Ford Falcon. Manual — part 199
303-14-10
Powertrain Control Management
303-14-10
DESCRIPTION AND OPERATION (Continued)
Fuel Pressure Regulator
Fuel Injector
The fuel pressure regulator is attached to the outlet
side of the fuel rail and controls the pressure within
the fuel rail. Fuel is delivered to each injector at the
same pressure to ensure the volume of fuel injected is
equal for each cylinder.
The regulator is a diaphragm-operated relief valve.
One side of the diaphragm senses fuel pressure, and
the other side is connected to the intake manifold
vacuum. Fuel pressure is established by a spring
pre-loading applied to the diaphragm. Balancing one
side of the diaphragm with manifold vacuum
maintains a constant pressure across the fuel
injectors. Excess fuel is bypassed through the
regulator and returned to the fuel tank. Fuel pressure
is high when engine vacuum is low.
Intake Air System
The intake air system provides clean air to the engine,
optimises airflow and is designed to minimise
induction noise. The intake air system consists of:
Air Cleaner Assembly
Inlet Ducting
Electronic Throttle Body
Inlet Manifold
Air Cleaner Assembly
The air cleaner assembly is an essential component
of the intake air system. The air cleaner assembly
houses a disposable air filter element that removes
Item
Description
dust from the intake air. The air cleaner element must
be periodically replaced according to the maintenance
1
O-ring
schedule.
2
Filter
3
Adjusting Sleeve
Air Mass Measurement System
4
Weld
The I6 and V8 engines use the “speed density” fuel
5
Shells (2 of)
injection system. In this system, the PCM has stored
in its memory the theoretical mass of intake air that
6
Weld
will be drawn into the engine at any given speed of
7
Weld
operation. Using the engine speed sensor (Crankshaft
8
Support Ring
Position CKP) signal, the Intake Air Temperature and
Manifold Absolute Pressure sensor (T-MAP), the PCM
9
O-ring
can compute the intake air mass, and from it the fuel
10
Seat & Spray Plate Assy.
required to be injected into the engine for combustion.
11
Tube Assy.
This amount of fuel injected is further corrected by
12
Needle, Ball & Armature Assy.
feedback information obtained from the Heated
Oxygen Sensor (HEGO) sensor, providing close loop
13
Spring
control of fuel injection. A further feature of this
14
Coil & Bobbin Assy.
system is the ability to ‘re-calibrate’ itself for changes
15
Plastic Body
in fuel requirements as the engine wears and the
sensors age. This is known as adaptive strategy or
learning and is an additional function derived from
HEGO sensor information.
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Powertrain Control Management
303-14-11
DESCRIPTION AND OPERATION (Continued)
two ports in the Phaser, one port will retard the cam
timing (‘Retard port’) and the other will advance the
timing (‘Advance port’). An Oil Control Valve (OCV),
one for each camshaft, is used to control the flow of
oil into the retard and advance ports of both cams.
The OCV is controlled by the PCM.
The PCM uses a pulse width modulated (PWM)
voltage or ‘Duty Cycle’ (DC) to control each OCV to
attain the desired camshaft angle. VCT1 output
controls the inlet camshaft OCV. VCT2 controls the
exhaust camshaft OCV.
A 3 + 1 tooth wheel on the front of each camshaft with
an associated sensor mounted on the intake and
exhaust sides of the cylinder head are used to
calculate the ‘Actual cam angle’ for both camshafts.
The two sensors are called, intake cam position or
Intake Air Ducting
‘CID1’ and exhaust cam position or ‘CID2’. Intake and
The intake air ducting connects the air filter assembly exhaust cam positions are calculated separately.
to the throttle body. The ducts prevent entry of foreign
The PCM uses engine rpm, throttle position and
material to the air intake system after the air filter. The
engine load to determine the optimum camshaft
design minimises restriction and is tuned to reduce
timing setting or ‘Desired Cam Angle’ for both
intake noise.
camshafts.
Electronic Throttle Control
Once the PCM has determined the Desired Cam
Angle, it will control the Duty Cycle output VCT1 and
The Electronic Throttle Body (ETB) controls the
VCT2, to the intake and exhaust OCVs based on the
amount of air admitted to the engine by restricting the
difference between the Desired Cam Angle and the
air intake with a throttle plate.
