Ford F150 Pickup. Instruction — part 1339

Compressed Natural Gas

DO NOT modify system configuration or components or replace components with components not specifically
designed for use with natural gas. Manufacturer has specifically designed materials and precisely calibrated
each component and system configuration for efficient operation. Use of different parts or materials can
produce an untested configuration that can result in fire or personal injury or cause engine damage.

It is important that bi-fuel vehicles be properly maintained by bi-fuel trained personnel. If a concern occurs, it is
important that correctly trained personnel diagnose the cause. If a concern relates to fuel system, correct part
replacement is imperative to keep vehicle operating at normal performance. Bi-fuel components and gasoline
specific components are not interchangeable. If vehicle is not serviced in accordance with bi-fuel service
procedures, damage can occur and vehicle warranty may be invalidated.

Fuel supply lines are always pressurized. When servicing fuel-related components, DO NOT smoke or carry
lighted tobacco or an open flame of any type. Flammable mixtures may be present and can ignite, resulting in
personal injury. The natural gas fuel system is always pressurized to 95 psi (655 kPa) downstream of fuel
pressure regulator and up to 3600 psi (24,821 kPa) upstream of fuel pressure regulator. Use care when servicing
fuel system, or personal injury can occur. The natural gas fuel supply manifold is pressurized to 95 psi (655
kPa). Fuel pressure must be relieved prior to any fuel system service. Fuel system pressure must be relieved
before any component can be removed. Fuel tanks must be evacuated prior to tank removal. Removal of
components without pressure relief or tank evacuation can cause natural gas to escape into the air and cause
injury or death. Observe all warnings when performing the natural gas leak test. See LEAK TEST - ALL BI-
FUEL VEHICLES under FUEL SYSTEMS.

Inertia Fuel Shutoff Switch Reset Procedure

Turn ignition off. Check for fuel leaks in engine compartment. If no leak is present, reset IFS switch by pushing
reset button on top of switch. Turn ignition switch to ON position or START position for a few seconds, then to
OFF position again. Again, check for leaking fuel.

FUEL SYSTEMS

FUEL SYSTEM PRESSURE RELEASE

gas is lighter than air.

WARNING:

If you see or smell gasoline at any time other than during fueling, DO NOT
reset Inertia Fuel Shutoff (IFS) switch.

NOTE:

With IFS in CLOSED position, reset button can be depressed an additional 1/16"
against the spring.

WARNING:

Before performing any tests or diagnostics on CNG or LPG components
or systems, read all cautions and warnings in CNG/LPG SAFETY
PRECAUTIONS article in GENERAL INFORMATION.

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE System & Component Testing - Bi-Fuel - Gasoline/CNG

CNG fuel pressure must be released prior to any fuel system service. To release CNG fuel pressure, see FUEL
SYSTEM PRESSURE RELEASE under FUEL SYSTEMS in REMOVAL, OVERHAUL &
INSTALLATION - F150 PICKUP - BI-FUEL - GASOLINE/CNG article. Failure to follow these instructions
may result in personal injury.

LEAK TEST - ALL BI-FUEL VEHICLES

Ensure fuel tank is filled to half of maximum pressure. Pressurize the entire fuel system. Beginning with the fill
valve, follow the entire system applying a quantity of mild soapy water to each fitting or component seam
through to fuel injectors. Leaks in the system will exhibit soapy bubbles. If any leaks are discovered, evacuate
fuel system. See FUEL SYSTEM PRESSURE RELEASE under FUEL SYSTEMS in REMOVAL,
OVERHAUL & INSTALLATION - F150 PICKUP - BI-FUEL - GASOLINE/CNG article. Repair any leaks
detected. Fill the fuel tank to full pressure. Repeat soapy water application and repair any leaks discovered.

FUEL TANK INSPECTION (IN-VEHICLE)

1. Raise and support vehicle. Examine vehicle underbody and chassis in general area near fuel tank(s) for

any indication of collision damage, malfunction, fire or excessive mud/dirt accumulation. Examine fuel
tank stone/heat shield for any indication of collision damage, malfunction, fire or excessive mud/dirt
accumulation. Remove fuel tank stone/heat shield. Examine fuel tank(s) and stone/heat shield interior for
any foreign objects (such as stones or gravel) or foreign materials (such as mud, salt, liquids or chemical
residue).

