Sistema de aire motor ford 6.4L Air Management System

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Air Management System Components

SeriesSequentialTurbocharger

ChargeAirCooler

IntakeManifold

AirFilter/FilterMinder

ExhaustGasRecirculation(EGR)System

Air Management System Features

Theseriessequentialturbochargerisalowpressure/highpressuredesignworkinginserieswithaturbochargeractuatoronthehighpressureturbinecontrollingtheboostpressures.

Thechargeaircoolerisutilizedtoreducethetemperatureofthepressurizedairthereforeinducingacooler/denserairchargeintotheintakemanifoldformaximumefficiency.

Anairfilter/filtermindercombinationisutilzedtocleantheincomingairandprovideameansformonitoringtheconditionoftheairfilterviathefilterminder.

TheEGRsystemisdesignedtoreduceexhaustemissions.

AIR MAnAgeMent SySteM

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Compressor Inlet (from air cleaner)

Low Pressure Turbocharger

EGR Valve

Throttle BodyEGR CoolerVertical

TurbochargerActuator

TurbochargerCrossover Tube

High Pressure Turbocharger

EGR Cooler Horizontal

EGR Diesel Oxidation Catalyst(EDOC)

Intake Manifold

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System Flow

Airentersthesystemthroughtheairfilterwhereparticlesareremovedfromtheair.Theairfilterhasafilterminderonittowarntheoperatorofarestrictedairfilter.

Aftertheairisfiltered,themassoftheairandtemperaturearemeasuredbythemassairflowsensor(MAF)andtheintakeairtemperaturesensor#1(IAT1).

Thefilteredairisthendirectedpastthecrankcaseventilationsystemwherecrankcasevaporsandfreshairaremixed.

Aftermixingwithcrankcasevaporsthefreshairmixtureisdrawnintothelowpressureturbochargercompressorthenthecompressedairissenttothehighpressureturbochargerwhereitisfurthercompressedbeforebeingsenttothechargeaircooler(CAC).

The(CAC)coolsthecompressedairviaanair-to-aircooler,thenthecondensedairpassesthroughtheEGRthrottle,mixeswithcooledEGRgases,thenenterstheintakemanifold.

Theintakemanifolddirectsthecooledairtotheintakeportsofthecylinderheads.

Theburnedairfuelmixtureispushedoutofthecylinderintotheexhaustmanifoldwhichcollectstheexhaustandroutesittothehighpressureturbochargersturbinewheel.

Theexhaustuppipe,connectedtothepassengersideexhaustmanifoldhasapassagethatdirectsexhausttotheexhaustgasrecirculation(EGR)coolersandthentotheEGRvalve.

TheEGRvalvecontrolstheflowofexhaustintotheintakesystemwherethegasesaremixedwithintakeairtoreduceNOx(OxidesofNitrogen)emissionsandnoise.

Thehotandexpandingexhaustgasesthatareroutedtotheseriessequentialturbochargerturbines,spintheturbinewheelsthroughflowandexpansion.Thespinningturbinewheelsthenspinthecompressorwheelsviacommonshafts.

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Air Filter Housing/ Filter Minder

Theairfilterislocatedonthepassengersideoftheenginecompartmentbetweenthebatteryandthecowl.

Afilterminder,deviceusedtomeasurefilterrestriction,islocatedontheoutletsideoftheairfilterhousingjustbeforetheMAFsensor.

Freshair,fromthepassengersidefenderarea,isdrawnintotheairfilterandparticulatesareremovedfromtheairbeforegoingtotheengine.

Air Filter Element

Thenewairfilterelementisareplaceablecartridgeseparatefromthehousing.

Theairfilteriscapableofholding750gramsofparticulatesbeforeneedingreplacement.

Thefilterelementisahoneycombdesign.

Charge Air Cooler (CAC)

TheCACislocatedinthefrontoftheradiator.

