Ford Falcon. Manual — part 173
303-04b-2
Fuel Charging and Controls — Turbocharger
303-04b-2
SPECIFICATIONS
NOTE:Oil threads with engine oil.
NOTE:Do not oil threads that require thread sealant
or thread locker.
Torque Specifications (Turbocharger)
Description
Nm
Exhaust Manifold to Cylinder Head
27
Heat Shield to Exhaust Manifold (M8
20
Bolt, 2 places)
Turbocharger to Exhaust Manifold
Stud
27
Nut
55
Dump-Pipe to Turbocharger
Stud
15
Nut
25
Pencil Brace to Dump-Pipe
25
HEGO Sensor to Dump-Pipe
25
Oil Return Pipe to Turbocharger
20
Oil Return Pipe to Sump
20
Water Supply Tube to Turbocharger
45
Water Return Tube to Turbocharger
45
Oil Supply Tube to Turbocharger
20
Oil Supply Tube to Nut & Filter
20
Assembly
Oil Supply Nut & Filter Assembly to
20
Cylinder Block
Torque Specifications (Intercooler & Ducting)
Description
Nm
Studs to cushion connectors
15
Cushion connector to intercooler 15
15
Nuts holding brackets to cushion
20
connectors
Mounting brackets to front cross
25
member
Screw hose clamps on air ducting
2
pipes & hoses
Under headlight duct retaining screw
8
Boost pressure sensor screw
2
Wastegate solenoid bracket retaining
8
screw
Cross-over duct nuts
9
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303-04b-3
Fuel Charging and Controls — Turbocharger
303-04b-3
DESCRIPTION AND OPERATION
Turbocharger
Applicable to the XR6 Turbo model only
Item
Description
1
Coolant Supply Line
2
Oil Supply Line
3
Oil Outlet Line
4
Coolant Outlet Line
The turbocharger consists of two elements, a turbine
and a compressor both installed on a single shaft and
contained within housings.
The turbocharger bearings are supplied oil from the
engine via the oil supply tube. This is returned to the
oil pan via the oil return pipe.
The turbocharger housing also receives coolant from
the engine cooling system, to assist with turbocharger
Item
Description
cooling.
1
Exhaust manifold
The turbine element of the turbocharger is mounted
on the exhaust manifold and uses the energy of the
2
Turbine side of turbo
exhaust gas to drive the compressor. The compressor 2
Compressor side of turbo
feeds air to the engine via the intercooler.
Boost Control
The turbocharger is governed by means of a
wastegate valve. The wastegate valve diverts some of
the exhaust gas past the turbine and therefore
regulates the speed of the turbine. The wastegate
valve is controlled by a pressure operated actuator.
The actuator incorporates a diaphragm, and uses
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303-04b-4
Fuel Charging and Controls — Turbocharger
303-04b-4
DESCRIPTION AND OPERATION (Continued)
regulated air pressure to control the wastegate. This
The PCM uses the BPS output voltage to control
actuator is preset during manufacture and must not be boost pressure, dependent upon engine load,
tampered with.
temperature and RPM. The control system increases
engine intake pressure by diverting excess pressure
away from the wastegate actuator through the
Wastegate Solenoid Valve. The solenoid valve is
controlled by the PCM’s TURBO output.
CONNECTIONS AT PCM
Pin C2
Boost Pressure Sensor
(BPS) Signal
Pin C28
BPS Signal Return
(SIGRTN)
Pin C21
TURBO
Pin B45
Vehicle Reference
Voltage (VREF)
Intake air pressure is further controlled by a blow-off
valve, which dumps excess pressure into the low
The air pressure to the actuator diaphragm is
pressure side of the intake system when the throttle is
regulated by use of a Boost Pressure Sensor (BPS)
closed.
and a Wastegate Control Solenoid (WCS).
The blow-off valve is actuated by intake manifold
The Boost Pressure Sensor is located on the
pressure, via a rubber hose from the intake manifold.
aluminium duct beneath the driver’s side headlight.
The blow-off valve is situated in the Cross-Over Duct
The Wastegate Control Solenoid is mounted
on top of the engine.
underneath the fuse box.
Item
Description
Charge Air Cooler (Intercooler)
1
Wastgate Control Solenoid
The Charge Air Cooler (CAC) is an air-to-air cooler.
2
Boost Pressure Sensor
The compressed air from the turbocharger flows
through the cooler, and is cooled by outside air
The BPS measures the absolute pressure of the
flowing over the vanes of the CAC.
pre-throttle intake system for cruise control and
wastegate control strategy. The pressure sensing
The lower temperature of the charge air increases its
element in the BPS employs a Piezo resistive sensor
density, so giving improved engine efficiency and
that outputs a voltage proportional to absolute
power.
pressure.
The CAC is mounted in front of the radiator with four
rubber isolated mounts.
BPS Specification
Absolute Pressure (kPa)
Signal Voltage (V)
10
0.3
50
1.0
100
1.9
150
2.8
200
3.7
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303-04b-5
Fuel Charging and Controls — Turbocharger
303-04b-5
DESCRIPTION AND OPERATION (Continued)
Heatshielding
Two heatshields cover the exhaust manifold and the
turbocharger, to protect surrounding engine bay
components from heat damage.
A heatshield is also fitted over the engine mount
under the turbocharger, to protect the mount from
radiated heat.
Item
Description
1
Rear exhaust manifold heatshield
2
Front exhaust manifold heatshield
3
Engine mount heatshield
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