Ford F150 Pickup. Instruction — part 1264

Fig. 9: Removing Fuel Tank Temperature Sensor
Courtesy of FORD MOTOR CO.

RELAYS & SOLENOIDS

BI-FUEL RELAY MODULE

FUEL RAIL SOLENOID

Removal & Installation

The fuel rail solenoid is mounted in fuel rail. The manufacturer does not provide a procedure to replace the
solenoid. See Fig. 10 .

NOTE:

Removal and installation information is not available from manufacturer.

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE Removal & Installation - F150 Pickup - Bi-Fuel - Gasoline/CNG

Fig. 10: Locating Fuel Rail Solenoid
Courtesy of FORD MOTOR CO.

FUEL TANK SOLENOID VALVE

Removal & Installation

Evacuate the CNG fuel tank(s). See COMPRESSED NATURAL GAS FUEL TANK EVACUATING under
FUEL SYSTEM PRESSURE RELEASE. Remove the fuel tank(s). See FUEL TANK . Remove harness
connector. See Fig. 11 . Remove solenoid valve. Thoroughly clean the solenoid valve threads in the fuel tank
bore. If any resistance is felt during the valve installation remove the valve and inspect and clean the threads.
Lubricate NEW "O" ring seal with 5W-30 motor oil or equivalent. To install, reverse the removal procedure.
After installation is complete, fuel lines and fittings must be leak tested. See LEAK TEST - ALL BI-FUEL
VEHICLES under FUEL SYSTEMS in SYSTEM & COMPONENT TESTING - BI-FUEL -
GASOLINE/CNG article.

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE Removal & Installation - F150 Pickup - Bi-Fuel - Gasoline/CNG

Fig. 11: Locating Fuel Tank Solenoid Valve Connector
Courtesy of FORD MOTOR CO.

FUEL SYSTEMS

FUEL SYSTEM PRECAUTIONS

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Do not modify the system configuration or components, or replace components with components not
specifically designed for use with natural gas. Ford Motor Company has specifically designed the
materials, components and system configuration for this vehicle, and each particular system is precisely
calibrated for efficient operation. The use of different parts or materials can produce an untested
configuration that can result in fire or personal injury, or cause engine damage.

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

CAUTION: When battery is disconnected, vehicle computer and memory systems

may lose memory data. Driveability problems may exist until computer
systems have completed a relearn cycle. See COMPUTER RELEARN
PROCEDURES article in GENERAL INFORMATION before disconnecting
battery.

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE Removal & Installation - F150 Pickup - Bi-Fuel - Gasoline/CNG

fuel service procedures, damage can occur and the warranty may be invalidated.

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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.

z

The natural gas fuel system is always pressurized to 95 psi (655 kPa) downstream of the fuel pressure
regulator and up to 3600 psi (24,821 kPa) upstream of the fuel pressure regulator. Use care when
servicing the fuel system or personal injury can occur.

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The natural gas fuel supply manifold is pressurized to 95 psi (655 kPa). Fuel pressure must be relieved
prior to any fuel system service.

z

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 natural gas to escape into the air and cause injury or death. Observe all fuel system precautions on
any fuel system repair.

FUEL SYSTEM PRESSURE RELEASE

Compressed Natural Gas Fuel Line Venting

1. Raise the vehicle on the hoist.

2. Remove the fuel tank shield. See Fig. 12 .

3. Disconnect the tank valve connectors. See Fig. 13 .

4. Set the fuel selector switch to "ALT" and run the vehicle until the indicator lamp goes out. See Fig. 14 .

5. To pressurize the system, reverse the procedure.

WARNING:

Do not modify the system configuration or components. Do not install
components not specifically designed for use with natural gas. Ford
Motor Company has specifically designed the materials, components and
system configuration for the 5.4L F-Series Bi-Fuel vehicle, and each
particular system is precisely calibrated for efficient operation. The use of
different parts or materials can produce an untested configuration that
can result in fire or personal injury or cause engine damage.

WARNING:

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 the fuel pressure regulator and up to 3600
psi (24,821 kPa) upstream of the fuel pressure regulator. Use care when
servicing the fuel system or personal injury can occur. 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 natural
gas to escape into the air and cause injury or death.

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE Removal & Installation - F150 Pickup - Bi-Fuel - Gasoline/CNG