fuel cap FORD E SERIES 2002 4.G Natural Gas Vehicle Supplement Manual

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 21ÉC (70ÉF) or 24 800 kPa
(3 600 psi) at 21ÉC (70ÉF). 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.
Service to high-pressure fuel system components must be
conducted only at qualified dealerships by qualified technicians.
Failure to do so may cause damage to components or cause bodily
harm.
On F-Series natural gas vehicles,do not modify or replace the bed
with any non-OEM components. Should the bed need to be removed for
service or replacement, it should be done by a qualified dealership using
qualified technicians. Do not sit, stand or place heavy loads on in-bed
tank cover. Any bed cap added to this vehicle must be well ventilated.
Failure to provide adequate ventilation could result in gas vapor build up
over time potentially resulting in a combustible mixture.
Introduction
3

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 vehicle
should be exercised when fueling a NGV. In particular, for safety reasons,
an enginemustalways be turned off when refueling is occurring. Always
use the recommended fill nozzle to refuel your vehicle.
Two methods for filling the fuel tanks are available to NGV owners. The
fast-fill method, described below, is available at many of the commercial
and privately owned filling stations. The slow-fill method, also described
below, is available for purchase or lease from a number of commercial or
natural gas utility companies.
Fast fill procedure
ªFast-fillingº a NGV involves rapidly (typical fill time: 3±5 minutes)
raising the pressure in the vehicle's tanks by ªfast-fillº refueling station.
ªFast-fillingº a vehicle provides the greatest convenience to the driver in
terms of time spent refueling. However, present ªfast-fillº refueling
technology does not presently allow a NGV to be completely refueled to
its maximum rated capacity. Therefore, ªfast-fillingº results in a reduced
driving range and an initial fuel gauge reading of Full. However, within
approximately 10 minutes, the fuel gauge of a NGV that has been
ªfast-filledº will drop about 1/8th of a tank lower to reflect the reduced
amount of fuel that was actually added.
Slow fill procedure
ªSlow-fillingº a NGV involves slowly raising the pressure in the vehicle's
fuel tank(s) by a slow fill station (typical fill rate: 6-8 hours).
ªSlow-fillingº usually is done overnight and allows the greatest amount of
fuel to be added to a NGV. A properly functioning ªslow-fillº refueling
station will fill the NGV's fuel tank(s) to a fuel gauge reading of ªfullº at
a temperature of 21ÉC (70ÉF).
The fueling point, or fuel receptacle is located near the driver's side.
When refueling, the enginemustbe shut off.
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.
Servicing your vehicle
12

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 fueling procedures provided by the natural gas
dealer and dispense the CNG until the fuel tanks are full or until the flow
stops.
4. When refueling is complete, follow the natural gas dispensing
equipment's operating procedures to shut the natural gas flow off.
5. Remove the dispensing connector and put protective cap on the
vehicle's fuel receptacle. Close the fuel door.
Refill capacities Ð BTU equivalent
E-Series (3 000 psi)
Fueling method Standard tank With extended range
tank
Slow-fill 60.9L (16.1 gallons) 92.7L (24.5 gallons)
Fast-fill 51.8L (13.7 gallons) 78.7L (20.8 gallons)
E-Series (3 600 psi)
Fueling method Standard tank With extended range
tank
Slow-fill 70.0L (18.5 gallons) 106.0L (28.0 gallons)
Fast-fill 59.4L (15.7 gallons) 90.1L (23.8 gallons)
E-Series Cutaway (3 000 psi)
Fueling
methodStandard tank w/One In-body
Tankw/Two In-body
Tanks
Slow-fill 60.9L
(16.1 gallons)89.7L
(23.7 gallons)118.1L
(31.2 gallons)
Fast-fill 51.8L
(13.7 gallons)76.1L
(20.1 gallons)100.7L
(26.6 gallons)
Servicing your vehicle
13

E-Series Cutaway (3 600 psi)
Fueling
methodStandard tank w/One In-body
Tankw/Two In-body
Tanks
Slow-fill 70.0L
(18.5 gallons)102.6L
(27.1 gallons)135.5
(35.8 gallons)
Fast-fill 59.4L
(15.7 gallons)87.1L
(23.0 gallons)115.1L
(30.4 gallons)
F-Series (3 000 psi)
Fueling method Standard tanks
Slow-fill 71.9L (19.0 gallons)
Fast-fill 60.9L (16.1 gallons)
F-Series (3 600 psi)
Fueling method Standard tanks
Slow-fill 82.1L (21.7 gallons)
Fast-fill 70.0L (18.5 gallons)
Crown Victoria (3 000 psi)
Fueling method Standard tanks With extended range
system
1
Slow-fill 37.9L (10.0 gallons) 56.8L (15.0 gallons)
Fast-fill 32.4L (8.6 gallons) 48.6L (12.8 gallons)
Crown Victoria (3 600 psi)
Fueling method Standard tanks With extended range
system
1
Slow-fill 48.5L (12.8 gallons) 64.0L (16.9 gallons)
Fast-fill 39.3L (10.4 gallons) 51.9L (13.7 gallons)
1Police 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 two additional
CNG fuel tanks mounted in the luggage compartment. Maximum cargo
capacity for these vehicles is 29 kg (65 lbs.).
E-Series vehicles with the extended range fuel system have one
additional CNG fuel tank mounted in the cargo area behind the rear seat.
Servicing your vehicle
14

TRAILER TOWING
On E-Seriesand F-Series models, your NGV has the capability for towing
using the factory installed step-bumper. Refer to the following chart for
weight ratings:
F-Series
All 2 267 kg (5 000 lbs.)
E-Series Van/Wagon
All except Regular Van (E-250 and
E-350) and Super Van (E-250)
with 3.73 axle2 267 kg (5 000 lbs.)
Regular Van (E-250 and E-350)
and Super Van (E-250) with 3.73
axle2 041 kg (4 500 lbs.)
It is recommended that the vehicleNOTbe modified for towing (i.e.-any
frame-mounted hitches).
On Crown Victoria and E-Series Cutaway models, your vehicle is not
equipped with a trailer towing option. It is recommended that the vehicle
notbe modified for towing.
TOWING YOUR CNG VEHICLE
Refer to your Owner's Guide for towing procedure except E-Series
vehicles with the optional tank package whichMUSTbe flat-bed towed.
NGV REFUELING STATIONS
To obtain a directory of all the refueling stations in the United States,
contact the American Gas Association (AGA) at (703) 841±8400. In
Canada, contact Union Gas at 1±800±265±5277.
SERVICING YOUR VEHICLE
The following is a brief description of unique maintenance items for your
NGV. For a complete list of maintenance items and intervals, refer to
yourService Guide.
Tank inspection and replacement
For your protection, the CNG fuel tanks require visual inspection every
three years or 58 000 kilometers (36 000 miles) whichever comes first.
The purpose of the inspection is to check for exterior damage to the
Servicing your vehicle
15