Ford 6.4L Power Stroke - Wiring Diagram

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88

wiring diagram (single alt. ) r e f e r e n c e o n ly

Refer to Ford Wiring Diagrams for Wiring

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
- Front of Engine10
- Left Front of Engine10
Component Locations10
- 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
- 6.4L Vs 6.0L Flexplate16
- High Pressure Fuel Injection Pump & Rear Geartrain16
- Rocker Pedestal16
- Cooling System Features17
Internal Coolant Flow17
Cooling System Flow: External Flow18
External Coolant Flow18
- Cooling System Flow: Back of Front Cover19
- Oil Cooler Coolant Flow19
- Cooling System Flow: Oil Cooler19
- Injector Sleeve20
- Cooling System Flow: EGR Coolers20
Coolant Pump & Front Cover20
- 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
- Oil Cooler Cover26
- Front Cover26
- Oil Filter Base26
- Oil Filter27
- Turbocharger Oil Supply27
- Oil Pump Flow (Back Side)27
- Turbocharger Oil Drain Tubes28
- Oil Pan / Bed Plate28
- Fuel Supply System Features29
- Fuel Supply System30
- Fuel Flow30
- Engine Fuel Flow30
- HFCM Fuel Flow31
- HFCM (Horizontal Fuel Conditioning Module)31
- HFCM Components31
- 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 Open39
- Vanes Partially Closed39
- Vanes Closed39
- 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
- Nozzle Needle47
- Valve Mushroom, Return Spring, and Control Piston47
- Valve Piston47
- Pre-Main Injection48
Stages of Injection48
- Main Injection49
- End of Main Injection50
- Sensors Overview52
Electrical Components52
- 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
- Fuel System Service Cleanliness: Fuel Injectors, Fuel Rail74
- Oil Filter: Replacement74
- Fuel Filter: Replacement74
Unique Service Procedures74
- Fuel System Service Cleanliness: High Pressure Fuel Injection Pump75
- Fuel System Service: High Pressure Fuel Tube Service75
- Fuel System Service: High Pressure Fuel Tubes75
- 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
- Crossover Tube Seal Installation78
- EGR Valve Removal78
- Crossover Tube Seal Removal78
- 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
- Intake Manifold and Gaskets81
- Exhaust Up-Pipe Service81
- EGR Cooler Service81
Appendix82
Torque Charts83
- Standard Torque Chart84
- Cylinder Head Bolts85
- Flywheel Bolts85
- Bedplate Bolts (Main Bearing Bolts)85
- Exhaust Manifold Bolts86
- Vibration Damper Bolts86
- Intake 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
- Wiring Diagram90
- Diagnostic Codes91

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