Crownvic Manual

1999-2004 Ford Dedicated CNG and Multiport Injection Bi-Fuel CNG Vehicles
student guide
This Student Guide contains information and activities for conducting the the following courses:
3-Day Dedicated CNG and Multiport Injection Bi-Fuel CNG Vehicles Course Code 41S01T0 FCS-14006-REF 2-Day Dedicated CNG Vehicles Course Code 41F01T0 2-Day Multiport Injection Bi-Fuel CNG Vehicles Course Code 41F02T0
March, 2004
IMPORTANT SAFETY NOTICE

Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles, as well as the personal safety of the individual doing the work. This manual provides general directions for accomplishing service and repair work with tested, effective techniques. Following these directions will help assure reliability. There are numerous variations in procedures, techniques, tools, and parts for servicing vehicles, as well as in the skill of the individual doing the work. This manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Accordingly, anyone who departs from instructions provided in this manual must first establish that he/she compromises neither his/her personal safety nor the vehicle integrity by his/her choice of methods, tools or parts. As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each one is there for a specific purpose. NOTES give you added information that will help you to complete a particular procedure. CAUTIONS are given to prevent you from making an error that could damage the vehicle. WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury. The following list contains some general WARNINGS that you should follow when you work on a vehicle. Always wear safety glasses for eye protection. Use safety stands whenever a procedure requires you to be under the vehicle. Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure. Set the parking brake when working on the vehicle. If you have an automatic transmission, set it in PARK unless instructed otherwise for a specific service operation. If you have a manual transmission, it should be in NEUTRAL (engine OFF) or NEUTRAL (engine ON) WITH THE PARKING BRAKE ON unless instructed otherwise for a specific operation. Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide. Keep yourself and your clothing away from moving parts, such as the fan and belts, when the engine is running. To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter, and muffler. Do not smoke while working on the vehicle. To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle. Tie long hair securely behind your head. Keep hands and other objects clear of the radiator fan blades. Electric cooling fans can start to operate at any time by an increase in underhood temperatures, even though the ignition is in the OFF position. Therefore, care should be taken to ensure that the electric cooling fan is completely disconnected when working under the hood. The recommendations and suggestions contained in this manual are made to assist the dealer in improving his dealership parts and/or service department operations. These recommendations and suggestions do not supersede or override the provisions of the Warranty and Policy Manual or the Workshop Manual.
In any cases where there may be a conflict, the provisions of the Warranty and Policy Manual or the Workshop Manual shall govern. The descriptions, testing procedures, and specifications in this handbook were in effect at the time the handbook was approved for printing. Ford Motor Company reserves the right to discontinue models at any time, or change specifications, design, or testing procedures without notice and without incurring obligation. Any reference to brand names in this manual is intended merely as an example of the types of tools, lubricants, materials, etc., recommended for use. Equivalents, if available, may be used. The right is reserved to make changes at any time without notice. Produced and Coordinated by Technical Support Operations, Ford Customer Service Division March, 2004
Contents
INTRODUCTION AND PREREQUISITE REVIEW
ALTERNATIVE FUEL VEHICLE (AFV) CURRICULUM ........................................................................... Intro-2 Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicle Instructor-Led Course Description ........ Intro-3 Course Terminal Objectives .................................................................................................................. Intro-3 Audience ................................................................................................................................................. Intro-3 Course Prerequisites ............................................................................................................................. Intro-3 Evaluation ............................................................................................................................................... Intro-4 Student Guide ......................................................................................................................................... Intro-4 SERVICE STANDARDS ........................................................................................................................... Intro-5 Prerequisite Review ............................................................................................................................... Intro-6
LESSON 1: INTRODUCTION TO CNG VEHICLES

COMPRESSED NATURAL GAS (CNG) VEHICLES .................................................................................... 1 - 2 WHAT IS NATURAL GAS? .......................................................................................................................... 1 - 3 Alternative Fuel Comparison Table ........................................................................................................... 1 - 4 Identification of Ford Dedicated and Bi-Fuel CNG Vehicles .................................................................... 1 - 5 Changes to Base Vehicle Components on Dedicated CNG and Multiport Bi-Fuel CNG Vehicles .......1 - 6 Changes to Base Vehicle Operating Strategies .......................................................................................1 - 7 Supplemental Information On Alternative Fuel Vehicles ........................................................................1 - 8
LESSON 2A: DEDICATED CNG OPERATION

DEDICATED CNG VEHICLE THEORY OF OPERATION ......................................................................... 2 A - 2 CNG FUEL SYSTEM PRESSURES ......................................................................................................... 2 A - 6 ACTIVITY 2A WORKSHEET A .......................................................................................................... 2 A - 10 ACTIVITY 2A WORKSHEET B .......................................................................................................... 2 A - 11 ACTIVITY 2A WORKSHEET C .......................................................................................................... 2 A - 12 ACTIVITY 2A WORKSHEET D .......................................................................................................... 2 A - 13
LESSON 2B: MULTIPORT BI-FUEL CNG VEHICLE OPERATION

MULTIPORT BI-FUEL CNG VEHICLE THEORY OF OPERATION ......................................................... 2 B - 2 CNG FUEL SYSTEM PRESSURES ........................................................................................................ 2 B - 7 ACTIVITY 2B WORKSHEET E .......................................................................................................... 2 B - 10 ACTIVITY 2B WORKSHEET F .......................................................................................................... 2 B - 11 ACTIVITY 2B WORKSHEET G .......................................................................................................... 2 B - 12 ACTIVITY 2B WORKSHEET H .......................................................................................................... 2 B - 13 LESSON 3A: DEDICATED CNG COMPONENTS INTRODUCTION TO DEDICATED CNG COMPONENTS ......................................................................... 3A - 2 CNG Fuel Fill Valve .................................................................................................................................. 3A - 3 Fuel Tanks ................................................................................................................................................ 3A - 4 Solenoid Tank Valve ................................................................................................................................. 3A - 5 Fuel Tank Vent Box .................................................................................................................................. 3A - 7 Fuel Lines ................................................................................................................................................. 3A - 8 Quarter-Turn Valve (1999-2003 Crown Victoria Dedicated CNG vehicles) ......................................... 3A - 10
Fuel Filters ............................................................................................................................................. 3A - 11 High Pressure Regulator ...................................................................................................................... 3A - 12 Fuel Injection Supply Manifold ............................................................................................................. 3A - 14 Fuel Injectors ......................................................................................................................................... 3A - 16 CNG FUEL SYSTEM CONTROL MODULES AND INPUT/OUTPUT DEVICES ..................................... 3A - 18 Inputs and Outputs Chart ..................................................................................................................... 3A - 19 Powertrain Control Module (PCM) ........................................................................................................ 3A - 20 Unique CNG PCM Input Devices .......................................................................................................... 3A - 21 Unique CNG Outputs of the PCM ......................................................................................................... 3A - 22 60-Pin Alternative Fuel Control Module (AFCM) ................................................................................. 3A - 23 90-Pin Alternative Fuel Control Module (AFCM) ................................................................................. 3A - 24 AFCM Outputs ....................................................................................................................................... 3A - 25 ACTIVITY 3A WORKSHEET I ............................................................................................................ 3A - 28 ACTIVITY 3A - WORKSHEET J .............................................................................................................. 3A - 29 ACTIVITY 3A WORKSHEET K ........................................................................................................... 3A - 30 ACTIVITY 3A WORKSHEET L ........................................................................................................... 3A - 31
LESSON 3B: MULTIPORT BI-FUEL CNG COMPONENTS

INTRODUCTION TO MULTIPORT BI-FUEL CNG VEHICLE COMPONENTS ......................................... 3B - 2 CNG Fuel Fill Valve .................................................................................................................................. 3B - 3 Fuel Tanks ................................................................................................................................................ 3B - 4 Solenoid Tank Valve ................................................................................................................................. 3B - 5 CNG Fuel Lines ........................................................................................................................................ 3B - 7 Coalescent Filter ..................................................................................................................................... 3B - 9 High Pressure Regulator ...................................................................................................................... 3B - 10 CNG Fuel Injection Supply Manifold .................................................................................................... 3B - 11 Gasoline Fuel Injection Supply Manifold ............................................................................................. 3B - 12 CNG and Gasoline Fuel Injectors ......................................................................................................... 3B - 13 CNG and Gasoline Fuel Injectors (continued) .................................................................................... 3B - 14 CNG FUEL SYSTEM CONTROL MODULES AND INPUT/OUTPUT DEVICES ..................................... 3B - 15 Inputs and Outputs Chart ..................................................................................................................... 3B - 16 Powertrain Control Module (PCM) ........................................................................................................ 3B - 17 Alternative Fuel Control Module (AFCM) ............................................................................................. 3B - 18 AFCM Input Devices .............................................................................................................................. 3B - 19 AFCM Outputs ....................................................................................................................................... 3B - 23 AFCM Outputs ....................................................................................................................................... 3B - 24 AFCM Outputs ....................................................................................................................................... 3B - 25 ACTIVITY 3B WORKSHEET M .......................................................................................................... 3B - 29 ACTIVITY 3B - WORKSHEET N ............................................................................................................. 3B - 30 ACTIVITY 3B WORKSHEET O ........................................................................................................... 3B - 31 ACTIVITY 3B WORKSHEET P ........................................................................................................... 3B - 32
LESSON 4: DIAGNOSIS AND SERVICE

CNG FUEL SYSTEM DIAGNOSIS AND SERVICE ...................................................................................... 4 - 2 SYMPTOM-TO-SYSTEM-TO-COMPONENT-TO-CAUSE (SSCC) DIAGNOSTIC STRATEGY .................... 4 - 3 SERVICE AREA PRECAUTIONS ................................................................................................................ 4 - 5 PRELIMINARY DIAGNOSTIC STEPS ......................................................................................................... 4 - 6 IDENTIFICATION AND RETRIEVAL OF CNG SYSTEM DIAGNOSTIC TROUBLE CODES (DTCs) .......... 4 - 8
ii
SERVICE PUBLICATION NAVIGATION ......................................................................................................4 - 9 Powertrain Control/Emissions Diagnosis (PC/ED) Manual .....................................................................4 - 9 Workshop Manual .....................................................................................................................................4 - 11 Wiring Diagrams (EVTMs) ....................................................................................................................... 4 - 11 COMPONENT AND SYSTEM TESTING AND SERVICE .......................................................................... 4 - 12 Cooling System Pressure Testing ........................................................................................................... 4 - 13 CNG REFUELING PROCEDURES ........................................................................................................... 4 - 14 CNG CONTAMINATION ............................................................................................................................4 - 16 FUEL FILL VALVE FILTER ........................................................................................................................ 4 - 17 COALESCENT FILTER SERVICE .............................................................................................................4 - 18 FUEL INJECTOR CLEANING ...................................................................................................................4 - 19 FUEL TANK REMOVAL ............................................................................................................................. 4 - 20 FUEL LINE SERVICE ................................................................................................................................ 4 - 21 Fuel System Leak Testing ........................................................................................................................ 4 - 22 Crown Victoria Vent Box Leak Test ......................................................................................................... 4 - 24 FUEL SYSTEM VENTING .......................................................................................................................... 4 - 25 Solenoid Tank Valve Diagnostics ............................................................................................................ 4 - 27 DEMONSTRATION 1 - CNG VEHICLE DIAGNOSTICS ............................................................................ 4 - 29 DEMONSTRATION 1 WORKSHEET ......................................................................................................... 4 - 30 DEMONSTRATION 2 - DEDICATED CNG OR MULTIPORT BI-FUEL CNG VENTING AND SOLENOID DIAGNOSIS ......................................................................................................................................... 4 - 33 DEMONSTRATION 2 WORKSHEET ......................................................................................................... 4 - 34 ACTIVITY 4 WORKSHEET Q ................................................................................................................ 4 - 38 ACTIVITY 4 WORKSHEET R ................................................................................................................ 4 - 40 ACTIVITY 4 WORKSHEET S ................................................................................................................. 4 - 42 ACTIVITY 4 WORKSHEET T ................................................................................................................. 4 - 44
APPENDIX 1: COMPRESSED NATURAL GAS SAFETY

Natural Gas Vehicle Fuel System Standards ........................................................................... Avoiding Fire or Explosion Hazards ........................................................................................ Venting CNG Fuel ...................................................................................................................... VISUAL INSPECTION ................................................................................................................. PAINTING A CNG VEHICLE ....................................................................................................... Solenoid Tank Valves ................................................................................................................. Fuel System Modifications ....................................................................................................... Health Hazards........................................................................................................................... Appendix 1 -2 Appendix 1 -2 Appendix 1 -3 Appendix 1 -5 Appendix 1 -5 Appendix 1 -6 Appendix 1 -7 Appendix 1 -8
APPENDIX 2: AFV NEW GENERATION STAR TESTER OPERATION

Alternative Fuel Vehicle (AFV) DTC Retrieval ......................................................................... Appendix 2 - 2 Clearing Alternative Fuel Vehicle (AFV) DTCs ........................................................................ Appendix 2 - 6 NGS Parameter Identification Data (PID) Function ................................................................ Appendix 2 - 7 NGS PID Viewing Options ...................................................................................................... Appendix 2 - 11
GLOSSARY ....................................................................................................... Glossary - 1 TOOL LIST ROTUNDA ORDER FORM
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iv

OBJECTIVES
Introduce the Ford Alternative Fuel Curriculum Administer the prerequisite review
CONTENTS
Alternative Fuel Vehicle (AFV) Curriculum Ford 1999-2003 Dedicated CNG and Multiport Bi-Fuel CNG Vehicle Instructor-Led Course Description Course Terminal Objectives Audience Course Prerequisites Evaluation Student Guide Service Standards Prerequisite Review
1999 - 2003 Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles
March, 2004
Intro - 1
ALTERNATIVE FUEL VEHICLE (AFV) CURRICULUM

ALTERNATIVE FUEL VEHICLE CURRICULUM MAP
Alternative Fuel Vehicle New Generation STAR Web-Based Training - Course CodeWB 31S09W0 (Optional for Ford Dealership Technicians, Mandatory for Fleet Technicians) Alternative Fuel Handling Safety Web-Based Training - Course CodeWB 31S10W0
(Mandatory for all Technicians)
Flexible Fuel Vehicle Web-Based Training - Course CodeWB 31S11W0

(Mandatory for Ford Dealership Technicians, Optional for Fleet Technicians)
1999-2003 Ford Bi-Fuel CNG/LPG Vehicle (3-Day) Instructor-Led Training - Course Code 31S13T0 (Mandatory for Ford Dealership Technicians, Optional for Fleet Technicians)
Ford Bi-Fuel CNG Vehicle (2-Day) Instructor-Led Training - Course Code 31F16T0 (Fleet Technicians Only) Ford Bi-Fuel LPG Vehicle (2-Day) Instructor-Led Training - Course Code 31F17T0 (Fleet Technicians Only)
1999-2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles (3Day) Instructor-Led Training- Course Code 41S01T0
(Mandatory for Ford Dealership Technicians, Optional for Fleet Technicians)
Ford Dedicated CNG Vehicles (2-Day) Instructor-Led Training - Course Code 41F01T0 (Fleet Technicians Only)
Ford Multiport Bi-Fuel CNG Vehicles (2Day) Instructor-Led Training - Course Code 41F02T0 (Fleet Technicians Only)
Ford Electric Ranger Instructor-Led Training - Course Code 34N07T0

(Optional for all Technicians)
Courses of the Alternative Fuel Vehicle (AFV) Curriculum The Alternative Fuel Vehicle (AFV) Curriculum consists of seven courses related to Alternative Fuel Vehicle (AFV) diagnosis and service. With the exception of the Ford Electric Ranger Course, each course in the curriculum is a building block for the next course in the curriculum. This curriculum is designed for technicians who want to learn the methods and techniques to properly diagnose and service AFV systems and components.
Curriculum Goals
The goals of this curriculum are as follows: Provide the necessary training to enable technicians to FIX IT RIGHT THE FIRST TIME, ON TIME. Increase technician productivity with respect to AFV diagnosis and service. Increased customer satisfaction.
Intro - 2 March, 2004 1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles
INTRODUCTION AND PREREQUISITE REVIEW Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles Instructor-Led Course Description
This is the second instructor-led course in the Alternative Fuel Vehicle Curriculum. It is a three-day course facilitated by an instructor. This course is designed to provide hands-on opportunities for technicians to learn and improve their skills with respect to utilizing tools and equipment and to apply knowledge learned in previous curriculum courses.
Course Terminal Objectives

Using the information and activities provided by this course the technician will: accurately diagnose and repair Dedicated CNG and Multiport Bi-Fuel CNG vehicle concerns using the appropriate tools and equipment. employ appropriate methods and techniques when servicing Dedicated CNG and Multiport Bi-Fuel CNG vehicle systems and components.
Audience
This course is designed and intended for Ford Motor Company dealership technicians who are enrolled in the STST Alternative Fuel Vehicle Curriculum. Additionally, this course is also designed for training service technicians of Ford Designated Fleets.
Course Prerequisites
A technician taking this course should have the following prerequisite skills, knowledge, and/or experience: Automotive Electrical 34S14T0 Automotive Electronics 34S19T0 Engine Performance Theory and Operation 31S07T0 Engine Performance Diagnosis and Testing 31S10T0 Additionally, technicians attending this course must have completed the following: Alternative Fuel Vehicle New Generation STAR Web-Based Training WB 31S09W0 (Mandatory for Fleet Technicians, optional for Ford Dealership Technicians). Alternative Fuel Safety Web-Based Training WB 31S10W0 (Mandatory for all Technicians). Flexible Fuel Vehicle Web-Based Training WB 31S11W0 (Mandatory for Ford Dealership Technicians).
March, 2004
Intro - 3
INTRODUCTION AND PREREQUISITE REVIEW Evaluation

Hands-on skills and course related knowledge is evaluated on the afternoon of the third day. Hands-on evaluations will be conducted with exercises in: Dedicated CNG and Multiport Bi-fuel CNG vehicle system diagnosis. Dedicated CNG and Multiport Bi-Fuel CNG vehicle system service. service publication CD-ROM/DVD navigation. special tool usage. In order to pass the course, you must demonstrate acceptable skills at the evaluated hands-on exercises AND you must answer at least 80% of the written post test questions correctly.
Student Guide
The Student Guide contains the worksheets used at the workstations for each of the three days. You must complete each worksheet. IMPORTANT: Actively participate in exercise reviews. This is your opportunity to ask questions and clear up any areas that you may not fully understand.
Intro - 4
March, 2004
SERVICE STANDARDS
Mission Statement All dealership personnel will treat every customer as a potential lifetime purchaser, communicating a professional image that embraces honesty and concern for customer wants and needs. Dealer-to-Customer Service Standards Appointment available within one day of the customers requested service day. Write-up begins within four minutes of arrival. Service needs courteously identified, accurately recorded on Repair Order, and verified with customer. Standard 4 Vehicles Serviced Right on the First Visit: Service status provided within one minute of inquiry. Vehicle ready at agreed upon time. Thorough explanation of work done, coverages and charges. The technician is the most important player when it comes to Standard 4. Fix It Right the First Time, on Time Why: Customers tell us Fixing It Right the First Time, On Time is one of the top reasons they would decide to return to a dealer to buy a vehicle and get their vehicles serviced. Technician Training It is our goal to help the technician acquire all of the skills and knowledge necessary to Fix It Right the First Time, On Time. We refer to this as competency. Technicians Role The technicians role is to acquire the skills and knowledge for competency in your specialty via: FMT (self-study) FORDSTAR Network (new model and curriculum) New Model (self-study and instructor-led) STST (instructor-led) Web-Based Training (self-study) Benefits The successful implementation of standards means: Satisfied customers Repeat vehicle sales Increased service department utilization Recognition that Ford and Lincoln/Mercury technicians are the Best in the Business
March, 2004
Intro - 5
Prerequisite Review
Introduction
This course begins with a review of the content covered in the prerequisite web-based courses. The review is designed to help you recall the key points and basic concepts of these courses. Comprehension of these key points and concepts is essential to being successful in this course. Directions: Select the best answer for the questions listed on the following pages.
1. The A. B. C. D.
vehicle and engine selection screen is necessary when using which of the following? Digital measurement systems. Diagnostic data link. New Generation STAR Setup. Internal systems tests.
2. If there is an arrow at the right bottom of the menu screen it indicates which of the following? A. There are more menu selections below. B. There are more menu selections above. C. The NGS is in digital measurement mode. D. The NGS is in active command mode. 3. A list of available control modules can be viewed by entering: A. diagnostic data link. B. generic OBDII functions. C. internal system tests. D. special functions. 4. To retrieve DTCs you should select which of the following? A. Diag test modes. B. Data link diagnostics. C. View rec areas. D. Internal systems tests. 5. A diagnostic trouble code (DTC) received during a KOEO/KOER on-demand self-test is: A. caused by a communication error. B. caused by a network error. C. a fault that has occurred, but may not be occurring now. D. a fault that is occurring now.
Intro - 6
March, 2004
INTRODUCTION AND PREREQUISITE REVIEW PREREQUISITE REVIEW (continued)

6. What connector is the NGS connected to on an AFV when retrieving DTCs? A. Powertrain control module (PCM) connector. B. Data link connector (DLC). C. Alternative fuel vehicle (AFV) module. D. At the C4008 connector. 7. Continuous DTCs (memory codes) can be caused by: A. a fault that has occurred, but may not be occurring now. B. a fault that is occurring now. C. both a and b. D. neither a nor b. 8. _______ enables you to view input signals and output commands. A. Diag test modes B. PID data monitor & record C. Active command mode D. DTC library 9. The A. B. C. D. sampling rate at which the NGS can operate is directly affected by _______ the PID priority. the number of PIDs selected. the number of DTCs. the type of DTCs. can be selected by using which of the following methods? Individual. Groups. Individual and groups. Individual and blocks. the NGS begins capturing data, the data will continue to be captured until: CANCEL is pressed. button-7 on the numeric keypad is pressed. the TRIGGER is pressed. button-3 on the numeric keypad is pressed.
10. PIDs A. B. C. D. 11. Once A. B. C. D.
March, 2004
Intro - 7

12. The A. B. C. D. Active command mode: prioritizes PIDs. allows you to link with vehicle control modules. tests the operation of the module communication networks. tests the modules ability to control selected outputs.
13. When servicing a bi-fuel vehicle always retrieve _______ first. A. base vehicle DTCs B. AFV DTCs C. fuel system DTCs D. electrical system DTCs 14. A vehicle with a 3000 psi fuel storage system can be refilled with which of the following? A. A 3000 psi pump. B. A 3600 psi pump. C. Either A or B. D. Neither A nor B. 15. Incorrect use of the Contour manual lockout/manual bypass may cause which of the following? A. A fuel leak. B. Excess pressure. C. Poor operating conditions. D. None of the above. 16. You should never service a component on a dedicated CNG vehicle: A. when there is gasoline in the tank. B. when there is pressure in the CNG fuel lines. C. when the vehicle is in gasoline mode. D. when the compuvalve is open. 17. If a CNG vehicle is parked in the shop and natural gas is accidentally released, it would accumulate in which of the following areas? A. In the vehicle. B. Near the floor. C. Near the ceiling. D. None of the above. 18. What must be done prior to servicing the CNG fuel tank on a dedicated CNG vehicle ? A. The vehicle must be switched to CNG mode. B. The vehicle must be emptied of all gasoline. C. The tank must be vented. D. All of the above.
Intro - 8
March, 2004

19. If a LPG vehicle is parked in the shop and propane is accidentally released, it would accumulate in which of the following areas? A. In the vehicle. B. Near the floor. C. Near the ceiling. D. None of the above. 20. If a LPG bi-fuel vehicle requires painting, and the vehicle will be placed in a paint oven, what must be done to the LPG tank? A. It must be covered. B. It must be vented. C. It must be removed. D. The vehicle cannot be placed in a paint oven. 21. When performing a liquid leak detection test, dishwashing soap may be used to identify leaks? A. Yes. B. No. C. On CNG vehicles only. D. On LPG vehicles only. 22. Which of the following must be performed prior to servicing a propane fueled vehicle? A. The manual shut-off valve must be opened. B. The manual shut-off valve must be closed. C. The pressure relief tank valve must be opened. D. The pressure relief tank valve must be closed. 23. Which of the following is a major difference between ethanol and gasoline? A. Gasoline is flammable. B. Ethanol is more chemically reactive. C. Ethanol is combustible. D. All of the above. 24. Which of the following must never occur when working on a FF vehicle? A. Take medication for the treatment of alcohol abuse. B. Drink ethanol. C. Inhale large quantities of ethanol. D. All of the above. 25. If fuel ethanol gets on your skin, you should: A. seek immediate medical attention. B. immediately put gloves on. C. move to fresh air. D. wash with soap and water.
March, 2004
Intro - 9
INTRODUCTION AND PREREQUISITE REVIEW NOTES
Intro - 10
March, 2004

OBJECTIVES CONTENTS
Compressed Natural Gas Vehicles What Is Natural Gas? Alternative Fuel Comparison Table Identification of Ford Dedicated and BiFuel CNG Vehicles Changes to Base Vehicle Components on Dedicated and Multiport Bi-Fuel CNG Vehicles Changes to Base Vehicle Operating Strategies Supplemental Information On Alternative Fuel Vehicles
Upon completion of this lesson the student will be able to:
Identify the characteristics of natural gas. Describe the operating characteristics of natural gas fueled vehicles. Identify the unique characteristics of fuelignition and combustion of natural gas.
March, 2004
1-1
COMPRESSED NATURAL GAS (CNG) VEHICLES
Ford Clean-Earth Logo Cars, vans, trucks, buses, and other on-road vehicles using traditional fuels produce more than 60 percent of all carbon monoxide (CO) pollution. They also are the second largest national source of hydrocarbons (HCs) at 29 percent and nitrogen oxides (NOx) at 31 percent, the major ingredients of unhealthful ground-level ozone. In many urban areas, motor vehicles are the single largest source of major criteria pollutants. Motor vehicles also emit more than 50 percent of all hazardous air pollutants. Regardless of improvements in emissions technology, conventionally fueled motor vehicles will continue to contribute to air pollution because the number of vehicles in use and the vehicle-miles traveled will continue to grow. Due to the favorable properties of natural gas as an engine fuel, Compressed Natural Gas (CNG) fueled vehicles produce lower levels of all pollutant emissions than either conventional or reformulated gasoline and diesel fuel. Vehicles operating on CNG can reduce exhaust emissions of CO by approximately 70 percent, nonmethane organic gas (NMOG) by 89 percent and NOx by 87 percent. Vehicles operating on CNG can also reduce carbon dioxide (CO2) the principle greenhouse gas exhaust emissions by 20 - 30 percent. Ford Motor Company is a leader in the development and introduction of alternative fueled vehicles. For more than two decades Ford has developed cutting edge technology to enable the effective use of alternative fuels. The Ford commitment to maintaining a clean environment has led to the cleanest running, most efficient, and technologically advanced alternative fueled vehicles in the world. This training class will cover theory, operation, components, diagnosis, and service of compressed natural gas (CNG) vehicles. The vehicles covered in this course include: 1999-2004 Crown Victoria dedicated CNG fueled vehicle 1999-2004 F-Series and E-Series dedicated CNG fueled light trucks 20031/2 & 2004 F-Series Multiport Bi-Fuel CNG fueled light trucks
1-2 March, 2004 1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles
WHAT IS NATURAL GAS?
Compressed Natural Gas Logo According to Ford Motor Company Chairman, Bill Ford, A good company delivers excellent products and services; a great one does all that and strives to make the world a better place. Ford has been demonstrating this commitment by developing natural gas fueled vehicles for decades. With recent improvements in technology and the need for cleaner operating vehicles, widespread use of natural gas as a vehicle fuel makes good sense. Compared to gasoline, natural gas fueled vehicles can reduce 85 to 90 percent emissions of carbon monoxide and reactive hydrocarbons that contribute to smog. Natural gas offers vehicle mileage that compares to the equivalent amount of gasoline. When operating on natural gas, vehicle performance is similar to operation on gasoline. Since the U.S. and Canada have the largest natural gas reserves in the world, its use as a vehicle fuel reduces dependence on imported oil. A major advantage of natural gas is that CNG has a higher octane level than gasoline. The higher octane rating indicates that CNG burns more slowly providing smoother power strokes. As you can see, natural gas has many advantages over other types of alternative fuels, and its use in powering vehicles is sure to expand in the future.
March, 2004
1-3
LESSON 1: INTRODUCTION TO CNG VEHICLES Alternative Fuel Comparison Table

