Ford F150 Pickup. Manual — part 1167

Gas Association Pamphlet C6.2 guidelines. If any of the flaws cannot be completely measured in the
vehicle, the tank must be removed from the vehicle for further inspection.

10. If the tanks have been or are suspected of having been exposed to a corrosive chemical spill, the tank

must be removed from the vehicle for further inspection of the complete composite surface, including the
area under the tank straps. If there is any indication of chemical attack, such as blistering, cracking or
delamination, the tanks must be condemned and replaced with new tanks.

11. The acceptance criteria for cuts and abrasions are different from those listed in Section 6.5.1 of the

Compressed Gas Association Pamphlet C6.2. These tanks have extra epoxy resin and a clear coat to
reduce the sensitivity to surface damage. The following are the composite wrap inspection criteria:

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Level 1 Abrasions: These are defined as minor abrasions, such as scuffs less than 0.254 mm (0.010
inch) deep, and are acceptable without repair.

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Level 2 Abrasions: These are defined as abrasions having some exposed fibers or flat spots with a
depth between 0.254 mm (0.010 inch) and 0.762 mm (0.030 inch). Level 2 abrasions must be
repaired before the tank is returned to service.

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Level 1 Cuts: These are defined as cuts or scratches less than 0.254 mm (0.010 inch) deep and are
acceptable without repair regardless of length, number or direction.

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Level 2 Cuts: These cuts have a maximum depth up to 0.762 mm (0.030 inch) and a maximum
length up to 203 mm (8 inches). Level 2 cuts must be repaired before the tank is returned to service.

12. Repair of the damage to composite wrap is as follows:

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Level 2 cuts and abrasions are to be coated with epoxy resin. Mix and apply commercial room
temperature cure, two-component epoxy resin according to the manufacturer's manuals. Frayed
fibers must be cut away before application of the epoxy resin.

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Tanks with damage exceeding Level 2 must be condemned in accordance with Step 14.

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The criteria for other damage to the composite wrap are defined in the Compressed Gas
Association Pamphlet C6.2.

13. The metal tank ends are protected with a multi-coat system using epoxy and polyurethane coatings. Chips

in the coating must be evaluated and repaired. The metal tank end external inspection criteria are as
follows:

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Level 1 Chips: These are chips or abrasions which do not penetrate the black epoxy coating. The
steel or gray primer has not been exposed. Level 1 chips require no repair.

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Level 2 Chips: These are chips or abrasions which penetrate the black epoxy coating and must be
repaired as follows to prevent corrosion:

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Sand the damaged area to remove rust and rough up the surrounding coating.

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Clean the damaged area with a commercial pre-paint cleaning solvent.

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Apply a zinc-rich, cold galvanizing compound (Rust-Oleum TM Zinc-Rich or equivalent
commercial product).

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Dents: Tanks with dents to the metal ends which exceed 1.524 mm (0.060 inch) in depth must be
removed from service and condemned.

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Gouges: Tanks with sharp gouges penetrating the coating and into the metal liner must be removed
from service and condemned.

14. Condemned tanks, whether due to damage or expiration, shall be removed from the vehicle and destroyed

as follows:

2003 Ford Pickup F150

2003 GENERAL INFORMATION Fuel System - General Information - Natural Gas - F150 Pickup

1. Vent and remove the fuel tanks. Refer to FUEL SYSTEMS .

2. Remove the fuel tank solenoid valve. Refer to FUEL SYSTEMS .

3. Purge the fuel tank with compressed air for 30 seconds.

4. Destroy the fuel tank by drilling a 12.7-mm (0.50-inch) diameter hole in the fuel tank sidewall.

15. Fuel Tank Straps: Examine the fuel tank straps for correct positioning of the rubber isolators. Replace the

rubber isolators as necessary.

16. Inspection Record: Record the date, vehicle mileage and the results of the fuel tank inspection.

TORQUE MULTIPLICATION CONVERSION

1. Record the torque value to be obtained as A.

2. Measure the distance from the center of the torque wrench handgrip to the center of the torque wrench

drive. Record this measurement as B.

Fig. 60: Measuring Distance B
Courtesy of FORD MOTOR CO.

3. Measure the distance from the center of the torque wrench adapter opening to the center of the torque

wrench adapter drive. Record this measurement as C.

NOTE:

When using a torque wrench adapter, the distance from the torque wrench
drive to the adapter drive changes the actual torque value. Apply the
following formula (A x B dagger B - C = D) to obtain the correct torque
value.

2003 Ford Pickup F150

2003 GENERAL INFORMATION Fuel System - General Information - Natural Gas - F150 Pickup

Fig. 61: Measuring Distance C
Courtesy of FORD MOTOR CO.

4. Example: multiply the torque value to be obtained A (120) by the length of the torque wrench B (12).

Subtract the length of the torque wrench adapter C (2) from the length of the torque wrench B (12).
Divide the product of A x B (1440) by the difference of B - C (10) to obtain the torque multiplication
conversion D (144).

2003 Ford Pickup F150

2003 GENERAL INFORMATION Fuel System - General Information - Natural Gas - F150 Pickup

Fig. 62: Calculating Torque Multiplication Conversion D (144)
Courtesy of FORD MOTOR CO.

2003 Ford Pickup F150

2003 GENERAL INFORMATION Fuel System - General Information - Natural Gas - F150 Pickup