Fuel Injection System

CRANKSHAFT POSITION SENSOR
5.9L
The Crankshaft Position (CKP) sensor is located near the outer edge of the flywheel (starter ring gear).

Engine speed and crankshaft position are provided through the CKP sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing.

The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it.

Fig.24 CKP Sensor Operation - 5.9L Engine:

On 5.9L V-8 engines, the flywheel/drive plate has 8 single notches, spaced every 45 degrees, at its outer edge.

The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. For each engine revolution, there are 8 pulses generated on V-8 engines.

8.0L
The engine will not operate if the PCM does not receive a CKP sensor input.

Fig.23 CKP Sensor Location - 8.0L V-10 Engine:

The Crankshaft Position (CKP) sensor is located on the right-lower side of the cylinder block, forward of the right engine mount, just above the oil pan rail.

Fig.25 CKP Sensor Operation - 8.0L V-10 Engine:

The Crankshaft Position (CKP) sensor detects notches machined into the middle of the crankshaft.

There are five sets of notches. Each set contains two notches. Basic ignition timing is determined by the position of the last notch in each set of notches. Once the Powertrain Control Module (PCM) senses the last notch, it will determine crankshaft position (which piston will next be at Top Dead Center). An input from the camshaft position sensor is also needed. It may take the module up to one complete engine revolution to determine crankshaft position during engine cranking.

The PCM uses the signal from the camshaft position sensor to determine fuel injector sequence. Once crankshaft position has been determined, the PCM begins energizing a ground circuit to each fuel injector to provide injector operation.

FUEL PUMP RELAY
The 5-pin, 12-volt, fuel pump relay is located in the Power Distribution Center (PDC). Refer to the label on the PDC cover for relay location.

The Powertrain Control Module (PCM) energizes the electric fuel pump through the fuel pump relay. The fuel pump relay is energized by first applying battery voltage to it when the ignition key is turned ON, and then applying a ground signal to the relay from the PCM.

Whenever the ignition key is turned ON, the electric fuel pump will operate. But, the PCM will shutdown the ground circuit to the fuel pump relay in approximately 1-3 seconds unless the engine is operating or the starter motor is engaged.

IDLE AIR CONTROL MOTOR
The IAC stepper motor is mounted to the throttle body and regulates the amount of air bypassing the control of the throttle plate. As engine loads and ambient temperatures change, engine rpm changes. A pintle on the IAC stepper motor protrudes into a passage in the throttle body, controlling air flow through the passage. The IAC is controlled by the Powertrain Control Module (PCM) to maintain the target engine idle speed.

At idle, engine speed can be increased by retracting the IAC motor pintle and allowing more air to pass through the port, or it can be decreased by restricting the passage with the pintle and diminishing the amount of air bypassing the throttle plate.

The IAC is called a stepper motor because it is moved (rotated) in steps, or increments. Opening the IAC opens an air passage around the throttle blade which increases RPM.

The PCM uses the IAC motor to control idle speed (along with timing) and to reach a desired MAP during decel (keep engine from stalling).

The IAC motor has 4 wires with 4 circuits. Two of the wires are for 12 volts and ground to supply electrical current to the motor windings to operate the stepper motor in one direction. The other 2 wires are also for 12 volts and ground to supply electrical current to operate the stepper motor in the opposite direction.

To make the IAC go in the opposite direction, the PCM just reverses polarity on both windings. If only 1 wire is open, the IAC can only be moved 1 step (increment) in either direction. To keep the IAC motor in position when no movement is needed, the PCM will energize both windings at the same time. This locks the IAC motor in place.

In the IAC motor system, the PCM will count every step that the motor is moved. This allows the PCM to determine the motor pintle position. If the memory is cleared, the PCM no longer knows the position of the pintle. So at the first key ON, the PCM drives the IAC motor closed, regardless of where it was before. This zeros the counter. From this point the PCM will back out the IAC motor and keep track of its position again.

When engine rpm is above idle speed, the IAC is used for the following:
- Off-idle dashpot (throttle blade will close quickly but idle speed will not stop quickly)
- Deceleration air flow control
- A/C compressor load control (also opens the passage slightly before the compressor is engaged so that the engine rpm does not dip down when the compressor engages)
- Power steering load control
- The PCM can control polarity of the circuit to control direction of the stepper motor.