Actual Cam Angle. This difference is called the Cam
The accelerator pedal position sensor (APPS) senses
Angle Error. The Cam Angle Error for each cam is
the driver’s acceleration request to the PCM. The
calculated individually and used to control both
PCM processes this information into an output signal
camshafts independently to a single Desired Cam
for the ETB. The electric motor in the ETB moves the
Angle.
throttle plate through a gear set. The throttle plate is
An engine oil temperature sensor, which measures oil
adjusted and monitored by the PCM in a closed
temperature in the oil gallery, is used to compensate
control loop. The TP sensor provides the PCM with
for Phaser response with changing oil viscosity at
feedback on the actual position of the throttle plate.
different temperatures.
The electronic throttle body and the Positive
Crankcase Ventilation (PCV) provides airflow during
5.4L, 3 Valve V8 Engine
idle. The PCM trims the throttle continuously to
The 5.4, 3V, V8 Engine is fitted with variable inlet and
maintain the proper idle speed under all conditions
exhaust camshaft timing on each cylinder head bank.
from cold start to normal operating temperatures. It
The camshaft on each bank is variable over a
also compensates for additional loads such as
60-degree crank angle using two separate hydraulic
air-conditioning and power steering. The idle speed is
‘Phasers’, which are integral with the Bank1 and
not manually adjustable.
Bank2 camshaft drive sprockets.
Inlet Manifold
The camshaft timing is controlled by directing oil
under pressure (from the engine oil pump) into one of
The inlet manifold is an aluminium casting, which
two ports in the Phaser, one port will retard the cam
directs the intake air to the inlet ports on the cylinder
timing (‘Retard port’) and the other will advance the
head.
timing (‘Advance port’). An Oil Control Valve (OCV),
Variable Camshaft Timing
one for each camshaft, is used to control the flow of
oil into the retard and advance ports of both cams.
I6 Engine
The OCV is controlled by the PCM.
The I6 Engine is fitted with variable inlet and exhaust
The PCM uses a pulse width modulated (PWM)
camshaft timing. Both camshafts are variable over a
voltage or ‘Duty Cycle’ (DC) to control each OCV to
60-degree crank angle. This is achieved by two
attain the desired camshaft angle. VCT1 output
separate hydraulic mechanisms called ‘Phasers’,
controls the inlet RH Bank OCV. VCT2 controls the
which are integral with the intake and exhaust
LH Bank camshaft OCV.
camshaft drive sprockets.
A 4 + 1 tooth wheel on the front of each camshaft with
The camshaft timing is controlled by directing oil
an associated sensor mounted on the intake and
under pressure (from the engine oil pump) into one of exhaust sides of the cylinder head are used to
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Powertrain Control Management
303-14-12
DESCRIPTION AND OPERATION (Continued)
calculate the ‘Actual cam angle’ for both camshafts.
The two sensors, CID1 and CID2 measure the
camshaft angle on Bank 1 and Bank 2 respectively.
The PCM uses engine rpm, throttle position and
engine load to determine the optimum camshaft
timing setting or ‘Desired Cam Angle’ for both
camshafts.
Once the PCM has determined the Desired Cam
Angle, it will control the Duty Cycle output VCT1 and
VCT2, to the intake and exhaust OCVs based on the
difference between the Desired Cam Angle and the
Actual Cam Angle. This difference is called the Cam
Angle Error. The Cam Angle Error for each cam is
calculated individually and used to control both
camshafts independently to a single Desired Cam
Angle.
An engine oil temperature sensor in the engine sump
is used to compensate for Phaser response with
changing oil viscosity at different temperatures.
Intake Manifold Charge Control (IMCC) (I6
only)
To improve engine torque over the entire engine
operating range, the I6 engine has an Intake Manifold
Charge Control (IMCC) system, which contains two
air runners for each cylinder. A butterfly valve situated
in the intake runner for each cylinder controls the
effective length of the intake path. The Powertrain
Control Module (PCM) controls operation of the IMCC
system.
In normal operation, below approximately 3,800 RPM,
At low engine speeds a long intake path improves
the butterfly valves are closed, causing the intake air
volumetric efficiency, while at higher engine speeds a
to follow the longer path into the engine. At higher
short intake path provides better efficiency. Changing
engine speeds, above approximately 3,800 RPM, the
the effective length of the intake air path improves
butterfly valves open allowing the intake air to follow a
drivability and engine power throughout the engines
shorter path into the engine. A vacuum actuator
operating range. The lengths of the runners are
operates the butterfly valves. The Powertrain Control
designed to suit the Ram Air Effect of the I6 engine.
