Ford F150 Pickup. Instruction — part 1149

3. Fill the fuel tank to 1/2 maximum pressure.

4. Pressurize the entire fuel system.

5. Beginning with the fill valve follow the system through to the fuel injectors, apply a quantity of mild

soapy water to each fitting or component seam. Leaks in the system will exhibit soapy bubbles.

6. Repair any leaks discovered.

7. Fuel the tank to full pressure.

8. Repeat the soapy water application and repair any leaks discovered.

TANK INSPECTION - PURGING

WARNING:

The bi-fuel system pressure must be relieved prior to any leak repair
or personal injury may occur.

WARNING:

Avoid inhaling propane gas or occupying confined areas containing
propane. Propane is heavier than air. The heavier gas can displace or
push fresh air out of an area. In large quantities, propane can displace
enough oxygen to make the surrounding air unfit to breathe and possibly
cause illness. If a person breathes propane gas or air that lacks oxygen
due to the presence of propane gas, headache, dizziness, and weakness
in the extremities can occur. In severe cases, prolonged breathing of
propane-fouled air can cause suffocation. In the event of illness from
inhaling propane gas, move the victim immediately to fresh air and
contact a physician or medical emergency personnel for artificial
respiration or other required treatment.

WARNING:

Do not needlessly vent propane fuel during service, and do not open the
80% stop-fill valve while a vehicle is inside a building. When servicing the
fuel system, follow the recommended procedures to shut off the fuel
tanks and run the engine out of fuel before disconnecting the fuel system
components. If the fuel tank(s) are being serviced, have the fuel
evacuated by trained personnel at a local propane fuel station. Liquid
propane fuel vaporizes at normal barometric pressure at temperatures
above -42°C (-44°F), and expands to 270 times its volume as a liquid.
Unnecessary venting of propane fuel can create fire and health hazards
which could cause personal injury or death.

WARNING:

Be alert for situations that may cause the propane fuel system to vent
fuel. These include extremely hot days, parking near a space heater, or
hoisting a vehicle up near a ceiling heater. Release of propane fuel in a
confined area through the pressure relief valve could occur. The release
of propane fuel in a confined area could result in an accumulation of
flammable vapors. If fuel is vented near a heat source, a fire or explosion
could occur.

2003 Ford Pickup F150

2003 GENERAL INFORMATION Fuel System-General Information-Bi-Fuel - F150 Pickup

1. Open the outlet valve and release air pressure in the fuel tank.

2. Inject at least 20 ml (1 ounce) of anhydrous methanol for every 9 kg (20 lb) of propane capacity. Rotate

the fuel tank until the entire interior surface has been exposed to the anhydrous methanol.

3. Connect the tank to be purged to the propane vapor source.

4. Open the supply valve on the fuel tank and close the purge line valve.

5. Open the source valve and allow propane vapor to enter the tank.

6. When the tank pressure reaches 103 kPa (15 psi), close the source valve and open the purge line valve.

When the propane vapor is released into the atmosphere the anhydrous methanol containing any moisture
will be released to the atmosphere.

7. Pressurize and purge the tank a total of 5 times.

8. Pressurize the tank with propane vapor to 103 kPa (15 psi) for a sixth time and close all valves.

9. Disconnect the tank from the propane vapor source and store it at the 103 kPa (15 psi) pressure. This will

prevent moisture from entering the tank.

FUEL TANK INSPECTION

WARNING:

Do not use paint drying ovens for propane fueled vehicles. The heat of
paint drying ovens will increase the pressure in the fuel tanks. This could
cause venting of propane fuel vapor into the oven and result in a fire from
the heat or sparks in the electrical equipment. If the fuel is confined inside
an oven an explosion may occur. When refinishing the body panels of a
propane fueled vehicle use spot painting and drying methods.

WARNING:

If a confined area, such as a lubrication pit, has been subjected to
propane gas the area should be inspected for adequate oxygen levels by
a local health department before being entered or personal injury or death
may occur.

WARNING:

The fuel system pressure must be relieved before any component can be
removed. The fuel tanks must be evacuated prior to tank removal.
Removal of components without pressure relief or tank evacuation can
cause propane fuel to escape into the air and cause injury or death.

NOTE:

The fuel tank must be purged if the interior of the tank has been exposed to air
or if the tank is new. The moisture in normal air contains moisture that forms
ice crystals at propane storage pressures.

CAUTION: Do not purge the tank with liquid propane. Liquid propane turns any

moisture into ice crystals which prevents flushing. To prevent
moisture accumulation, purge the tank at a maximum pressure of 103
kPa (15 psi).

2003 Ford Pickup F150

2003 GENERAL INFORMATION Fuel System-General Information-Bi-Fuel - F150 Pickup

1. Raise and support the vehicle.

2. Examine the vehicle underbody and chassis in the general area near the fuel tank(s) for any indication of

collision damage, malfunction, fire or excessive mud/dirt accumulation.

3. Examine the fuel tank stone/heat shield for any indication of collision damage, malfunction, fire or

excessive mud/dirt accumulation.

4. Remove the fuel tank stone/heat shield.

5. Examine the fuel tank(s) and the stone/heat shield interior for any foreign objects (such as stones or

gravel) or foreign materials (such as mud, salt, liquids or chemical residue).

6. Remove any foreign material, using only a clean, dry cloth. Remove all foreign objects. Do not use water

or any cleaners.

7. Examine the fuel tank labels for the tank expiration date. Use a light and mirror to access labels hidden

from normal view. If the expiration date has been exceeded, condemn the tank, using the procedure in
Step 14 .

8. Inspect the tank sidewall and dome ends, following the general guidelines set forth in the Compressed

Gas Association Pamphlet C6.2. Inspect the tank(s) for the following:

z

abrasions

z

dents

z

cracking, blistering or peeling of clear coating

z

corrosion

z

cracks or gouges in the metal dome

z

cracks in the fiberglass overwrap

z

impact damage (cracking) in the fiberglass overwrap

z

cuts or gouges in the fiberglass overwrap

z

exposed fibers

z

delamination (separating) of the fiberglass overwrap

z

discoloration of the fiberglass overwrap

z

fire or heat damage, such as charring or discoloration

9. If any flaws are detected, measure the depth and length of the flaw in accordance with the Compressed

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

NOTE:

The following procedure is an in-vehicle, visual inspection for natural gas
fuel cylinders. A 1-year/19,310-km (12,000-mile) (whichever occurs first)
inspection interval is assumed.

NOTE:

The Compressed Natural Gas Pamphlet C6.2 can be obtained from the
Compressed Gas Association, Inc., 1725 Jefferson Davis Highway,
Arlington, VA 22202-4102.

2003 Ford Pickup F150

2003 GENERAL INFORMATION Fuel System-General Information-Bi-Fuel - F150 Pickup

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:

z

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.

z

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.

z

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.

z

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:

z

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 instructions. Frayed
fibers must be cut away before application of the epoxy resin.

z

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

z

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:

z

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.

z

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

z

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

z

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

z

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

z

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.

z

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:

1. Vent and remove the fuel tanks. Refer to FUEL TANK & LINES-NATURAL GAS .

2. Remove the fuel tank solenoid valve. Refer to FUEL TANK & LINES-NATURAL GAS .

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.

2003 Ford Pickup F150

2003 GENERAL INFORMATION Fuel System-General Information-Bi-Fuel - F150 Pickup