FORD E SERIES 2003 4.G Natural Gas Vehicle Supplement Manual

NATURAL GAS DISPENSING
Most dispensers have a digital indicator displaying the cost and amount
of fuel delivered to your vehicle. Fuel delivery to the vehicle is stopped
when the pressure of fuel stored on the vehicle equalizes with the
temperature compensated pressure of fuel stored at the station. As the
pressure between the station and vehicle equalizes, the cost and quantity
meters slow to a near stop. When this occurs, refueling is complete.
Certain noises can be expected during the refueling process and may
vary depending on the type of fuel station and your proximity to the fuel
compression and storage equipment. At the beginning of refueling you
might hear the rushing noise of gas entering the vehicle through the
station hose and tubing. At the end of refueling, the fuel receptacle on
the vehicle may make a high pitch noise or chatter. This is another
indication that refueling is nearly complete. Also, the station compression
equipment may turn on at any time during the refueling process.
FUEL QUALITY
Use only a CNG fuel that meets the specification of NFPA-52 and SAE
J1616 in your NGV. Specifications NFPA-52 and SAE J1616 place limits
on particulate contamination and moisture content to ensure a quality
CNG fuel.
The use of a CNG fuel that does not meet specifications NFPA-52 and
SAE J1616 isnot recommendedand may cause engine damage.
Use of poor quality CNG fuel may result in:
•component failure.
•leakage from the fueling point.
•poor vehicle operation.
Use of poor quality fuel may also result in your warranty being
invalidated.
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.
Servicing your vehicle
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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
“Fast-filling”a NGV involves rapidly (typical fill time: 3–5 minutes)
raising the pressure in the vehicle’s tanks by“fast-fill”refueling station.
“Fast-filling”a vehicle provides the greatest convenience to the driver in
terms of time spent refueling. However, present“fast-fill”refueling
technology does not presently allow a NGV to be completely refueled to
its maximum rated capacity. Therefore,“fast-filling”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
“fast-filled”will drop about 1/8th of a tank lower to reflect the reduced
amount of fuel that was actually added.
Slow fill procedure
“Slow-filling”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).
“Slow-filling”usually is done overnight and allows the greatest amount of
fuel to be added to a NGV. A properly functioning“slow-fill”refueling
station will fill the NGV’s fuel tank(s) to a fuel gauge reading of“full”at
a temperature of 21°C (70°F).
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 — BTU equivalent to gasoline
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 158” Wheelbase (3 000 psi)
Fueling
methodStandard
tanksWith Extended
Range - One
In-body TankWith Extended
Range - Two
In-body Tanks
Slow-fill 55.3L (14.6
gallons)84.0L (22.2
gallons)112.4L (29.7
gallons)
Fast-fill 46.9L (12.4
gallons)71.2L (18.8
gallons)95.8L (25.3
gallons)
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E-Series Cutaway 158”Wheelbase (3 600 psi)
Fueling
methodStandard
tanksWith Extended
Range - One
In-body TankWith Extended
Range - Two
In-body Tanks
Slow-fill 63.2L (16.7
gallons)96.1L (25.4
gallons)128.7 (34.0
gallons)
Fast-fill 53.8L (14.2
gallons)81.8L (21.6
gallons)109.4L (28.9
gallons)
E-Series Cutaway 176”Wheelbase (3 000 psi)
Fueling
methodStandard
tanksWith Extended
Range - One
In-body TankWith Extended
Range - 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)
E-Series Cutaway 176”Wheelbase (3 600 psi)
Fueling
methodStandard
tanksWith Extended
Range - One
In-body TankWith Extended
Range - 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)
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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 (3 600 psi)
Fueling method Standard tanks With extended range
system
1
Slow-fill 48.5L (12.8 gallons) 61.3L (16.2 gallons)
Fast-fill 41.6L (11.0 gallons) 52.6L (13.9 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 one additional
CNG fuel tank mounted in the luggage compartment.
E-Series vehicles with the extended range fuel system have one
additional CNG fuel tank mounted in the cargo area behind the rear seat.
TRAILER TOWING
On F-Series models, your NGV has the capability for towing up to 2,267
kg (5,000 lbs.) using the factory installed step-bumper. It is
recommended that the vehicleNOTbe modified for towing (i.e.-any
frame-mounted hitches).
Crown Victoria and E-Series Van/Wagon and Cutaway models are 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.
Servicing your vehicle
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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
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 contaminants; oil and water carryover
moisture from the fuel and trap it in the filter bowl.
The coalescent filter bowl should be drained every 48,000 kilometers
(30,000 miles). Perform fuel system depressurization procedure (outlined
in Service Manual) before disassembling the filter to avoid fuel pressure
regulator damage. The filter element (FG-985 on E-Series and F-Series
models; FG-976 on Crown Victoria models) and housing O-ring seal
should also be replaced every 48,000 km (30,000 miles).
Inspect and clean fuel fill valve filter
On Crown Victoria and F-Series models, the fuel fill valve filter is
located in the high-pressure fuel line. Inspection and cleaning
should only be done by a qualified technician.
The fuel fill valve filter should be inspected and cleaned annually. Fuel
fill valve filter replacement is only required when damage to the filter is
visible.
Spark plugs
Replace spark plugs every 96,000 kilometers (60,000 miles) on E-Series
and F-series models and every 60,000 km (36,000 miles) on Crown
Victoria models. Use recommended nickel-plated platinum spark plugs
with the Motorcraft part number AWSF-22FM1 (or equivalent) on
E-Series and F-series models and spark plugs with the Motorcraft part
number AWSF-22FM (or equivalent) on Crown Victoria models.
Servicing your vehicle
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