TheCACisanairtoaircoolerdesignedtolowerthetemperatureoftheaircomingoutoftheturbochargeroutletbeforeenteringtheintakemanifold.

Filter Minder

Air FIlter Housing

Air FIlter Element

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Series Sequential Turbocharger & Turbocharger Actuator

Theseriessequentialturbochargerforthe6.4LPowerStrokeDieselisdesignedtoprovideboostcontrolatlowandhighspeedsforimprovedthrottleresponse.

Theturbochargeractuatorisusedtocontrolthepositionofthevariablevanesinsidethehighpressureturbochargersturbinehousing.

Whenthevanesoftheturbochargerareclosed,theenginewillhaveahigherexhaustbackpressureandcreatemoreheatwhichwillinturnwarmtheenginefasterincoldambientconditions.

NOTE: There is an oxidation catalyst in the exhaust pipe for the EGR system that is utilized to crack hydrocarbons before they enter the EGR system.

Turbocharger Actuator

Thevariablevanesinsidethehighpressureturbochargersturbinehousingarenowcontrolledbytheturbochargeractuator.

Thehighpressureturbochargersturbinehousingcontainsvanesthatcontroltheeffectivesizeofthehousing.Thesevanesarecontrolledbytheturbochargeractuatorbywayofacontrolarm.Thecontrolarmconnectstheactuatortoapivotshaftwhichconnectstotheunisonringthatmovesthevanes.


Control Arm

Turbocharger Actuator Cooler

Theturbochargeractuatorisfittedwithacoolingplatetoreducethetemperatureoftheelectronicsinsidetheactuatorhousing.

Theactuatorcoolerusescoolantfromthefuelsystemcoolerastheheatexchangemedium.


TurbochargerActuator Cooler



Oxidation Catalyst

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INTAKE AIRFLOW (Blue)

Airentersthelowpressureturbochargerfromtheairfilter.

Thelowpressureturbochargercompressestheairandsendstheairthroughtheextensiontubeandthecrossovertubepriortoenteringthehighpressureturbocharger.

Thehighpressureturbochargerfurthercompressestheairandsendstheairtothechargeaircooler(CAC)wheretheairiscooledbyanair-to-aircoolerpriortoenteringtheintakemanifold.

EXHAUST AIRFLOW (Red)

Exhaustgasentersthehighpressureturbochargerturbinehousingafterbeingdirectedthroughtheexhaustup-pipesattherearoftheengine.

Thehighpressureturbochargerturbinecontainsthevaneswhicharecontrolledbytheturbochargeractuator.Thesevanescontinuallychangethevelocityoftheexhaustgasinthehighpressureturbochargerturbine.

Aftertheexhaustgashaspassedthroughthehighpressureturbochargerturbineitimmediatelyentersthelowpressureturbochargerturbine.

Oncetheexhaustgashaspoweredthelowpressureturbochargerturbinetheexhaustgasexitsthroughthehousingtowardstherearoftheenginewhereitisdirectedtotheexhaustaftertreatmentsystem.



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Vanes Closed

Duringengineoperationatlowenginespeedsandload,littleenergyisavailablefromtheexhausttogenerateboost.Inordertomaximizetheuseoftheenergythatisavailable,thevanesareclosed.Indoingso,theexhaustgasisacceleratedbetweenthevanesandacrosstheturbinewheel.Ingeneral,thisallowstheturbochargertobehaveasasmallturbocharger,increasingthewheelspeedquicklyatlowspeed.

ClosingthevanesalsoincreasesthebackpressureintheexhaustmanifoldwhichisusedtodrivetheexhaustgasthroughtheEGRcoolerandvalveintotheintakemanifold.

Theclosedvanepositionisalsousedforcoldambientwarmup.

Vanes Partially Closed

DuringEngineoperationatmoderateenginespeedsandload,thevanesarecommandedpartiallyopen.

ThevanesaresettothisintermediatepositiontosupplythecorrectamountofboosttotheengineforoptimalcombustionaswellasprovidingthenecessarybackpressuretodriveEGR.

