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

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 to 95 psi and removes impurities from the gas.
13.Low pressure fuel line-Supplies 95 psi of natural gas to the
injectors.
14.NGV module-Contains the unique powertrain electronics that are
required for an NGV.
F-Series Pick-up
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 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.
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4.Powertrain control module-Uniquely calibrated for NGV application.
5.Internal tank valve-One electronically actuated, normally closed
solenoid valve is located in each fuel tank. The valve is wired into the
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 tank caused by road
debris or other road hazards.Do not sit, stand or place heavy loads
on the fuel tank cover.
7.Stone shield-Protective shield to prevent damage to the fuel tank
caused by road debris or other road hazards.
8.Underbody fuel tank-A steel fuel tank located underbody.
9.High pressure fuel lines-Delivers high pressure fuel to the fuel
tanks and fuel pressure regulator.
10.Fuel pressure regulator/Coalescent fuel filter-Reduces fuel
pressure to 95 psi and removes impurities from the gas.
11.Low pressure fuel line-Supplies 95 psi of natural gas to the
injectors.
12.NGV module-Contains the unique powertrain electronics that are
required for an NGV.
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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.
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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.
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