The following table compares the characteristics of Propane, Compressed Natural Gas (CNG), Methanol, and Ethanol to Gasoline.
Characteristic Propane CNG Methanol Ethanol Regular Unleaded Gas (87 Octane) 87-93 114,000-125,000
Octane BTU per gallon
104 91,000
130 N.A.
100 70,000
100 83,000
Gallon Equivalent On-board fuel storage Miles/gallon as compared to g as. Relative tank siz e required to yield driving range equivalent to g as Temp/Pressure
1.15
122 cubic feet = 1 gallon of gasoline Gas
1.8
1.5
Liquid
Liquid
Liquid
Liquid
85%
N.A.
55%
70%
Tank is 1.25 times larger
atm T / 200 psi
atm T / 3000-3600 psi
atm T / atm P
atm T / atm P
atm T / atm P
Ignition Point (F)/ % Fuel in air Specific Gravity(air = 1.0) Cold Weather Capability Vehicle Pow er
920-1,120F/ 2-10% 1.52
1,200F/ 5-15% 0.55
800F/ 7-36% 1.4
850F/ 3-19% 1.59
450-900F/ 8% 4.4
Good
Good
P oor
P oor
Good
5-10% power loss
10-20% power loss
4% power increase
5% power increase Toxic
Standard
Toxicity
Nontoxic
Nontoxic
Highly toxic
Toxic
Corrosivity
Non-corrosive
Non-corrosive
Corrosive
Corrosive
Minimally corrosive
Vehicle Emissions
Source/ Feedstock
Clean burning, second only to natural gas. In EPA tests, a light duty propane vehicle emitted 93% less carbon monoxide, 57% less nitrogen oxide and 73% less hydrocarbons (there were no alcohol or evaporative emissions) than gasoline. Natural gas/ Petroleum refining
Overall cleanest burning fossil fuel. In EPA tests, a light duty natural gas vehicle emitted 98% less carbon monoxide, 65% less nitrogen oxide and 85% less non-methane hydrocarbons (there were no alcohol or evaporative emissions) than gasoline. Natural gas/ Crude oil
In EPA tests, a light duty methanol vehicle emitted 28.5% less carbon monoxide, 32% less nitrogen oxide and 28.5% less reactive organic gases (non-methane hydrocarbons, alcohol and aldehydes) than gasoline.
15-20% less carbon monoxide.Increased nitrogen oxide relative to gasoline.
Standard against which others are measured.
Natural gas/ C oal
Sugar and starch crops/ Biomass
Crude oil
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March, 2004
LESSON 1: INTRODUCTION TO CNG VEHICLES Identification of Ford Dedicated and Bi-Fuel CNG Vehicles
1FTEF2595VLA00001
Eighth letter 9 in VIN indicates factory-built Dedicated CNG Crown Victoria.
1FTEF25M5VLA00001
Eighth letter M in VIN indicates factory-built Dedicated CNG E or F-Series light truck.
1FTEF25Z5VLA00001
Eighth letter Z in VIN indicates factory-installed bi-fuel prep vehicle.
Typical Dedicated and Bi-Fuel CNG Vehicle Identification Number (VIN) A dedicated CNG vehicle uses only CNG for fuel. Customers that use this type of vehicle are generally those whose vehicles will be operated almost exclusively in urban areas. For these types of customers, a dedicated CNG vehicle makes sense because they generally fuel their vehicle at company owned facilities, or have CNG equipped fueling stations within their area of operation. However, there are situations and circumstances where CNG fueling facilities are limited. Ford, in an effort to provide its customers with maximum flexibility while reducing exhaust emissions, provides bi-fuel vehicles that can operate on either conventional gasoline or CNG. Identification of a factory-manufactured Ford dedicated CNG and bi-fuel CNG vehicles can be made using the vehicle identification number (VIN). The eighth digit/letter (reading left to right) of the VIN will be a 9 for all factory-manufactured dedicated CNG Crown Victorias. The eighth digit/letter (reading left to right) of the VIN will be an M for all factory-manufactured dedicated CNG E or F Series light trucks. The eighth digit/letter (reading left to right) of the VIN will be a Z for all factory-manufactured Ford bi-fuel vehicles. Additionally, a variety of Warning, Caution and Instruction labels are provided on the vehicle in critical areas of the CNG and driver control systems.
March, 2004
1-5
LESSON 1: INTRODUCTION TO CNG VEHICLES Changes to Base Vehicle Components on Dedicated CNG and Multiport Bi-Fuel CNG Vehicles
In order to ensure that vehicles that operate on CNG have the same service life and handling characteristics of a conventional vehicle, certain changes have been made to other vehicle components. Changes to the engine include: Intake and exhaust valve seat inserts. Revised and hardened intake valve seats. Stress-relieved (flame hardened) valves. Corrosion resistant intake valves. Positive valve rotation during operation. Platinum-tipped nickel-plated spark plugs (part # AGSF-22WM). Different pistons are used in the 4.6L engine (Crown Victoria only) to increase the compression ratio. Aluminum lower intake manifold is used on 4.6L and 5.4L engines. Changes to the chassis include: Upgraded suspension system to accommodate the weight of the additional fuel tanks. Additional fuel door for the CNG fuel fill valve (Multiport Bi-Fuel CNG only). It is important to be aware of these changes, in the event that any of these components require replacement during vehicle service.
1-6
March, 2004
LESSON 1: INTRODUCTION TO CNG VEHICLES Changes to Base Vehicle Operating Strategies

OBD II operating strategies have been relaxed for dedicated CNG and Multiport Bi-Fuel CNG vehicles. This is due to the unique operating characteristics of CNG fueled vehicles. The following chart provides information on specific changes to CNG operating strategies.
2004 1/4 Dedicated CNG E-Series
2003/2004 Crown Victoria Dedicated CNG
2003 1/2 F150 Bi-Fuel
Fuel SCP/CAN
60/90 Pin AFCM
CNG SCP 60-Pin Yes Yes Yes Yes Yes N/A N/A Yes Yes Yes No Yes
CNG/Gasoline SCP 90-Pin CNG No No Yes Yes Yes N/A No Yes Yes Yes No Yes Gasoline Yes Yes Yes Yes Yes N/A Yes Yes Yes Yes Yes Yes
CNG SCP 90-Pin No Yes Yes N/A Yes N/A N/A Yes Yes Yes No Yes
Cat Misfire Hego EGR Fuel S-Air Evap CCM Fuel Pump Idle Speed Purge Flow Others Yes = Enabled No = Not Enabled N/A = Not Applicable
March, 2004
1-7
LESSON 1: INTRODUCTION TO CNG VEHICLES Supplemental Information On Alternative Fuel Vehicles

There are many places where supplemental information can be obtained on AFVs. The following list provides various organizations, phone numbers, and websites where information is available for AFVs.
ORGANIZATION PHONE WEBSITE WWW.Car.Ford.com/AFV/Scroll down to left frame to "communications\THINK Group Safety" www.afdc.nrel.gov/altfuel/lpg_train.html www.afdc.doe.gov www.fleets.doe.gov www.cities.doe.gov www.eia.doe.gov www.ngvc.org www.aga.com www.Ingexpress.com
Ford Motor Company
877-ALT FUEL
Alternative Fuels Data Center National Alternative Fuels Hotline Clean Cities Hotline Energy Information Administration Natural Gas Coalition American Gas Association LNG Express National Ethanol Vehicle Association Renewable Fuels Association Propane Vehicle Council National Propane Gas Association American Methanol Institute California Energy Commission The Electric Vehicle Association of the Americas Electric Transportation Coalition National Alternative Fuels Training Consortium Arizona Dept. of Commerce Certified Compressed Natural Gas Cylinder Inspectors 800-385-8895 202-289-3835 202-371-6262 708-515-0600 202-467-5050 916-653-8634 800-438-3228 202-508-5995 800-423-1363 800-224-8437 202-586-8800 703-527-3022 703-841-8000
www.ethanolRFA.org www.propanegas.com/vehicle www.propanegas.com www.methanol.org www.energy.ca.gov www.evaa.org
www.naftp.nrcle.wva.edu www.state.az.us www.csa.international.org
1-8
March, 2004
LESSON 2A: DEDICATED CNG VEHICLE OPERATION
LESSON 2A: DEDICATED CNG OPERATION

OBJECTIVES CONTENTS
Dedicated CNG Vehicle Theory Of Operation CNG Fuel System Pressures
Identify the characteristics of natural gas. Describe the operating characteristics of natural gas fueled vehicles. Identify the unique characteristics of fuel ignition and combustion of natural gas. Explain the theory and operation of dedicated CNG fueled vehicles.
March, 2004
2A-1
DEDICATED CNG VEHICLE THEORY OF OPERATION

14 13 15 1 2 3 4
12 6
11
10
Typical Dedicated CNG Vehicle Components
Item 1 2 3 4 5 6 7 8 Description CNG Fuel Tank Solenoid Tank Valve
Item 9 10 11 12 13 14 15 16 Fuel Lines
Description
Alternative Fuel Control Module Fuel Rail Shutoff Solenoid Fuel Injector Fuel Rail Fuel Rail Pressure Sensor Engine Fuel Temperature Sensor
Upper Fuel Tank Temperature Sensor Fuel Tank Pressure Sensor Fuel Fill Valve Coalescent Filter Quarter-Turn Valve (open position) Fuel Pressure Regulator
2A-2
March, 2004
DEDICATED CNG VEHICLE THEORY OF OPERATION (continued)

Dedicated CNG vehicles can be equipped with either a 4.6 liter engine (Crown Victoria) or a 5.4 liter engine (E and F-series light trucks). The major components of a typical dedicated CNG fuel system include: Fuel Fill Valve Fuel Injection Supply Manifold Fuel Tanks Alternative Fuel Control Module (AFCM) (60 or 90-pin vehicle and MY dependent) Fuel Pressure Regulator and Coalescent Filter Assembly Fuel Injectors These components combine to provide the best performance and efficiency for vehicle operation on CNG fuel.
March, 2004
2A-3
DEDICATED CNG FUEL SYSTEM THEORY AND OPERATION (continued)

1
16
15
2
3 14
4 5
12 13 6
7 8 11
10 9
Typical Dedicated CNG Component Configuration (Crown Victoria Shown)
Item 1 2 3 4 5 6 7 8 Fuel Tank Rack Fuel Tank Solenoid Valve (One Per Tank) Fuel Fill Valve Pressure Regulator Coalescent Filter Quarter-Turn Valve (1999-2002) Fuel Rails and Injectors Fuel Rail Shutoff Valve Description Item 9 10 11 12 13 14 15 16 Description Lower Tank Rack Fuel Temperature Sensor Upper Tank Rack Fuel Temperature Sensor Fuel Tank Pressure Sensor Fuel Gauge Alternative Fuel Control Module (AFCM) Powertrain Control Module (PCM) Inertia Switch Fuel Relay/Fuel Tank Solenoid Valve Relay
2A-4
March, 2004
DEDICATED CNG FUEL SYSTEM THEORY AND OPERATION (continued)

The dedicated CNG fuel system on Ford vehicles operates as follows: When the ignition switch is turned to the run or start position, the PCM energizes the fuel relay/fuel tank solenoid valve relay (fuel pump relay). The fuel relay/fuel tank solenoid valve relay in turn sends voltage to the solenoid tank valves, causing them to open. The solenoid tank valves will initially only be activated for one second and then will be turned off unless the PCM receives a PIP signal indicating that the engine is cranking. This allows high-pressure natural gas to enter the fuel lines. The high-pressure natural gas passes through the high-pressure fuel lines, past the quarter-turn valve (Crown Victoria only) and into the high-pressure (coalescent) filter. In the coalescent filter, water and particulate contaminates are removed from the natural gas. Once the fuel passes through the coalescent filter, it then goes into the fuel pressure regulator. The regulator reduces the pressure of the fuel (110-125 psi for Crown Victoria or 95-110 psi for E & FSeries) and distributes it to the fuel rails via low-pressure fuel lines, through an open low-pressure solenoid shut-off valve. Fuel injectors located at the cylinder head inject the natural gas into the combustion chamber based on a signal sent to the injector from the PCM, via the AFCM module. 60-pin AFCM modules perform two functions:
It acts as a relay, using the low amperage signal from the PCM to turn on the high amperage injector circuit. It translates fuel tank pressure and temperature signals into fuel level indications for the fuel gauge.
90-pin AFCM modules used on 2004 E-Series Dedicated CNG vehicles perform the following functions: acts as a relay, using the low amperage signal from the PCM to turn on the high amperage CNG injector circuit. translates fuel tank pressure and temperature signals into fuel level indications for the fuel gauge. monitors injector operation for faults. stores many more DTCs than the 60-pin AFCM.
The fuel injectors are pulse width modulated (PWM) to deliver a calculated amount of fuel at the intake valve. Since fuel pressure is constant across all engine loads, only the length of time that the injectors are open determines the amount of fuel injected.
March, 2004
2A-5
CNG FUEL SYSTEM PRESSURES
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3000/3600 psi
CNG Fuel System Pressure Schematic

Item 1 2 3 4 Description CNG Fuel Tank (3000/3600 psi ) Coalescent Filter (3000/3600 psi ) Fuel Rails and Fuel Injectors (95 to 110 psi. E & F Series, 110 to 125 psi. Crown Victoria) High Pressure (3000/3600 psi.) Item 5 6 7 Description Low Pressure (95 to 110 psi. E & F Series, 110 to 125 psi. Crown Victoria) Pressure Regulator (enter at 3000/3600 psi, exit at 95 to 125 psi. Model Dependent) Fuel Fill Valve (3000/3600 psi)
CNG fuel systems operate at very high pressures. However, these pressures will change as the fuel passes along the fuel delivery system. The following is a description of the fuel pressures and how they change at different points in the fuel system. The CNG is introduced into the fuel system at the fuel fill valve. The pressure at the fill valve during fueling will be either 3000 psi or 3600 psi (vehicle and MY dependent). The fuel is stored in the fuel tank at pressures as high as 3000 or 3600 psi (vehicle and MY dependent). As the fuel moves out of the tank it remains at tank pressure as it passes through the solenoid tank valves and into the high-pressure fuel lines.
2A-6
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yyyy ;;;;
4
March, 2004
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CNG FUEL SYSTEM PRESSURES (continued)

The high pressure fuel lines carry the fuel at tank pressure throughout their length to the coalescent filter. Coalescent filter pressure is the same as the tank pressure. After leaving the coalescent filter, the fuel enters the pressure regulator. The pressure regulator lowers the fuel pressure from tank pressure (up to 3000/3600 psi) to 110 to 125 psi on Crown Victoria, or 95 to 110 psi on E & F-Series light trucks. This lower pressure fuel moves from the pressure regulator to the fuel rails and injectors. The fuel injectors are pulse width modulated (PWM) to deliver the fuel to the intake valve of the engine.
March, 2004
2A-7
LESSON 2A: DEDICATED CNG VEHICLE OPERATION NOTES
2A-8
March, 2004
ACTIVITY 2A
ACTIVITY 2A
OBJECTIVES
The purpose of this activity is to:
CONTENTS
Activity 2A - Worksheet A (Hands-On) Activity 2A - Worksheet B (Hands-On) Activity 2A - Worksheet C (Written) Activity 2A - Worksheet D (Written)
Reinforce the knowledge that the student has acquired from Lessons 1 and 2. Allow the student to review detailed information found in Lessons 1 and 2. Allow the student to locate and identify CNG fuel system components.
March, 2004
2A-9
ACTIVITY 2A ACTIVITY 2A WORKSHEET A (Hands-On) DEDICATED CNG FUEL SYSTEM COMPONENT LOCATION STUDENT ANSWER SHEET
Directions: Using the information in your Student Reference Guide and the service publications provided, go to the dedicated CNG classroom vehicle and answer the following questions. 1. Locate the following components on the vehicle. These components are tagged with letters or numbers. Write the letter/number of the component next to its name on the list below.
Fuel Fill Valve Fuel Tank Solenoid Valve Quarter-Turn Valve Coalescent Filter Fuel Pressure Regulator Fuel Rail Pressure Sensor Engine Fuel Temperature Sensor Fuel Injector Low-Pressure Solenoid Shut-off Valve High-Pressure Side Fuel Line Low-Pressure Side Fuel Line Alternative Fuel Control Module Fuel Shut-off Relay
END OF WORKSHEET
2A-10
March, 2004
ACTIVITY 2A ACTIVITY 2A WORKSHEET B (Hands-On) DEDICATED CNG NGS PRACTICE STUDENT ANSWER SHEET
Directions: Using the information you have learned from the NGS Web-Based Training Course, and the NGS Appendix found at the rear of this student guide, go to the dedicated CNG classroom vehicle and answer the following questions. 1. Connect the NGS to the classroom vehicle. What information must be programmed into the NGS before it can be used to view PIDs? 2. Start the vehicle and allow it to idle. Use the NGS to locate the PIDs listed below from the AFCM. Note the NGS definition of the PID, and the PID values presented.
PID GAGDRIVE TANK PR TMPSN1 TMPSN2
Definition
Value Presented
3. With the vehicle still idling, use the NGS to locate the PIDs listed below from the PCM. Note the NGS definition of the PID, and the PID values presented.
PID EFTA V F LI FRP V FS V FS V F FS V M
Definition
Value Presented
March, 2004
2A-11
ACTIVITY 2A ACTIVITY 2A WORKSHEET C (Written) INTRODUCTION TO CNG VEHICLES STUDENT ANSWER SHEET
Directions: Use the information presented in your Student Reference Guide (including the Appendix and Glossary in the back of the guide), and from the required prerequisite courses to answer the following questions. 1. What type of AFV customer is likely to use dedicated CNG vehicles? __________________________
_________________________________________________________________________________ PAGE#__________
2. List three reasons that natural gas is a good choice for vehicle alternative fuel.
_________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ PAGE#__________

3. Since natural gas is odorless and colorless in its natural state, what is added as a safety measure to help detect leaks? ____________________________________________________ PAGE#__________ 4. If a CNG vehicle has a gas leak in a building, where will the natural gas accumulate?
_________________________________________________________________________________ PAGE#__________
5. How many cubic feet of natural gas is equal to a gallon of gasoline? __________ PAGE#__________ 6. What advantage does the slower combustion rate of natural gas have when used in an internal combustion engine?_________________________________________________________________
_________________________________________________________________________________ PAGE#__________
7. Write the meaning of the acronyms listed below.
ACRONYM A FC M FTP FTT E FT FRP
DEFINITION
2A-12
March, 2004
ACTIVITY 2A ACTIVITY 2A WORKSHEET D (Written) DEDICATED CNG VEHICLE OPERATION STUDENT ANSWER SHEET
Directions: Use the information presented in your Student Reference Guide (including the Appendix and Glossary in the back of the guide), and from the required prerequisite courses to answer the following questions. 1. On a dedicated CNG vehicle with a 60-pin AFCM, what are the two purposes of the AFCM module?
_________________________________________________________________________________ _________________________________________________________________________________ PAGE#_______

2. On a 2003 Dedicated CNG Crown Victoria, the misfire monitor is (circle one) ENABLED or NOT ENABLED or NOT APPLICABLE. PAGE#_______ 3. When looking at the VIN of a Crown Victoria, how can you tell it is a factory- manufactured CNG fueled vehicle? __________________________________________________________________________ PAGE#_______ 4. What method is used to increase the compression of the 4.6 liter engine in a CNG fueled Crown Victoria?
_________________________________________________________________________________ PAGE#_______
5. What type of contaminates are removed from the natural gas by the coalescent filter?
_________________________________________________________________________________ PAGE#_______
6. On a dedicated CNG E-series, what is the pressure of the fuel once it passes the pressure regulator? ________________________________________________________________ PAGE#_______ 7. On a dedicated CNG vehicle, the fuel system monitor is (circle one) ENABLED or NOT ENABLED or NOT APPLICABLE. PAGE#_______ 8. What website could be used to get information on compressed natural gas cylinder standards? _____________________________________________________________ PAGE#_______ 9. Dedicated CNG vehicle fuel pressure ______________ under all engine loads. A. increases B. decreases C. varies D. is constant PAGE#_______
END OF WORKSHEET
March, 2004
2A-13
ACTIVITY 2A
NOTES
2A-14
March, 2004
OBJECTIVES
CONTENTS
Multiport Bi-Fuel CNG Vehicle Theory Of Operation CNG Fuel System Pressures
Identify the characteristics of natural gas. Describe the operating characteristics of natural gas fueled vehicles. Identify the unique characteristics of fuel ignition and combustion of natural gas. Explain the theory and operation of Multiport Bi-Fuel CNG vehicles.
March, 2004
2B-1
OPERATION LESSON 2B: MULTIPORT BI-FUEL CNG VEHICLE OPERATION
MULTIPORT BI-FUEL CNG VEHICLE THEORY OF OPERATION

14 13 15 12 11 3 10 1
8 7 6
Typical Multiport Bi-Fuel CNG Vehicle Components

Item 1 2 3 4 5 6 7 8 Description Solenoid Tank Valve CNG Fuel Tank Fuel Fill Valve Coalescent Filter Relays (ALT & Fuel Pump) High Pressure Fuel Line Low Pressure Fuel Line 90-pin AFCM Item 9 10 11 12 13 14 15 Description Fuel Rail Shutoff Solenoid Fuel Tank Pressure (FTP) Sensor CNG Pressure Regulator Gasoline Fuel Injector CNG Fuel Injector Fuel Rail Pressure (FRP) Sensor ALT/GAS Switch
2B-2
March, 2004
MULTIPORT BI-FUEL CNG VEHICLE THEORY OF OPERATION (continued)

Multiport Bi-Fuel CNG vehicles are equipped with a 5.4 liter engine (F-series light trucks). The major components of a Multiport Bi-Fuel CNG fuel system include: Fuel Fill Valve Gasoline Fuel Injection Supply Manifold CNG Fuel Injection Supply Manifold Gasoline Fuel Tank CNG Fuel Tank Powertrain Control Module (PCM) 90-Pin Alternative Fuel Control Module (AFCM) Fuel Pressure Regulator Coalescent Filter Assembly Gasoline Fuel Injectors CNG Fuel Injectors These components combine to provide the best performance and efficiency for vehicle operation on either gasoline or CNG fuel.
March, 2004
2B-3

1 18 19 2
17 3
20
16
ALT
15
GAS
X X X X X X X X X X X X X X X X X X X X X X X X
12 5 11 6
10 14 13 8
Multiport Bi-Fuel CNG Component Configuration

Item 1 2 3 4 5 Description Fuel Tank Fuel Tank Solenoid Valve Fuel Fill Valve Pressure Regulator Coalescent Filter Item 6 7 8 9 10 Description CNG Fuel Rail CNG Fuel Injectors Gasoline Fuel Rail Gasoline Fuel Injectors Fuel Rail Temperature (FRT) Sensor Item 11 12 13 14 15 Description Fuel Rail Pressure (FRP) Sensor Fuel Rail Shutoff Valve Alternative Fuel Control Module (AFCM) Fuel Tank Pressure (FTP) Sensor Fuel Guage Item 16 17 18 19 20 Description ALT/GAS Switch Powertrain Control Module (PCM) Gasoline Fuel Relay Inertia Switch Alternative Fuel Relay
2B-4
March, 2004

Multiport Bi-Fuel CNG Vehicle Operation on Gasoline The Multiport gasoline fuel system operates as follows: When the ignition switch is turned to the run or start position, the Alternative Fuel Control Module (AFCM) receives a signal from the ALT/GAS Switch indicating that the gasoline mode is selected. The AFCM in turn selects operation of the gasoline fuel injectors, and checks the gasoline fuel level signal to ensure that there is enough gasoline in the fuel tank for vehicle operation. Within milliseconds of these actions the AFCM signals the Powertrain Control Module (PCM) that the vehicle is to operate in the gasoline mode via the SCP network. The AFCM also activates the gasoline fuel pump relay which in turn activates the gasoline fuel pump. Upon receiving the signal indicating the type of fuel to be used, the PCM selects the operating parameters specific to gasoline operation. It then begins sending Pulse Width Modulated (PWM) fuel injector signals to the AFCM, which in turn acts as an injector driver and passes the signals the gasoline fuel injectors. From this point, vehicle operation is basically the same as that of a conventional gasoline vehicle. Multiport Bi-Fuel CNG Vehicle Operation on Natural Gas The Multiport CNG fuel system operates as follows: When the ignition switch is turned to the run or start position, the AFCM receives a signal from the ALT/ GAS switch indicating that the ALT fuel mode is selected. The AFCM in turn selects operation of the CNG fuel injectors, and checks the CNG fuel level by monitoring fuel pressure and temperature to determine fuel density. By comparing fuel pressure and temperature with precalibrated parameters, the AFCM determines if there is enough CNG for vehicle operation. Within milliseconds of these actions the AFCM signals the PCM that the vehicle is to operate in the ALT fuel mode via the SCP network. Upon receiving the signal indicating the type of fuel to be used, the PCM selects the operating parameters specific to natural gas operation. It then begins sending PWM fuel injector signals to the AFCM, which acts as an injector driver to amplify and direct these signals to the CNG fuel injectors. The AFCM also sends voltage to the ALT fuel relay, which in turns sends voltage to the fuel tank solenoid valve and the fuel rail shutoff valve. This voltage opens both valves. These valves will be opened for one second and then will be closed unless the PCM receives a PIP signal indicating that the engine is cranking. This allows high-pressure natural gas to enter the fuel lines. The high-pressure natural gas passes through the high-pressure fuel lines and into the high-pressure (coalescent) filter. In the coalescent filter, water and particulate contaminates are removed from the natural gas.
March, 2004
2B-5

Multiport Bi-Fuel CNG Vehicle Operation on Natural Gas (continued) Once the fuel passes through the coalescent filter it goes into the fuel pressure regulator. The regulator reduces the pressure of the fuel to 95-110 psi and distributes it to the fuel rails via low-pressure fuel lines through the open fuel rail shutoff valve. Fuel injectors located at the fuel rails inject the natural gas into the combustion chamber based on a signal sent to the injector from the PCM, via the AFCM module. The 90-pin AFCM module performs the following functions:
acts as a relay, using the low amperage signal from the PCM to turn on the high amperage CNG injector circuit. translates fuel tank pressure and temperature signals into fuel level indications for the fuel gauge. controls the gasoline fuel pump relay. controls the ALT fuel relay. monitors injector operation for faults.
Since fuel pressure is constant across all engine loads, only the length of time that the injectors are open determines the amount of fuel injected.
2B-6
March, 2004
CNG FUEL SYSTEM PRESSURES
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3000/3600 psi
CNG Fuel System Pressure Schematic