Note: There is actually an infinite number of vane positions between open and closed. The partially closed picture is for illustration purposes only.

Vanes Open

Duringengineoperationathighenginespeedsandload,thereisagreatdealofenergyavailableintheexhaust.

Excessiveboostunderhighspeed,highloadconditionscannegativelyaffectcomponentdurability,thereforethevanesarecommandedopenpreventingturbochargeroverspeed.

Essentially,thisallowstheturbochargertoactasalargeturbochargerwithminimalrestriction.


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EGR Valve

TheECMcontrolledEGR(ExhaustGasRecirculation)valveaddscooledexhaustgasestotheintakemanifoldtoreduceNOxemissions.

TheEGRvalveisopenedduringsteadystatethrottlepositionswhenexhaustbackpressuresarehigherthanintakemanifoldpressures(boost).

EGR Flow

TheEGRvalvehastwovalvesconnectedbyacommonshaft.

CooledexhaustgasenterstheloweropeningoftheEGRvalveafterleavingtheverticalEGRcooler.

Whenthevalveopensitallowsthecooledexhaustgastoflowthroughtwopassages,onepassageisthroughtheupperopeningoftheEGRvalve(uppervalve)andtheotheristhroughapassagebelowtheEGRvalve(lowervalve).

Bothpassagesmergetogetherpriortobeingmixedwiththefilteredincomingairbeforebeingsenttotheintakemanifold.

DualEGRCoolingSystem

TheEGRcoolingsystemisanairtocoolantheatexchangerthatisusedtocooltheexhaustgasesbeforetheyaresenttotheEGRvalve.

TheexhaustisroutedintotheEGRcoolersfromtheexhaustuppipesattherearoftheengine.

Theexhaustiscooledbypassingthroughmetaltubesthataresurroundedbyenginecoolant.Dependingonconditions,thetemperaturedropacrossthecoolerscouldbeasmuchas850F.

ThecooledexhaustisthenroutedtotheEGRvalvethatismountedtotheinletmixingchamber.

EGR Valve

EGR Cooler Horizontal

EGR Cooler Vertical

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Throttle Body

Thethrottlebodyisusedtoassistwiththeexhaustaftertreatmentsystem.

Intake Manifold

Theintakemanifoldonthe6.4LPowerStrokeDieselismadeofaluminumanddirectstheflowofairtotheintakeportsinthecylinderheads.

Themanifoldabsolutepressuresensor(MAP)andtheintakeairtemperature2sensor(IAT2)arebothmountedintheintakemanifold.

Throttle Body

Intake Manifold

IAT 2 MAP

Throttle Plate

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Fuel ManageMent SySteM

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High Pressure Common Rail Fuel System

Thehighpressurecommonrailfuelinjectionsystemwithpiezoelectricfuelinjectorsusespressurizedfuelandelectronicstoactuateandcontrolfuelinjectionintothecylinders.

High Pressure Common Rail Direct Injection Fuel System Components

Thefuelmanagementsystemiscomprisedofseveralsubsystems.

Eachsystemworkstogethertodeliverexcellentpowerandefficiencywhilemeetingtherequirementsofemissionsregulations.

High Pressure Common Rail Fuel System Advantages

Emissionsandnoisehavebeenreducedthroughimprovementsinrate,timingcontrol,andmultipleinjections.

ThehighpressuresystemspressurerelieffunctionisnowcontrolledbythePCV(PressureControlValve),whichismountedtothehighpressurefuelinjectionpump.

Thepiezofuelinjectorshelpreducenoisewhiledeliveringoptimumperformance.