2. Remove any foreign material, using only a clean, dry cloth. Remove all foreign objects. DO NOT use

water or any cleaners. Examine fuel tank labels for tank expiration date. Use a light and mirror to access
labels hidden from normal view. If expiration date has been exceeded, condemn tank, using procedures in
step 8.

WARNING:

CNG bi-fuel system is always pressurized to 100 psi downstream of fuel
pressure regulator. Fuel pressure upstream of fuel pressure regulator can
be as high as 3600 psi. Use care when servicing CNG fuel systems.

WARNING:

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

NOTE:

DO NOT use Rotunda Combustible Gas Detector on bi-fuel vehicles. Follow all
safety precautions. See FUEL SYSTEM SAFETY PRECAUTIONS and/or
CNG/LPG SAFETY PRECAUTIONS article in GENERAL INFORMATION.

NOTE:

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

NOTE:

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

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE System & Component Testing - Bi-Fuel - Gasoline/CNG

3. Inspect tank sidewall and dome ends, following general guidelines set forth in Compressed Gas

Association Pamphlet C6.2. Inspect tank(s) for abrasions, dents, cracking, blistering or peeling of clear
coating, corrosion, cracks or gouges in metal dome, cracks in fiberglass overwrap, impact damage
(cracking) in fiberglass overwrap, cuts or gouges in fiberglass overwrap, exposed fibers, delamination
(separating) of fiberglass overwrap, discoloration of fiberglass overwrap, and/or fire or heat damage, such
as charring or discoloration.

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

Association Pamphlet C6.2 guidelines. If any of the flaws cannot be completely measured in vehicle, tank
must be removed from vehicle for further inspection. If tanks have been or are suspected of having been
exposed to a corrosive chemical spill, tank must be removed from vehicle for further inspection of
complete composite surface, including area under tank straps. If there is any indication of chemical
attack, such as blistering, cracking or delamination, tanks must be condemned and replaced with new
tanks.

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

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

z

Level 1 Abrasions

These are defined as minor abrasions, such as scuffs less than .010" (0.254 mm) 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 .010-
.030" (.254-.762 mm). Level 2 abrasions must be repaired before tank is returned to service.

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Level 1 Cuts

These are defined as cuts or scratches less than .010" (.254 mm) 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 of .030" (.762 mm) and a maximum length of 8" (203 mm).
Level 2 cuts must be repaired before tank is returned to service.

6. Repair damage to composite wrap 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, 2-component epoxy resin according to manufacturer's instructions. Frayed fibers
must be cut away before application of epoxy resin.

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Tanks with damage exceeding Level 2 must be condemned using procedures in step 8.

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

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

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

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE System & Component Testing - Bi-Fuel - Gasoline/CNG

z

Level 1 Chips

These are chips or abrasions which do not penetrate 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 Black epoxy coating and must be repaired as follows
to prevent corrosion:

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

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

c. 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 metal ends which are more than .060" (1.524 mm) in depth must be removed
from service and condemned using procedures in step 8.

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Gouges

Tanks with sharp gouges penetrating coating and into metal liner must be removed from service
and condemned using procedures in step 8.

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

follows:

a. Vent and remove fuel tanks. See FUEL SYSTEM PRESSURE RELEASE and FUEL TANK

under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - F150 PICKUP - BI-
FUEL - GASOLINE/CNG article.

b. Remove fuel tank solenoid valve. See FUEL TANK SOLENOID VALVE under FUEL

SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - F150 PICKUP - BI-FUEL -
GASOLINE/CNG article.

c. Purge fuel tank with compressed air for 30 seconds.

d. Destroy fuel tank by drilling a .50" (12.7 mm) diameter hole in fuel tank sidewall.

9. Examine fuel tank straps for correct positioning of rubber isolators. Replace rubber isolators as necessary.

When completed, record date, vehicle mileage and results of fuel tank inspection.

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE System & Component Testing - Bi-Fuel - Gasoline/CNG