Item 1 2 3 4 Description CNG Fuel Tank (3600 psi ) Coalescent Filter (3600 psi ) Fuel Rails and Fuel Injectors (95 to 110 psi) High Pressure (3600 psi.) Item 5 6 7 Description Low Pressure (95 to 110 psi) Pressure Regulator (enter at 3600 psi, exit at 95 to 110 psi. Fuel Fill Valve (3600 psi)
CNG fuel systems operate at very high pressures. However, these pressures will change as the fuel passes along the fuel delivery system. The following is a description of the fuel pressures and how they change at different points in the fuel system. The CNG is introduced into the fuel system at the fuel fill valve. The pressure at the fill valve during fueling will be 3600 psi. The fuel is stored in the fuel tank at 3600 psi. As the fuel moves out of the tank it remains at tank pressure as it passes through the solenoid tank valve and into the high-pressure fuel lines.
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4
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March, 2004
2B-7
CNG FUEL SYSTEM PRESSURES (continued)

The high pressure fuel lines carry the fuel at tank pressure throughout their length to the coalescent filter. Coalescent filter pressure is the same as the tank pressure. After leaving the coalescent filter, the fuel enters the pressure regulator. The pressure regulator lowers the fuel pressure from tank pressure (3600 psi) to 95 to 110 psi. This lower pressure fuel moves from the pressure regulator to the fuel rails and injectors. The fuel injectors are pulse width modulated (PWM) to deliver the fuel into the engine.
2B-8
March, 2004
ACTIVITY 2B
ACTIVITY 2B
OBJECTIVES
CONTENTS
Activity 2B - Worksheet E (Hands-On) Activity 2B - Worksheet F (Hands-On) Activity 2B - Worksheet G (Written) Activity 2B - Worksheet H (Written)
Reinforce the knowledge that the student has acquired from Lessons 1 and 2B. Allow the student to review detailed information found in Lessons 1 and 2B. Allow the student to locate and identify CNG fuel system components.
March, 2004
2B-9
ACTIVITY 2B ACTIVITY 2B WORKSHEET E (Hands-On) MULTIPORT BI-FUEL CNG FUEL SYSTEM COMPONENT LOCATION STUDENT ANSWER SHEET
Directions: Using the information in your Student Reference Guide and the service publications provided, go to the Bi-Fuel CNG classroom vehicle and answer the following questions. 1. Locate the following components on the vehicle. These components are tagged with letters or numbers. Write the letter/number of the component next to its name on the list below.
Fuel Fill Valve Fuel Tank Solenoid Valve Coalescent Filter Fuel Pressure Regulator Regulator Coolant Line Fuel Rail Pressure (FRP) Sensor Fuel Rail Temperature (FRT) Sensor CNG Fuel Injector Gasoline Fuel Injector Fuel Rail Shutoff Valve High-Pressure Side Fuel Line Low-Pressure Side Fuel Line Alternative Fuel Control Module Alternative Fuel Relay Gasoline Fuel Pump Relay
END OF WORKSHEET
2B-10
March, 2004
ACTIVITY 2B ACTIVITY 2B WORKSHEET F (Hands-On) MULTIPORT BI-FUEL CNG NGS PRACTICE STUDENT ANSWER SHEET
Directions: Using the information you have learned from the NGS Web-Based Training Course, and the NGS Appendix found at the rear of this student guide, go to the Multiport Bi-Fuel classroom vehicle and answer the following questions. 1. Connect the NGS to the classroom vehicle. What information must be programmed into the NGS before it can be used to view PIDs? ____________________________________________________________ 2. Start the vehicle and allow it to idle. Use the NGS to locate the PIDs listed below from the AFCM. Note the NGS definition of the PID, and the PID values presented.
PID ALTFRUN FUEL S E L_S W MC _SW
D efinition
Value Presented
3. With the vehicle still idling, use the NGS to locate the PIDs listed below from the PCM. Note the NGS definition of the PID, and the PID values presented.
PID OS11 PIP RPM TP MODE VPWR MIL
Definition
Value Presented
END OF WORKSHEET
1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles March, 2004 2B-11
ACTIVITY 2B ACTIVITY 2B WORKSHEET G (Written) INTRODUCTION TO CNG VEHICLES STUDENT ANSWER SHEET
Directions: Use the information presented in your Student Reference Guide (including the Appendix and Glossary in the back of the guide), and from the required prerequisite courses to answer the following questions. 1. Compared with gasoline-powered vehicles, CNG fueled vehicles can reduce NOx emissions by how PAGE#___________ much?_______________________________________________________ 2. Compared to gasoline, the octane level of CNG is (circle one) HIGHER or LOWER. PAGE#__________ 3. What is usually the first indication of a natural gas leak? ____________________________________ PAGE#__________ 4. CNG is (circle one) LIGHTER or HEAVIER than air. 5. What is the ignition point temperature of CNG? _________________________ PAGE#__________ PAGE#__________
6. What changes are made to the suspension of a bi-fuel vehicle?________________________________ _______________________________________________________________________________________________________ ______________________________________________________________________________________________________ PAGE#__________ 7. Write the meaning of the acronyms listed below.
ACRONYM A FV A FC M FUEL_MODE FRT S E LS W
DEFINITION
END OF WORKSHEET
2B-12 March, 2004 1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles
ACTIVITY 2B ACTIVITY 2B WORKSHEET H (Written) MULTIPORT BI-FUEL CNG VEHICLE OPERATION STUDENT ANSWER SHEET
Directions: Use the information presented in your Student Reference Guide (including the Appendix and Glossary in the back of the guide), and from the required prerequisite courses to answer the following questions. 1. Which of the following are functions of the AFCM on an Multiport Bi-Fuel CNG Vehicle
A. Acts as a relay, using the low amperage signal from the PCM to turn on the high amperage CNG injector
circuit.
B. Translates fuel tank pressure and temperature signals into fuel level indications for the fuel gauge. C. Controls the gasoline fuel pump and ALT fuel relay. D. Monitors injector operation for faults.
E. All of the above. PAGE#_______
2. On a Multiport Bi-Fuel CNG Vehicle, the fuel system monitor is (circle one) ENABLED or NOT ENABLED or NOT APPLICABLE. PAGE#_______ 3. When looking at the VIN of a Multiport Bi-Fuel CNG Vehicle, how can you tell it is a factory- manufactured bi-fuel vehicle? ____________________________________________________________ PAGE#_______ 4. What is the maximum CNG pressure that can be used to refuel a Multiport Bi-Fuel CNG Vehicle? ____________________________________________________________________PAGE#_______ 5. What two components are controlled by the ALT fuel relay? _________________________________ _________________________________________________________________________________ PAGE#_______ 6. What two signals does the AFCM use to determine CNG fuel level?____________________________ _________________________________________________________________________________ PAGE#_______ 7. Which control module creates PWM signals to control the CNG fuel injectors? ___________________ PAGE#_______ 8. What is the website address for the Natural Gas Coalition? _____________________ PAGE#_______ 9. Multiport Bi-Fuel CNG Vehicle fuel pressure ______________ under all engine loads. A. increases B. decreases C. varies D. is constant PAGE#_______
END OF WORKSHEET
1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles March, 2004 2B-13
ACTIVITY 2B
NOTES
2B-14
March, 2004
LESSON 3A: DEDICATED CNG COMPONENTS

OBJECTIVES
CONTENTS
Introduction To Dedicated CNG Components CNG Fuel Fill Valve Fuel Tanks Solenoid Tank Valve Fuel Tank Vent Box - Crown Victoria Fuel Lines Quarter-Turn Valve Fuel Filters High Pressure Regulator Fuel Injection Supply Manifold Fuel Injectors CNG Fuel System Control Modules And Input/ Output Devices Inputs and Outputs Chart Powertrain Control Module (PCM) Unique CNG PCM Input Devices Unique CNG Outputs of the PCM Alternative Fuel Control Module (AFCM) AFCM Outputs
Identify advantages of dedicated CNG vehicles. Explain unique CNG components. Describe changes to base vehicle components on dedicated CNG vehicles. Explain changes to dedicated CNG vehicle operating strategies.
March, 2004
3A - 1
INTRODUCTION TO DEDICATED CNG COMPONENTS
Dedicated CNG Vehicles This lesson will provide information on dedicated CNG fuel system components. The vehicles covered in this lesson include: 1999-2004 Crown Victoria with dedicated CNG fuel system. 1999-2004 E & F-Series with dedicated CNG fuel system. Some components are only used on specific vehicles. If this is the case, the vehicle will be specified.
3A - 2
March, 2004
LESSON 3A: DEDICATED CNG COMPONENTS CNG Fuel Fill Valve 1
CNG Fill Valve

Item 1 Description CNG Fill Valve Item 2 Description Pressure Stamp (P36=3600 psi. valve, P30=3000 psi. valve)
COMPONENT FUNCTION Enables vehicle to receive CNG fuel. COMPONENT LOCATION Beneath the fuel fill door. DESCRIPTION AND OPERATION 1999 -2004 E & F Series allows a maximum of 3600 psi of CNG to be received into the CNG fuel tanks. 1999 -2004 Crown Victoria fill valve allows 3000 psi of CNG to be received into the CNG fuel tanks (build date up to July 31, 2001). 3600 psi fill valves are installed on vehicles built after August 1, 2001. 1999 - 2000 MY has a manual back flow valve that will allow tank venting (special service tools required). Fill valves were changed over from manual backflow type to non-manual backflow type during the 2001 MY. All service replacement fill valves will be non-manual backflow type.. 3600 psi fill valves will allow refueling at 3000 psi pump. 3000 psi fill valve equipped vehicles cannot be refueled at 3600 psi pumps. This is because 3000 psi fill valves have slightly larger fittings. This fitting difference is so slight it is not visually detectable. Refer to pressure rating stamp on fill valve fitting (P30=3000 psi valve, P36=3600 psi valve). POSSIBLE SYMPTOMS Valve fails to completely close after refueling causing leakage (often the result of driver failing to replace the valve dust cover after refueling).
1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles March, 2004 3A - 3
LESSON 3A: DEDICATED CNG COMPONENTS Fuel Tanks
Overhead View of CNG Fuel Tanks (NGV2 Type in F150) COMPONENT FUNCTION To store pressurized CNG fuel. COMPONENT LOCATION F-Series At front of truck bed near passenger compartment and beneath vehicle at midship location. Crown Victoria In the trunk of the vehicle and beneath the rear of vehicle. E-Series Behind rear axle under vehicle and in the interior passenger compartment (with optional tank). DESCRIPTION AND OPERATION The tank used for natural gas is designed and manufactured to meet NGV 2 requirements . NGV 2-1 CNG tanks are made of high strength steel. NGV 2-2 CNG tanks consist of a metal liner reinforced with resin impregnated continuous filament. Crown Victoria tanks are rated for use at 3000 psi (build date before July 31, 2001). E & F-Series tanks are rated at 3600 psi (1999 - 2002). Fuel tank configurations vary between vehicle type and model year (MY). Refer to the vehicle service publications for information on specific vehicle and MY. POSSIBLE SYMPTOMS Fuel leaks caused by impact damage. Unreadable build date tag (requires tank replacement).
3A - 4
March, 2004
LESSON 3A: DEDICATED CNG COMPONENTS Solenoid Tank Valve 1
2 4
Solenoid Tank Valve - F-Series

Item 1 2 Description Solenoid Tank Valves Flexible Fuel Line Item 3 4 Fuel Tanks FTP Sensor & FTT Sensor Connecting Tee Description
COMPONENT FUNCTION Prevents or allows fuel flow from the fuel tank. COMPONENT LOCATION Fitted into the fuel tank assembly. DESCRIPTION AND OPERATION The solenoid tank valve is an electrically actuated valve that prevents fuel flow from the fuel tank when the ignition is off. When the ignition is turned on the solenoids receive voltage and are actuated, via the fuel pump relay. When this occurs, fuel is allowed to flow to the other components of the fuel system. The valve has a manual lock down feature. Refer to the service manual for specific operation of the manual lock down feature. In the event of a stuck valve, the valve has a manual override that can be activated with manual override tool 134-00050. However, use of the manual override damages the valve requiring it to be replaced.
March, 2004
3A - 5
LESSON 3A: DEDICATED CNG COMPONENTS Solenoid Tank Valve (continued)
1 5 2
4
Solenoid Tank Valve (Front and Rear Views)
Item 1 2 3 Description Rear of Solenoid Tank Valve Pressure Relief Device (PRD) Electro-Mechanical Solenoid
3
Art 3B-4
Item 4 5
Description Front of Solenoid Tank Valve Manual Lock Down
DESCRIPTION AND OPERATION (continued) WARNING: IF THE MANUAL OVERRIDE FEATURE MUST BE USED, THE COMPLETE VALVE MUST BE REPLACED. Dedicated CNG vehicles have a Pressure Relief Device (PRD) integrated into their solenoid valves. The PRD is a metal-alloy insert that will melt if the tank is exposed to temperatures in excess of 100 C (212 F). This will allow the pressure inside the tank to be relieved, in the event that the tank is exposed to a fire condition. WARNING: A CNG FUEL TANK THAT SHOWS SIGNS OF FIRE DAMAGE MUST BE REPLACED. POSSIBLE SYMPTOMS Stuck open - unable to relieve pressure in fuel system during vehicle service. Stuck closed - fuel unable to move from fuel tank into fuel system resulting in reduced range or no-start condition.
3A - 6
March, 2004
LESSON 3A: DEDICATED CNG COMPONENTS Fuel Tank Vent Box
Item 1
Description Upper Fuel Tank Rack
Item 2
Description Fuel Tank Vent Box
Dedicated E-Series Fuel Tank Vent Box

Item 1 Description E-Series Extended Range Fuel Tank Item 2 Description E-Series Vent Box
COMPONENT FUNCTION: Removes natural gas vapors from the upper tank rack assembly. COMPONENT LOCATION: Crown Victoria Contained on the upper tank rack assembly. E-Series Will be present on any fuel tanks located inside passenger compartment. DESCRIPTION AND OPERATION: The fuel tank vent box is required to prevent natural gas vapors from entering the passenger compartment. In the event of a leak, vapors would be vented below the vehicle outside the passenger and trunk compartment. POSSIBLE SYMPTOMS Leaks in the vent box may allow CNG vapor to escape into vehicle trunk and passenger compartment.
March, 2004
3A - 7
LESSON 3A: DEDICATED CNG COMPONENTS Fuel Lines
Typical CNG Fuel Line

Item 1 Description Stainless Steel Fuel Line Item 2 Description Flexible Fuel Line
COMPONENT LOCATION Fuel lines run from the fill to the fuel tanks and to the other components of the CNG system. COMPONENT FUNCTION Carries CNG fuel from the fuel tanks to the various components of the fuel system. DESCRIPTION AND OPERATION Fuel lines are stainless steel with o-ring sealed fittings (CNG O-rings are identified by a yellow stripe). They are burst rated at 22,500 psi. and are electrically conductive. A fuel line assembly consists of flexible hose and/or stainless steel seamless tubing, end fittings, and tube nuts. The hose is a conductive polytetrafluoroethylene (PTFE) liner reinforced with a stainless steel wire braided covering. The fittings are inserted into the hose ends and crimped into place. The stainless steel tubing contains end fittings which are brazed to the tube. There are high pressure fuel lines that are identified by either 1/4 inch or 3/8-inch outer diameter Low pressure fuel lines are identified by a 1/2-inch outer diameter. The low pressure fuel line has a quick-connect at one end for connection to the fuel rail. The other fittings used on the natural gas vehicle to connect fuel components are SAE o-ring face seal tube fittings. There are two end types: an o-ring face seal end and a straight thread end. On tee and elbow fittings, a washer and a positionable nut are provided to aid in orientation of the fitting. The fuel lines meet all United States and Canadian safety specification.
3A - 8
March, 2004
LESSON 3A: DEDICATED CNG COMPONENTS Fuel Lines (continued) WARNING: NEVER USE AFTERMARKET REPLACEMENT FUEL LINES. USE ONLY ORIGINAL EQUIPMENT REPLACEMENT LINE ASSEMBLIES. FORD FUEL LINES ARE DESIGNED TO MEET SAFETY REQUIREMENTS. AFTERMARKET FUEL LINES OR HOSES MAY NOT COMPLY WITH THIS DESIGN. FAILURE TO COMPLY COULD RESULT IN FIRE OR EXPLOSION.
POSSIBLE SYMPTOMS Leakage due to damage or incorrect installation. Leakage is most likely to occur in the area of fittings and connections.
March, 2004
3A - 9
LESSON 3A: DEDICATED CNG COMPONENTS Quarter-Turn Valve (1999-2003 Crown Victoria Dedicated CNG vehicles)
Quarter-turn Valve (Open and Closed Position)

Item 1 Description Quarter-Turn Valve (Closed Position) Item 2 Description Quarter-Turn Valve (Open Position)
COMPONENT FUNCTION Isolates the fuel tanks and solenoid tank valves from the rest of CNG fuel system. COMPONENT LOCATION Bottom of vehicle below passenger seat. DESCRIPTION AND OPERATION The quarter-turn valve isolates the fuel tanks from the rest of the fuel system. It is used during some service and diagnostic procedures. When the valve handle is parallel to the fuel line the valve is open and will allow natural gas to flow to the fuel system. When the valve handle is at a right angle to the fuel line the valve is closed, preventing natural gas flow to the fuel system. POSSIBLE SYMPTOMS Leakage due to damage or incorrect installation. Incorrect valve position will prevent fuel from flowing through fuel system.
3A - 10
March, 2004
LESSON 3A: DEDICATED CNG COMPONENTS Fuel Filters 1
CNG Fuel Filters

Item 1 Description Coalescent Filter Item 2 Description Fill Valve Filter
COMPONENT FUNCTION Removes liquid and particulate contaminates from the CNG fuel system. COMPONENT LOCATION Particulate Filter 1999-2001 E-Series, 1999-2004 F-Series and Crown Victoria Dedicated CNG Vehicles located at the rear of the fuel fill valve. Coalescent Filter Crown Victoria immediately before the pressure regulator in front of the left rear wheel. Coalescent Filter E&F Series behind the transmission crossmember. The fill valve filter removes small particles during vehicle fueling. The coalescent filter removes particles and moisture from the fuel before it reaches the regulator. Both filters have regular replacement intervals, refer to maintenance chart. The coalescent filter also has a regular draining interval to remove liquid. POSSIBLE SYMPTOMS Plugged or partially plugged fuel fill valve filter may result in slow or no refueling capability. Plugged coalescent filter element will result in no start/no run condition. Partially plugged coalescent filter element may result in rough engine operation.
1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles March, 2004 3A - 11
LESSON 3A: DEDICATED CNG COMPONENTS High Pressure Regulator 5
4
High Pressure Regulator
Item 1 2 3 Description Thermostat 370 C (1000 F) Coolant Outlet Coolant Inlet Item 4 5 Description Low Pressure Fuel Outlet High Pressure Fuel Inlet (not shown)
COMPONENT FUNCTION Delivers CNG at nominal pressure for metering by fuel injectors. COMPONENT LOCATION Crown Victoria immediately after coalescent filter in front of the left rear wheel. F-Series left-hand frame rail near transmission crossmember. E-Series left-hand frame rail near transmission crossmember. DESCRIPTION AND OPERATION CNG is delivered to the regulator at fuel system pressure. The single-stage regulator reduces fuel pressure to a nominal 100 psi. Engine coolant is circulated through the regulator to prevent icing that may be caused when the fuel pressure is reduced. The regulated fuel then moves to the fuel injectors for metering and distribution.
3A - 12
March, 2004
LESSON 3A: DEDICATED CNG COMPONENTS High Pressure Regulator (continued)

POSSIBLE SYMPTOMS Possible engine coolant leak point. Damaged o-ring may result in CNG leak. Damaged regulator mechanism may result in a rough run/no run condition. Regulator icing may be the result of a stuck closed thermostat.
March, 2004
3A - 13
LESSON 3A: DEDICATED CNG COMPONENTS Fuel Injection Supply Manifold 2
Fuel Injection Supply Manifold (Crown Victoria Shown)

Item 1 2 Description Fuel Injection Supply Manifold Engine Fuel Temperature (EFT) Sensor Item 3 4 Description Fuel Rail Shutoff Solenoid Fuel Rail Pressure (FRP) Sensor
COMPONENT FUNCTION: Supplies fuel from the fuel pressure regulator to the fuel injectors. COMPONENT LOCATION: Top of engine. DESCRIPTION AND OPERATION: The fuel injection supply manifold is similar to the gasoline fuel injection supply manifold. Unique components of the CNG supply manifold include: Eight bolts mount the fuel injection supply. Elimination of the fuel return tube. Mounting ports for the: engine fuel temperature (EFT) sensor fuel rail pressure (FRP) sensor fuel rail shut-off solenoid A Schrader valve for test equipment connection (vehicle and MY dependent).
3A - 14 March, 2004 1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles
LESSON 3A: DEDICATED CNG COMPONENTS Fuel Injection Supply Manifold (continued)
POSSIBLE SYMPTOMS Damaged o-rings may result in CNG leak CNG odor in engine and possibly passenger compartments.
March, 2004
3A - 15
LESSON 3A: DEDICATED CNG COMPONENTS Fuel Injectors 1
Gasoline and CNG Fuel Injectors

Item 1 2 D escription C NG Fuel Injector wi th Aqua C olored C ap C NG Fuel Injector Nozzle (si ngle large openi ng) Item 3 4 D escription Gasoli ne Fuel Injector Nozzle (muli ple small openi ngs) Gasoli ne Fuel Injector
COMPONENT FUNCTION: Meters the fuel going into the engine combustion chambers. COMPONENT LOCATION: Top of engine cylinder heads. DESCRIPTION AND OPERATION: The fuel injectors used on dedicated CNG are high-flow type (95 lb. per hr.) that were originally designed for use on Indy race cars. CNG injectors can often be identified by the aqua-colored cap on the injector body, however some dedicated CNG injectors installed after the 2000 model year may also be gray. CNG injectors can always be identified by the size of the injection nozzles. It is a single large nozzle, compared to the multiple small openings that are used on gasoline injectors nozzles.
3A - 16 March, 2004 1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles
LESSON 3A: DEDICATED CNG COMPONENTS Fuel Injectors (continued)

DESCRIPTION AND OPERATION (continued) The injectors are pulse width modulated (PWM) using signals sent from the PCM via the AFCM. Because of the higher pressure and increased fuel flow requirements of CNG fuel, electrical resistance of the injectors (4.5 ohms) is significantly lower than that of conventional gasoline injectors (14.5 ohms). Because of the higher current draw of these injectors, a separate injector driver (AFCM) module is required. The fuel injectors are cycled open (ON) and closed (OFF) to deliver a calculated amount of fuel at the intake valve. Since fuel pressure is constant across all engine loads, only the length of time the injectors are open determines the amount of fuel injected. Because of the high working pressure of CNG and its physical properties, CNG injectors make more noise than gasoline injectors. POSSIBLE SYMPTOMS Damaged o-rings may result in CNG leak. Clogged injectors can cause a hard start/no start condition. Engine miss/rough operation can result from individual injector malfunctions. Fuel injector concerns can be diagnosed with the Power Balance Test to identify a suspect cylinder, then a Noid light can be used to verify the signal from the PCM. Also an injector tester (part of special tool kit) can be applied to diagnosis.
March, 2004
3A - 17
CNG FUEL SYSTEM CONTROL MODULES AND INPUT/OUTPUT DEVICES

Microprocessors have not only changed the way that vehicles operate, but they have also changed the expectations of the average consumer. Before the advent of the microprocessor, most people considered 100,000 miles to be the maximum life expectancy of the powertrain on a car or truck. However, on modern vehicles they have come to expect a vehicles powertrain to last 200,000 miles and more! How has this dramatic increase in powertrain life expectancy been accomplished? The microprocessor! On todays vehicles the powertrain control module (PCM) automatically adjusts the operation of the vehicle to not only meet the operating requirements of the conditions and driver, but it also adjusts the operation to compensate for normal component age and wear. This results in a vehicle that not only lasts longer, but also runs better with less maintenance over its operating life. For this reason it is essential that modern service technicians understand the operation of vehicle control modules and how they control powertrain operation. All control modules use input devices to monitor vehicle operating conditions. The signals received by these devices determine the modules operating strategy. The control module then modifies vehicle operation by sending control signals to vehicle output devices. The following is a description of dedicated CNG vehicle control modules and their input/output devices.
3A - 18
March, 2004
LESSON 3A: DEDICATED CNG COMPONENTS Inputs and Outputs Chart
INPUTS
Engine Fuel Temperature (EFT) Sensor
OUTPUTS
Fuel Pump Relay
Fuel Rail Pressure (FRP) Sensor
POWERTRAIN CONTROL MODULE (PCM)
Fuel Rail Shutoff Solenoid/Fuel Tank Solenoid Valves
Injector Input Signals Sent Via Hardwired Circuits (1 circuit per injector)
Signals Sent Via the J1850 Network
Fuel Tank Pressure (FTP) Sensor Fuel Tank Temperature (FTT) Sensor (upper rack) Fuel Tank Temperature (FTT) Sensor (lower rack)
Fuel Injectors
ALTERNATIVE FUEL CONTROL MODULE (AFCM)
Fuel Gauge
Low Fuel Indicator Lamp
March, 2004
3A - 19
LESSON 3A: DEDICATED CNG COMPONENTS Powertrain Control Module (PCM)
Powertrain Control Module (PCM) COMPONENT FUNCTION: The Powertrain Control Module (PCM) is an on-board microprocessor that controls the operation of vehicle powertrain components. COMPONENT LOCATION: Varies with vehicle. Refer to EVTM for location on specific models. DESCRIPTION AND OPERATION: The PCM on a dedicated CNG fueled vehicle operates in the same manner as on a conventional gasoline fueled vehicle. The PCM receives input information from various sensors on the vehicle that indicate the operating conditions of the vehicle. The PCM then uses pre-programmed calibrations to determine what actions need to be taken to maintain optimal vehicle operation. The PCM then commands various devices to modify vehicle operation as required to maintain optimal vehicle operation. POSSIBLE SYMPTOMS Symptoms of PCM concerns can range from no-start to incorrect operation of any PCM controlled system.
3A - 20
March, 2004
LESSON 3A: DEDICATED CNG COMPONENTS Unique CNG PCM Input Devices
Unique CNG PCM Inputs

Item 1 Description Engine Fuel Temperature (EFT) Sensor Item 2 Description Fuel Rail Pressure (FRP) Sensor
Dedicated CNG vehicles have many of the input and output devices that are normally found on a gasoline fueled vehicle. These inputs and outputs operate in the conventional manner and perform the same functions as they would on gasoline fueled vehicles. However, for this training course, we will focus only on those devices that are unique to the dedicated CNG fueled vehicles. Unique CNG Inputs to the PCM Engine Fuel Temperature (EFT) Sensor (2-wire) (also known as the Fuel Rail Temperature (FRT) Sensor) The EFT sensor monitors fuel temperature in the fuel injection supply manifold. The PCM uses the temperature indications for fuel control calculations. Some vehicles have two temperature sensors. This will vary by model and year. Fuel Rail Pressure (FRP) Sensor (3-wire) Monitors the fuel pressure in the fuel rail. This data is used by the PCM for fuel control calculations.
March, 2004
3A - 21
LESSON 3A: DEDICATED CNG COMPONENTS Unique CNG Outputs of the PCM
2 1
Unique CNG PCM Outputs