Fuel Management System Major Components

FuelSupplySystem

HighPressureFuelInjectionPump

HighPressureFuelTubes

Sensors

Injectors

ElectricalComponents

Actuators

Fuel Management System Features

Emissions

Noise

RateControl

TimingControl

PCV(pressurecontrolvalve)

VCV(volumecontrolvalve)

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High Pressure Fuel System Flow

FuelissuppliedtothehighpressurefuelinjectionpumpafterbeingfilteredbyboththeHFCM(horizontalfuelconditioningmodule)andtheenginemountedfuelfilter.

Thehighpressurefuelinjectionpumpisgeardrivenoffofthecamshaftgearattherearoftheengine.

Oncethehighpressurefuelinjectionpumppressurizesthefuelitisroutedtotwo(2)highpressurefuelrailsupplytubes,oneforeachbank.

HIgH PReSSuRe Fuel SySteM

Thehighpressurefuelrailsupplytubesroutethefueltothehighpressurefuelraillocatedunderthevalvecover.

Thehighpressurefuelrailinletprotrudesthroughthevalvecoverspaceratthebackoftheengineandoilissealedbyarubberseal.

Thehighpressurefuelrailroutesfueltoeachofthefour(4)fuelinjectorsthroughfour(4)separatefuelinjectorsupplytubesalllocatedunderthevalvecover.

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High Pressure Pump Operation

Afterbeingfilteredattheenginemountedfuelfilter,fuelisdirectedtothehighpressurefuelinjectionpump.

BeforefuelenterstheVolumeControlValve(VCV)thepressureissteppedupbytheInternalTransferPump(ITP).TheITPislocatedinsidethehighpressurefuelinjectionpumpandisdrivenbyitsmainshaft.

TheVCVcontrolshowmuchfuelentersthethree(3)mainpumppistons.

AportionofthefuelleavingtheITPissenttoalubricationvalvewhichallowsfueltolubricateandcooltheinternalmechanicalcomponentsofthehighpressurefuelinjectionpump.

Thehighpressurefuelinjectionpumpmainshafthasanoffsetjournalthatactuateseachofthethree(3)pistonsastheshaftrotates.

Theoffsetjournalofthemainshaftutilizesafree-spinninghubtomakecontactwiththethree(3)pistons.

1)ITP(internaltransferpump)2)VCV(volumecontrolvalve)3)High-PressureFuelInjectionPumpElement4)PCV(pressurecontrolvalve)5)InletPressureControlValve6)LubricationValve7)EdgeFiltera)FuelInletb)High-PressureConnectionc)FuelReturn

Thepistonsstarttheircompressionstrokeviatheoffsetjournalandarereturnedtorestviaspringpressure.

ThepistonsreceivefuelfromtheVCVthroughaonewaycheckvalve.Fuelisdrawnintothecylinderwhilethepistonisreturningtorest.

Theoutletcheckvalveballisclosedwhilefuelisbeingdrawninduetothesuction(lowpressurearea)ofthepistonreturningtorestandthepressureexertedbytheothertwopistons.

Oncethepistonstartsitscompressionstroke,theinletcheckvalveclosesviaspringandfuelpressureandtheoutletcheckvalveopensduetoincreasingfuelpressureforcingthecheckvalveballawayfromitsseat.

Thepressurecontrolvalve(PCV)controlsthepressureinthesystembyrestrictingfuelflowtothereturnline(pressureistheresistancetoflow).

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High Pressure Fuel Injection Pump & Cover

Thehighpressurefuelinjectionpumpisinstalledinthecrankcase.

Thepumpisathree(3)pistonrotarystylepumpthatisdrivenbythereargeartrain.

Eachbankofcylindershasitsownpumpoutletandhighpressurefuelsupplytube.

PCV (Pressure Control Valve) VCV (Volume Control Valve)

ThePCVandVCVarebothinstalledinthehighpressurefuelinjectionpump.

ThePCVandVCVARENOTSERVICEABLE.

High Pressure Fuel Rail & Fuel Rail Pressure Sensor (FRP)

Fuelunderextremelyhighpressuresisdeliveredtothefuelinjectorsfromthefuelrailbywayofthefuelinjectorsupplytubes.

