Table Of Contents - Ford 6.4L Power Stroke Manual

Table of Contents

Important Safety Notice2
Table Of Contents4
6.4L Power Stroke Diesel Overview7
Features7
Horsepower & Torque7
6.4L Power Stroke Diesel Specifications8
Engine Serial Number9
Serial Number Label9
Emissions Label9
Component Locations10
Front Of Engine10
Left Front Of Engine10
Left Of Engine11
Left Rear Of Engine11
Rear Of Engine12
Right Rear Of Engine12
Right Side Of Engine13
Right Front Of Engine13
Top Of Engine14
High Pressure Common Rail Fuel System15
Cylinder Head & Head Bolts15
Fulcrum Plate & Rocker Arms15
Rocker Pedestal16
High Pressure Fuel Injection Pump & Rear Geartrain16
6.4L Vs 6.0L Flexplate16
Cooling System Features17
Internal Coolant Flow17
External Coolant Flow18
Cooling System Flow: External Flow18
Cooling System Flow: Back Of Front Cover19
Oil Cooler Coolant Flow19
Cooling System Flow: Oil Cooler19
Cooling System Flow: Egr Coolers20
Coolant Pump & Front Cover20
Injector Sleeve20
Glow Plug Sleeve21
Degas Bottle21
Lubrication System Features22
Lubrication System Oil Flow23
Pick-Up Tube / Oil Aeration24
Oil Pressure Regulator24
Gerotor Oil Pump24
Lube System Flow: Oil Cooler25
Front Cover26
Oil Filter Base26
Oil Cooler Cover26
Oil Pump Flow (Back Side)27
Oil Filter27
Turbocharger Oil Supply27
Turbocharger Oil Drain Tubes28
Oil Pan / Bed Plate28
Fuel Supply System Features29
Fuel Supply System30
Fuel Flow30
Engine Fuel Flow30
Hfcm (Horizontal Fuel Conditioning Module)31
Hfcm Components31
Hfcm Fuel Flow31
Engine Mounted Fuel Filter32
Fuel Pressure Regulator32
Fuel Return Banjo Fittings32
Air Management System Components34
Air Management System Features34
• Series Sequential Turbocharger34
Egr34
System Flow35
Air Filter Housing/ Filter Minder36
Air Filter Element36
Charge Air Cooler (Cac)36
Series Sequential Turbocharger & Turbocharger Actuator37
Turbocharger Actuator37
Turbocharger Actuator Cooler37
Intake Airflow (Blue)38
Exhaust Airflow (Red)38
Vanes Closed39
Vanes Partially Closed39
Vanes Open39
Egr Valve40
Egr Flow40
Dual Egr Cooling System40
Throttle Body41
Intake Manifold41
High Pressure Common Rail Direct Injection42
Fuel System Components42
High Pressure Common Rail42
Fuel System Advantages42
High Pressure Fuel System Flow43
High Pressure Pump Operation44
Fuel Management System44
High Pressure Fuel Injection Pump & Cover45
Pcv (Pressure Control Valve)45
Vcv (Volume Control Valve)45
High Pressure Fuel Rail & Fuel Rail Pressure Sensor (Frp)45
Piezo Electric Fuel Injector46
Injector & O-Ring46
Piezo Actuator46
Valve Piston47
Valve Mushroom, Return Spring, And Control Piston47
Nozzle Needle47
Stages Of Injection48
Pre-Main Injection48
Main Injection49
End Of Main Injection50
Electrical Components52
Sensors Overview52
Ap (Accelerator Pedal Position)53
Baro (Barometric Pressure)54
Ckp (Crankshaft Position)55
Cmp (Camshaft Position)56
Ect (Engine Coolant Temperature)57
Egrvp (Egr Valve Position)58
Eop (Engine Oil Pressure)59
Eot (Engine Oil Temperature)60
Iat1 (Intake Air Temperature #1)61
Iat2 (Intake Air Temperature #2)62
Frp (Fuel Rail Pressure)63
Maf (Mass Air Flow)64
Map (Manifold Absolute Pressure)65
Ep (Exhaust Pressure)66
Fts (Fuel Temperature Sensor)67
Egrt Outlet (Egr Cooler Outlet Temperature)68
Control Devices69
Glow Plug Control Module (Gpcm)69
Exhaust Gas Recirculation Valve (Egr Valve)70
Ecm (Engine Control Module)71
Glow Plug System71
Glow Plug Control Module(Gpcm) & Glow Plug Harness71
Glow Plug72
Fuel Injector72
Unique Service Procedures74
Oil Filter: Replacement74
Fuel Filter: Replacement74
Fuel System Service Cleanliness: Fuel Injectors, Fuel Rail74
Fuel System Service Cleanliness: High Pressure Fuel Injection Pump75
Fuel System Service: High Pressure Fuel Tubes75
Fuel System Service: High Pressure Fuel Tube Service75
Fuel System Service: Fuel Injector Service76
Fuel System Service: Removing And Installing Injector Gasket76
Fuel System Service: Fuel Injector Lubrication76
Checking Fuel Pressure77
Turbocharger Lifting Bracket77
Turbocharger Assembly Tool77
Egr Valve Removal78
Crossover Tube Seal Removal78
Crossover Tube Seal Installation78
High Pressure Fuel Injection Pump: Gear Service79
Cutting T-Joints: Rear Cover79
Cutting T-Joints: Front Cover79
Checking Oil Pressure80
Checking Cylinder Head Flatness80
Checking Cylinder Head Flatness: Straight Edge Placement80
Egr Cooler Service81
Exhaust Up-Pipe Service81
Intake Manifold And Gaskets81
Appendix82
Torque Charts83
Standard Torque Chart84
Cylinder Head Bolts85
Flywheel Bolts85
Bedplate Bolts (Main Bearing Bolts)85
Intake Manifold Bolts86
Vibration Damper Bolts86
Exhaust Manifold Bolts86
Fuel Components Assembly Procedure87
High Pressure Pump And Pump-To-Rail Hp Tubes Installation Procedure87
Injector-Pipe-Rail Sub-Assembly Process87
Fulcrum Plate / Rocker Arm Support Assembly88
Cooler Mounting Clamps88
Fuel Rail Pressure Sensor (Frp)88
Wiring Diagram89
Diagnostic Codes91