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Home >> Ford >> 2013 >> Explorer Police Interceptor, FWD >> Repair and Diagnosis (Single Page) >> Engine Performance >> System >> Engine Controls - Description & Operation (Except Diesel & Hybrid) >> Turbocharger And Charge Air Cooler (CAC) Systems >> Turbocharger System >> Charge Air Cooler (CAC) System

Charge Air Cooler (CAC) System

The CAC system cools the intake air which has been heated by the turbocharger. The removal of heat from the pressurized air going into the CAC increases the air density which improves combustion efficiency, engine horsepower, and torque. The system consists of a CAC radiator in the grille and tubing to interconnect these components. The CAC is positioned after the turbocharger directly in the flow of the intake air. As the heated air flows through the CAC, it is cooled by the airflow through the grille. The PCM maintains a desirable intake air temperature by monitoring the TCBP/CACT (located at the throttle body) and the MAP/IAT2 (located at the intake manifold) sensors.

Fig 1: Identifying 4 Cylinder Turbocharger System
G08291397Courtesy of FORD MOTOR CO.
Fig 2: Identifying 6 Cylinder Turbocharger System
G08291398Courtesy of FORD MOTOR CO.
Fig 3: 4 Cylinder Turbocharger Airflow Diagram (Vacuum Actuated Wastegate)
G08291399Courtesy of FORD MOTOR CO.
Turbocharger System Component
1 Intake Air
2 Compressed Air
3 Exhaust Air
4 Air Filter
5 MAF/IAT Sensor (MAF Not Used)
6 Turbocharger Intake Compressor
7 Turbocharger Bypass Valve Solenoid
8 Turbocharger Wastegate Regulating Valve Solenoid
9 Wastegate Vacuum Sensor
10 Turbocharger Exhaust Turbine
11 Outlet To Exhaust System
12 Turbocharger Wastegate
13 Turbocharger Wastegate Regulating Valve Solenoid Vent
14 Exhaust Manifold
15 Cylinder Head
16 Vacuum Pump
17 Intake Manifold
18 Vacuum Supply
19 Vacuum Reservoir
20 MAP Sensor
21 Intake Throttle Assembly
22 Turbocharger Boost Pressure/Charger Air Cooler Temperature (TCBP/CACT) Sensor
23 CAC
24 Turbocharger Bypass Valve
Fig 4: 4 Cylinder Turbocharger Airflow Diagram (Pressure Actuated Wastegate)
G08291400Courtesy of FORD MOTOR CO.
Turbocharger System Component
1 Intake Air
2 Compressed Air
3 Exhaust Air
4 Air Filter
5 MAF/IAT Sensor (MAF Not Used)
6 Turbocharger Intake Compressor
7 Turbocharger Bypass Valve Solenoid
8 Vacuum Pump
9 Cylinder Head
10 Turbocharger Exhaust Turbine
11 Outlet To Exhaust System
12 Turbocharger Wastegate
13 Exhaust Manifold
14 Intake Manifold
15 MAP Sensor
16 Intake Throttle Assembly
17 Turbocharger Boost Pressure/Charger Air Cooler Temperature (TCBP/CACT) Sensor
18 CAC
19 Turbocharger Bypass Valve
Fig 5: 6 Cylinder Turbocharger Airflow Diagram
G08291401Courtesy of FORD MOTOR CO.
Turbocharger System Component
1 Turbocharger Bypass Valve Left Bank (Bank 2) (If Equipped)
2 Charge Air Cooler (CAC)
3 Turbocharger Intake Pressure And Temperature (TCIPT) Sensor (If Equipped)
4 Turbocharger Bypass Valve Right Bank (Bank 1) (If Equipped)
5 Turbocharger Bypass Valve Right Bank (Bank 1) (Integrated In Turbocharger) (If Equipped)
6 Turbocharger Right Bank (Bank 1)
7 Wastegate Right Bank (Bank 1)
8 Manifold Absolute Pressure/Intake Air Temperature 2 (MAP/IAT2) Sensor
9 Throttle Body
10 Turbocharger Boost Pressure/Charger Air Cooler Temperature (TCBP/CACT) Sensor
11 Wastegate Left Bank (Bank 2)
12 Turbocharger Left Bank (Bank 2)
13 Turbocharger Bypass Valve Left Bank (Bank 2) (Integrated In Turbocharger) (If Equipped)