IAC Stepper Motor Program: The PCM is also equipped with a memory program that records the number of steps the IAC stepper motor most recently advanced to during a certain set of parameters. For example: The PCM was attempting to maintain a 1000 rpm target during a cold start-up cycle. The last recorded number of steps for that may have been 125. That value would be recorded in the memory cell so that the next time the PCM recognizes the identical conditions, the PCM recalls that 125 steps were required to maintain the target. This program allows for greater customer satisfaction due to greater control of engine idle.

Another function of the memory program, which occurs when the power steering switch (if equipped), or the A/C request circuit, requires that the IAC stepper motor control engine rpm, is the recording of the last targeted steps into the memory cell. The PCM can anticipate A/C compressor loads. This is accomplished by delaying compressor operation for approximately 0.5 seconds until the PCM moves the IAC stepper motor to the recorded steps that were loaded into the memory cell. Using this program helps eliminate idle-quality changes as loads change. Finally, the PCM incorporates a No-Load engine speed limiter of approximately 1800 - 2000 rpm, when it recognizes that the TPS is indicating an idle signal and IAC motor cannot maintain engine idle.

A (factory adjusted) set screw is used to mechanically limit the position of the throttle body throttle plate. Never attempt to adjust the engine idle speed using this screw. All idle speed functions are controlled by the IAC motor through the PCM.

INTAKE AIR TEMPERATURE SENSOR
The 2-wire Intake Manifold Air Temperature (IAT) sensor is installed in the intake manifold with the sensor element extending into the air stream.

The IAT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as intake manifold sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases.

The IAT sensor provides an input voltage to the Powertrain Control Module (PCM) indicating the density of the air entering the intake manifold based upon intake manifold temperature. At key-on, a 5-volt power circuit is supplied to the sensor from the PCM. The sensor is grounded at the PCM through a low-noise, sensor-return circuit.

The PCM uses this input to calculate the following:
- Injector pulse-width
- Adjustment of spark timing (to help prevent spark knock with high intake manifold air-charge temperatures)

The resistance values of the IAT sensor is the same as for the Engine Coolant Temperature (ECT) sensor.

MANIFOLD ABSOLUTE PRESSURE SENSOR
On 5.9L engines, the MAP sensor is mounted on the side of the engine throttle body. The sensor is connected to the throttle body with a rubber L-shaped fitting.

On the 8.0L 10 Cylinder engine, the MAP sensor is mounted into the right side of the intake manifold.

The MAP sensor is used as an input to the Power- train Control Module (PCM). It contains a silicon based sensing unit to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When Manifold Absolute Pressure (MAP) equals Barometric pressure, the pulse width will be at maximum.

A 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5V For a pressure swing of 0-15 psi, the voltage changes 4.0V. To operate the sensor, it is supplied a regulated 4.8 to 5.1 volts. Ground is provided through the low-noise, sensor return circuit at the PCM.

The MAP sensor input is the number one contributor to fuel injector pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or at a higher altitude, because the air density changes with altitude. It will also help to correct for varying barometric pressure. Barometric pressure and altitude have a direct inverse correlation; as altitude goes up, barometric goes down. At key-ON, the PCM powers up and looks at MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure (relative to altitude). Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key-ON. The difference between current voltage and what it was at key-ON, is manifold vacuum.

During key-ON (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring a known good sensor.

As the altitude increases, the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key-on, the barometric pressure needs to be updated. Any time the PCM sees Wide Open Throttle (WOT), based upon Throttle Position Sensor (TPS) angle and RPM, it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively.

The PCM uses the MAP sensor input to aid in calculating the following:
- Manifold pressure
- Barometric pressure
- Engine load
- Injector pulse-width
- Spark-advance programs
- Shift-point strategies (certain automatic transmissions only)
- Idle speed
- Decel fuel shutoff

The MAP sensor signal is provided from a single piezo-resistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As manifold pressure changes, the diaphragm moves causing the element to deflect, which stresses the silicone. When silicone is exposed to stress, its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor also contains electronics that condition the signal and provide temperature compensation.

The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; meaning as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg. Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is approximately 29.92 in Hg. For every 100 feet of altitude, barometric pressure drops 0.10 in. Hg. If a storm goes through it can change barometric pressure from what should be present for that altitude. You should know what the average pressure and corresponding barometric pressure is for your area.

OXYGEN SENSOR
The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Depending on the emission package, the vehicle may use a total of either 2 or 4 sensors.

