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Table of contents
Introduction
2
Instrumentation
4
Servicing your vehicle
5
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Copyright © 2003 Ford Motor Company
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Introduction Introduction ABOUT THIS SUPPLEMENT This booklet supplements your Owner Guide and is part of the owner’s portfolio. It describes the operation of your natural gas vehicle (NGV) and how it differs from a standard gasoline powered vehicle. Therefore it is very important that you read this guide and thoroughly familiarize yourself and others operating the vehicle with this information. Some of the information in this supplement replaces certain instructions in the Owner Guide. Please re
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Introduction COMPRESSED NATURAL GAS (CNG) FUEL SYSTEM Your vehicle is equipped with a dedicated compressed natural gas (CNG) fuel system that is under high pressure. Depending upon the application, the CNG fuel system is rated at a pressure of 20,700 kPa (3,000 psi) at 21°C (70°F) or 24,800 kPa (3,600 psi) at 21°C (70°F). Refer to the label on the fuel filler door to determine the fuel system pressure rating. Use caution when servicing or maintaining any of the components of the CNG fuel system.
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Instrumentation Instrumentation FUEL GAUGE The fuel gauge in your NGV behaves similarly to a typical gasoline fuel gauge. However, the gauge operation is based on the pressure and temperature of the natural gas, not on the level of liquid gasoline. Depending upon application, a fuel gauge reading of Full will occur at a pressure of approximately 20,700 kPa (3,000 psi) or 24,800 kPa (3,600 psi), at a temperature of approximately 21°C (70°F). The NGV fuel gauge will provide a linear reading from t
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Servicing your vehicle Servicing your vehicle CNG FUEL SYSTEM COMPONENT IDENTIFICATION The following illustrations depict the major unique components of the CNG fuel system. All of these unique components are constructed of special materials that withstand the effects of CNG. NEVER replace a unique CNG fuel system component with a standard gasoline fuel system component or any aftermarket component. E-Series Van 5
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Servicing your vehicle E-450 Cutaway 1. Fuel rail sensors - An injection pressure sensor and an engine fuel temperature sensor provide engine fuel information to the powertrain control module. 2. Isolation solenoid valve - Blocks fuel flow from supply line to injection manifold when the engine is off. 3. Engine - A modified 5.4L gasoline engine with Sequential Electronic Fuel Injection (SEFI), an improved valvetrain and a high compression ratio. 4. Powertrain control module - Uniquely calibrated
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Servicing your vehicle 9. Aft axle fuel tanks - Two steel fuel tanks located behind the rear axle. 10. Midship fuel tank - A steel fuel tank located underbody. 11. High pressure fuel lines - Delivers high pressure fuel to the fuel tanks and fuel pressure regulator. 12. Fuel pressure regulator/Coalescent fuel filter - Reduces fuel pressure and removes impurities from the gas. 13. Low pressure fuel line - Supplies natural gas to the injectors. 14. AFV module - Contains the unique powertrain electr
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Servicing your vehicle vehicle’s inertia switch. If the engine cranks but does not start after a collision, the fuel solenoid valve inertia switch may have been activated. The inertia switch is a device intended to close the fuel solenoid valve when your vehicle has been involved in a substantial jolt. 6. Standard fuel tanks - Two steel fuel tanks located in the bed of the truck. 6b. In-bed tank cover - Cover to prevent damage to the fuel tanks. Protective shield to prevent damage to the fuel ta
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Servicing your vehicle 2. Isolation solenoid valve - Blocks flow from the injection manifold when the engine is off. 3. Engine - Is a modified 4.6L engine with Sequential Electronic Fuel Injection (SEFI) and increased compression ratio. 4. Engine coolant lines - Provide required heat to high pressure regulator. 5. Powertrain control module - Required for NGV application. 6. Sealed vent box - Vented to underbody. Dispenses natural gas vapor to atmosphere if vapor becomes present. 7. Tank pressure
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Servicing your vehicle ADAPTERS DO NOT use fuel receptacle adapters when refueling your vehicle. The profiles of both the natural gas vehicle receptacle and the fuel station nozzles are specified by ANSI/AGA NGV1-1994, CGA NGV1-M94. These profiles are specified for compressed natural gas vehicles and fuel stations for safety purposes. Three separate adapter profiles are available. P24, P30 and P36 respectively, are specified for the three different service pressures of 16,500 kPa (2,400 psi), 20
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Servicing your vehicle indication that refueling is nearly complete. Also, the station compression equipment may turn on at any time during the refueling process. FUEL QUALITY Do not use liquefied natural gas (LNG) or a CNG that is derived from a process such as flashing (heating LNG). Failure to use the correct type of fuel may cause damage to the engine and fuel system components. Use only a CNG fuel that meets the specification of NFPA-52 and SAE J1616 in your NGV. Specifications NFPA-52 and
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Servicing your vehicle SERVICING YOUR NATURAL GAS VEHICLE Service to the CNG fuel system should be conducted at a qualified dealership by a trained NGV technician only. Failure to do so may cause damage to components or cause bodily harm. FUELING Do not fuel your vehicle with the ignition on the ON position. Failure to do so may cause component damage. Fueling a NGV, with a few exceptions, is very similar to fueling a gasoline vehicle. The same care and cautions used when fueling a gasoline vehi
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Servicing your vehicle Use caution when fueling your vehicle. Make sure the engine is turned off and all flammable material is extinguished. Observe all Dispensing Equipment Safety Standards and Operating Procedures. The procedure is the same for both fast-fill and slow-fill fueling. 1. Open fuel door and determine the pressure rating of your vehicle’s fuel system. 2. Remove protective cap from the vehicle’s fuel receptacle. Remove any debris that may be present. 3. Follow the natural gas fuelin
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Servicing your vehicle E-Series Cutaway 158” Wheelbase (3600 psi) Fueling Standard With Extended With Extended method tanks Range - One Range - Two In-body Tank In-body Tanks Slow-fill 63.2L 96.1L 128.7 (16.7 gallons) (25.4 gallons) (34.0 gallons) Fast-fill 53.8L 81.8L 109.4L (14.2 gallons) (21.6 gallons) (28.9 gallons) E-Series Cutaway 176” Wheelbase (3000 psi) Fueling Standard With Extended With Extended method tanks Range - One Range - Two In-body Tank In-body Tanks Slow-fill 60.9L 89.7L 118.
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Servicing your vehicle Crown Victoria (3600 psi) Fueling method Standard tanks With extended range 1 system Slow-fill 45.0L (11.9 gallons) 59.1L (15.6 gallons) Fast-fill 38.2L (10.1 gallons) 50.3L (13.3 gallons) 1 Police and Taxi vehicles. Extended range fuel system Crown Victoria Police and Taxi vehicles with the extended range fuel system have a 5–passenger seating configuration with one additional CNG fuel tank mounted in the luggage compartment. E-Series vehicles with the extended range fuel
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Servicing your vehicle The purpose of the inspection is to check for exterior damage to the tank which would shorten its usable life span. This inspection should only be done by qualified NGV Ford service technicians. The expiration date for the tank replacement is stated on each tank label See instructions on fuel container for inspection and service life. Coalescent fuel filter assembly Your vehicle is equipped with a coalescent fuel filter assembly. Its primary function is to remove contamina