Module (PCM) controls vacuum to the actuator via a
solenoid valve.
NOTE: On I6 Turbo engines, there are no butterfly
valves.
Ignition System
The ignition Coil-On-Plug (COP) assembly consists of
a coil mounted on top of a spark plug. For each of the
engine’s cylinders, there is a corresponding COP
assembly.
Individual low side coil drives in the PCM control the
COP’s that ignites the air-fuel mixture within the
cylinders. The COP’s provide a controlled high
voltage spark to each spark plug at the correct time
under all engine operating conditions.
The ignition system comprises:
Individual coil drives: one per cylinder
Spark Plugs
Crankshaft Position Sensor (CKP) input
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Powertrain Control Management
303-14-13
DESCRIPTION AND OPERATION (Continued)
Camshaft Position Sensors (Cylinder
The powertrain control module (PCM) controls the
Identification) (CID1 & 2)
Evaporative (EVAP) Canister Purge solenoid. The
solenoid controls the flow of vapours from the carbon
Spark Advance Map
canister to the intake manifold for combustion during
various engine operating modes. The EVAP canister
The Powertrain Control Module (PCM) memory
purge solenoid is a normally closed valve.
contains a complex spark advance map to ensure
optimum ignition timing under all conditions. The ideal Canister purge occurs at all engine operating
advance is applied ensuring the best possible
conditions including idle and after engine warm-up.
performance, economy and minimal emissions.
The solenoid valve purges continuously until the EGO
sensor detects no more fuel vapours. The solenoid
Spark Plugs
valve then shuts down for a two minute period before
starting the purge cycle again.
Spark plugs are described in Section 303-07.
Positive Crankcase Ventilation
Engine Cooling System
The Positive Crankcase Ventilation (PCV) system
The engine cooling system is described in Section
cycles crankcase gases back through the engine
303-03A. The Powertrain Control Module (PCM)
where they are burned during the combustion
controls operation of the Electro Drive Fans 1-2
process. The PCV valve regulates the amount of
(EDF1-2). The PCM operates both fans at low or high
ventilating air entering the intake air system and
speeds through relays depending on engine
prevents any backfire from reaching the crankcase.
temperature load and A/C System pressure. The PCM
uses the Cylinder Head Temperature Sensor (CHT)
Catalyst and Exhaust System
and Air Conditioner Refrigerant Pressure Transducer
(ACPT), Vehicle Speed and Air Conditioner Control
The exhaust system carries engine emissions from
Relay, B2 (ACR) signals to calculate the cooling
the engine through the exhaust manifold, engine pipe,
requirements, then switches the fan relays
and catalytic converter to the atmosphere. The
accordingly.
exhaust system is described in Section 309-00. A
Heated Exhaust Gas Oxygen Sensor (HEGO) is
The PCM transmits CHT information to the instrument
mounted before the catalytic converter. The catalytic
cluster temperature gauge and the Climate Control air
converter reduces the concentration of carbon
conditioning on the CAN line.
monoxide, unburned hydrocarbons and oxides of
Engine Cooling Strategy (excludes LPG)
nitrogen in the exhaust emissions to an minimum
level.
The I6 and V8 engine cooling strategy ensures the
continued operation of the engine in the event of
Heated Oxygen Sensors
coolant loss or extremely high temperatures. If the
The Heated Exhaust Gas Oxygen Sensor (HEGO)
engine temperature exceeds approximately 120
provides the Powertrain Control Module (PCM) with a
degrees, to maintain a safe engine operating
voltage level that relates to the oxygen content of the
temperature, the fuel injectors are sequentially shut
exhaust gas.
off to allow each cylinder to be cooled by the intake
air. The engine may run rough when operating in
overheat management strategy mode. The jewel in
the cluster will light when the PCM senses that the
engine has exceeded a safe operating temperature.
The jewel will flash when fail-safe cooling strategy no
longer can keep the engine running. Shortly
afterwards, the engine will shutdown.
Evaporative Emission System
The Evaporative Emission System prevents fuel
vapours from the fuel tank being vented to the
atmosphere. Fuel vapours from the fuel tank are
collected in a carbon canister while the engine is not
running. The vapours remain trapped within the
canister until it is purged to the inlet manifold, where
the vapours are burnt as part of the normal
Item
Description
combustion process.
1
Fuel Injector
The Powertrain Control Module (PCM) monitors
2
HEGO Sensor
several system inputs to determine when purging the
vapours will have minimum impact on engine
operation.
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