Item 1 Description Fuel Relay/Fuel Tank Solenoid Valve Relay Item 2 Description Fuel Rail Shutoff Solenoid
Fuel Relay/Fuel Tank Solenoid Valve Relay The fuel tank solenoid valve relay is identified as the FUEL PUMP RELAY on the vehicle relay cover. When the key is in the off position, the relay is open and power to the fuel tank solenoid valves and the fuel rail shutoff solenoid is interrupted. This isolates the fuel in the fuel tanks when the key is in the OFF position. When the key is turned ON, the relay closes, allowing power to the fuel tank solenoid valves and the fuel rail shutoff solenoid, causing them to open. The inertia shutoff switch is also on this circuit and can cause the valves and solenoid to close in the event of an accident. Fuel Rail Shutoff Solenoid The fuel rail shutoff solenoid isolates the fuel rail from the upstream fuel system when the engine is not operating. This minimizes the amount of fuel available to flow through the fuel injectors when the vehicle is off. It also limits the amount of fuel that can escape through the fuel rails in the event of an accident that causes fuel rail damage. During initial key ON, the valve will open for one second and then close again if the PCM does not detect a PIP signal that indicates the engine is being cranked or is running.
3A - 22
March, 2004
LESSON 3A: DEDICATED CNG COMPONENTS 60-Pin Alternative Fuel Control Module (AFCM)
Typical 60-Pin Alternative Fuel Control Module (AFCM)

Item 1 Description 60-Pin Alternative Fuel Control Module (AFCM)
COMPONENT FUNCTION: Acts as a relay, using the low amperage signal from the PCM to turn on the high amperage injector circuit. Converts signals from various inputs into a fuel level voltage signal for use by the fuel gauge. COMPONENT LOCATION: F-Series and Crown Victoria On front radiator support E-Series Left side of engine compartment DESCRIPTION AND OPERATION: The AFCM performs two separate functions: The injector driver function acts as a relay. It uses low-amperage PCM signals to control the highamperage injector driver output required to activate the fuel injectors. This is necessary to operate the fuel injectors at the higher operating pressures of natural gas. The AFCM performs no fuel delivery calculations. Fuel level calculations are made by the AFCM based on the data received from two fuel tank rack temperature sensors (2001 MY and earlier) and the fuel tank pressure sensor. The module then outputs the fuel level signal as a voltage to the fuel gauge.
POSSIBLE SYMPTOMS No-start/hard-start condition. Rough engine operation.
March, 2004
3A - 23
LESSON 3A: DEDICATED CNG COMPONENTS 90-Pin Alternative Fuel Control Module (AFCM)
90-Pin Alternative Fuel Control Module (AFCM)

Item 1 Description 90-Pin Alternative Fuel Control Module (AFCM)
COMPONENT FUNCTION: Acts as a relay, using the low amperage signal from the PCM to turn on the high amperage injector circuit. Converts signals from various inputs into a fuel level voltage signal for use by the fuel gauge. Monitors input and output devices for correct operation and stores DTCs. COMPONENT LOCATION: 2004 E-Series Left side of engine compartment DESCRIPTION AND OPERATION: The 90-Pin AFCM:
acts as a relay, using the low amperage signal from the PCM to turn on the high amperage CNG injector circuit. translates fuel tank pressure and temperature signals into fuel level indications for the fuel gauge. monitors injector operation for faults. stores many more DTCs than the 60-pin AFCM.
POSSIBLE SYMPTOMS No-start/hard-start condition. Rough engine operation.
3A - 24
March, 2004

Alternative Fuel Control Module (AFCM) Inputs
AFCM Inputs
Item 1 2 Description Solenoid Tank Valve Fuel Tank Temperature (FTT) Sensor Item 3 4 Description Fuel Tank Pressure (FTP) Sensor Fuel Tanks
Fuel Tank Pressure Sensor Crown Victoria The fuel tank pressure sensor is located on the upper rack assembly. E & F-series - May be mounted on the solenoid connecting tee, which in turn mounts to the solenoid tank valve. Also may be mounted on the coalescent filter or pressure regulator (configuration is vehicle and MY dependent). The pressure data it provides are used by the AFCM for fuel indication calculations. Fuel Tank Temperature Sensors Crown Victoria there is a Fuel Tank Temperature (FTT) sensor for the tanks mounted outside the vehicle and a FTT sensor for the tanks mounted inside the vehicle . E & F Series Mounted on the solenoid connecting tee, which in turn mounts to the solenoid tank valve. The sensor provides data for AFCM fuel indication calculations.
March, 2004
3A - 25
LESSON 3A: DEDICATED CNG COMPONENTS AFCM Outputs
3 2
AFCM Outputs
Item 1 2 Fuel Gauge Low Fuel Indicator Lamp Description Item 3 4 Description CNG Fuel Injector Fuel Rail
Fuel Injectors The natural gas fuel injectors are similar to gasoline injectors. However, in some ways they are unique. Natural gas injectors deliver a larger volume of fuel to the cylinders. This is required since CNG is a vapor and is not as energy dense as gasoline. The injectors have a higher noise level than gasoline injectors. This is due to the higher working pressure of the injectors and because of the physical properties of natural gas. CNG injectors can be identified by their aqua color cap (MY dependent) and by their larger size in comparison to gasoline injectors.
Fuel Gauge The fuel gauge on a dedicated CNG fueled vehicle is similar in appearance to a fuel gauge on a gasoline fueled vehicle. CNG fuel level indications are based on the calculations of the AFCM. Using signals from the fuel tank pressure and fuel tank temperature sensors, the AFCM sends a voltage signal to the fuel gauge. The amount of voltage received determines the position of the fuel quantity needle on the face of the gauge, giving the driver a visual cue of the amount of fuel in the tanks. Low Fuel Indicator Lamp When the fuel level drops to between 1/8 and 1/16 of a tank the AFCM will illuminate the low fuel indicator lamp, providing the driver a reminder of the vehicle fuel status.
3A - 26
March, 2004
ACTIVITY 3A
ACTIVITY 3A
OBJECTIVES
CONTENTS
Activity 3A - Worksheet I (Hands-On) Activity 3A - Worksheet J (Hands-On) Activity 3A - Worksheet K (Written) Activity 3A - Worksheet L (Written)
Reinforce the knowledge that the student has acquired from Lessons 1, 2A, and 3A. Allow the student to review detailed information found in Lessons 1,2A, and 3A. Allow the student to locate and identify Dedicated CNG vehicle fuel system components.
March, 2004
3A - 27
ACTIVITY 3A ACTIVITY 3A WORKSHEET I (Hands-On) DEDICATED CNG FUEL SYSTEM COMPONENT IDENTIFICATION STUDENT ANSWER SHEET
Directions: Using the information in your Student Reference Guide and the service publications provided, go to the dedicated CNG classroom vehicle and answer the following questions. 1. The following are descriptions of component functions. The components that perform these functions have been tagged by your instructor with letters/numbers. Read the function description provided then locate the component that performs that function and note the letter/number and component name in the space provided.
TAG LETTER/NUMBER
COMPONENT NAME
COMPONENT DESCRIPTION Removes particulate and water contamination from the CNG fuel system Meters the fuel going into the engine combustion chambers Sends voltage to the solenoid tank valve when the key is in the ON position Monitors fuel temperature in the supply manifold Carries fuel from the fuel tank to the pressure regulator Contains a pressure relief device Converts low-amperage signals to high-amperage signals for use by the fuel injectors Provides the PCM with pressure indications for fuel control calculations Provides the AFCM with pressure information Interrupts fuel flow in the fuel rails when the engine is not operating May have a manual backflow feature Converts fuel tank pressure into usable pressure for the injectors
END OF WORKSHEET
3A - 28
March, 2004
ACTIVITY 3A ACTIVITY 3A - WORKSHEET J DEDICATED CNG NGS OPERATION STUDENT ANSWER SHEET
Directions: Using the information you have learned from the NGS Web-Based Training Course, and the NGS Appendix found at the rear of this student guide, go to the dedicated CNG classroom vehicle and answer the following questions.. 1. In the AFCM module, select the PIDs listed in the table below for viewing. Start the vehicle and allow it to idle while viewing these PIDs. Note what data are being displayed for each PID. Refer to the service manual supplement and note the meaning of the data displayed.
PID GAGDRIVE TANK PR TMPSN1 TMPSN2
DATA DISPLAYED
READING AT IDLE
2. Perform the following steps while viewing the PIDs listed in Question 1.
While viewing the PIDs, raise the engine rpm to 2000 (monitor with NGS RPM PID) Press trigger to capture data, then allow the vehicle to run for 20 seconds. Save the data in area 3 of the NGS memory. Shut the vehicle off.
3. View the recording in the TABLE mode. What is the highest + time recorded on the display? ______________________________________________________________________________ 4. Press the RWD button. What occurs? _________________________________________________ 5. Press the PLAY button. What occurs?_________________________________________________ 6. Exit the TABLE mode and select the GRAPH mode. Which two PIDs are displayed? ______________________________________________________________________________ 7. Press the 2 button. What occurs? ____________________________________________________ 8. Press the 9 button. What occurs? _____________________________________________________ 9. Press the 8 button. What occurs?______________________________________________________ 10. Press the 3 button. What occurs? ____________________________________________________
END OF WORKSHEET
March, 2004
3A - 29
ACTIVITY 3A ACTIVITY 3A WORKSHEET K (Written) DEDICATED CNG FUEL SYSTEM COMPONENT LOCATION STUDENT ANSWER SHEET
Directions: Using the information you have learned from the prerequisite courses and your Student Reference Guide, answer the following questions. 1. What is the service life of a fuel tank? ________________________________________________ PAGE#_______ 2. What is a visual indication that a fuel injector is made for use with CNG? _________________________________________________________________________________________________ PAGE#_______ 3. List the valves and sensors that are mounted to the fuel injection supply manifold. _______________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ PAGE#_______ 4. In the event a solenoid tank valve is stuck closed, what should be used to vent the fuel tanks? _________________________________________________________________________________________________ What must be done if this action is performed? _________________________________________________________________________________________________ PAGE#_______ 5. When the quarter-turn valve handle is at a right angle to the fuel line, the valve is (circle one) OPEN OR CLOSED. PAGE#_______ 6. How are the o-rings used to seal fuel lines identified? ____________________________________ PAGE#_______ 7. The following is a list of inputs and outputs. In the appropriate space, note if they are an input or output and the control module with which they work.
COMPONENT NAME Fuel Pump Relay Fuel Injectors FRP Sensor FTP Sensor EFT Sensor Fuel Gauge
INPUT OR OUTPUT
CONTROL MODULE
END OF WORKSHEET
3A - 30
March, 2004
ACTIVITY 3A ACTIVITY 3A WORKSHEET L (Written) DEDICATED CNG FUEL SYSTEM COMPONENT LOCATION STUDENT ANSWER SHEET
Directions: Using the information you have learned and your Student Reference Guide, answer the following questions. 1. List two base vehicle components that are changed in order to ensure that CNG vehicles have the same service life and handling characteristics as a conventional vehicle. _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ PAGE#_______ 2. What is the physical difference between 3000 and 3600 psi. fuel fill valves? _________________________________________________________________________________________________ _________________________________________________________________________________________________ PAGE#_______ 3. What is the burst rating of CNG fuel lines? _____________________________________________ PAGE#_______ 4. What two sensors are used on dedicated CNG vehicles for fuel level calculations? _________________________________________________________________________________________________ PAGE#_______ 5. On a E-series, what is the pressure of the CNG fuel between the fuel tank and the coalescent filter _________________________________________________________________________________________________ PAGE#_______ 6. On a Crown Victoria what is the pressure of the CNG fuel when it leaves the pressure regulator? _________________________________________________________________________________________________ PAGE#_______
CONTINUED ON NEXT PAGE
March, 2004
3A - 31
ACTIVITY 3A ACTIVITY 3A WORKSHEET L (Written) DEDICATED CNG FUEL SYSTEM COMPONENT LOCATION STUDENT ANSWER SHEET (continued)
7. What is the electrical resistance of a CNG fuel injector? ___________________________________ PAGE#_______ 8. At what temperature will the PRD melt on a CNG solenoid tank valve? _______________________ PAGE#_______ 9. At what temperature will the thermostat in the pressure regulator close? ______________________ PAGE#_______ 10. What are the symptoms of a vent box leak on a CNG Crown Victoria? _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ PAGE#_______
END OF WORKSHEET
3A - 32
March, 2004
LESSON 3B: MULTIPORT BI-FUEL COMPONENTS

OBJECTIVES
CONTENTS
Introduction To Multiport Bi-Fuel CNG Components CNG Fuel Fill Valve Fuel Tanks Solenoid Tank Valve Fuel Lines Fuel Filters High Pressure Regulator Fuel Injection Supply Manifolds Fuel Injectors CNG Fuel System Control Modules And Input/ Output Devices Inputs and Outputs Chart Powertrain Control Module (PCM) Unique CNG PCM Input Devices Unique CNG Outputs of the PCM Alternative Fuel Control Module (AFCM) AFCM Outputs
Identify advantages of Multiport Bi-Fuel CNG vehicles. Explain unique Multiport Bi-Fuel components. Describe changes to base vehicle components on Multiport Bi-Fuel CNG vehicles. Explain changes to Multiport Bi-Fuel CNG vehicle operating strategies.
March, 2004
3B - 1
MULTIPORT BI-FUEL CNG VEHICLE COMPONENTS
Multiport Bi-Fuel CNG/Gasoline Vehicle This lesson will provide information on the unique components and systems of Multiport Bi-Fuel CNG vehicle components. The vehicles covered in this lesson include: F-Series light trucks with Multiport bi-fuel CNG and gasoline fuel systems.
3B - 2
March, 2004
LESSON 3B: MULTIPORT BI-FUEL CNG COMPONENTS CNG Fuel Fill Valve
1 2
CNG Fill Valve

Item 1 Description CNG Fill Valve Item 2 Description Pressure Stamp
COMPONENT FUNCTION Enables vehicle to receive CNG fuel. COMPONENT LOCATION Beneath the fuel fill door in front of the gasoline fuel fill opening of the pickup box. DESCRIPTION AND OPERATION 3600 psi fill valves will allow refueling at both 3600 and 3000 psi pumps. This is because 3600 psi fill valves have slightly larger fittings. This fitting difference is so slight it is not visually detectable. Refer to pressure rating stamp on fill valve fitting. Bi-fuel CNG fill valves have a backflow check valve that is visible at the opening. There is also a replaceable o-ring located in the valve opening. This o-ring should be replaced according to the maintenance schedule . POSSIBLE SYMPTOMS Valve fails to completely close after refueling causing leakage (often the result of driver failing to replace the valve dust cover after refueling). O-ring damage may cause leakage during refueling.
March, 2004
3B - 3
LESSON 3B: MULTIPORT BI-FUEL CNG COMPONENTS Fuel Tanks
CNG Fuel Tank (NGV2 Type 1 in Multiport F150) COMPONENT FUNCTION To store pressurized CNG fuel. COMPONENT LOCATION At front of truck bed near passenger compartment. DESCRIPTION AND OPERATION The tank used for natural gas is designed and manufactured to meet NGV 2 requirements . NGV 2-1 CNG tanks are made of high strength steel. NGV 2-2 CNG tanks consist of a metal liner reinforced with resin impregnated continuous filament. Multiport Bi-Fuel CNG Vehicle CNG fuel tank is NGV2-1 and are rated at 3600 psi. POSSIBLE SYMPTOMS Fuel leaks caused by impact damage. Unreadable build date tag (requires tank replacement). Any tank exposed to open flame must be replaced.
3B - 4
March, 2004
LESSON 3B: MULTIPORT BI-FUEL CNG COMPONENTS Solenoid Tank Valve
4 1
3
Solenoid Tank Valve - F-Series
Item 1 2 Description CNG Fuel Tank Solenoid Tank Valve Item 3 4 Description Solenoid Tank Valve Connector Flexible Fuel Line
COMPONENT FUNCTION Prevents or allows fuel flow from the fuel tank. COMPONENT LOCATION Fitted into the fuel tank assembly. DESCRIPTION AND OPERATION The solenoid tank valve is an electrically actuated valve that prevents fuel flow from the fuel tank when the ignition is off. When the ignition is turned on the solenoid receives voltage and are actuated (opened), via the ALT fuel relay. When this occurs, fuel is allowed to flow to the other components of the fuel system. The valve has a manual lock down feature. Refer to the service manual for specific operation of the manual lock down feature. In the event of a stuck valve, the valve has a manual override that can be activated with manual override tool 134-00050. However, use of the manual override damages the valve requiring it to be replaced.
March, 2004
3B - 5
LESSON 3B: MULTIPORT BI-FUEL CNG COMPONENTS Solenoid Tank Valve (continued)
1 5 2
4
Solenoid Tank Valve (Front and Rear Views)
Item 1 2 3 Description Rear of Solenoid Tank Valve Pressure Relief Device (PRD) Electro-Mechanical Solenoid
3
Art 3B-4
Item 4 5
Description Front of Solenoid Tank Valve Manual Lock Down
DESCRIPTION AND OPERATION (continued) WARNING: IF THE MANUAL OVERRIDE FEATURE MUST BE USED, THE COMPLETE VALVE MUST BE REPLACED. Multiport Bi-Fuel CNG Vehicles have a Pressure Relief Device (PRD) integrated into their solenoid valves. The PRD is a metal-alloy insert that will melt if the tank is exposed to temperatures in excess of 100 C (212 F). This will allow the pressure inside the tank to be relieved, in the event that the tank is exposed to a fire condition. WARNING: A CNG FUEL TANK THAT SHOWS SIGNS OF FIRE DAMAGE MUST BE REPLACED. POSSIBLE SYMPTOMS Stuck open - unable to relieve pressure in fuel system during vehicle service. Stuck closed - fuel unable to move from fuel tank into fuel system resulting in reduced range or no-start condition.
3B - 6
March, 2004
LESSON 3B: MULTIPORT BI-FUEL CNG COMPONENTS CNG Fuel Lines
Typical CNG Fuel Lines

Item 1 Description Stainless Steel Fuel Line Item 2 Description Flexible Fuel Line
COMPONENT LOCATION Fuel lines run from the fill to the fuel tanks and to the other components of the CNG system. COMPONENT FUNCTION Carries CNG fuel from the fuel tanks to the various components of the fuel system. DESCRIPTION AND OPERATION Fuel lines are stainless steel with o-ring sealed fittings (CNG O-rings are identified by a yellow stripe). They are burst rated at 22,500 psi. and are electrically conductive. A fuel line assembly consists of flexible hose and/or stainless steel seamless tubing, end fittings, and tube nuts. The hose is a conductive polytetrafluoroethylene (PTFE) liner reinforced with a stainless steel wire braided covering. The fittings are inserted into the hose ends and crimped into place. The stainless steel tubing contains end fittings which are brazed to the tube. There are high pressure fuel lines that are identified by either 1/4 inch or 3/8-inch outer diameter Low pressure fuel lines are identified by a 1/2-inch outer diameter. The low pressure fuel line has a quick-connect at one end for connection to the fuel rail. The other fittings used on the natural gas vehicle to connect fuel components are SAE o-ring face seal tube fittings. There are two end types: an o-ring face seal end and a straight thread end. On tee and elbow fittings, a washer and a positionable nut are provided to aid in orientation of the fitting. The fuel lines meet all United States and Canadian safety specification.
1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles March, 2004 3B - 7
LESSON 3B: MULTIPORT BI-FUEL CNG COMPONENTS CNG Fuel Lines (continued) WARNING: NEVER USE AFTERMARKET REPLACEMENT FUEL LINES. USE ONLY ORIGINAL EQUIPMENT REPLACEMENT LINE ASSEMBLIES. FORD FUEL LINES ARE DESIGNED TO MEET SAFETY REQUIREMENTS. AFTERMARKET FUEL LINES OR HOSES MAY NOT COMPLY WITH THIS DESIGN. FAILURE TO COMPLY COULD RESULT IN FIRE OR EXPLOSION.
POSSIBLE SYMPTOMS Leakage due to damage or incorrect installation. Leakage is most likely to occur in the area of fittings and connections.
3B - 8
March, 2004
LESSON 3B: MULTIPORT BI-FUEL CNG COMPONENTS Coalescent Filter
2
Disassembled Coalescent Filter
Item 1 Description Coalescent Filter Housing Item 2 Description Paper Filter Element
COMPONENT FUNCTION Removes liquid and particulate contaminates from the CNG fuel system. COMPONENT LOCATION Behind the transmission crossmember. DESCRIPTION AND OPERATION The coalescent filter uses a paper filter element to remove particles and moisture from the fuel before it reaches the regulator. The coalescent filter has a regular draining interval to remove liquid. The paper filter element must be replaced at specified maintenance intervals, refer to the vehicle owners manual for specified intervals. POSSIBLE SYMPTOMS Plugged coalescent filter element will result in no start/no run condition. Partially plugged coalescent filter element may result in rough engine operation.
March, 2004
3B - 9
LESSON 3B: MULTIPORT BI-FUEL CNG COMPONENTS High Pressure Regulator 5
3 2
High Pressure Regulator

Item 1 2 3 Description Fuel Inlet (from Coalescent Filter) Engine Coolant Lines Fuel Tank Pressure ( FTP) Sensor Item 4 5 Description Pressure Relief Discharge Vent Fuel Outlet
COMPONENT FUNCTION Delivers CNG at nominal pressure for metering by fuel injectors. COMPONENT LOCATION At right front of engine compartment DESCRIPTION AND OPERATION CNG is delivered to the regulator at fuel system pressure. The single-stage regulator reduces fuel pressure to a nominal 100 psi. Engine coolant is circulated through the regulator to prevent icing that may be caused when the fuel pressure is reduced. The regulated fuel then moves to the fuel injectors for metering and distribution. POSSIBLE SYMPTOMS Possible engine coolant leak point. Damaged o-ring may result in CNG leak. Damaged regulator mechanism may result in a rough run/no run condition. Regulator icing may be the result of a stuck closed thermostat.
3B - 10 March, 2004 1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles
LESSON 3B: MULTIPORT BI-FUEL CNG COMPONENTS CNG Fuel Injection Supply Manifold
CNG Fuel Injection Supply Manifold

Item 1 Description CNG Fuel Injection Supply Manifold Item 2 Description CNG Fuel Injector
COMPONENT FUNCTION: Supplies fuel from the CNG fuel pressure regulator to the CNG fuel injectors. COMPONENT LOCATION: Top of engine. DESCRIPTION AND OPERATION: The CNG and gasoline fuel injection supply manifolds run next to each other on top of the engine. Unique components of the CNG supply manifold include: Eight bolts mount the fuel injection supply. Elimination of the fuel return tube. Mounting ports for the: fuel rail temperature (FRT) sensor fuel rail pressure (FRP) sensor fuel rail shutoff solenoid POSSIBLE SYMPTOMS Damaged o-rings may result in CNG leak CNG odor in engine and possibly passenger compartments. Damaged gasket may result in vacuum leak which would result in rough running and possible DTC.
March, 2004
3B - 11
LESSON 3B: MULTIPORT BI-FUEL CNG COMPONENTS Gasoline Fuel Injection Supply Manifold
Gasoline Fuel Injection Supply Manifold

Item 1 Description Gasoline Fuel Injection Supply Manifold Item 2 Description Gasoline Fuel Injector
COMPONENT FUNCTION: Supplies fuel from the gasoline fuel pump to the gasoline fuel injectors. COMPONENT LOCATION: Top of engine. DESCRIPTION AND OPERATION: The CNG and gasoline fuel injection supply manifolds run next to each other on top of the engine. The gasoline fuel injection supply manifold operates in the same manner as the manifold on a conventional gasoline-fueled vehicle. POSSIBLE SYMPTOMS Damaged o-rings may result in gasoline leak. Damaged gasket may result in vacuum leak which would result in rough running and possible DTC. Gasoline odor in engine and possibly passenger compartments.
3B - 12
March, 2004
LESSON 3B: MULTIPORT BI-FUEL CNG COMPONENTS CNG and Gasoline Fuel Injectors 1
Gasoline and CNG Fuel Injectors

Item 1 2 Description CNG Fuel Injector with Aqua Colored Cap CNG Fuel Injector Nozzle (single large opening) Item 3 4 Description Gasoline Fuel Injector Nozzle (multiple small openings) Gasoline Fuel Injector
COMPONENT FUNCTION: Meters the fuel going into the engine combustion chambers. COMPONENT LOCATION: Top of fuel injection supply manifolds (CNG injectors on CNG manifold, gasoline on gasoline manifold). DESCRIPTION AND OPERATION: Conventional gasoline injectors are used for gasoline delivery on Multiport Bi-Fuel CNG Vehicles. CNG fuel injectors are high-flow type (95 lb. per hr.) that were originally designed for use on Indy race cars. CNG injectors can often be identified by the aqua-colored cap on the injector body, however some CNG injectors may also be gray.
LESSON 3B: MULTIPORT BI-FUEL CNG COMPONENTS CNG and Gasoline Fuel Injectors (continued)
Fuel Injectors (in-vehicle view)

Item 1 Description CNG Injector Item 2 Description Gasoline Injector
DESCRIPTION AND OPERATION (continued) CNG injectors can always be identified by the size of the injection nozzles. It is a single large nozzle, compared to the multiple small openings that are used on gasoline injectors nozzles. CNG injectors are pulse width modulated (PWM) using signals sent from the PCM via the AFCM. Because of the higher pressure and increased fuel flow requirements of CNG fuel, electrical resistance of the injectors (4.5 ohms) is significantly lower than that of the gasoline injectors (14.5 ohms). Because of the higher current draw of these injectors, a separate injector driver (AFCM) module is required. The fuel injectors are cycled open (ON) and closed (OFF) to deliver a calculated amount of fuel at the intake valve. Since CNG fuel pressure is constant across all engine loads, only the length of time the CNG injectors are open determines the amount of fuel injected. Because of the high working pressure of CNG and its physical properties, CNG injectors make more noise than the gasoline injectors. POSSIBLE SYMPTOMS Damaged o-rings may result in CNG or gasoline leak. Clogged injectors can cause a hard start/no start condition on the fuel system being used. Engine miss/rough operation can result from individual injector malfunctions. Fuel injector concerns can be diagnosed with the Power Balance Test to identify a suspect cylinder, then a Noid light can be used to verify the signal from the PCM. Also an injector tester (part of special tool kit) can be applied to diagnosis.
3B - 14
March, 2004
CNG FUEL SYSTEM CONTROL MODULES AND INPUT/OUTPUT DEVICES

