may cause battery discharge.
Generator Load
Generator Load Input (GLI) circuit is used by PCM to determine generator load on engine. As generator load
2003 Ford Pickup F150
2003 ENGINE PERFORMANCE Theory & Operation - CNG, Flex-Fuel & Gasoline
increases, PCM will adjust idle speed accordingly. This helps reduce idle surges due to switching high current
loads. GLI signal is sent to PCM from voltage regulator/generator. GLI signal is a variable frequency duty
cycle. Normal operating frequency is 40-250 Hz. Normal signal DC voltage (referenced to ground) is between
1.5 volts (low generator load) and 10.5 volts (high generator load).
Generator Monitor
The regulator uses a Generator Monitor (GEN MON) signal to provide feedback to Powertrain Control Module
(PCM) with charging system information. GEN MON signal lets PCM know when the charging system
receives a transient electrical load which would normally affect idle stability. Because PCM can anticipate
additional loads, PCM can choose to reduce regulator set point or increase engine idle speed, both of which are
calibratable features. Charge indicator will be illuminated if PCM fails to see a signal on generator monitor line
for a time period greater than 500 milliseconds. This telltale command will also be used to indicate over-voltage
conditions detected by PCM controlled generator.
WIRING DIAGRAMS
CARS
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On Crown Victoria, see ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article.
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On Focus, see ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article.
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On Grand Marquis, see ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article.
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On LS, see ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article.
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On Marauder, see ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article.
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On Mustang, see ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article.
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On Sable, see ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article.
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On Taurus, see ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article.
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On Thunderbird, see ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article.
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On Town Car, see ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article.
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On ZX2, see ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article.
TRUCKS
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On Aviator, see ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article.
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On Cab and Chassis F350 Super Duty, see ENGINE PERFORMANCE in SYSTEM WIRING
DIAGRAMS article.
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On Cutaway E350 Super Duty, see ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS
article.
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On Econoline E150, see ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article.
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On Econoline E250, see ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article.
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On Econoline E350 Super Duty, see ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS
article.
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On Escape, see ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article.
2003 Ford Pickup F150
2003 ENGINE PERFORMANCE Theory & Operation - CNG, Flex-Fuel & Gasoline
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On Expedition, see ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article.
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On Explorer, see ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article.
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On Explorer Sport, see ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article.
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On Explorer Sport Trac, see ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article.
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On Excursion, see ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article.
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On E450 Super Duty, see ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article.
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On E550 Super Duty, see ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article.
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On F450 Super Duty, see ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article.
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On F550 Super Duty, see ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article.
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On Mountaineer, see ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article.
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On Navigator, see ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article.
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On Pickup F150, see ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article.
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On Pickup F250 Super Duty, see ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS
article.
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On Pickup F350 Super Duty, see ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS
article.
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On Ranger, see ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article.
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On RV Cutaway E350 Super Duty, see ENGINE PERFORMANCE in SYSTEM WIRING
DIAGRAMS article.
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On Windstar, see ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article.
2003 Ford Pickup F150
2003 ENGINE PERFORMANCE Theory & Operation - CNG, Flex-Fuel & Gasoline
2003 ENGINE PERFORMANCE
Vacuum Diagrams - Trucks
INTRODUCTION
This article contains underhood schematics of vacuum hose routing. Canada and some states or metropolitan
areas in the United States require periodic emission, or Inspection/Maintenance (I/M) tests. Use these vacuum
diagrams during a visual inspection for one of these tests. This will assist in identifying improperly routed
vacuum hoses, which may cause driveability and/or computer-indicated malfunctions.
PCM CALIBRATIONS
Powertrain calibration information is printed in the lower right corner of the Vehicle Emission Control
Information (VECI) label. Only the base calibration information is printed. Revision levels will not appear. For
the current model year, Ford Motor Company is using 3 different protocols which describe powertrain base
calibration. These protocols are designed to provide worldwide standardization for vehicle calibration. If
electronic calibration strategy has been used since 1998 and carried into current model year, Protocol 1 will be
used. See Fig. 1 . If electronic calibration strategy has been used since 1999 and is carried into current model
year, Protocol 2 will be used. See Fig. 2 . For electronic calibration strategies introduced since the 2000 model
year, Protocol 3 will be used. See Fig. 3 . See PROTOCOL 3 CODE DESCRIPTIONS .
NOTE:
References to Econoline include Cutaway and RV Cutaway. References to F250-
550 Super Duty Pickup include Cab & Chassis.
2003 Ford Pickup F150
2003 ENGINE PERFORMANCE Vacuum Diagrams - Trucks
2003 Ford Pickup F150
2003 ENGINE PERFORMANCE Vacuum Diagrams - Trucks
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