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

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 read this supplement carefully and
completely. Refer to the Owner Guide for complete vehicle information.
WARNINGS
Warnings remind you to be especially careful in those areas of the
vehicle where carelessness can cause damage to your vehicle or possible
personal injury to yourself, your passengers or others. Please read all
warnings carefully.
ABOUT THE WARRANTIES
The normal vehicle warranties will apply to your NGV. For further
information, refer to your Warranty Information Booklet.
Specified maintenance procedures must be followed. Repairs must be
made by trained personnel.
It is important that your NGV be properly maintained by qualified Ford
trained gaseous fuel service technicians. If a problem occurs, it is
important that properly trained personnel diagnose and repair the cause.
If the problem relates to the fuel system, proper part replacement is
imperative to keep your vehicle operating correctly. NGV fuel system
components and standard gasoline fuel system components are not
interchangeable. If your NGV is not maintained in accordance with
approved service procedures, damage may occur and your warranty may
be invalidated.
Any modification to the fuel system of your NGV voids the Ford New
Vehicle Limited Warranty.
Introduction
2

12.Tank temperature sensors-One each in set of tanks (solenoid
valves) used for fuel indication.
13.Optional fuel tank-A fiber-wrapped steel fuel tank (total of three
tanks in the trunk). Also has a sealed vent box which vents to the
underbody. Dispenses natural gas vapor to the atmosphere if vapor is
present.
14.Two fuel tanks-Located underbody to facilitate fuel system design.
15.Stone and heat shield-Protective shield able to prevent damage to
the fuel tanks caused by road debris or other road hazards.
16.High pressure fuel lines-Delivers high pressure fuel to the pressure
regulator.
17.Pressure regulator and coalescent fuel filter assembly-Reduces
the fuel pressure to the fuel injection pressure of 125 psi.
18.Low pressure fuel lines-Supplies 125 psi of natural gas to the
engine.
19.Fuel rail sensors-One injection pressure sensor and one engine fuel
temperature sensor provide engine fuel information to the PCM.
ADAPTERS
DO NOTuse 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), 20,700 kPa (3,000
psi) and 24,800 kPa (3,600 psi).
Your vehicle’s service pressure may be 20,700 kPa (3,000 psi) or 24,800
kPa (3,600 psi), depending upon application. Refer to the label on the
fuel filler door:
•If your vehicle’s fuel system is rated at 20,700 kPa (3,000 psi), it can
be refueled using a P30 or P24 nozzle. However, use of a P24 nozzle
will result in an incomplete fill.
•If your vehicle’s fuel system is rated at 24,800 kPa (3,600 psi), it is
refueled using a P36 nozzle only.
DO NOT over pressurize the CNG fuel system or damage to the
fuel system and possible personal injury may occur.
Servicing your vehicle
10