TheFRPsensorislocatedontheenginesrightsidehighpressurefuelrail.

High Pressure Fuel Injection Pump

Pressure Control Valve (PCV)

Volume Control Valve (VCV)

FRP Sensor

High Pressure FuelInjection Pump Cover

Electrical Connector Electrical Connector

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Piezo Electric Fuel Injector

PiezoElectricallyActuated

HighElectricalEffeciency

HighVoltageSupply

Upto5InjectionsPerCombustionEvent

Selfextractingholddownclamp

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Fuel Injector Features

TheinjectorusesaPiezoActuatortoelectricallycontroltheinjectionswithextremeprecision.

ThePiezoActuatoristurnedonforapproximately0-400s(microsecondormillionthofasecond)for2injections.

Nospecialtoolsareneededtoremovetheinjectorsfromtheirbore.Theinjectorisslowlyremovedfromitsborebyremovingtheself-extractingholddownclampbolt.

Injector & O-ring

Theinjectorhasone(1)replaceableo-ringontheoutsideofthebody,andone(1)replaceablesoftsteelcombustiongasketonthetipoftheinjector.

Theinjectorspiezoactuatorhasasingletwo(2)pinconnectorthatislocatedunderthevalvecover.

Thefuelchargingharnesshasasinglemainconnectionpointatthefrontofthevalvecoverspacer.

Piezo Actuator

Thepiezoactuatorisanelectricallyenergizeddevicethatactssimilartoasolenoidbutismuchmoreprecise.

Apiezoactuatorisacompositionofpiezodiscs,thatwhenelectricallyenergized,causethediscstodeformresultinginanexpansion.Thisexpansionresultsinalongitudinalmotionthuscontrollingtheinjector.

Whenenergized,thepiezoactuatorpushesdownwardagainstthevalvepiston.ThepiezoactuatorisreturnedtoitsnonenergizedstateviatheECMswitchingthepolarityoftheelectricalfeedtotheinjector.

Fuel InletFrom HighPressure Fuel Rail

Piezo Actuator

O-RingFuel Return LineDrain Holes

Soft SteelCombustion Gasket

Piezo Actuator(non-energized)

ElectricalConnector

Piezo Actuator(energized)

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Valve Piston

Thevalvepistonisutilizedforonemainpurpose:

1) Ittransferstheupanddownmovementfrom thePiezoActuatortotheValveMushroom.

Valve Mushroom, Return Spring, and Control Piston

ThevalvemushroomisahydrauliccheckvalvethatallowshighpressurefueltobleedoffintothefuelreturnpassagedirectlyaboveitwheneverthePiezoActuatorisenergized.

Thevalvemushroomisheldinaclosed(sealed)positionwheneverthePiezoActuatorisnotenergizedviahighpressurefuelandspringpressure.

Thecontrolpistonutilizesitslargesurfaceareaforadownwardforcetoovercomethepressureexertedbythesmallersurfaceareaofthenozzleneedleinthehighpressurechambertokeepthenozzleneedleinaclosedposition.

Nozzle Needle

Thenozzleneedleisaninwardlyopeningtypewhichliftsoffitsseateverytimethepressureinthehighpressurechamberexceedsthepressureinthecontrolpistonchamber,i.e.whenthepiezoisactuated.

Theneedlecontrolspringisusedtoholdthenozzleneedleinaclosedposition.

Fuelisatomizedathighpressurethroughthenozzletipssixsprayholes.

Valve Piston

Valve Mushroom

Valve Mushroom

High PressureFuel

Needle ControlSpring

Control Piston

Valve MushroomReturn Spring

Fuel Return Passage

Control Piston

Nozzle Needle

High Pressure Chamber

Spray Holes (6 holes)

Control PistonChamber

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Two Stages of Injection

MainInjection

EndofMainInjection

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Stages of Injection

Theinjectioncyclehastwo(2)stages.

Maininjection.

Endofmaininjection.