Multiport Bi-Fuel CNG Vehicles have a unique control system that utilizes both the PCM and the AFCM to meter either CNG or gasoline to the engine. These control modules depend on input devices to monitor vehicle operating conditions. The signals received by these devices determine both modules operating strategies. Based on the information received from the inputs, the PCM and AFCM work together to modify vehicle operation by sending control signals to vehicle output devices. The following is a description of Multiport Bi-Fuel CNG Vehicle control modules and their input/output devices.
March, 2004
3B - 15
INPUTS
Inputs and Outputs Chart
OUTPUTS
AFCM
AFCM VSS IAT EGR
POWERTRAIN CONTROL MODULE (PCM)
Spark Advance
MIL
Injector Input Signals Sent Via Hardwired Circuits (1 circuit per injector)
Signals Sent Via the J1850 (SCP) Network
PCM Gasoline Fuel Injectors CNG Fuel Injectors ALT Fuel Relay Fuel Rail Shutoff Solenoid/Fuel Tank Solenoid Valve Gasoline Fuel Pump Relay HEC Module Fuel Gauge (CNG or gasoline) Low Fuel Indicator Light Fuel Selector Light
PCM
Gasoline Fuel Level Signal ALT/GAS Switch
Fuel Rail Pressure (FRP) Sensor Fuel Rail Temperature (FRT) Sensor Fuel Tank Pressure (FTP) Sensor
ALTERNATIVE FUEL CONTROL MODULE (AFCM)
3B - 16
March, 2004
LESSON 3B: MULTIPORT BI-FUEL CNG COMPONENTS Powertrain Control Module (PCM)
Powertrain Control Module (PCM) COMPONENT FUNCTION: The Powertrain Control Module (PCM) is an on-board microprocessor that controls the operation of vehicle powertrain components. COMPONENT LOCATION: Lower right hand side of engine compartment in bulkhead. DESCRIPTION AND OPERATION: The PCM on a Multiport Bi-Fuel CNG Vehicle utilizes two different sets of preprogrammed strategies. Each strategy is specific to the type of fuel upon which the vehicle is operating. The AFCM tells the PCM which type of fuel is to be used (based on the signal from the ALT/GAS Switch , then the PCM selects the correct strategy to be used. The PCM receives input information from various sensors on the vehicle that indicate the operating conditions of the vehicle. The PCM then uses the appropriate preprogrammed calibrations to determine what actions need to be taken to maintain optimal vehicle operation for the type of fuel being used. The PCM then commands various devices to modify vehicle operation as required to maintain optimal vehicle operation. The PCM is both and input to and output of the Alternative Fuel Control Module (AFCM). POSSIBLE SYMPTOMS Symptoms of PCM concerns can range from no-start to incorrect operation of any PCM controlled system.
LESSON 3B: MULTIPORT BI-FUEL CNG COMPONENTS Alternative Fuel Control Module (AFCM)
Multiport Alternative Fuel Control Module (AFCM) COMPONENT FUNCTION: Acts as a relay, using the low amperage signal from the PCM to turn on the high amperage CNG injector circuit. Converts signals from various inputs into a fuel level voltage signal for use by the fuel gauge. Provides diagnostic capability for the CNG fuel system in the form of Diagnostic Trouble Codes (DTCs) and PID readings. COMPONENT LOCATION: On front radiator support DESCRIPTION AND OPERATION: The AFCM acts as a relay for CNG injector operation. It uses low-amperage PCM signals to control the high-amperage injector driver output required to activate the fuel injectors. This is necessary to operate the fuel injectors at the higher operating pressures of natural gas. During gasoline operations the AFCM turns on the fuel pump and utilizes a set of gasoline injector drivers to control the gasoline fuel injectors as commanded by the PCM. The AFCM performs no fuel delivery calculations. Fuel level calculations are made by the AFCM based on the data received from the fuel tank pressure sensor. The module then outputs the fuel level signal to the Hybrid Electronic Control (HEC) module, which in turn sends signals to the fuel gauge. The AFCM will store DTCs relating to its operation. Additionally, it enables a scan tool to monitor the operation of its inputs and outputs using the scan tool PID function. POSSIBLE SYMPTOMS No-start/hard-start condition. Rough engine operation.
3B - 18
March, 2004
LESSON 3B: MULTIPORT BI-FUEL CNG COMPONENTS AFCM Input Devices
FRT and FRP

Item 1 Description Fuel Rail Pressure (FRP) Sensor (right side of fuel rail under fuel shut-off solenoid bracket) Item 2 Description Fuel Rail Temperature (FRT) Sensor
Inputs to the AFCM Fuel Rail Temperature (FRT) Sensor (2-wire) The FRT sensor monitors CNG fuel temperature in the CNG fuel injection supply manifold. The PCM uses the temperature indications for fuel control calculations. The AFCM uses the temperature indications for fuel level calculations. FRT signals are sent to the PCM from the AFCM via the SCP network. Fuel Rail Pressure (FRP) Sensor (3-wire) Monitors the fuel pressure in the CNG fuel injection supply manifold. This data is used by the PCM for fuel control calculations. FRP signals are sent to the PCM from the AFCM via the SCP network.
March, 2004
3B - 19

AFCM Input Devices (continued)
Fuel Tank Pressure (FTP) Sensor

Item 1 Description CNG Pressure Regulator Item 2 Description Fuel Tank Pressure (FTP) Sensor
Fuel Tank Pressure (FTP) Sensor May be mounted in one of several locations - It may be mounted on the solenoid connecting tee, which in turn mounts to the solenoid tank valve. Also may be mounted on the coalescent filter or pressure regulator (configuration is vehicle and MY dependent). The pressure data it provides are used by the AFCM for fuel indication calculations.
3B - 20
March, 2004

AFCM Input Devices (continued)
ALT/GAS Switch
Item
1 2 CNG ALT/GAS Switch
Description
ALT/GAS Indicator (Illuninates when vehicle is operating in CNG Mode)
All bi-fuel vehicles have a ALT/GAS Switch mounted on the instrument panel that allows the driver to select whether the vehicle runs on CNG or gasoline.
Note:
CNG bi-fuel vehicles default to gasoline operating mode at or below 13 F. CNG bi-fuel vehicles will switch over to gasoline operating mode if fuel rail pressure drops below 75 psi. The PCM determines which type of fuel to use based on engine coolant temperature (ECT) or cylinder head temperature (CHT) sensor signals. Switch allows the driver to select either CNG or gasoline operating mode. The fuel selector light indicates if the vehicle is operating in the CNG or gasoline mode. Notifies the driver if a communication or emissions critical fault has occurred. These functions make the switch and light both an input and output.
COMPONENT FUNCTION
COMPONENT LOCATION Instrument panel left of the steering wheel.
DESCRIPTION AND OPERATION The ALT/GAS Switch is a single pole double throw (SPDT) switch with a self-contained green LED light.
March, 2004 3B - 21

AFCM Input Devices (continued) DESCRIPTION AND OPERATION (continued)
The switch is supplied with battery voltage through the AFCM and returns voltage on either the ALT (CNG) or GAS (gasoline) selector line. If battery voltage is not returned on the ALT/FUEL line, the system defaults to gasoline mode. When illuminated, the switch LED indicates that the vehicle is being operated in the CNG mode. The switch LED is controlled by the AFCM, not the position of the switch. This means that even if the switch is in the ALT position, the LED will not illuminate unless the vehicle is actually operating on CNG. Remember, the CNG operating mode is dependent on ECT sensor temperature readings. Bi-fuel vehicles must be started with the ALT/GAS Switch in the mode (either ALT or GAS) desired. Changing the position of the ALT/GAS Switch after the vehicle is running will not cause the vehicle to change the fuel being used. In order to change the fuel being used, the ignition must be placed in the OFF position, then the position of the ALT/GAS Switch is changed, then the vehicle can be started using the desired fuel.
SYMPTOMS If an emissions critical fault occurs in the CNG system the AFCM will flash the fuel indicator light and the PCM will illuminate the malfunction indicator light (MIL) to notify the driver of the condition.
3B - 22
March, 2004
LESSON 3B: MULTIPORT BI-FUEL CNG COMPONENTS AFCM Outputs
4 3
AFCM Outputs
Item 1 2 Fuel Gauge Low Fuel Indicator Lamp Description Item 3 4 Description CNG Fuel Injector Gasoline Fuel Injector
Fuel Injectors The AFCM determines weather the gasoline or CNG injectors are to be used based upon input information. It then acts as the injector driver for the type of injectors selected. For more details refer to the fuel injector operation section found earlier in this lesson. Fuel Gauge The fuel gauge on a Multiport bi- fuel vehicle is similar in appearance to a fuel gauge on a gasoline fueled vehicle. CNG fuel level indications are based on the calculations of the AFCM. In the gasoline mode, the AFCM receives the gasoline fuel gauge signal via the SCP network. It then sends this signal to the Hybrid Electronic Control (HEC) module which in turn controls the fuel gauge. In the CNG mode, the AFCM sends a pulse width modulated signal to the HEC module to indicate the level of CNG in the fuel tanks. The signal is based on fuel density which the AFCM interprets from the fuel tank pressure (FTP) sensor and fuel rail temperature (FRT) sensor signals. The HEC module in turn sends a signal to the fuel gauge which controls the position of the fuel quantity needle, giving the driver a visual cue of the amount of fuel in the tanks. Low Fuel Indicator Lamp When the fuel level drops to between 1/8 and 1/16 of a tank the AFCM will illuminate the low fuel indicator lamp via the HEC module, providing the driver a reminder of the vehicle fuel status.
March, 2004
3B - 23
Multiport Bi-Fuel System Relays

Item 1 Description ALT Fuel Relay Item 2 Description Fuel Pump Relay (Gasoline)
ALT Fuel Relay When the key is in the off position, the relay is open and power to the fuel tank solenoid valve and the fuel rail shutoff valve is interrupted. This isolates the fuel in the fuel tanks when the key is in the OFF position. When the key is turned ON, the AFCM closes the relay, allowing power to the fuel tank solenoid valve and the fuel rail shutoff valve, causing them to open. During initial key ON, the relay will close for one second and then open again if the PCM does not detect a PIP signal that indicates the engine is being cranked or is running. The inertia shutoff switch is also on this circuit and can cause the valves to close in the event of an accident. Fuel Pump Relay The AFCM uses the fuel pump relay to turn the gasoline fuel pump on when gasoline fuel is to be used When the key is turned ON, the AFCM closes the relay, allowing power to the gasoline fuel pump, turning it on. The inertia shutoff switch is also on this circuit and can shut the fuel pump off in the event of an accident. During initial key ON, the relay will close for one second and then open again if the PCM does not detect a PIP signal that indicates the engine is being cranked or is running.
3B - 24
March, 2004
Fuel Rail Shutoff Solenoid and ALT/GAS Switch Light

Item 1 Description ALT/GAS Switch Indicator Item 2 Description Fuel Rail Shutoff Solenoid
Fuel Rail Shutoff Solenoid The fuel rail shutoff solenoid isolates the fuel rail from the upstream fuel system when the engine is not operating. This minimizes the amount of fuel available to flow through the fuel injectors when the vehicle is off. It also limits the amount of fuel that can escape through the fuel rails in the event of an accident that causes fuel rail damage. During initial key ON, the valve will open for one second and then close again if the PCM does not detect a PIP signal that indicates the engine is being cranked or is running. ALT/GAS Switch Indicator Light: The ALT/GAS Switch indicator light is a 12 volt LED, incorporated into the switch and powered when the vehicle is running on CNG. It is controlled by the AFCM, not the position of the switch. For more details refer to the ALT/GAS Switch operation section found earlier in this lesson.
March, 2004
3B - 25
LESSON 3B: MULTIPORT BI-FUEL CNG COMPONENTS NOTES
3B - 26
March, 2004
ACTIVITY 3B
ACTIVITY 3B
OBJECTIVES
CONTENTS
Activity 3B - Worksheet L (Hands-On) Activity 3B - Worksheet M (Hands-On) Activity 3B - Worksheet N (Written) Activity 3B - Worksheet O (Written)
Reinforce the knowledge that the student has acquired from Lessons 1, 2B, and 3B. Allow the student to review detailed information found in Lessons 1, 2B, and 3B. Allow the student to identify the location, function, and operation of Multiport Bi-Fuel CNG Vehicle components.
March, 2004
3B - 27
ACTIVITY 3B NOTES
3B - 28
March, 2004
ACTIVITY 3B ACTIVITY 3B WORKSHEET M (Hands-On) MULTIPORT BI-FUEL SYSTEM COMPONENT IDENTIFICATION STUDENT ANSWER SHEET
Directions: Using the information in your Student Reference Guide and the service publications provided, go to the dedicated CNG classroom vehicle and answer the following questions. 1. The following are descriptions of component functions. The components that perform these functions have been tagged by your instructor with letters/numbers. Read the function description provided then locate the component that performs that function and note the letter/number and component name in the space provided.
TAG LETTER/NUMBER
COMPONENT NAME
COMPONENT DESCRIPTION Stores fuel at a maximum of 3600 psi Meters CNG fuel going into the engine combustion chambers Sends voltage to the solenoid tank valve and the fuel rail shutoff valve when the key is in the ON position Enables the driver to select either CNG or gasoline Is shut off by the AFCM during CNG operation Contains a pressure relief device Stores fuel injector DTCs Provides the AFCM with temperature indications for fuel level calculations Provides the AFCM with pressure information Interrupts fuel flow in the fuel rails when the engine is not operating Allows the AFCM to control gasoline fuel pump operation Converts fuel tank pressure into usable pressure for the injectors
END OF WORKSHEET
March, 2004
3B - 29
ACTIVITY 3B ACTIVITY 3B - WORKSHEET N MULTIPORT BI-FUEL NGS OPERATION STUDENT ANSWER SHEET
Directions: Using the information you have learned from the NGS Web-Based Training Course, and the NGS Appendix found at the rear of this student guide, go to the dedicated CNG classroom vehicle and answer the following questions.. 1. In the AFCM module, select the PIDs listed in the table below for viewing. Start the vehicle and allow it to idle while viewing these PIDs. Note what data are being displayed for each PID. Refer to the service publications and note the meaning of the data displayed.
PID ALT SOFFSOL CNG TANKPR FRPREAB FRTMPAB
DATA DISPLAYED
READING AT IDLE
2. Perform the following steps while viewing the PIDs listed in Question 1.
While viewing the PIDs, raise the engine rpm to 2000 (monitor with NGS RPM PID) Press trigger to capture data, then allow the vehicle to run for 20 seconds. Save the data in area 3 of the NGS memory. Shut the vehicle off.
3. View the recording in the TABLE mode. What is the highest + time recorded on the display? ____ ______________________________________________________________________________ 4. Press the RWD button. What occurs? __________________________________________________ 5. Press the PLAY button. What occurs? ___________________________________________________ 6. Exit the TABLE mode and select the GRAPH mode. Which two PIDs are displayed? ______________________________________________________________________________ 7. Press the 2 button. What occurs? ____________________________________________________
8. Press the 9 button. What occurs? ____________________________________________________ 9. Press the 8 button. What occurs? ____________________________________________________ 10. Press the 3 button. What occurs? ____________________________________________________
END OF WORKSHEET
3B - 30
March, 2004
ACTIVITY 3B ACTIVITY 3B WORKSHEET O (Written) MULTIPORT BI-FUEL SYSTEM COMPONENT DESCRIPTION AND OPERATION STUDENT ANSWER SHEET
Directions: Using the information you have learned from the prerequisite courses and your Student Reference Guide, answer the following questions. 1. The CNG fuel fill valve on a Multiport Bi-Fuel CNG Vehicle is stamped with 3600. What does this indicate? ______________________________________________________________________________ PAGE#_______ 2. What type of fuel injector has a single large orifice in the nozzle? ___________________________ PAGE#_______ 3. Which part of the coalescent filter should be replaced during scheduled maintenance? ___________ ______________________________________________________________________________ PAGE#_______ 4. In the event a solenoid tank valve is stuck closed, what should be used to vent the fuel tanks? _____ ______________________________________________________________________________ What must be done if this action is performed? ____________________________________________ PAGE#_______ 5. What is the typical resistance of a CNG fuel injector? _____________________PAGE#_______ 6. Which control module performs fuel delivery calculations? ________________ PAGE#_______ 7. What two relays allow the AFCM to control fuel delivery to both the CNG and gasoline fuel systems? ________________________________________________________________________________ PAGE#_______ 8. What is the function of the FRT sensor?__________________________________________________ ________________________________________________________________________________________________ PAGE#_______ 9. How are FRP sensor signals sent to the PCM? __________________________________________ ________________________________________________________________________________________________ PAGE#_______ 10. Which control module uses FTP sensor signals for fuel level calculations? ____________________ PAGE#_______ 11. During cold weather, which temperature sensor(s) provides the PCM with readings that it uses to determine if the vehicle should default to gasoline operation? ______________________________ PAGE#_______ 12. If a Multiport bi-fuel vehicALT/GAS Switch is placed in the ALT position, but there is no CNG fuel in the fuel tank, the fuel indicator light will be (Circle one) ON or OFF PAGE#_______
END OF WORKSHEET
March, 2004
3B - 31
ACTIVITY 3B ACTIVITY 3B WORKSHEET P (Written) MULTIPORT BI-FUEL SYSTEM COMPONENT DESCRIPTION AND OPERATION STUDENT ANSWER SHEET
Directions: Using the information you have learned and your Student Reference Guide, answer the following questions. 1. What system is modified in order to accommodate the weight of additional fuel tanks on a Multiport Bi-Fuel CNG Vehicle? ____________________________________________________________PAGE#_______ 2. If an emissions critical fault is detected by the AFCM, what action will it take to alert the driver to the condition? __________________________________________________________ PAGE#_______ 3. What will occur if the driver changes the position of the ALT/GAS Switch while driving? __________________________________________________________________PAGE#_______ 4. Which control module sends a signal to the fuel gauge to change the position of the fuel quantity needle? __________________________________________________________________PAGE#_______ 5. On a Multiport Bi-Fuel CNG Vehicle, what is the pressure of the CNG fuel between the coalescent filter and the pressure regulator?_______________________________________________PAGE#_______ 6. On a Multiport Bi-Fuel CNG Vehicle, what is the pressure of the CNG fuel when it leaves the pressure regulator? __________________________________________________________________PAGE#_______ 7. What safety device is in wired into both the CNG and gasoline fuel systems? __________________________________________________________________PAGE#_______ 8. While testing the voltage on the ALT fuel relay circuit, after KOEO the voltage from the relay to the fuel rail shutoff valve goes from battery voltage to 0 after 1 second. Technician A says that this indicates the ALT fuel relay is opening. Technician B says that this is normal operation. Who is right? A. Technician A B. Technician B C. Both A and B D. Neither A nor B PAGE#_______ 9. What is the outer diameter of low pressure CNG fuel lines? ___________________ PAGE#_______ 10. During a visual inspection of a Multiport Bi-Fuel CNG Vehicle fuel tank it is noted that the tank build date cannot be read. Technician A says that the build date can be checked using the vehicle VIN, and a new build date sticker must be attached to the tank. Technician B says that since the tank is made of high strength steel it is an NGV 2-2 type tank. Who is right? A. Technician A B. Technician B C. Both A and B D. Neither A nor B PAGE#_______
END OF WORKSHEET
3B - 32 March, 2004 1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles

OBJECTIVES
Upon completion of this lesson the student will be able to: Introduction Service Standards Preliminary Diagnostic Steps Identification and Retrieval of CNG System Diagnostic Trouble Codes Diagnostic Strategy Component and System Testing and Service Coolant System Pressure Testing Fueling Dedicated CNG Vehicles CNG Contamination Fuel Fill Valve Filter Coalescent Filter Service Fuel Injector Cleaning Fuel Tank Removal Fuel Line Service Fuel System Leak Testing Crown Victoria Vent Box Leak Testing Fuel System Venting Solenoid Tank Valve Diagnostics
CONTENTS
Identify Ford service standards. Explain the Ford diagnostic strategy. Describe preliminary diagnostic steps. Identify CNG component tests. Describe dedicated CNG fueling procedures. Explain common dedicated CNG vehicle service procedures. Perform service publication navigation. Perform CNG fuel venting procedures.
4-1 March, 2004
4- 1
CNG FUEL SYSTEM DIAGNOSIS AND SERVICE

When diagnosing a vehicle concern, most experienced automotive technicians follow a standard procedure. They do this automatically, sometimes without even being aware of it, because their years of experience have taught them that by following a standard procedure they are less likely to miss a small, easy-to-fix item that may be responsible for a malfunction. Few things are more aggravating than replacing an expensive, hard-to-service component, only to find out that it did not correct the concern. Then, upon further investigation, finding out that the real cause was a broken wire that would have been seen had a thorough visual inspection been performed. This lesson will focus on using systematic diagnostic procedures for identifying and correcting Dedicated CNG vehicle and Multiport Bi-Fuel CNG Vehicle concerns.
4-2
March, 2004
SYMPTOM-TO-SYSTEM-TO-COMPONENT-TO-CAUSE (SSCC) DIAGNOSTIC STRATEGY

After studying the methods of many successful technicians, Ford has developed a diagnostic strategy that will help you to quickly and efficiently locate and correct most vehicle concerns. This method is the Symptom-to-System-to-Component-to-Cause (SSCC) diagnostic strategy. As you have seen dedicated CNG fueled vehicles are unique in many ways. The differences in these vehicles mean that the diagnosis and service procedures are also unique. This makes following a diagnostic strategy even more critical. Ford recommends the SSCC diagnostic strategy. To follow this strategy, all you have to do is follow the words in the title.
SYMPTOM =
VERIFIED VEHICLE CONCERN
1. First, determine the Symptom of the customer concern. Ensure that you understand exactly what the customer is concerned about. Try and determine if the concern is a malfunction or if it is a normal tendency of a CNG fueled vehicle. This is important because some customers may not be familiar with the normal operating characteristics of a vehicle that is operating on CNG.
SYSTEM = IDENTIFY VEHICLE SYSTEM RESPONSIBLE FOR SYMPTOM

2. Next, determine which System on the vehicle could be causing the symptom. There is no sense in checking the air pressure of the tires if the vehicle has no power. On CNG fueled vehicles, this step requires that you determine if the symptom is being caused by the CNG fuel system or by a base vehicle system.
March, 2004
4- 3
SYMPTOM-TO-SYSTEM-TO-COMPONENT-TO-CAUSE (SSCC) DIAGNOSTIC STRATEGY (CONTINUED)
COMPONENT = DETERMINE
EXACTLY WHICH COMPONENT OF THE SYSTEM NEEDS ADJUSTMENT OR HAS FAILED
3. Once you identify the particular system responsible for the symptom, you then need to determine which Component(s) within that system could be the cause for the customer concern. Diagnostic tests are usually isolation tests. The idea behind them is to check the operation of a specific component, without other components in the system affecting the component being tested. On CNG fueled vehicles, this requires product knowledge, skill, and your ability to know how to use and interpret special tools.
CAUSE = IDENTIFY AND CORRECT THE CAUSE OF THE FAILURE

TO PREVENT A REPEAT OF THE FAILURE
4. Once the failed component is identified, you should always try and determine the Cause of the failure. For example, the component causing a system not to get power may be a blown fuse, but if you dont repair the short that caused the fuse to fail, then the new fuse will fail as well.
4-4
March, 2004
SERVICE AREA PRECAUTIONS

The following service area precautions should always be followed prior to bringing a dedicated CNG vehicle into a service bay: Ensure the CNG fuel system has no obvious leaks. The vehicle should not be exposed to temperatures over 100 F (38 C). Ensure that the vehicle is not parked within 10 feet (3 meters) of: Any source of heat Any source of open flame Any source of ignition (such as metal grinders or other spark-generating tools or devices) An overhead heater
March, 2004
4- 5
PRELIMINARY DIAGNOSTIC STEPS

Whenever a vehicle is brought in with a customer concern, the following preliminary diagnostic steps should always be performed. Each of these steps is very important in determining and correcting the source of a concern. 1. Verify customer concern. Determine whether the concern is caused by a malfunction or whether it is because the customer is not familiar with CNG-fueled vehicle operation. 2. Check OASIS, Ford (dedicated CNG and Multiport Bi-Fuel CNG Vehicles) TSBs, and vehicle service history. OASIS may provide you with important information on any technical service bulletins that may have been issued for the vehicle. The service history may give you some insight to the kind of service the vehicle has had in the past and whether the current concern may be related to this service. 3. Perform a thorough visual inspection. Many vehicle concerns can be found and corrected by performing a visual inspection. A loose wire, corroded ground, or disconnected sensor can have a dramatic effect on vehicle operation. During your visual inspection, double-check the following: Adequate fuel Quarter-turn valve fully open (if equipped) Fuse condition and security Electrical connector condition and security Damage, leaks and/or kinks in fuel lines and tank Damage, leaks and/or kinks in vacuum lines and connectors Damage, leaks and/or kinks in coolant hoses and fittings Loose, damaged or incorrect type of spark plugs or secondary ignition wires Damaged ignition system Vehicle timing within specifications 4. Check for installation of non-factory add-on equipment. Improper installation of add-on equipment can cause incorrect electrical signals from reaching components and modules, which can result in vehicle operating concerns. 5. On Multiport Bi-Fuel CNG Vehicles perform both key on engine off (KOEO) and key on engine running (KOER) self-tests in the gasoline mode. Using the New Generation STAR (NGS) tester, identify and service any base vehicle concerns prior to diagnosing the CNG fuel system. . 5. Retrieve continuous DTCs. Continuous codes indicate a fault that has occurred in the past (usually during the previous 40 trips). These may indicate a fault that is still occurring or an intermittent fault that may not currently be occurring. Retrieving continuous DTCs is usually done with the NGS. Retrieve DTCs from both the PCM and AFCM. Refer to the workshop manual for the vehicle you are working on.
4-6
March, 2004
PRELIMINARY DIAGNOSTIC STEPS (continued.)