Medium and Heavy Duty 8.0L V-10 Engine:
Four sensors are used (2 upstream, 1 pre-catalyst and 1 post-catalyst). With this emission package, the 1/1 upstream sensor (left side) is located in the left exhaust downpipe before both the pre-catalyst sensor (1/2), and the main catalytic convertor. The 2/1 upstream sensor (right side) is located in the right exhaust downpipe before both the pre-catalyst sensor (1/2), and the main catalytic convertor. The pre-catalyst sensor (1/2) is located after the 1/1 and 2/1 sensors, and just before the main catalytic convertor. The post-catalyst sensor (1/3) is located just after the main catalytic convertor.

Heavy Duty 5.9L Engine: Two sensors are used. They are both referred to as upstream sensors (left side is referred to as 1/1 and right side is referred to as 2/1). With this emission package, a sensor is located in each of the exhaust downpipes before the main catalytic convertor.

An O2 sensor is a galvanic battery that provides the PCM with a voltage signal (0-1 volt) inversely proportional to the amount of oxygen in the exhaust. In other words, if the oxygen content is low, the voltage output is high; if the oxygen content is high the output voltage is low. The PCM uses this information to adjust injector pulse-width to achieve the 14.7-to-1 air/fuel ratio necessary for proper engine operation and to control emissions.

The O2 sensor must have a source of oxygen from outside of the exhaust stream for comparison. Current O2 sensors receive their fresh oxygen (outside air) supply through the O2 sensor case housing.

Four wires (circuits) are used on each O2 sensor: a 12-volt feed circuit for the sensor heating element; a ground circuit for the heater element; a low-noise sensor return circuit to the PCM, and an input circuit from the sensor back to the PCM to detect sensor operation.

Oxygen Sensor Heaters/Heater Relays: Depending on the emissions package, the heating elements within the sensors will be supplied voltage from either the ASD relay, or 2 separate oxygen sensor relays. Refer to Wiring Diagrams to determine which relays are used.

The O2 sensor uses a Positive Thermal Co-efficient (PTC) heater element. As temperature increases, resistance increases. At ambient temperatures around 70 °F, the resistance of the heating element is approximately 4.5 ohms. As the sensor's temperature increases, resistance in the heater element increases. This allows the heater to maintain the optimum operating temperature of approximately 930° - 1100 °F (500 ° - 600 °C). Although the sensors operate the same, there are physical differences, due to the environment that they operate in, that keep them from being interchangeable.

Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle.

In Closed Loop operation, the PCM monitors certain O2 sensor input(s) along with other inputs, and adjusts the injector pulse width accordingly. During Open Loop operation, the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors.

Upstream Sensors: Two upstream sensors are used (1/1 and 2/1). The 1/1 sensor is the first sensor to receive exhaust gases from the # 1 cylinder. They provide an input voltage to the PCM. The input tells the PCM the oxygen content of the exhaust gas. The PCM uses this information to fine tune fuel delivery to maintain the correct oxygen content at the downstream oxygen sensors. The PCM will change the air/ fuel ratio until the upstream sensors input a voltage that the PCM has determined will make the downstream sensors output (oxygen content) correct.

The upstream oxygen sensors also provide an input to determine mini-catalyst efficiency. Main catalytic convertor efficiency is not calculated with this package.

Downstream Sensors: Two downstream sensors are used (1/2 and 2/2). The downstream sensors are used to determine the correct air-fuel ratio. As the oxygen content changes at the downstream sensor, the PCM calculates how much air-fuel ratio change is required. The PCM then looks at the upstream oxygen sensor voltage, and changes fuel delivery until the upstream sensor voltage changes enough to correct the downstream sensor voltage (oxygen content).

The downstream oxygen sensors also provide an input to determine mini-catalyst efficiency. Main catalytic convertor efficiency is not calculated with this package.

Medium and Heavy Duty 8.0L V-10 Engine: Four oxygen sensors are used O2 upstream, 1 pre-catalyst and 1 post-catalyst). The upstream sensors (1/1 and 2/1) will fine-tune the air-fuel ratio through the Powertrain Control Module (PCM). The pre-catalyst (1/2) and post-catalyst (1/3) sensors will determine catalytic convertor efficiency (efficiency of the main catalytic convertor). This is also done through the PCM.

Heavy Duty 5.9L Engine: Downstream sensors are not used with this emissions package, meaning catalytic convertor efficiency is not calculated with this package. Two upstream sensors are used. The left upstream sensor (1/1) will monitor cylinders 1, 3, 5 and 7. The right upstream sensor (2/1) will monitor cylinders 2, 4, 6 and 8. The PCM monitors the oxygen content of the sensors, and will fine-tune the air- fuel ratio.