Thisinjectionsystemiscapableofperformingbothstepsoftheinjectioncycleupto5timesperfiringcycle.

Pre-Main Injection

Thepiezoelectricfuelinjectorisconstantlybeingfilledwithfuelviathehighpressurefuelinjectionpump.

Highpressurefuelfromthehighpressurefuelinjectionpumpentersthefollowingareas:

- controlpistonchamber(2).

- springsideofthevalvemushroom(4).

- highpressurechamber(3).

Theneedlecontrolspring(9)holdstheneedleonitsseatsothatfuelcannotenterthecombustionchamber.

Thepiezoactuator(1)isinanon-energizedstate.

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Main Injection Step 1

Fuelunderpressurefromtherail(7)reachesthecontrolpistonchamber(2)andthehighpressurechamber(3)ofthenozzleneedle(5).

Theboreholetothefuelreturnlineisclosedviathevalvemushroom(4),whichisheldclosedbyaspringandhighpressurefuel.

Thesurfaceareaofthecontrolpistonismuchlargerthanthesurfaceareaofthenozzleneedleinthehighpressurechamber.

Theforce(F1)exertedbythecontrolpistonduetoitslargersurfaceareaalongwiththeforceoftheneedlecontrolspringovercomestheforce(F2)exertedbythesmallersurfaceareaofthenozzleneedleinthehighpressurechamberwhichholdsthenozzleneedleclosed.

Main Injection Step 2

Whenthepiezoactuator(1)iscommandedon,theactuatorisenergized(whichcausesthepiezodiscstodeformandcreateadownwardforce)andpushesthevalvepiston(8)downward.

Thedownwardforceofthevalvepistonpushesthevalvemushroom(4)andspringdownwhichopensupaboreholethatconnectsthehighpressurefueltothefuelreturnline(6).

Whenthishappensitallowsasmallamountofhighpressurefueltoenterthefuelreturnline(6)effectivelydroppingthepressureinthecontrolpistonchamber(2).

Thispressuredropisenoughfortheforce(F2x)onthenozzleneedle(5)inthehighpressurechambertoovercometheforce(F1x)inthecontrolpistonchamber(2).

Thisallowsthenozzleneedle(5)tomoveupwarduncoveringthesixsprayholesandallowinghighpressurefueltoatomizeandenterthecombustionchamber.

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F1

F2

F1x

F2x

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End of Main Injection Step 1

Thehighpressurefuel,thatisallowedtoescapepastthevalvemushroom(4)intothefuelreturnline(6),isrouteddownadrilledpassagetothedrainholesinthesidesoftheinjectorjustbelowtheO-ringsealtowardsthebaseoftheinjector.

Thefuelisthenroutedthroughthecylinderheadandexitsthroughabanjofittingonthefrontsideofthecylinderheadbeforebeingreturnedtothefuelsupplysystem.

End of Main Injection Step 2

WhentheEngineControlModule(ECM)determinesthatthecorrectinjectorontimehasbeenreached,itswitchesthepolarityofthepiezoactuator(1)whichcausesthepiezodiscstoreturntoanon-enerrgizedstate.

Switchingthepolarityofthepiezoactuator(1)enablesthevalvemushroom(4)toseatviaspringpressureandcompletelyblocktheboredpassagethatconnectsthehighpressurefueltothefuelreturnline.

Seatingthevalvemushroom(4)allowsthepressuretobuildinthecontrolpistonchamber(2)andequalthatinthehighpressurechamber(3).

Oncethesetwochambershaveequalizedinpressurethedownwardforce(F1)ofthecontrolvalvewillovercometheupwardforce(F2)ofthenozzleneedleduetothelargersurfaceareaofthecontrolvalve.

Thecontrolvalvethenmovesdownwardeffectivelyclosingthenozzleneedle(5),blockinganyfuelfromenteringthecombustionchamber.

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Sistema de aire motor ford 6.4L Air Management System