6. Perform key on engine off (KOEO) self-tests. KOEO tests will identify current faults that can be detected with the engine off. 7. Perform key on engine running (KOER) self-tests. KOER tests will identify current faults that can be detected with the engine running. 8. Diagnostic Sequence for Multiport Bi-Fuel CNG Vehicles. When performing diagnostics on a Multiport Bi-Fuel CNG Vehicle, always check base gasoline vehicle systems before diagnosing CNG system faults. This should be done because a marginal condition on a base vehicle system that will not cause a malfunction during gasoline operation may cause a concern during CNG operation. Example: Deteriorated secondary ignition wires that will not cause an engine miss when operating on gasoline may cause a miss when operating on CNG. This is due to the higher ignition temperature of natural gas.
March, 2004
4- 7
IDENTIFICATION AND RETRIEVAL OF CNG SYSTEM DIAGNOSTIC TROUBLE CODES (DTCs)

On a dedicated CNG and Multiport Bi-Fuel CNG Vehicles, the presence of a DTC in the CNG system is indicated by the illumination of the Malfunction Indicator Light (MIL). The MIL will remain on while the fault condition actively continues or for the next two trips with no active faults. Note: A vehicle trip is defined as the operating state of the vehicle when the following criteria are met: Start and warm-up sensor until ECT/CHT sensor indicates approximately 82 C (180 F) Idle for 45 seconds Accelerate to 45 mph at 1/4 throttle in approximately 10 seconds Drive at steady throttle at 30-40 mph for approximately 1 minute Drive 20-45 mph (no WOT) for 4 minutes Decelerate and idle for 10 seconds Accelerate to 55 mph at 1/2 throttle for approximately 10 seconds Steady throttle at 40-65 mph The light will extinguish if the fault condition discontinues for more than two trips. The fault code is stored and may be retrieved during service. Dedicated CNG and Multiport Bi-Fuel CNG Vehicles have the capability to store CNG diagnostic trouble codes (DTCs) in both the PCM and AFCM. These codes can help to locate and diagnose the cause of a CNG system fault. However, not all faults will set a DTC. In these cases, use of the Symptom Charts in the PC/ED manual is recommended. For further information on DTC indications and retrieval, refer to the subsection of this lesson. For additional information on the operation of the NGS, refer to the NGS Web Course. NOTE: The AFCM will only store DTCs for faults relating to components that it monitors. These include: Fuel tank pressure sensors Fuel tank temperature sensors Battery voltage Fuel Injectors (Multiport vehicles only)
4-8
March, 2004
SERVICE PUBLICATION NAVIGATION

During diagnosis and service of CNG vehicles, you may need to refer to many different service publications. It is essential that you are able to navigate through these publications to locate diagnosis and service information. The following is a brief description of these publications. Powertrain Control/Emissions Diagnosis (PC/ED) Manual - This publication will provide you with both base and CNG system driveability diagnostic and emission information. Workshop Manual - This publication will provide you with service information for both the base vehicle systems and the CNG fuel system. Wiring Diagrams - This publication will give you electrical schematics, electrical component and connector location and information for base vehicle systems and the CNG fuel system. Service publications are available in multiple formats including: Paper publications CD-ROM/DVD Web-based at the Professional Technician Society website which is linked through the Ford QC Dealer.com Web-based at the Ford Fleet website at www.fleet.ford.com
Powertrain Control/Emissions Diagnosis (PC/ED) Manual

The Powertrain Control/Emissions Diagnosis (PC/ED) manual is the primary source for diagnostic information for the CNG fuel system. This manual provides a step-by-step approach for diagnosing driveability, emission and powertrain control system symptoms. Before beginning diagnosis, always reference any Technical Service Bulletins (TSBs) or On-line Automotive Service Information System (OASIS) information when this is available. Information on Dedicated CNG and Multiport bi-fuel CNG systems is found in the conventional PC/ ED, not the OBD II Bi-Fuel LPG/CNG Powertrain Control/Emissions Diagnosis (PC/ED) Manual. This manual is used in conjunction with the Body, Chassis, Electrical, Powertrain Workshop Manuals and the Wiring Diagram Manuals. The Workshop Manuals are used to provide additional diagnostics when directed by this manual. The Workshop Manuals are also used for component removal and replacement information. Refer to the Wiring Diagram Manuals for vehicle specific wiring information and component, connector and splice location. The following is a description of the information contained in each section of the PC/ED. Section 1: Description And Operation This section contains description and operation information on powertrain control systems and components. This section is designed to give the technician a general knowledge of the powertrain control system. It should be used when general information about the powertrain control system is desired, and is rarely referenced from other sections of the manual.
March, 2004
4- 9
LESSON 4: DIAGNOSIS AND SERVICE Powertrain Control/Emissions Diagnosis (PC/ED) Manual (continued)
Section 2: Diagnostic Methods The Diagnostic Methods section contains information on specific diagnostic tasks that are used during diagnosis. Descriptions of specific diagnostic methods are included, as well as detailed instructions on how to access or perform the tasks. This section provides the technician with step-by-step instructions for performing routine diagnostic tasks. Section 3: Symptom Charts All diagnosis begins in Section 3 with Step 1: Diagnostic Quick Test. If the Diagnostic Quick Test is completed and no DTCs are received, the technician may be directed to Step 2: No DTCs Present Symptom Chart Index (refer to Section 3 for details). The No DTCs Present Symptom Chart Index contains the list of symptoms addressed in this manual, and will send the technician to the appropriate Step 3: No DTCs Present Symptom Chart. If no DTCs are present and the vehicle symptom is not listed in the Step 2: No DTCs Present Symptom Chart Index, the technician should go the appropriate Workshop Manual to continue diagnosis. Section 4: Diagnostic Subroutines Section 4 contains the Powertrain Diagnostic Trouble Code (DTC) "Go To" Charts. These charts will be referenced if a DTC is received in Section 3. Also included in this section are the Powertrain DTC descriptions and list of possible causes. Section 5: Pinpoint Tests All the pinpoint tests are included in Section 5. Never enter a Pinpoint Test unless directed there. When directed to a Pinpoint Test, always read the information and look at the schematic included at the beginning of the Pinpoint Test. Section 6: Reference Values Section 6 contains the "Typical Diagnostic Reference Values" charts.
4 - 10
March, 2004
LESSON 4: DIAGNOSIS AND SERVICE Workshop Manual

Information on performing service and repair procedures on CNG vehicles is found in the vehicle workshop manual. The vehicle workshop manual is available in book, CD-ROM, and web-based (at the PTS website) formats.
Wiring Diagrams (EVTMs)

The standard Ford Wiring Diagram Manual (EVTM) contain wiring diagrams for both the base vehicle systems and the CNG fuel system. In addition to diagrams of the vehicle wiring, information such as component location, wiring connector diagrams, and other vehicle information can be found in the wiring diagram manual. Wiring diagrams are available in in book, CD-ROM, and web-based (at the PTS website) formats.
March, 2004
4- 11
COMPONENT AND SYSTEM TESTING AND SERVICE

When diagnosing the CNG fuel system of dedicated CNG and Multiport Bi-Fuel CNG Vehicles, there are unique component and system tests that may be required. Additionally, due to the unique nature of CNG and of the components of the CNG fuel system service procedures require extra care and attention to detail. It is essential that whenever servicing a CNG fuel system that all safety procedures be followed, and that the procedures spelled out in the service publication be performed as described without taking shortcuts. This section describes some of these tests and how to interpret their results and some important service procedures. WARNING: FOLLOW ALL WARNINGS AND CAUTIONS AS DESCRIBED IN THIS STUDENT REFERENCE GUIDE AND AS DESCRIBED IN THE SERVICE PUBLICATIONS WHEN PERFORMING ANY OF THE TESTS DESCRIBED IN THIS SECTION.
4 - 12
March, 2004
LESSON 4: DIAGNOSIS AND SERVICE Cooling System Pressure Testing

Cooling system pressure testing procedures are basically the same as on any other type of vehicle. However, because the high-pressure regulator of the CNG fuel system uses engine coolant, additional components have been added to the cooling system. These additional components slightly change the use and interpretation of the cooling system pressure test. Connect the Pressure Tester as described in the base vehicle workshop manual. When performing the leak-down portion of the cooling system pressure test, be aware that a drop in the pressure may be the result of a coolant leak in the high-pressure regulator, its hoses or seals. If the cooling system fails to maintain the specified pressure during the leak-down test, closely inspect the high-pressure regulator and all coolant connecting hoses.
March, 2004
4- 13
CNG REFUELING PROCEDURES

6 1 2
4
CNG Fueling
Item 1 Description CNG Refueling Pump Nozzle Refueling Nozzle Locking Handle (Locked Position) Refueling Nozzle Lock Indication Arrows (Arrows pointing in the same direction indicates nozzle is locked on fill valve) Item 4
Description Refueling Nozzle Lock Indication Arrows (Arrows pointing at each other indicates nozzle is not locked on fill valve) Refueling Nozzle Locking Handle (Locked Position) CNG Refueling Pump Nozzle
WARNING: TO AVOID THE IGNITION OF FUEL VAPORS THAT ARE VENTED TO THE ATMOSPHERE:
THE ENGINE MUST BE SHUT OFF. EXTINGUISH ALL SMOKING MATERIAL. NEVER ATTEMPT TO OVERPRESSURIZE THE CNG SYSTEM.
Turn the engine off. Turn the selector knob on the fill nozzle to VENT position. Connect the quick coupling, on the fill nozzle, securely to the system fill valve. Turn the selector knob on the fill nozzle to the ON position. Switch on the service pump. A noise will be heard as the cylinder begins to fill. Watch the pressure gauge on the service pump. When the gauge reads approximately 3000 or 3600 psi (vehicle and model year dependent), or when the fill pressure begins to move very slowly, the CNG tanks are full.
4 - 14
March, 2004
CNG REFUELING PROCEDURES (continued)

NOTE: After filling, the operator may notice a variance in pressure as the vehicle stabilizes. CNG tank pressure will vary with ambient air temperature. At 70 F, tank pressure is approximately 3000 or 3600 psi. For every 10 F difference add or subtract 100 psi. For example: If the air temperature is 80 F, then the tank pressure would be 3000 + 100 or 3100 psi. If the air temperature is 60 F, then the tank pressure would be 3000 - 100 or 2900 psi. Shut off service pump. Place the selector on the fill nozzle to the VENT position. A short hiss of pressure is heard as a small amount of natural gas is vented into vent hose. Disconnect the quick coupling on the fill nozzle. NOTE: A CNG vehicle with a 3600 psi fuel system can be fueled at a 3000 psi pump (although only to 3000 psi), however a CNG vehicle with a 3000 psi fuel system cannot be fueled at a CNG pump that dispenses fuel at 3600 psi.
March, 2004
4- 15
CNG CONTAMINATION
Natural gas for vehicles is taken from a gas utilitys distribution network. A compressor station is used to dispense the fuel when filling a vehicle. Many times, these compressors discharge excess oil that mixes with the natural gas. Minute portions of this oil are acceptable and can be beneficial to lubricate the internal injector components. But excess contamination is harmful and can deteriorate performance and cause excessive wear and, eventually, component failure. Another concern is water contamination of natural gas. Natural gas designated for residential use is allowed to have 7 pounds of water per 1 million cubic feet of gas. SAE standards for natural gas used in vehicles is 1/2 pound of water per 1 million cubic feet of gas. CAUTION: Never use natural gas that has been liquefied then converted back to gas. This process removes all lubrication qualities from the gas and will result in component damage. The solution for contamination problems is proper filtration systems at the fueling stations. Some gas utility companies have been slow to respond or acknowledge the problem. Fuel contamination may result in intermittent leaks in the CNG fill valve. This is caused by water in the fuel freezing during fueling, then holding the valve open until it melts. Particulate contamination can also cause the valve to stick open. The technician should be mindful of the amount of oil and water found in the system during routine maintenance (e.g., cleaning and changing the filters). If a large quantity of oil or water is present in the system, the technician should recommend to the customer the following items: Change Filling Stations - The contamination will not necessarily be the same from location to location. Accelerated Maintenance Schedule - By cleaning and changing the filters on a more frequent basis, the system can be kept cleaner. NOTE: Multiport Bi-Fuel CNG Vehicles should run a minimum of 1 tank of gasoline every 60 days. This prevents the gasoline in the gasoline fuel tank from varnishing and helps prevent clogging of the gasoline fuel injectors.
4 - 16
March, 2004
FUEL FILL VALVE FILTER
Fuel Fill Valve Filter

Item 1 2 3 Description Filter Removal/Installation Tool (134-00115) Fuel Fill Valve Filter Fuel Fill Valve
Some CNG vehicles may have a fuel fill valve filter. This filter should be cleaned annually. The following procedure should be used when servicing the fuel fill valve filter. Vent fuel lines. Disconnect the fuel tube from the rear of the fuel fill valve. Remove the fuel fill valve straight fitting. Using the fuel fill valve filter removal tool, remove the fill valve filter by turning the fill filter counterclockwise.
March, 2004
4- 17
COALESCENT FILTER SERVICE
1 2
Coalescent Filter Assembly

Item 1 Filter Description Item 2 Drain Plug Description
The coalescent filter removes water and particulate contamination from the CNG fuel system. It has a drain plug that allows water to be drained at each oil change and a filter that is replaced on a normal maintenance schedule (refer to vehicle owners manual for schedule). Filter Removal 1. Bleed the fuel lines. 2. Place container under coalescent filter assembly. 3. Remove drain plug and allow all liquid to drain. 4. Remove coalescent filter housing from base by rotating the housing counterclockwise. 5. Move filter element back and forth while pulling it downward. 6. Remove and discard filter element and o-ring. Filter Installation 1. Lubricate new o-ring seal with clean 5W-20 engine oil meeting Ford specification WSS-M2C153-F. 2. Install new o-ring and filter. 3. Install coalescent filter housing. Tighten to specifications. 4. Install drain plug and tighten to specifications.
4 - 18
March, 2004
FUEL INJECTOR CLEANING

Due to the use of fuel that does not meet SAE standards for CNG vehicles, concerns have arisen that are caused by partially or completely clogged fuel injectors. Symptoms of this concern include: Rough Idle No Start in Cold Driveability concerns Diagnosis and Service Procedure: Perform normal diagnostics per Ford Service Procedures. If it is identified that the injectors are partially or completely clogged perform the following procedure to clean the CNG Injectors: 1. Start vehicle and idle at 1500 rpm for 5 minutes, if the vehicle will not start due to clogged injectors, the injectors may be completely stuck closed. If this is the case, attempt to free them by applying 12 Volts directly to the injector coil: A. Apply battery voltage to the side of the injector connector to which the red wire circuit 361 connects. B. Ground the other side of the connector momentarily and listen for an audible click to confirm that the injector has opened. Caution: Do not ground the injector for more than 10 seconds. Prolonged grounding may result in damage to the injector. C. If an injector remains stuck, wait 10 seconds and repeat steps A and B. Note: If the injector does not produce an audible click after three attempts, replace the injector (refer to vehicle workshop manual). 1. If injector operation is confirmed, perform the following procedure for cleaning the injectors. 2. Remove CNG coalescent filter bowl after properly venting the fuel line (per Ford CNG Venting Procedure for Servicing Filter Bowl). 3. Check for dirt or oil in the filter bowl - Clean it if necessary. 4. Remove the coalescent filter element. 5. Fill the filter bowl to the top with Iso-Propyl Alcohol (with strength of at least 90%). 6. Reinstall the bowl (torque for bowl: 30 +/- 5 Ft-lb, torque for drain plug: 8 +/- 2 Ft-lb). 7. Start engine and idle at 1500 rpm for 10 minutes. 8. Repeat step 2 and Reinstall the Filter element and the bowl. 9. Test drive vehicle to confirm removal of rough idle. In some cases of severe injector clogging, this procedure will have to be repeated. If the concern is not corrected repeat the procedure as required. This procedure is explained in detail in TSB 01-22-1 for all dedicated CNG vehicles and Multiport Bi-Fuel CNG Vehicles. TSB 01-23-1 explains fuel injector cleaning for all other bi-fuel CNG vehicles.
March, 2004
4- 19
FUEL TANK REMOVAL
Crown Victoria CNG Fuel Tanks
Multiport Bi-Fuel CNG Fuel Tank CNG fuel tank removal procedures will vary based upon the model year and vehicle type being worked on. Whenever fuel tank removal is required it is essential that the workshop manual procedures are strictly followed with special emphasis on the safety procedures called out in the workshop manual.
4 - 20
March, 2004
FUEL LINE SERVICE
High Pressure Fuel Line Fitting
Item 1 2
Description CNG Fuel Line Fitting O-Ring (with yellow stripe)
When servicing dedicated CNG and Multiport Bi-Fuel CNG Vehicles, fuel line removal and replacement is often required. CNG fuel systems use high-pressure stainless steel fuel lines that have oring servicing these, use the following precautions: Whenseals. Whenever a fuel line fitting nut is loosened, the o-ring on the line must be replaced. Use only the correct o-ring (yellow stripe), or an o-ring that the packaging specifies can be used for CNG, when replacement is required. When connecting components to fuel lines, always get the fuel line fitting started into the component fitting before tightening the component to the vehicle. This is important because CNG fuel lines are stainless steel and should not be bent. When installing fuel tanks, always connect the fuel lines before tightening the tank retaining straps. Once installed, always check fittings for leaks with liquid leak detector.
March, 2004
4- 21
LESSON 4: DIAGNOSIS AND SERVICE Fuel System Leak Testing
Rotunda Electronic Leak Detector Fuel system leak testing is one of the most critical test procedures performed. Never assume that a vehicle has no leaks in the fuel system. There are two methods that are used to identify leaks in the fuel system: The electronic leak detector (to narrow down the location of the leak). The liquid leak detector (to pinpoint the exact location of the leak). Both methods should be used whenever vehicle service is performed to verify the security of the system. Always use the electronic leak detector first to avoid contamination by the liquid detector. Most leaks in the fuel system will occur around fittings and connectors. Place special emphasis on these when looking for leaks. Always keep an eye out for damaged fuel lines. Even a small amount of impact damage to a fuel line can result in an CNG leak. Before attempting to determine if a fuel leak exists, ensure that the solenoid tank valves are open so that ample fuel can flow from the tank. Electronic Leak Detector: The Rotunda Electronic Leak Detector 134-00049 identifies CNG leaks electronically by detecting the presence of hydrocarbons. This type of equipment is sensitive to the presence of any hydrocarbons, which may give misleading results. Any time the detector indicates a leak, verify the results with a liquid leak detector. Liquid Leak Detector: The liquid leak detector uses a glycerin-based liquid to identify leaks. After applying the liquid, watch the suspect area closely. If bubbles begin to expand from the area, a leak is indicated.
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March, 2004
LESSON 4: DIAGNOSIS AND SERVICE Fuel System Leak Testing (continued)
Leak Testing a Fitting

Item 1 Description Typical Locations to Apply Liquid Leak Detector
Leak Testing a Fitting Whenever a fuel line fitting has been opened it must be check for leaks after reassembly. This must be done using liquid leak detector. When checking for leaks apply the liquid leak detector on the line fitting. Watch for bubbles rising around the fitting (bubbles indicate there is a leak).
March, 2004
4- 23
LESSON 4: DIAGNOSIS AND SERVICE Crown Victoria Vent Box Leak Test 2
Crown Victoria Vent Box Leak Test Tools

Item 1 Description Rotunda Evaporative Emission Tester 134-00056 Item 2 Description Pressure Test Adapter Tool 134-00122
In the event the smell of natural gas is detected either in the vehicle passenger compartment or the trunk of a dedicated CNG Crown Victoria, the vent box should be tested for a leak.
WARNING: LOCATE AND CORRECT SOURCES OF CNG LEAK ON VEHICLE BEFORE INSTALLING THE VENT BOX.
Refer to the workshop manual for exact procedures for the year vehicle you are working on. The following is a general overview of the test procedure. Close the fuel tanks using the manual lockdown on the solenoid tank valve. Disconnect the fuel line and wiring harness between the upper and lower tank rack assemblies at the lower tank rack. Install the vent box pressure test adapter in the flexible vent tube. Use the Rotunda Evaporative Emission Tester 134-00056 to pressurize the vent box to 20 inches of water. Monitor the pressure drop for two minutes. The pressure cannot decay below 14 inches of water. If the pressure test fails, test all sealing surfaces with a liquid leak detector. Correct the source of any CNG leaks (on the vehicle) and reinstall the vent box. Retest to verify repair; connect fuel lines and wiring connectors.
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March, 2004
FUEL SYSTEM VENTING
2 3 4 5 6
7 8 9
10
Vent Stack Assembly
Item 1 2 3 4 5 D escription 1/2 Inch Vent Pi pe Vent Stack Support C onnectors Vent Stack Hose C onnectors (part of 134-00114)
Item 6 7 8 9 10
D escription Pressure Gauge (part of 134-00114) Fi ll Valve C onnector (part of 134-00114) Bui ldi ng Floor Groundi ng C able (part of 134-00114) Support Groundi ng Rod
30 ft. of Vent Tool Hose(part of 134-00114) Vent Tool (part of 134-00114)
WARNING: VENTING OF FUEL REQUIRES THE USE OF A VENT STACK THAT IS APPROVED AND EQUIPPED FOR THE PROCEDURE. FOLLOW LOCAL REGULATIONS AND CONSULT YOUR LOCAL FIRE AND ENVIRONMENTAL AUTHORITIES FOR SPECIFIC REGULATIONS. THE TOP OF THE VENT STACK MUST BE A MINIMUM HEIGHT ABOVE THE STRUCTURE TO WHICH IS ATTACHED. CONTACT LOCAL AUTHORITY HAVING JURISDICTION TO DETERMINE CORRECT HEIGHT.
March, 2004
4- 25
FUEL SYSTEM VENTING (continued)

When servicing the fuel system of a dedicated CNG fueled vehicle, the fuel system usually must be vented. Dedicated CNG vehicles may use three different methods for fuel system venting: 1. Fuel line venting at the fuel injection supply manifold (MY and Model dependent). Vents the fuel system from the fuel injection supply manifold to the tank solenoids. Required prior to replacement of any fuel system component. Fuel lines are vented from the fuel injection supply manifold since the fuel pressure regulator is not designed to backflow reliably. 2. Fuel tank venting at the fill valve (on vehicles equipped with manual backflow MY and Model dependent). Should only be performed to replace an expired or damaged tank or to replace a damaged fuel solenoid tank valve. Must be confirmed with use of the override tool. Requires that the vented solenoid be replaced once the override tool is used. Required prior to fuel tank replacement or solenoid valve removal. Can be performed only after solenoid diagnostics have been completed. 3. Fuel line and tank venting using vent tools on vehicles without manual backflow or fuel injections supply manifold Schrader valve (MY and Model dependent). Can be used to vent either the tanks or the fuel system from the fuel injection supply manifold to the tank solenoids. The fuel system from the fuel injection supply manifold to the tank solenoids must be vented prior to replacement of any fuel system component (after verification of correct operation of tank solenoids). For tank replacement the complete venting of the fuel tank must be confirmed with use of the override tool. Requires that the vented solenoid be replaced once the override tool is used. Required prior to fuel tank replacement or solenoid valve removal. Can be performed only after solenoid diagnostics have been completed. These three venting procedures allow only the portion of the system being serviced to be vented. Always refer to the vehicle workshop manual for instructions on the correct procedure for venting the vehicle upon which you are working.
4 - 26
March, 2004
LESSON 4: DIAGNOSIS AND SERVICE Solenoid Tank Valve Diagnostics

As with most types of diagnostic tests, solenoid diagnostics use isolation tests to determine if the tank solenoid valves are functional.
WARNING: ALWAYS ASSUME THAT ALL FUEL SYSTEM COMPONENTS ARE UNDER FULL SYSTEM PRESSURE AT ALL TIMES. USE CAUTION WHEN SERVICING FUEL SYSTEM COMPONENTS.
Solenoid tank valve diagnostics are critical. As with all Pinpoint Tests, these test procedures must be performed precisely and in the correct sequence. This is even more critical with CNG vehicles since fuel tanks and lines are under very high pressure. Always refer to the fuel system section of the workshop manual for the correct procedures when diagnosing CNG solenoid tank valves. NOTE: Some threads on AFVs are Left-Handed. Always refer to service publications when performing vehicle and component service procedures.
March, 2004
4- 27

NOTES
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March, 2004
DEMONSTRATION 1
DEMONSTRATION 1 - CNG VEHICLE DIAGNOSTICS

OBJECTIVES The purpose of this activity is to: CONTENTS Demonstration 1 Worksheet Alternative Hands-On Worksheet
Reinforce the knowledge that the student has acquired from Lesson 4. Allow the student to review detailed information found in Lesson 4. Enable the students to see and practice diagnostic procedures. Provide the students with service publication navigation practice.
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DEMONSTRATION 1 DEMONSTRATION 1 WORKSHEET DEDICATED CNG OR MULTIPORT BI-FUEL CNG VEHICLE DIAGNOSIS STUDENT ANSWER SHEET
Directions: This vehicle has a customer concern of "runs rough." Follow along with your instructor to diagnose this concern. Answer the questions below as the diagnosis is performed. Also list the test steps that are performed and their results in the table provided. 1. Does the reason for the engine roughness seem to be the result of a miss in several cylinders, or a single cylinder? ______________________________________________________________________ _______________________________________________________________________________ 2. List any DTCs that are present._______________________________________________________
3. Based upon this preliminary diagnosis, which of the systems or components listed below could be a likely source of this miss? A. Idle Air Control (IAC) - YES or NO. Why? __________________________________________
_______________________________________________________________________________________________________________________________ ______________________________________________________________________________________________________________________________ ___________________________________________________________________________ ______________________________________________________________________________
B. Mass Air Flow (MAF) - YES or NO. Why?____________________________________________

_______________________________________________________________________________
C. Secondary Ignition System - YES or NO. Why?________________________________________

_______________________________________________________________________________ _______________________________________________________________________________
D. Fuel Delivery System - YES or NO. Why? ___________________________________________

_______________________________________________________________________________ _______________________________________________________________________________
E. Exhaust System - YES or NO. Why? ________________________________________________

_______________________________________________________________________________ _______________________________________________________________________________
F. PCV System - YES or NO. Why? ___________________________________________________

_______________________________________________________________________________ _______________________________________________________________________________
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March, 2004
DEMONSTRATION 1 DEMONSTRATION 1 WORKSHEET DEDICATED CNG OR MULTIPORT VEHICLE DIAGNOSIS STUDENT ANSWER SHEET (continued)
4. Continue the diagnosis using the service publications and list the diagnostic test steps and their results in the table below.
DIAGNOSTIC TEST STEP
RESULTS
March, 2004
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DEMONSTRATION 2
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March, 2004
DEMONSTRATION 2
DEMONSTRATION 2 - DEDICATED CNG OR MULTIPORT BI-FUEL VENTING AND SOLENOID DIAGNOSIS

OBJECTIVES The purpose of this activity is to: CONTENTS Demonstration 2 Worksheet
Reinforce the knowledge that the student has acquired from Lesson 4. Allow the student to review detailed information found in Lesson 4. Enable the students to see and practice solenoid tank valve diagnostic procedures. Enable the students to see and practice fuel venting procedures. Provide the students with service publication navigation practice.
March, 2004
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DEMONSTRATION 2 DEMONSTRATION 2 WORKSHEET DEDICATED CNG OR MULTIPORT BI-FUEL FUEL VENTING AND SOLENOID DIAGNOSIS STUDENT ANSWER SHEET
Directions: Follow along with your instructor while the class performs fuel venting and solenoid diagnosis procedures. Answer the questions below as the activity is performed. 1. A CNG fueled vehicle should not be parked within 10 feet of what three things in a workshop? ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ PAGE#_______ 2. If a vehicle requires that a fuel tank be vented, what must be determined before venting can be performed? ____________________________________________________________________ PAGE#_______ 3. When is fuel line venting required? __________________________________________________ ______________________________________________________________________________ PAGE#_______ 4. When is fuel tank venting required? _________________________________________________ ______________________________________________________________________________ PAGE#_______ 5. What service publication (your Student Reference Guide is not a service publication) contains information for diagnosing solenoid tank valves? ________________________________________________ PAGE#_______ 6. During venting of fuel from a CNG tank, why is it essential that the vehicle be grounded? ______________________________________________________________________________ ______________________________________________________________________________ PAGE#_______ 7. You are preparing to perform solenoid diagnostics. After disconnecting the solenoid tank valve connectors, you attempt to run the vehicle out of fuel. After 10 minutes the vehicle still does not stall. What does this indicate? _______________________________________________________________________ PAGE#_______ 8. You are performing solenoid diagnostics on a vehicle with a manual backflow feature and full fuel tanks. You have installed the vent tool and disconnected the electrical connectors to the fuel tank solenoids. While monitoring the pressure gauge on the vent tool, you have no pressure at the bleed valve after 1 minute. What does this indicate? __________________________________________ ______________________________________________________________________________ PAGE#_______ 9. To verify tank solenoid status, in what sequence should the fuel tanks be vented (on multiple fuel tank vehicles based on the solenoid tank valve status)? _________________________________________ PAGE#_______
CONTINUED ON NEXT PAGE