Engines equipped with either a downstream sensor(s), or a post-catalytic sensor, will monitor catalytic convertor efficiency. If efficiency is below emission standards, the Malfunction Indicator Lamp (MIL) will be illuminated and a Diagnostic Trouble Code (DTC) will be set. Refer to Monitored Systems in Emission Control Systems for additional information.

PTO SWITCH
This Powertrain Control Module (PCM) input is used only on models equipped with aftermarket Power Take Off (PTO) units.

The input is used only to tell the PCM that the PTO has been engaged. The PCM will disable (temporarily shut down) certain OBD II diagnostic trouble codes when the PTO is engaged.

When the aftermarket PTO switch has been engaged, a 12V + signal is sent through circuit G113 to PCM pin A13. The PCM will then sense and determine that the PTO has been activated.

THROTTLE BODY
The throttle body is located on the intake manifold. Fuel does not enter the intake manifold through the throttle body. Fuel is sprayed into the manifold by the fuel injectors.

Filtered air from the air cleaner enters the intake manifold through the throttle body. The throttle body contains an air control passage controlled by an Idle Air Control (1AC) motor. The air control passage is used to supply air for idle conditions. A throttle valve (plate) is used to supply air for above idle conditions.

Certain sensors are attached to the throttle body The accelerator pedal cable, speed control cable and transmission control cable (when equipped) are connected to the throttle body linkage arm.

A (factory adjusted) set screw is used to mechanically limit the position of the throttle body throttle plate. Never attempt to adjust the engine idle speed using this screw. All idle speed functions are controlled by the PCM.

THROTTLE POSITION SENSOR
The 3-wire Throttle Position Sensor (TPS) is mounted on the throttle body and is connected to the throttle blade.

The TPS is a 3-wire variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the resistance (output voltage) of the TPS changes.

The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from 0.26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing.

The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations:
- Ignition timing advance
- Fuel injection pulse-width
- Idle (learned value or minimum TPS)
- Off-idle (0.06 volt)
- Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage)
- Deceleration fuel lean out
- Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage)
- A/C WOT cutoff (certain automatic transmissions only)

Fig.50 Fuel Injectors:

FUEL INJECTOR
A separate fuel injector is used for each individual cylinder

The fuel injectors are electrical solenoids. The injector contains a pintle that closes off an orifice at the nozzle end. When electric current is supplied to the injector, the armature and needle move a short distance against a spring, allowing fuel to flow out the orifice. Because the fuel is under high pressure, a fine spray is developed in the shape of a pencil stream. The spraying action atomizes the fuel, adding it to the air entering the combustion chamber.

An individual fuel injector is used for each individual cylinder. The top (fuel entry) end of the injector is attached into an opening on the fuel rail.

The nozzle (outlet) ends of the injectors are positioned into openings in the intake manifold just above the intake valve ports of the cylinder head. The engine wiring harness connector for each fuel injector is equipped with an attached numerical tag (INJ 1, INJ 2 etc.). This is used to identify each fuel injector.

The injectors are energized individually in a sequential order by the Powertrain Control Module (PCM). The PCM will adjust injector pulse width by switching the ground path to each individual injector ON and OFF. Injector pulse width is the period of time that the injector is energized. The PCM will adjust injector pulse width based on various inputs it receives.

Battery voltage is supplied to the injectors through the ASD relay

The PCM determines injector pulse width based on various inputs.

PCM Output
The nozzle ends of the injectors are positioned into openings in the intake manifold just above the intake valve ports of the cylinder head. The engine wiring harness connector for each fuel injector is equipped with an attached numerical tag (INJ 1, INJ 2 etc.). This is used to identify each fuel injector with its respective cylinder number.

The injectors are energized individually in a sequential order by the Powertrain Control Module (PCM). The PCM will adjust injector pulse width by switching the ground path to each individual injector ON and OFF. Injector pulse width is the period of time that the injector is energized. The PCM will adjust injector pulse width based on various inputs it receives.

Battery voltage (12 volts +) is supplied to the injectors through the ASD relay. The ASD relay will shutdown the 12 volt power source to the fuel injectors if the PCM senses the ignition is ON, but the engine is not running. This occurs after the engine has not been running for approximately 1.8 seconds.

The PCM determines injector on-time (pulse width) based on various inputs.