Ford Falcon. Manual - part 173

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Fuel Charging and Controls — Turbocharger 

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SPECIFICATIONS

NOTE:Oil threads with engine oil.
NOTE:Do not oil threads that require thread sealant

or thread locker.
Torque Specifications (Turbocharger)

Description

Nm

Exhaust Manifold to Cylinder Head

27

Heat Shield to Exhaust Manifold (M8

20

Bolt, 2 places)
Turbocharger to Exhaust Manifold

Stud

27

Nut

55

Dump-Pipe to Turbocharger

Stud

15

Nut

25

Pencil Brace to Dump-Pipe

25

HEGO Sensor to Dump-Pipe

25

Oil Return Pipe to Turbocharger

20

Oil Return Pipe to Sump

20

Water Supply Tube to Turbocharger

45

Water Return Tube to Turbocharger

45

Oil Supply Tube to Turbocharger

20

Oil Supply Tube to Nut & Filter

20

Assembly
Oil Supply Nut & Filter Assembly to

20

Cylinder Block

Torque Specifications (Intercooler & Ducting)

Description

Nm

Studs to cushion connectors

15

Cushion connector to intercooler 15

15

Nuts holding brackets to cushion

20

connectors
Mounting brackets to front cross

25

member
Screw hose clamps on air ducting

2

pipes & hoses
Under headlight duct retaining screw

8

Boost pressure sensor screw

2

Wastegate solenoid bracket retaining

8

screw
Cross-over duct nuts

9

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Fuel Charging and Controls — Turbocharger 

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DESCRIPTION AND OPERATION

Turbocharger

Applicable to the XR6 Turbo model only

Item

Description

1

Coolant Supply Line

2

Oil Supply Line

3

Oil Outlet Line

4

Coolant Outlet Line

The turbocharger consists of two elements, a turbine

and a compressor both installed on a single shaft and

contained within housings.
The turbocharger bearings are supplied oil from the

engine via the oil supply tube. This is returned to the

oil pan via the oil return pipe.
The turbocharger housing also receives coolant from

the engine cooling system, to assist with turbocharger

Item

Description

cooling.

1

Exhaust manifold

The turbine element of the turbocharger is mounted

on the exhaust manifold and uses the energy of the

2

Turbine side of turbo

exhaust gas to drive the compressor. The compressor 2

Compressor side of turbo

feeds air to the engine via the intercooler.

Boost Control

The turbocharger is governed by means of a

wastegate valve. The wastegate valve diverts some of

the exhaust gas past the turbine and therefore

regulates the speed of the turbine. The wastegate

valve is controlled by a pressure operated actuator.

The actuator incorporates a diaphragm, and uses

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Fuel Charging and Controls — Turbocharger 

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DESCRIPTION AND OPERATION (Continued)

regulated air pressure to control the wastegate. This

The PCM uses the BPS output voltage to control

actuator is preset during manufacture and must not be boost pressure, dependent upon engine load,

tampered with.

temperature and RPM. The control system increases

engine intake pressure by diverting excess pressure

away from the wastegate actuator through the

Wastegate Solenoid Valve. The solenoid valve is

controlled by the PCM’s TURBO output.

CONNECTIONS AT PCM

Pin C2

Boost Pressure Sensor

(BPS) Signal

Pin C28

BPS Signal Return

(SIGRTN)

Pin C21

TURBO

Pin B45

Vehicle Reference

Voltage (VREF)

Intake air pressure is further controlled by a blow-off

valve, which dumps excess pressure into the low

The air pressure to the actuator diaphragm is

pressure side of the intake system when the throttle is

regulated by use of a Boost Pressure Sensor (BPS)

closed.

and a Wastegate Control Solenoid (WCS).

The blow-off valve is actuated by intake manifold

The Boost Pressure Sensor is located on the

pressure, via a rubber hose from the intake manifold.

aluminium duct beneath the driver’s side headlight.

The blow-off valve is situated in the Cross-Over Duct

The Wastegate Control Solenoid is mounted

on top of the engine.

underneath the fuse box.

Item

Description

Charge Air Cooler (Intercooler)

1

Wastgate Control Solenoid

The Charge Air Cooler (CAC) is an air-to-air cooler.

2

Boost Pressure Sensor

The compressed air from the turbocharger flows

through the cooler, and is cooled by outside air

The BPS measures the absolute pressure of the

flowing over the vanes of the CAC.

pre-throttle intake system for cruise control and

wastegate control strategy. The pressure sensing

The lower temperature of the charge air increases its

element in the BPS employs a Piezo resistive sensor

density, so giving improved engine efficiency and

that outputs a voltage proportional to absolute

power.

pressure.

The CAC is mounted in front of the radiator with four

rubber isolated mounts.

BPS Specification

Absolute Pressure (kPa)

Signal Voltage (V)

10

0.3

50

1.0

100

1.9

150

2.8

200

3.7

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Fuel Charging and Controls — Turbocharger 

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DESCRIPTION AND OPERATION (Continued)

Heatshielding

Two heatshields cover the exhaust manifold and the

turbocharger, to protect surrounding engine bay

components from heat damage.
A heatshield is also fitted over the engine mount

under the turbocharger, to protect the mount from

radiated heat.

Item

Description

1

Rear exhaust manifold heatshield

2

Front exhaust manifold heatshield

3

Engine mount heatshield

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