4 - 34 March, 2004 1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles
DEMONSTRATION 2 DEMONSTRATION 2 WORKSHEET DEDICATED CNG OR MULTIPORT BI-FUEL FUEL VENTING AND SOLENOID DIAGNOSIS STUDENT ANSWER SHEET
10. Where can you find information on the replacement interval of the coalescent filter? ______________________________________________________________________________ PAGE#_______ 11. What lubricant should be used on the o-rings of the coalescent filter when the filter element is replaced? ______________________________________________________________________________ PAGE#_______ 12. When connecting fuel lines to system components, why should you always get the line fitting nut started into the component fuel line fitting before tightening the nut? ______________________________________________________________________________ PAGE#_______ 13. What are the two methods for checking fuel lines for leaks? ______________________________________________________________________________ PAGE#_______ 14. After installing fuel lines and pressurizing the system, what should always be done? ______________________________________________________________________________ PAGE#_______
March, 2004
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ACTIVITY 4
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March, 2004
ACTIVITY 4
ACTIVITY 4
OBJECTIVES The purpose of this activity is to: CONTENTS Activity 4 - Worksheet Q (Hands-On) Activity 4 - Worksheet R (Hands-On) Activity 4 - Worksheet S (Written) Activity 4 - Worksheet T (Written)
Reinforce the knowledge that the student has acquired from Lesson 4. Allow the student to review detailed information found in Lesson 4. Enable the students to practice diagnostic procedures. Provide the students with service publication navigation practice.
March, 2004
4- 37
ACTIVITY 4 ACTIVITY 4 WORKSHEET Q (Hands-On) DEDICATED CNG VEHICLE DIAGNOSIS STUDENT ANSWER SHEET
Directions: Go to the dedicated CNG classroom vehicle and use the information in your Student Reference Guide and the service publications to perform the tasks and answer the questions below. 1. Review the vehicle repair order. What is listed as the customer concern? _____________________ 2. While the vehicle was sitting in the lot, one of the other technicians thought that he detected the smell of gas. What should you do before bringing the vehicle into the service bay?_____________ ______________________________________________________________________________ 3. Perform a leak test on the vehicle. Note any areas that you suspect may be leaking. ____________ ______________________________________________________________________________ 4. Perform the preliminary diagnostic steps. What are the results of these steps? _________________ ______________________________________________________________________________ ______________________________________________________________________________
5. When diagnosing this concern, what publication will provide you with diagnostic direction? ______________________________________________________________________________ 6. If any DTCs were present, where in this publication should you look for the specific pinpoint test that you need to perform? _________________________________________________________
WORKSHEET CONTINUED ON NEXT PAGE
4 - 38
March, 2004
ACTIVITY 4 ACTIVITY 4 WORKSHEET Q (Hands-On) (continued) DEDICATED CNG VEHICLE DIAGNOSIS STUDENT ANSWER SHEET
7. Diagnose the concern. List the diagnostic steps you perform and their results in the table below. NOTE: THE NUMBER OF ROWS IN THE TABLE DOES NOT INDICATE THE NUMBER OF STEPS THAT MUST BE PERFORMED. USE ADDITIONAL PAPER IF REQUIRED.
RESULTS
8. What are the results of your diagnosis? Note: List component names and electrical circuits that may be involved. ______________________________________________________________________ 9. If you repaired this concern, what should you do before returning the vehicle to the customer? ______________________________________________________________________________ RETURN THE WORKSTATION TO THE CONDITION THAT YOU FOUND IT END OF WORKSHEET
March, 2004
4- 39
ACTIVITY 4 ACTIVITY 4 WORKSHEET R (Hands-On) MULTIPORT BI-FUEL CNG VEHICLE DIAGNOSIS STUDENT ANSWER SHEET
Directions: Go to the Multiport bi-fuel classroom vehicle and use the information in your Student Reference Guide and the service publications to perform the tasks and answer the questions below. 1. Review the vehicle repair order. What is listed as the customer concern? _____________________ ______________________________________________________________________________ 2. While the vehicle was sitting in the lot, one of the other technicians thought that he detected the smell of gas. What should you do before bringing the vehicle into the service bay? _____________ ______________________________________________________________________________ 3. Perform a leak test on the vehicle. Note any areas that you suspect may be leaking. ____________ ______________________________________________________________________________ 4. Perform the preliminary diagnostic steps. When checking for DTCs on a bi-fuel vehicle, which control module should you retrieve DTCs from first?____________________________________ 5. List any DTCs found in the control modules. PCM__________________________________________________________________________ AFCM ________________________________________________________________________ 6. When diagnosing this concern, list the publication and section of the service publication that will provide you with diagnostic direction ? ______________________________________________
WORKSHEET CONTINUED ON NEXT PAGE
4 - 40
March, 2004
ACTIVITY 4 ACTIVITY 4 WORKSHEET R (Hands-On) (continued) MULTIPORT BI-FUEL CNG VEHICLE DIAGNOSIS STUDENT ANSWER SHEET
8. Diagnose the concern. List the diagnostic steps you perform and their results in the table below. NOTE: THE NUMBER OF ROWS IN THE TABLE DOES NOT INDICATE THE NUMBER OF STEPS THAT MUST BE PERFORMED. USE ADDITIONAL PAPER IF REQUIRED.
RESULTS
9. What are the results of your diagnosis? Note: List component names and electrical circuits that may be involved. _______________________________________________________________ 10. If you repaired this concern, what should you do before returning the vehicle to the customer? ______________________________________________________________________________ RETURN THE WORKSTATION TO THE CONDITION THAT YOU FOUND IT
END OF WORKSHEET
March, 2004
4- 41
ACTIVITY 4 ACTIVITY 4 WORKSHEET S (Written) SERVICE PUBLICATION NAVIGATION STUDENT ANSWER SHEET
Directions: Use the information you have learned and the publications provided to answer the following questions. 1. The following is a list of preliminary diagnostic steps. Use the student guide to determine the correct sequence in which these steps should be performed, then place a number next to each step to indicate its position in the sequence.
STEP SEQUENCE
DIAGNOSTIC PROCEDURES Perform KOER test Check OASIS and TSBs Verify concern Check installation of non-factory equipment Perform visual inspection Perform KOEO tests Retrieve continuous DTCs
2. A customer brings a dedicated 2001 CNG Crown Victoria into your facility with a concern of backfiring during deceleration. What publication will provide you with diagnostic direction? ______________________________________________________________________________ 3. Which section of this publication provides you with a description of the natural gas fuel system? ______________________________________________________________________________ 4. In what section of this publication will you find the "Symptom Charts"? _______________________ 5. Based on the symptom listed in question 2, and assuming that there are no DTCs stored in any control module memory, which symptom chart should you refer?____________________________________ 6. Which pinpoint test are you directed to for this symptom? ____________________________________ 7. You are working on a dedicated CNG vehicle that requires replacement of the filter element inside the coalescent filter. What service publication will provide you with removal and installation information for this component? __________________________________________________________________ 8. The AFCM will store DTCs for faults relating to which two sensors? _________________________ ______________________________________________________________________________
END OF WORKSHEET
4 - 42
March, 2004
ACTIVITY 4
NOTES
March, 2004
4- 43
ACTIVITY 4 ACTIVITY 4 WORKSHEET T (Written) SERVICE PUBLICATION NAVIGATION STUDENT ANSWER SHEET
Directions: Use the information you have learned, the publications provided, and the data table on the next page to answer the following questions. 1. What cell numbers of the wiring diagrams contain engine controls schematic and connector information for a Dedicated CNG 2001 E-Series truck? _________________________________ 2. According to the 2001 PC/ED manual, what are the possible causes for DTC P0192 that are specific for CNG vehicles?________________________________________________________________ 3. On a Dedicated 2002 E-Series Truck, what is the correct torque for tightening a replacement fuel tank temperature sensor? ______________________________________________________________ 4. A customer brings an 2001 E-Series Truck to you with the concern of "vehicle range has suddenly decreased". You perform preliminary diagnostics and find no DTCs and no engine operation issues. This leads you to suspect that a solenoid tank valve is stuck closed. The vehicle is equipped with midship fuel tank, rear aft-axle fuel tank, forward aft-axle fuel tank, and extended range fuel tank. Use the vehicle service publications and the information on the Data Sheet on the next page to identify the cause of this concern.
TE S T S TE P RESULTS PURPOSE OF TEST STEP
5. Using the SSCC diagnostic method, what component is the source of the concern? _____________ ______________________________________________________________________________ END OF WORKSHEET
4 - 44 March, 2004 1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel CNG Vehicles
ACTIVITY 4 ACTIVITY 4 WORKSHEET T (Written) SERVICE PUBLICATION NAVIGATION STUDENT ANSWER SHEET (continued)
Directions: Use the Data Table below to answer question 4. This is done by comparing the service publication pinpoint test steps to the pinpoint test steps listed below. The RESULTS COLUMN of the table lists the results of the tests you perform, use these results to select the next step that must be performed. Continue doing this until you've identified the cause of the concern. NOTE: SOME STEPS BELOW ARE NOT USED IN THE DIAGNOSIS AND ARE ONLY INCLUDED AS DISTRACTORS. Select only the steps that are required. DATA TABLE
TE S T S TE P PPT A11 P P T A 21 PPT A6 HB1 P P T A 18 PPT A5 Section 310-01B Symptom Chart P P T A 16 P P T A 19 PPT A9 PPT A4 P P T A 13 PPT A1 P P T A 12 PC/ED Symptom Chart 10 PPT A3 PPT HB2 P P T A 10 PPT A8 Section 310-00B PPT HB3 PPT HB4 RESULTS Pressure is 0 psi Pressure is 0 psi Pressure is 0 psi Go to Section 310-00B Pressure is 0 psi when scan tool triggered 0 ohms Symptom "Unable to Vent Tanks" Go to PPT A1 Pressure is 0 psi 0 volts 0 volts 12 volts No Pressure is 0 psi 0 volts Go to PPT HB1 No 900 psi., fuel level OK and power present at Solenoid Greater than 10K ohms No Go to Section 310-01B Symptom Chart 0 volts 0 ohms
March, 2004
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ACTIVITY 4
NOTES
4 - 46
March, 2004
CNG SAFETY APPENDIX
APPENDIX 1: COMPRESSED NATURAL GAS SAFETY

The information presented in this appendix is for use as a supplement to that presented in the Alternative Fuel Vehicle (AFV) Web-Based Course.
March, 2004
Appendix 1 - 1
CNG SAFETY APPENDIX Natural Gas Vehicle Fuel System Standards

The National Fire Protection Association (NFPA) has specified Technical Standard #52 for the design and building of CNG fuel systems. The Canadian Gas Association (CGA) has adopted similar standards. These standards also recommend or prohibit certain service procedures for natural gas fuel systems. Many states and provinces have adopted these technical standards as law. There are also other local laws that apply to CNG fuel system service and fuel handling. Many of the WARNINGS and service precautions described in this program are based on NFPA Standard #52. These practices are required for safety and must be followed. Note: Many states and provinces regard as law NFPA #52, or the CGA standards respectively. There are also other local laws that apply to CNG fuel systems, and they should be observed.
WARNING: OBSERVE THE FOLLOWING PRECAUTIONS DURING SERVICE OF CNG VEHICLES. FAILURE TO OBSERVE EACH OF THESE WARNINGS COULD RESULT IN FIRE OR EXPLOSION IF FUEL IS IGNITED, AND ASPHYXIATION FROM THE RELEASE OF NATURAL GAS. Avoiding Fire or Explosion Hazards WARNING: DO NOT PARK OR SERVICE A CNG FUELED VEHICLE NEAR ANY SOURCE OF FIRE, SUCH AS OPEN FLAME, CIGARETTES OR SMOKING MATERIALS, SPARKS, EXCESSIVE HEAT, WELDING, OR BODY GRINDING EQUIPMENT. AVOID PLACING THE VEHICLE NEAR ELECTRICAL EQUIPMENT THAT DISCHARGES SPARKS THROUGH NORMAL OPERATION, FOR EXAMPLE, MOTORS, ELECTRICAL SWITCHES, AND RADIO TRANSMISSION EQUIPMENT.
Vent the CNG system using the recommended service procedures before storing a CNG vehicle indoors. Avoid servicing a CNG vehicle with a natural gas leak indoors. Determine the source of the leak, vent the fuel system as necessary then repair the natural gas leak. If any source of fire or ignition contacts natural gas, a fire could result. If the fuel is confined and ignited in an enclosed, unventilated area, an explosion could result. Be alert for the odor of natural gas. Natural gas is normally colorless and odorless. As a safety measure, a scent (ethyl mercaptan) is added to aid detection of fuel leaks. Do not smoke or carry lighted tobacco when servicing or handling CNG fuel system components. Store natural gas fueled vehicles and components away from heat, fire and any source of sparks. Because natural gas is lighter than air, accidentally released gas will accumulate near the ceiling of a building.
Appendix 1 - 2
March, 2004
CNG SAFETY APPENDIX Venting CNG Fuel Natural gas can be vented (discharged) into the atmosphere. However, when performing this procedure, the steps described in the following warning must be observed. WARNING: ALWAYS VENT CNG TANKS IN A WELL-VENTILATED AREA THAT IS APPROVED AND EQUIPPED FOR THE PROCEDURES. EXTINGUISH ALL SMOKING MATERIALS. NEVER VENT NEAR OPEN FLAME, HEAT SOURCES AND SPARKS. ALWAYS USE APPROVED VENTING TOOLS AND PROCEDURES AS DESCRIBED IN THE SERVICE MANUAL. NEVER DISCHARGE GAS BY OPENING THE TANK VALVES. HIGH PRESSURE CAN CAUSE SERIOUS INJURY. ALWAYS GROUND THE VEHICLE AND NATURAL GAS SYSTEM. HIGH PRESSURE ESCAPING CAN CAUSE STATIC ELECTRICITY BUILDUP AND SUBSEQUENT SPARKING. VENTING OF FUEL TANKS REQUIRES THE USE OF A VENT STACK THAT IS APPROVED AND EQUIPPED FOR THE PROCEDURE. FOLLOW LOCAL REGULATIONS AND CONSULT YOUR LOCAL FIRE AND ENVIRONMENTAL AUTHORITIES FOR SPECIFIC REGULATIONS. USE ONLY ELECTRICALLY CONDUCTIVE SEALANT ON NATURAL GAS LINES. NEVER USE CONVENTIONAL TEFLON TAPE OR PIPE SEALANT.
Note: Copies of the National Fire Protection Association (NFPA) regulations can be purchased by writing or calling: National Fire Protection Association 1 Batterymarch Park, P.O. 9101 Quincy, MA 02269-9101 Toll Free Phone 1-800-344-3555
March, 2004
Appendix 1 - 3
CNG SAFETY APPENDIX CNG Fuel Tank Safety

The tank used for natural gas is designed and manufactured to meet requirements of either NGV 1 or NGV 2. This is a series of standards as adopted by the American National Standards Institute (ANSI) and the American Gas Association (AGA). This standard contains specifications for the material, design, manufacture and testing of serially produced, refillable containers intended only for the storage of compressed natural gas for vehicle operations. NGV 1 CNG tanks are made of high strength steel. NGV 2 CNG tanks consist of a metal liner reinforced with resin impregnated continuous filament. CONTOUR tanks are rated for use at 3000 psi. These tanks are rated for use at 3000 psi (CONTOUR, CROWN VICTORIA) and 3600 psi (E&F-SERIES TRUCKS).
WARNING: TANKS SHOULD NEVER BE OVERPRESSURIZED.

If damage to the tank is observed during maintenance/repair, the tank must be inspected and approved by qualified personnel. If the tank is rejected, the tank must be replaced before the vehicle is returned to service.
WARNING: THE TANK MUST BE VISUALLY INSPECTED EVERY 36 MONTHS OR 36,000 MILES (58,000 KM), WHICHEVER COMES FIRST, TO MAINTAIN COMPLIANCE WITH FEDERAL REGULATION. THE SERVICE LIFE OF A CNG FUEL TANK IS 15 YEARS FROM THE DATE OF MANUFACTURE LISTED ON THE TANK'S LABEL. IF THE TANK LABEL IS MISSING OR UNREADABLE, THE TANK MUST BE REPLACED. A TANK THAT DOES NOT PASS THE INSPECTION CRITERIA MUST BE REPLACED BEFORE THE VEHICLE IS RETURNED TO SERVICE USING NATURAL GAS.
Appendix 1 - 4
March, 2004
CNG SAFETY APPENDIX VISUAL INSPECTION

The visual inspection is for external damage and deterioration. The inspection must be performed by QUALIFIED PERSONNEL in accordance with the manufacturers established inspection criteria and the procedures outlined in pamphlet C-6.4 from the Compressed Gas Association (CGA). A technician that finds tank damage and/or deterioration must note this on the repair order. This damage must be communicated to the customer prior to releasing the vehicle. Levels of tank damage determine whether the damaged tank can be repaired or must be replaced. These levels of damage will be explained later in this section.
QUALIFIED PERSONNEL are those that are so designated by the Department of Transportation and prevailing authorities responsible for containers used to carry, contain and/or transport gas, hazardous materials and similar materials. The address of the Compressed Gas Association is: Compressed Gas Association 1725 Jefferson Davis Hwy. Arlington, VA 22202 (703) 412-0900
PAINTING A CNG VEHICLE

If a CNG bi-fuel vehicle requires painting, and the vehicle will be placed in a paint oven, the CNG tank must be vented (emptied of fuel). This is done to prevent an overpressure condition during a soak in the paint oven.
WARNING: FAILURE TO COMPLETELY EMPTY THE FUEL TANK PRIOR TO THE VEHICLE BEING PLACED IN A PAINT OVEN CAN CREATE A FIRE AND EXPLOSION HAZARD. TANKS INVOLVED IN ACCIDENTS:
CNG bi-fuel vehicles that have been involved in an accident must have the fuel tank inspected and approved by qualified personnel before being returned to service.
WARNING: TANKS THAT HAVE BEEN SUBJECT TO FIRE MUST BE CONDEMNED AND REMOVED FROM SERVICE.
PRESSURE RELIEF DEVICE Additionally, all CNG tank valves have a lead insert inside that will melt if the tank is exposed to temperatures in excess of 100 C (212 F). This will allow the pressure inside the tank to be relieved, in the event that the tank is exposed to excessive heat or a fire. Note: The pressure relief device is a separate part from the solenoid tank valve used on Contour bi-fuel vehicles, while it is part of the solenoid tank valves used on all other CNG fueled vehicles.
March, 2004
Appendix 1 - 5
CNG SAFETY APPENDIX Solenoid Tank Valves

CNG vehicles can have any one of three different types of tank valves. The following lists the type of tank valves used on the various CNG vehicles. CNG/Gasoline Bi-Fuel Vehicle Tank Valve 1996 E & F-Series - Manual Tank Valve with external pressure relief device (PRD). 1998-2002 E & F-Series - Solenoid Tank Valve with internal PRD. 1996-1999 Contour - Solenoid Tank Valve with external PRD. Dedicated CNG Vehicle Tank Valve 1996-2002 Crown Victoria - Solenoid Tank Valve with internal PRD. 1997-2002 E & F-Series - Solenoid Tank Valve with internal PRD. Most CNG vehicles have electrically actuated solenoid tank valves. These are normally closed valves that are actuated when the ignition key is turned on.
WARNING: INCORRECT USE OF THE MANUAL LOCKOUT/MANUAL BYPASS FEATURE OF A 1996-1999 CONTOUR SOLENOID TANK VALVE CAN CAUSE EXCESS PRESSURE IN THE FUEL TANK. THIS EXCESS PRESSURE MAY CREATE A FIRE OR EXPLOSION HAZARD.
Appendix 1 - 6
March, 2004
CNG SAFETY APPENDIX Fuel System Modifications WARNING: DO NOT MODIFY THE FUEL SYSTEM OR COMPONENTS, OR REPLACE COMPONENTS WITH PARTS THAT DONT MEET FORD SPECIFICATIONS. THE CNG FUEL SYSTEM IS DESIGNED AND BUILT TO CONFORM TO THE NATIONAL FIRE PROTECTION ASSOCIATION STANDARD # 52, AND SIMILAR CANADIAN GAS ASSOCIATION STANDARDS, WHICH DEFINE THE SPECIALLY APPROVED MATERIALS, COMPONENT CONSTRUCTION, AND SYSTEM CONFIGURATION REQUIRED FOR CNG FUEL SYSTEMS. IN ADDITION, THE PARTICULAR SYSTEM INSTALLED ON ALL VEHICLES IS PRECISELY CALIBRATED FOR EFFICIENT OPERATION. THE USE OF DIFFERENT PARTS OR MATERIALS COULD PRODUCE AN UNTESTED CONFIGURATION THAT COULD RESULT IN FIRE, EXPLOSION, AND PERSONAL INJURY, OR CAUSE ENGINE DAMAGE FROM INCORRECT FUEL METERING. THE USE OF FORD SPECIFIED PARTS, AVAILABLE AT AN AUTHORIZED FORD DEALER, IS RECOMMENDED.
March, 2004
Appendix 1 - 7
CNG SAFETY APPENDIX Health Hazards WARNING: AVOID INHALING NATURAL GAS OR OCCUPYING CONFINED AREAS CONTAINING NATURAL GAS. IN LARGE QUANTITIES, NATURAL GAS CAN DISPLACE ENOUGH OXYGEN TO MAKE THE SURROUNDING AIR UNFIT TO BREATHE, AND POSSIBLY CAUSE ASPHYXIATION. IF A PERSON BREATHES NATURAL GAS OR AIR WHICH LACKS OXYGEN DUE TO THE PRESENCE OF NATURAL GAS, HEADACHE, DIZZINESS, AND WEAKNESS IN THE EXTREMITIES CAN RESULT. IN THE EVENT OF ASPHYXIATION FROM INHALING NATURAL GAS, MOVE THE VICTIM IMMEDIATELY TO FRESH AIR AND CONTACT A PHYSICIAN OR MEDICAL EMERGENCY PERSONNEL FOR ARTIFICIAL RESPIRATION OR OTHER REQUIRED TREATMENT. IF THE ODOR OF NATURAL GAS IS PRESENT IN AN AREA, WARN ALL PERSONS IN THE AREA TO EXTINGUISH ALL FLAMES AND TOBACCO. SHUT OFF ELECTRICAL AND AIR POWER EQUIPMENT AND EVACUATE THE AREA IMMEDIATELY. VENTILATE THE AREA UNTIL THE ODOR OF GAS IS NO LONGER PRESENT.
Appendix 1 - 8
March, 2004
NGS APPENDIX
APPENDIX 2: AFV NEW GENERATION STAR TESTER OPERATION

The information presented in this appendix is for use as a supplement to that presented in the AFV New Generation STAR (NGS) Web-Based Course.
March, 2004
Appendix 2 - 1
NGS APPENDIX Alternative Fuel Vehicle (AFV) DTC Retrieval
BF 5-1
NGS Main Menu Fault codes for both the base vehicle and AFV systems can be retrieved and cleared using the New Generation Star (NGS) tester. The following are the procedures for retrieving AFV trouble codes. 1. Insert correct program card into NGS. 2. Connect the NGS into the 16-pin OBD II data link connector (DLC). 3. Turn the ignition key to the ON position: 4. Program the appropriate information into the VEHICLE AND ENGINE SELECTION menu. NOTE: 1998 vehicles can be tested for MIL (PCM) and AFCM codes only. All AFCM PIDS must be pulled with GFI card (Rotunda Part #164-R0904) and Cable (Rotunda part #164-R0906). PIDS are viewed by connecting the NGS to the J/108 connector at the VCL.
Appendix 2 - 2
March, 2004
NGS APPENDIX Alternative Fuel Vehicle (AFV) DTC Retrieval (continued)
BF 5-1A
Selecting Diagnostic Data Link Menu 5. Next, select DIAGNOSTIC DATA LINK from the menu and press the trigger.
BF 5-2
Selecting Data Link Diagnostic Menu 6. Perform DATA LINK DIAGNOSTICS to ensure that the J1850 network is functional. 7. If a fault is indicated in the J1850 data bus, correct the fault and recheck the vehicle symptom before performing any further diagnostic tests.
March, 2004
Appendix 2 - 3
BF 5-3
Selecting AFCM Module Diagnostics 8. For AFV system diagnostics, select the AFCM MODULE (for base vehicle system diagnostics, select POWERTRAIN CONTROL MODULE).
BF 5-4
AFCM Advisory Screen
The AFCM advisory screen will appear to notify you that there are similar PIDs and DTCs to those used for the PCM. In the AFCM mode these PIDs and DTCs may have a different meaning than those found for the PCM.
Appendix 2 - 4
March, 2004
BF 5-5
Selecting Diagnostic Test Mode Menu 9. Select the DIAGNOSTIC TEST MODES menu.
BF 5-6
Retrieving DTCs 10. Select RETRIEVE / CLEAR CONTINUOUS DTCs. 11. Press START.
March, 2004
Appendix 2 - 5
NGS APPENDIX Clearing Alternative Fuel Vehicle (AFV) DTCs
BF 5-7
NGS Displaying DTCs 12. Any codes present will then be displayed. 13. Write down all DTCs displayed. Refer to the Specific Code Diagnostics chart in the service manual supplement (1998 MY) or the PC/ED Manual (1999 MY and later) for diagnostic information on any DTCs present. 14. DTCs should be cleared whenever directed by a pinpoint test and after performing vehicle service. The procedure for clearing codes is to: Retrieve DTCs as previously described. Once DTCs have been retrieved, press the CLEAR button (7). If a code reappears, a fault is still present. If, after correcting all DTCs or if no DTCs are present, the symptom still exists, refer to the Specific Condition Diagnostics Chart in the service manual supplement (1998) or the DTC chart in the PC/ED manual (1999 and later).
Appendix 2 - 6
March, 2004
NGS APPENDIX NGS Parameter Identification Data (PID) Function
BF 5-8
Selecting PID Menu There are situations where a sensor or component has deteriorated; yet its signal is not outside the programmed calibrations of the module. In these cases, operation of the vehicle may be affected, yet no DTC will be stored in memory. For this reason, the NGS has the Parameter Identification Data (PID) mode. The PID mode of the NGS allows you to see the signal as interpreted by the module. In this way, you can watch the signal and determine if it is responding within specifications, or if its operation is erratic or slow. The following procedure allows you to enter the PID menu, select, view and record PIDs: 1. To enter the PID menu, first, enter the AFCM menu in the DIAGNOSTIC DATA LINK menu, as you did to retrieve codes. 2. Then, enter the PID DATA MONITOR AND RECORD menu. NOTE: 1998 vehicles can be tested for MIL (PCM) and AFCM codes only. All AFCM PIDS must be pulled with GFI card (Rotunda Part #164-R0904) and Cable (Rotunda part #164-R0906). PIDS are viewed by connecting the NGS to the J/108 connector at the VCL.
March, 2004
Appendix 2 - 7
NGS APPENDIX NGS Parameter Identification Data (PID) Function (continued)
BF 5-9
AFCM PID Screen 3. A PID screen similar to the one shown here will appear. 4. To select an individual PID, first, use the scroll bar to highlight the PID you wish to select, then press trigger. An asterisk will appear next to the PID, indicating that it has been selected for viewing and recording. 5. To select a BLOCK (group) of PIDs at the same time, press the BLOCK button (button 6), and then press TRIGGER. As you rotate the scroll bar through the PIDs, they will be highlighted. 6. When you have highlighted the desired group, press TRIGGER again and asterisks will appear next to the selected PIDs. 7. To select the maximum number of PIDs for viewing, press the MAX button. 8. Press the START button and the PID values will appear. You can now watch the signals to determine if they are acting normally, or if they could be the cause of the concern. 9. The NGS not only can monitor PID, but it can record it as well. This function is very useful when driving a vehicle or when diagnosing an intermittent fault. When you pushed the START button to view the PID data, the NGS began recording the data. The NGS will continue recording PID data until the memory fills. When the memory is full, the data at the beginning of the recording will drop off and new data will be stored. The amount of time it takes to fill the memory will depend on the number and complexity of the PIDs selected.
Appendix 2 - 8
March, 2004

10. Along the bottom of the screen the instructions tell you to press trigger to CAPTURE data: Once the trigger is pressed, the NGS will continue to record data. However, data at the beginning of the recording will not drop off. The NGS will continue to save data until you press TRIGGER again to SAVE the data, or until recorder memory is full. In this way, the NGS will have data in memory both before and after you pressed the TRIGGER to CAPTURE data. For example, assume you are driving a vehicle with a poor performance concern and no DTCs are present.
This pinpoint test specifies certain PIDs to view. Since you cannot view the PIDs and drive at the same time, you decide to record the PIDs during vehicle operation. Select the PIDs you wish to view (those specified by the test and any others you feel may be helpful). While driving, you notice a sudden loss of engine power. Press the trigger to capture the data. You can now drive the vehicle until the recorder memory is full or you can press the trigger again to save the data before the memory fills. Data will be saved from both before and after the trigger was pressed to capture data. This allows you to see the data before, as well as after the concern occurred.
March, 2004
Appendix 2 - 9
BF 5-10
Saving a PID Recording 11. Once you press the trigger to save the data, a message will appear informing you that the data is being saved. This screen will appear. 12. Always store data before attempting to view the recording.
Highlight the area of the NGS memory that you want to store the recording, then press TRIGGER. The NGS will warn you that any existing recording in that area will be overwritten.
13. Press TRIGGER again and the data will be saved in the area you selected. 14. To view the recording, select VIEW RECORDING area or return to the main menu. 15. Highlight the VIEW RECORDING areas and press TRIGGER. The NGS will ask you to select the recording area you wish to view. 16. Highlight the area you wish to view and press TRIGGER. 17. Once you have brought up the stored data, you need to select which sensor data you wish to view: Single Selection - To make a single selection, scroll to that selection and press TRIGGER. An asterisk will appear before the selected PID. MAX - The MAX button will select only the first or top four PIDs, regardless of the number that are available in the recording. CLEAR - The CLEAR button will deselect all PIDs.
Appendix 2 - 10
March, 2004
NGS APPENDIX NGS PID Viewing Options
BF 5-11
PID Table Display Once you have selected a PID or several PIDs to view, you need to choose how you want to view them. The options are table display and graph display. Either of the two formats can be printed as well. TABLE DISPLAY: The table display will allow you to view up to four of the recorded PIDs at a time, at various speeds. The Point-in-Time recording will display on the left side of the screen. To move forward through the recording, turn the scroll dial clockwise. To move backward through the recording, turn the scroll dial counterclockwise. Time 0.0 (T) is the point in the recording at which the data were captured (trigger pressed). A minus sign (-) in front of a number designates it as the time before capture. The PIDs being viewed are displayed across the top of the screen with their respective values underneath them. Review of the captured data is controlled by the specific functions displayed above the corresponding numeric keypad button.
INFO - The INFO button will display the information screen. This screen contains information about the recording, such as recording area, vehicle, type of link, TRIGGER point, type of module, and recording size. REW - The REW button will move backward through the recording at fast speed. STOP - The STOP button will stop the playback of the recording. PLAY - The PLAY button will move forward through the recording at normal speed. FWD - The FWD button will fast-forward the recording.
March, 2004
Appendix 2 - 11
NGS APPENDIX NGS PID Viewing Options (continued)
BF 5-12
NGS Graph Display GRAPH DISPLAY: The graphing capability of NGS allows you to make visual comparisons between closely related PIDs so that you may determine whether or not their interaction is correct. It also allows you to see a glitch that is not obvious on the table format. Just as with the table display, up to four PIDs can be selected for graphing, but only two at a time can be displayed. When the graph display appears on the screen, the names of the two currently selected PIDs will appear - one on the right and one on the left. If more than two PIDs have been selected for viewing, you can change what is displayed on the screen by using the numeric keypad. To change the left-hand PID, push number 2 on the numeric keypad. To change the right-hand PID, push the number 9 on the numeric keypad. The graph display screen will display a section of the recording that represents a portion of the recording. The PIDs currently being viewed are displayed to the left and right sides of the screen. There will be three sets of numbers also located to the left and/or right side of the screen. These numbers refer to the following:
The top number represents the value of the PID at the beginning of the recording. The middle number shows the value of the PID where the vertical cursor is positioned. The bottom number represents the value of the PID at the end of the graph. To move the vertical cursor to the left, turn the scroll dial counterclockwise or clockwise.
The following functions are displayed on the screen just below the graph:
The - Time button (3) will move the screen toward the beginning of the recording. The + Time button (8) will move the screen toward the end of the recording.
Appendix 2 - 12
March, 2004
GLOSSARY
GLOSSARY
The following is a list of terms and acronyms used throughout this book.
AFCM AFS AFV AUX B+ BARO BASE VEHICLE BAUD-RATE BI-FUEL VEHICLE BFIM BIT CAUSE CFH CHT CGA CLCF CL_COR CLEAN AIR ACT Alternative Fuel Control Module Alternative Fuel System Alternative Fuel Vehicle Auxiliary Battery Voltage Barometric Sensor The gasoline operating system of the vehicle. Baud-rate refers to how many bits per second we can send over a connection. A vehicle that can operate on two different types of fuel (LPG and gasoline). Bi-Fuel Injector Module (previous term used for Multiport Injection Vehicles) Binary Digit. The NGS uses BIT to describe the amount of information it can process at one time. PID that indicates reason vehicle changes fuel operating mode (LPG to GAS or Gas to LPG) Cubic Foot per Hour Cylinder Head Temperature Canadian Gas Association Closed Loop Correction Factor (1998 and earlier MY) Closed Loop Correction Factor (1999 and later MY) The clean air act requires the installation of more advanced pollution control equipment and changes to industrial operations and even community life-style that will lead to reductions in emissions of air pollutants. Compressed Natural Gas Common The compuvalve uses preprogrammed strategies to control operation of the alternative fuel system on a bi-fuel vehicle. It then meters fuel flow going into the engine. Cold Start Heater The wire(s) that run between control modules over which the modules communicate. Data Link Connector Diagnostic Trouble Code Digital Voltage and Ohm Meter
CNG COM COMPUVALVE
CSH DATA BUS
DEDICATED VEHICLE A dedicated vehicle uses only CNG for fuel. DLC DTC DVOM
1999 - 2004 Ford Dedicated CNG and Multiport Bi-Fuel Vehicles
March, 2004
Glossary - 1
GLOSSARY
GLOSSARY (continued)
ECT EEC-V EFT EGR Engine Coolant Temperature Electronic Engine Control Version 5 Engine Fuel Temperature Exhaust Gas Recirculation
ENERGY POLICY ACT The energy policy act provides for improved energy efficiency. It includes provisions to allow for greater competition in energy sales. ETHYL MERCAPTAN A scent that is added to LPG for safety and leak detection. EVTM FORD TECHNICAL SERVICE HOTLINE FAP FRPREAB FRTMPAB FTTMP FCV FRP FRT FRPBREAB FSP FTP FTT FUEL_MODE GFI HD5 Electrical Vacuum Troubleshooting Manual 1-800-826-4694 Fuel Absolute Pressure (98 and earlier MY) Fuel Absolute Pressure (99 and later MY) Engine Fuel Temperature Bank 1 Signal Recieved from the Fuel Tank Temperature Sensor Fuel Control Valve Fuel Rail Pressure Fuel Rail Temperature Fuel Absolute Pressure (99 and later MY) Fuel Storage Pressure Fuel Tank Pressure Fuel Tank Temperature Fuel Operating Mode (CNG or GAS) Gaseous Fuel Injection Ford requires the LPG fuel used in there systems to meet HD5 standards. HD5 limits the amount of propene (a different type of gas than propane) that may be in the LPG mixture. Too much propene can lead to plastic-like deposits to form in the fuel system. In California Ford requires the LPG fuel used in there systems to meet HD10 standards. The difference between HD10 and HD5 is the amount of propene (a different type of gas than propane) that may be in the LPG mixture. Too much propene can lead to plastic-like deposits to form in the fuel system. Heated Oxygen Sensor Intake Air Temperature Key On Engine Off Key On Engine Running KiloPascals Absolute Liquid Crystal Display
HD10
HO2S IAT KOEO KOER KPA LCD
Glossary - 2
March, 2004
GLOSSARY
GLOSSARY (continued)
LED LPG MAF MAP MIL MULTIPLEXING NFPA NGS OBD OPMODE PC/ED PCM PCV PD PID PROTOCOL PSI PWM RCV RPM SELSW SIG SIG RTN SPDT SSCC STOICHIOMETRIC SW B+ TPS TSB VCL VECI VIN VSS WOT Light Emitting Diode Liquefied Petroleum Mass Air Flow Manifold Absolute Pressure Malfunction Indicator Lamp A computer strategy that allows module-to-module communication during normal vehicle operation. National Fire Protection Association New Generation STAR On-board Diagnostics Operating Mode Powertrain Control/Emission Diagnosis Powertrain Control Module Pressure Control Valve Preliminary Diagnostics Parameter Identification A computer language that allows communication between control modules. Pounds per Square Inch Pulse Width Modulated Regulator Control Valve Revolutions Per Minute Fuel Selector Switch Position Signal Signal Return Single Pole Double Throw Symptom-to-System-to-Component-to-Cause Ideal air/fuel ratio. Switched Battery Voltage Throttle Position Sensor Technical Service Bulletin Vehicle Communications Link Vehicle Emissions Control Information Vehicle Identification Number Vehicle Speed Sensor Wide Open Throttle
March, 2004
Glossary - 3
GLOSSARY
NOTES
Glossary - 4
March, 2004
TOOL LIST
ROTUNDA TOOL LIST AND ORDER FORM The tools listed below were used during the presentation of this course. It is essential that correct tools be used during transmission service and repair. For your convenience, the tools are listed below and a Rotunda Order Form can be found on the following pages.
New Generation STAR (NGS) Tester 007-00500 Digital Multimeter 007-00001 104-pin Breakout Box 014-00950 Spring Lock Coupling Disconnect Tools D87L-9280-A Spring Lock Coupling Disconnect Tool D87L-9280-B Spring Lock Coupling Disconnect Tool T83P-19326-C Contour Vent Kit 164-R0911 Rotunda Natural Gas Service Kit 134-00254 (Contents include the following:) Manual Override Tool 134-00050 Fuel Fill Valve Filter Remover/Installer Tool 134-00115 Fuel Rail Pressure Test & Venting Kit 134-00116 Fuel Filler Neck Venting Tool 134-00117 Venting Hose 134-00118 Electronic Fuel Injector Tester 134-00119 Electrical Harness for Venting Tanks 134-00120 Grounding Cable 134-00121 Vent Box - Pressure Test Adapter 134-00122 Electronic Leak Detector 134-00049 E&F Series CNG Venting Adapter 134-00225 Rotunda Gaseous Fuel Service Kit 164-R0912 (Contents include the following:) NGS Tester Program Card 164-R0905 NGS Tester Adapter Cable 164-R0906 Fuel Pressure Sensor R&I Tool 164-R0906 Tank Valve Wrench 164-R0908 Tank Solenoid Ring Wrench 164-R0909 Tank Solenoid Valve Core Wrench 164-R0910 Venting Kit 164-R0911
TOOL LIST
ORDER FORM
QTY.
(if required)
FAX NUMBER 1-800-762-6181
ITEM NUMBER PREFIX BAL. OF NO. COL. 1 COL. 2
ADDITIONAL SPECIFICATIONS OPTIONAL: CATALOG PAGE NO.
DESCRIPTION
UNIT PRICE
EXTENDED TOTAL
PART I
Dealer Parts Code #: Dealer Name: Address: City, State, Zip: Phone #: Fax #: Attention:
PART II
Buyer, having been quoted both an installment Price and a lesser Cash Price, hereby purchases from Seller on installment price basis, upon the terms and conditions set forth on the face hereof, the equipment to be delivered and installed at Buyers premises, as described above and agrees to pay Seller the Installment Price therefore as so set forth until paid in full.
TOTAL
30 Day Open Account Installment Plan (Fixed Rate) 12 Mo. (Minimum $1,000) 24 Mo. (Minimum $3,000) 48 Mo. (Minimum $10,000) 60 Mo. (Minimum $15,000) (Reverse side must be completed) 90 Days Same as Cash (Minimum $1,000) 36 Mo. (Minimum $5,000)
PART III
(ORDERS OVER $4,000)
FCSD CREDIT MANAGER APPROVAL
Notice To Buyer: Order Date: Ship to arrive by (Date or ASAP): Address: City, State, Zip:
1. Do not sign this contract before you read it or if it contains any blank spaces. 2. You are entitled to an exact copy of the contract you sign. 3. Under the law you have the right to pay off in advance the full amount due and under certain circumstances to obtain partial refund of the time charge. BUYER ACKNOWLEDGES RECEIPT OF A TRUE AND COMPLETELY FILLED IN COPY OF THIS CONTRACT AT THE TIME OF SIGNING.
September 1999 315-195 Prices subject to change without notice
PRINT NAME
AUTHORIZED DEALERSHIP SIGNATURE (BUYER)
DEALER: Be sure you have completed Parts I and II for all orders, Part III for Installment Plan Orders 315-195 (Previous editions may not be used)
FOR TELEPHONE ORDERS USE THE ROTUNDA TOLL-FREE NUMBER 1-800-ROTUNDA (768-8632) FOR TELEPHONE ORDERS USE THE ROTUNDA TOLL-FREE NUMBER 1-800-ROTUNDA (768-8632)
TERMS & CONDITIONS

1. Payment and Terms of Payment. a. If Buyer has requested the Dealer Open Account payment plan via the Ford Dealer Statement in Part II of the order form, and Seller agrees to sell pursuant to such plan, then Buyer shall pay the total purchase price shown on the invoice. b . If Buyer has requested the Installment Plan (Fixed Rate) in Part II of the order form, and Seller agrees to sell pursuant to such Plan, then Buyer shall pay the Down Payment (if any), and the Time Balance in equal monthly installments in accordance with the terms set forth below. c . If Buyer has requested the Installment Plan (Variable Rate) in Part II of the order form, and Seller agrees to sell pursuant to such Plan, then Buyer shall pay the Total Cash Price and any interest thereon in accordance with the Loan and Security Agreement to be executed by Buyer and Seller. 2. Title. Title to Equipment purchased by Buyer from Seller shall pass to Buyer upon Sellers receipt of all amounts owing by Buyer to Seller hereunder. 3. Risk of Loss. Seller shall be responsible for risk of loss until Equipment is delivered to the location set forth herein, at which time risk of loss shall be the responsibility of Buyer. 4. Acceptance and Inspection. Buyer shall be deemed to have accepted Equipment upon Sellers delivery. Equipment shall be deemed to have been delivered in good condition unless Buyer gives Seller notice to the contrary within 10 days after Sellers delivery. 5. Delays. Seller shall not be liable for any failure or delay in delivering Equipment, or for any failure to perform any provision hereof, resulting from fire, flood or other casualty, riot, strike or other labor difficulty, governmental regulation or other restriction, or any other cause beyond Sellers control. 6. Unconditional Obligation. Buyers obligation to make payments to Seller or its assignee shall be absolute and unconditional and shall continue unmodified despite any loss, damage or other interruption in the use of Equipment. The obligation of Buyer to pay in full any amounts due under this contract shall not be subject to dispute, claim, counterclaim, defense or other right which Buyer may have to assert against Seller or the manufacturer of Equipment. Buyer acknowledges that: (a) Buyer has selected Equipment and Manufacturer, and Buyer has determined Equipments suitability and fitness for the Buyers purpose, (b) Seller is not the manufacturer of Equipment, and (c) Manufacturer issues its own warranty and performs the obligations under such warranty. 7. Warranty. THE MANUFACTURERS WARRANTY SHALL BE BUYERS EXCLUSIVE REMEDY, RECOURSE OR DAMAGE FOR ANY DEFECT IN WORKMANSHIP OR MATERIAL OR ANY FAILURE OF THE EQUIPMENT. SELLER MAKES NO WARRANTIES, REPRESENTATIONS, INDEMNITIES OR GUARANTEES WHATSOEVER WITH RESPECT TO EQUIPMENT EITHER EXPRESS OR IMPLIED, ARISING BY LAW OR CUSTOM, INCLUDING ANY IMPLIED WARRANTY OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. THE LIABILITY OF THE SELLER SHALL BE LIMITED TO EXPRESS OBLIGATION TO DELIVER THE EQUIPMENT. UNDER NO CIRCUMSTANCES SHALL SELLER BE LIABLE OR RESPONSIBLE FOR ANY SPECIAL, INDIRECT, INCIDENTAL, CONSEQUENTIAL OR PUNITIVE DAMAGES, WHETHER FORESEEABLE OR UNFORESEEABLE, WHICH BUYER MAY INCUR, EXPERIENCE OR CLAIM, INCLUDING, BUT NOT LIMITED TO, CLAIMS FOR LOSS OF PROFITS, INTERRUPTION IN BUSINESS, LOST OPPORTUNITY, WORK STOPPAGE OR OTHER IMPAIRMENT OF ASSETS, ARISING OUT OF MISREPRESENTATION, NEGLIGENCE, STRICT LIABILITY, IN TORT OR OTHERWISE, ON ACCOUNT OF ENTERING INTO OR RELYING ON THIS AGREEMENT, EVEN IF SELLER HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. 8. Freight and Taxes. Freight costs and applicable taxes will be added to the final invoice and will be borne by Buyer. 9. Security Interest. Buyer hereby grants to Seller a continuing security interest in the Equipment, including all products and proceeds thereof, until all amounts due hereunder are paid. Buyer agrees to execute, and pay filing fees for, any financing statement or other documents deemed necessary by Seller to maintain a valid security interest in the Equipment. 10. Maintenance. Buyer shall use the Equipment carefully and properly. Buyer, at Buyers own expense, shall maintain and repair all items of the Equipment in order to keep them in good order and condition and, in particular, shall comply fully with the maintenance, operating, usage or other instructions provided by the manufacturer. Buyer authorizes Seller, or any third party appointed by Seller, to inspect the Equipment when necessary. Buyer shall at all times keep the Equipment free and clear of all liens, charges or encumbrances. 11. Personal Property. Ford proprietary diagnostic equipment (including the software, if applicable) shall be kept at Buyers premises as listed on the reverse side and shall remain personal property regardless of how and to what degree it may be affixed or attached to any building or structure or what may be the consequence of its removal from such building or structure. Buyer shall not encumber the Equipment (including software, if applicable) until all amounts owing to Seller hereunder are paid. In addition, Seller grants to Buyer, and Buyer accepts, a non-exclusive license to use the Equipment (including the software, if applicable) in accordance with the terms and conditions set forth herein. The license (and Equipment) shall not be leased, sold, assigned or otherwise transferred, in whole or in part. In the event, Buyer proposes to lease, sell assign or otherwise transfer the Equipment (and/or its software, if applicable), in whole or in part, to any person or entity, Ford Motor Company shall have a Right of First Refusal to purchase the Equipment (including all software, if applicable) for Ten and 00/100 Dollars ($10.00) in U.S. currency. 12. Insurance and Indemnification. Buyer shall defend, indemnify and hold harmless Seller from and against, and at Buyers own expense provide insurance satisfactory to Seller covering any and all losses, damages, claims, expenses and other liabilities (including attorneys fees,) relating to or arising out of: (I) damage, loss, theft, or destruction of the Equipment, or (ii) death, injury or property damage connected with the use, operation or condition (including without limitation, defects whether or not discoverable by any party) of the Equipment. Buyer shall promptly notify Seller of any such claim. Seller shall have the right to participate, at its own expense, in any proceeding for which Buyer has undertaken the defense of Seller, and in no event shall Buyer settle any claim against Seller without Sellers prior written consent, Buyer shall provide evidence of such insurance to Seller upon demand. Seller is under no obligation to examine any insurance certificate or advise Buyer that its insurance does not comply with the requirements set forth herein. The losses covered by insurance shall in all cases be payable to Seller and Buyer as their interests may appear. If Buyer fails to insure the Equipment as herein provided, Seller may, but is not obligated to, place such insurance upon the Equipment and the Buyer agrees to pay to Seller on demand the premiums for such insurance placed by Seller. In no event shall any insurance coverage be deemed to limit or replace Buyers obligation to indemnify Seller as provided herein. 13. Default. In the event that Buyer: (a) fails to pay any amount due hereunder within ten (10) days of the due date, (b) fails to comply with any other provision hereof, (c) files, or if there is filed against Buyer, any petition under any bankruptcy or insolvency laws or suffers the appointment of any trustee or receiver for all or any part of Buyers business or assets, or (d) has any assignment (voluntarily or involuntarily), lien, attachment or levy issued against the Equipment (unless such petition, assignment or appointment, lien, attachment or levy is withdrawn or nullified within twenty (20) days) then Buyer shall be in default hereunder and all of Buyers indebtedness and obligations to Seller shall, at Sellers option, become immediately due and payable, and Seller may, at its option, terminate this contract and repossess any and all items of Equipment with or without legal process and sell the same at private or public sale without prior notice to Buyer to the extent permitted by law. Upon request, Buyer shall deliver the Equipment to Seller at a place designated by Seller. Repossession and/or sales of the Equipment upon such default shall not affect the Sellers right to retain all payments made prior to repossession or to recover the balance due hereunder for any deficiency. Buyer shall reimburse Seller all costs of collection, repossession and resale (including reasonable attorneys fees, court costs and other expenses incurred by Seller.) Buyer hereby releases Seller from any liability for damages resulting from repossession hereunder. The rights and remedies of Seller, in the event of default herein mentioned shall not be deemed exclusive but shall be cumulative and in addition to all other rights and remedies existing under law, and may be enforced successively or concurrently. Waiver by Seller of any default shall not be deemed a waiver of any other default.
14. General. The waiver by either party of, or failure to claim, a breach of any provision of this contract shall not be deemed to be a waiver of any provision of this contract, shall not be deemed to be a waiver of any subsequent breach or to affect in any way the effectiveness of such provision. This contract constitutes the entire agreement between the parties and may not be changed except by an instrument in writing signed by the party to be charged. This contract may not be assigned by Buyer without the Sellers prior written consent. Seller may assign this contract at any time but shall not thereby be relieved from any liability hereunder. In the event that one or more clauses of this contract are found to be unenforceable, illegal or contrary to public policy by court of competent jurisdiction, the remainder of this contract shall remain in full force and effect except for the unenforceable, illegal or other provisions. This agreement is a Michigan agreement and shall be interpreted, construed and enforced in accordance with the laws of the State of Michigan, United States of America. Each of the parties here to agrees that any legal or equitable action or proceeding with respect to this agreement shall be brought only in any court of the State of Michigan, or in any court of the United States of America sitting in Michigan, and each of the parties hereto submits to and accepts generally and unconditionally the jurisdiction of those courts with respect to such partys person and property. Each party hereby irrevocably waives any objection to the laying of venue of any such action or proceeding in the above described courts.
15. Finance Charge. Monthly portion of Finance Charge (Part III, Item 3) due is calculated each month by multiplying 1/12 of the annual finance charge rate times the remaining portion of the Unpaid Balance of Cash Price, and is added to the portion of the Unpaid Balance of Cash Price due each month.
PART III
Installment Plan Agreement 1. Cash Price 2. Down Payment (if any)
3. Unpaid Balance of Cash Price (Difference between 1 and 2)
4. Finance Charge (Finance charge will reduce each month) Call 1-800-768-8632 for the current finance charge rate.
5. Time Balance (3 + 4)
6. Number of Installments 12 24 36 48 60 equal monthly installments. Taxes and transportation (if any) will be billed separately.
7. Installment Payment Price (1 + 4)
I agree to pay the time Balance set forth in accordance with the above schedule and the terms and conditions of this order form. Dealer Signature:
Date:
MAIL COMPLETED ORDER FORM TO: ROTUNDA EQUIPMENT PROGRAM P.O. Box 1450 Kenosha, WI 53141 September 1999
315-195
Prices subject to change without notice

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1999-2004 Ford Dedicated CNG and Multiport Injection Bi-Fuel CNG Vehicles

IMPORTANT SAFETY NOTICE

LESSON 1: INTRODUCTION TO CNG VEHICLES

LESSON 2A: DEDICATED CNG OPERATION

LESSON 2B: MULTIPORT BI-FUEL CNG VEHICLE OPERATION

LESSON 3B: MULTIPORT BI-FUEL CNG COMPONENTS

LESSON 4: DIAGNOSIS AND SERVICE

APPENDIX 1: COMPRESSED NATURAL GAS SAFETY

APPENDIX 2: AFV NEW GENERATION STAR TESTER OPERATION

GLOSSARY ....................................................................................................... Glossary - 1 TOOL LIST ROTUNDA ORDER FORM

INTRODUCTION AND PREREQUISITE REVIEW

INTRODUCTION AND PREREQUISITE REVIEW

INTRODUCTION AND PREREQUISITE REVIEW

ALTERNATIVE FUEL VEHICLE (AFV) CURRICULUM

Flexible Fuel Vehicle Web-Based Training - Course CodeWB 31S11W0

Ford Electric Ranger Instructor-Led Training - Course Code 34N07T0

Course Terminal Objectives

INTRODUCTION AND PREREQUISITE REVIEW Evaluation

INTRODUCTION AND PREREQUISITE REVIEW

INTRODUCTION AND PREREQUISITE REVIEW

INTRODUCTION AND PREREQUISITE REVIEW PREREQUISITE REVIEW (continued)

10. PIDs A. B. C. D. 11. Once A. B. C. D.

INTRODUCTION AND PREREQUISITE REVIEW PREREQUISITE REVIEW (continued)

INTRODUCTION AND PREREQUISITE REVIEW PREREQUISITE REVIEW (continued)

INTRODUCTION AND PREREQUISITE REVIEW NOTES

LESSON 1: INTRODUCTION TO CNG VEHICLES

LESSON 1: INTRODUCTION TO CNG VEHICLES

Upon completion of this lesson the student will be able to:

LESSON 1: INTRODUCTION TO CNG VEHICLES

COMPRESSED NATURAL GAS (CNG) VEHICLES

LESSON 1: INTRODUCTION TO CNG VEHICLES

WHAT IS NATURAL GAS?

LESSON 1: INTRODUCTION TO CNG VEHICLES Alternative Fuel Comparison Table

Octane BTU per gallon

122 cubic feet = 1 gallon of gasoline Gas

Tank is 1.25 times larger

Tank is 3.5 times larger

Tank is 1.8 times larger

Tank is 1.5 times larger

atm T / 200 psi

atm T / 3000-3600 psi

920-1,120F/ 2-10% 1.52

1,200F/ 5-15% 0.55

800F/ 7-36% 1.4

850F/ 3-19% 1.59

5-10% power loss

10-20% power loss

5% power increase Toxic

15-20% less carbon monoxide.Increased nitrogen oxide relative to gasoline.

Standard against which others are measured.

Natural gas/ C oal

Sugar and starch crops/ Biomass

LESSON 1: INTRODUCTION TO CNG VEHICLES Changes to Base Vehicle Operating Strategies

2003/2004 Crown Victoria Dedicated CNG

2003 1/2 F150 Bi-Fuel

LESSON 1: INTRODUCTION TO CNG VEHICLES Supplemental Information On Alternative Fuel Vehicles

Ford Motor Company

www.ethanolRFA.org www.propanegas.com/vehicle www.propanegas.com www.methanol.org www.energy.ca.gov www.evaa.org

www.naftp.nrcle.wva.edu www.state.az.us www.csa.international.org

LESSON 2A: DEDICATED CNG VEHICLE OPERATION

LESSON 2A: DEDICATED CNG OPERATION

Upon completion of this lesson the student will be able to:

Dedicated CNG Vehicle Theory Of Operation CNG Fuel System Pressures

_________________________________________ _ _______________________________ PAGE#

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